Detecting Welds in the Wire Industry: MAC®’s Reliable Nondestructive Testing
Quality control is the backbone of the wire industry, where precision and reliability are non-negotiable. Defects like butt welds in insulated conductor cables can jeopardize the integrity of a product, leading to costly returns and damage to a manufacturer’s reputation. Magnetic Analysis Corporation (MAC®), a pioneer in nondestructive testing solutions, is helping wire mills tackle these challenges through its Minimac® digital eddy current test equipment.
Butt welds, an unavoidable byproduct of high-speed wire production, can present a significant hurdle for wire manufacturers. These defects have been rejected outright by end-users, making it essential for manufacturers to detect and remove them during production. MAC’s Minimac® digital eddy current test instrument has become an answer for wire manufacturers facing these quality rejects. The Minimac®, designed for high performance and cost-effective detection of these butt welds, has recently helped a premier wire mill in Mexico. After a successful on-site demonstration, the company incorporated five Minimac® systems into its production line. These systems now inspect insulated copper cables ranging from 2.5 mm to 10 mm in diameter, ensuring that defective sections are identified and removed before shipment. The Minimac® features advanced encircling coil sensors and a CP65NS coil platform, allowing for accurate positioning and vibration control during high-speed testing (currently operating at 120 meters per minute).
The results have been remarkable. Customer returns due to weld defects have been virtually eliminated, and the company is now exploring the possibility of expanding testing to multi-conductor cables at speeds of up to 200 meters per minute. This level of precision and efficiency has solidified their reputation for delivering reliable, high-quality products.
For nearly a century, MAC has been a trusted leader in nondestructive testing, providing tailored solutions for industries worldwide. The Minimac® is a testament to MAC’s commitment to our customers and their reputations. With the Minimac®, wire manufacturers can confidently meet the highest quality standards, ensuring their products exceed customer expectations and have a brand reputation that stands out in a competitive market.
For more information on how MAC can help your company maintain impeccable quality, visit https://www.mac-ndt.com/minimac
MAC CP 65NS with bushing is shown testing single wire cable.
Minimac® Eddy Current Test Instrument
Display screen of Minimac® with defect shown.
