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The process of manufacturing efficient and high-performance industrial pumps  involves a series of inspections and tests, both before and after assembly.

These inspections and tests are helpful to verify that the manufacturing processes are carried out in accordance to fabrication criteria and required standards.

It is important to keep in mind that industrial pumps are normally exposed to many factors during operation. Some of those factors are:

  • Mechanical loads.
  • Hydraulic loads.
  • Thermal variations.
  • Environmental factors.

Therefore, the manufacturer needs to make sure the pump is ready to deal with all those factors which arise in the worst-case scenarios to guarantee they will operate efficiently and reliably.

Non-destructive testing for industrial pumps

Non-destructive testing is a great way to verify the pumps being manufactured are ready to operate efficiently and reliably.

Some common non-destructive tests applied on pumps include:

Ultrasonic tests

Ultrasonic tests are a great way to verify the performance of different areas of the pumps. Common areas tested with ultrasound technology include:

  • Material thickness
  • Material hardness
  • Material cracks and other discontinuities
  • Corrosion
  • Integrity of welds

It is clear that verifying the performance of the areas mentioned above is essential during and after the production of the pumps to guarantee proper operation.

This type of tests can be performed with tools such as:

Ultrasonic thickness gauges

ultrasonic thickness measurement

In photo: ultrasonic thickness measurement SAMA Tools

Ultrasonic hardness testers

Ultrasonic hardness tester

In photo: Ultrasonic hardness tester SAMA Tools

Ultrasonic flaw detectors

flaw inspections

In photo: flaw inspections SAMA Tools

Magnetic particle detection

These types of tests can be performed by measuring instruments such as our ultrasonic thickness gauges, ultrasonic hardness testers or ultrasonic flaw detectors.

As the name suggests, this type of non-destructive test uses the magnetic particle method for the detection of possible flaws on the surface or at sub-surface levels of the materials.

This test is particularly useful to verify the integrity of welded areas and cast parts, with the possibility to identify cracks and other defects before the pump goes into operation.

Tools such as our AC/DC magnetic detector and our digital gaussmeter can be of great help when performing magnetic particle tests on pumps.

AC/DC magnetic detector and our digital gaussmeter

In photo: AC/DC magnetic detector and our digital gaussmeter SAMA Tools

Dye penetrant test

This is a typical metallurgic test to verify the integrity of materials. It takes advantage of highly capillary liquids that are used to reveal possible defects and discontinuities on the material. This helps identify problems in welds, and other critical areas of the pumps.

Some penetrating liquids we offer include:

  • Fluorescent penetrant spray
  • White penetrating spray
  • Red penetrating spray

These are three important non-destructive tests that are recommended to guarantee that pumps are ready to withstand the factors mentioned above, especially those related to the operation of machines, such as mechanical and hydraulic loads.

Nevertheless, there is another important aspect to verify during and fabrication, and even after certain operational time, when maintenance is required.

Read on as we explain further.

Penetrant spray

In photo: Penetrant spray SAMA Tools

Dealing with the environment

Pumps that are exposed to the environment, especially under tough conditions, require special protection to guarantee operation without failure.

A common practice is applying special coatings to protect against corrosion and other environmental effects. To achieve the required coating protection, both the surface of the materials being coated and the coating applied need to comply with certain requirements.

Some examples of these requirements are:

  • Adequate surface roughness
  • Proper adherence of the coating
  • Correct coating thickness
  • Expected coating elasticity
  • Specific hardness and abrasion resistance

To verify compliance with these requirements, some tests and measurements must be carried out. Tools that are necessary include:

In addition, pumps must be design to very tight tolerances and require high-precision manufacturing processes to operate at the highest possible efficiency. And those tolerances must be maintained throughout their lifespan. Moreover, thermal variations from operation or from exposure to the environment in different seasons may affect the dimensions of different parts, thus drifting away from the tolerance ranges.

A good way to ensure the parts of the pump are within the tolerance range, and identify whether thermal variations are having an impact is by performing dimensional verifications.

However, for some parts, dimensional verifications may require special measuring instruments. But any manufacturer striving for excellence knows the investment is worth it. And this is the case with several of our customers in this sector.

quality control

Photo by www.canva.com

Other verifications to produce industrial pumps

There are also special measuring instruments that help the customers to guarantee the dimensions of different parts in pumps and pressure units comply with their standards.

Among the most chosen tools, there are the outside micrometers with exchangeable anvils and carbide tipped measuring faces reading 0,01mm – SAX101

With these instruments, you can measure even the biggest parts of pumps, including outside coverings while ensuring the tolerances are met to values as small as 0,01 mm.

Failure to comply with dimensional tolerances could result in reduced efficiency and/or reliability of products, which may bring different consequences such as:

  • Increased customer dissatisfaction
  • Reduced profitability
  • Loss of reputation

Fortunately, all those consequences can be avoided by implementing the right quality control (QC) and quality assurance (QA) processes while using the right tools.

customers satisfation

Photo by www.canva.com

Now that you have a complete picture of what checks are needed to produce high-performance pumps, you can count on our SAMA Tools brand for the supply of both standard measuring instruments, such as external micrometers, calipers, dial gauges, and a wide variety of non-destructive testing tools.

Because our mission is to support our customers in their quality control activities, we strive to provide them with the best solutions to cover their needs.
If you need help with measuring instruments, or would like advice on the best tool for your specific case, do not hesitate to contact our technical department.
You can call us at 0584/3923420584/392453 or, alternatively, contact us by e-mail at sales@samatools.it

Coating thickness measurement is an essential activity for many industries, which rely on the quality of their coatings and paintings.

These industries normally use coating thickness measurement as an accurate technique to verify that coatings applied on their products comply with their standards.

What is Coating Thickness Measurement?

As the name suggests, coating thickness measurement is a non-destructive testing method to measure the thickness of a coating applied on the surface of a product.

Apart from keeping the integrity of the part, an interesting aspect of this non-destructive measuring method is that it can be applied on both dry and wet coatings. The main difference between dry and wet coating thickness measurement will be the type of instrument employed.

Why is coating thickness measurement essential in many industries?

The fact that coating thickness measurement can be performed on both dry and wet coatings makes it a great solution for different industries and at different points of their production processes.

For example, quality control (QC) and maintenance departments can benefit from dry coating measurement tools to carry out inspections of dry insulating layers applied on metal substrate, such as paint and plastic layers.

These inspections are commonly performed to identify:

  •  Loss of coating layer that may result in corrosion.
  •  Incorrect coating thickness that may lead to premature failure of the coating.
  •  Coating thickness matches design requirements.
  •  Coating coming from suppliers matches order requirements (incoming goods inspection).

Timely detecting any problem on the coating can result in an increased lifespan of the coated part and a very significant reduction of costs in the long term.

Moreover, having the appropriate coating thickness allows achieving the desired balance between aesthetics and protection of the coated part. Thick coatings that are not even may result in undesired textures and the possibility of paint cracking leading to failure.

 

High accuracy digital coating thickness gauges - SA8850

Watch the video: High accuracy digital coating thickness gauges – SA8850

How to measure coating thickness?

As described before, there are two forms of measuring coating thickness: dry coating thickness measurement and wet coating thickness measurement.

Dry measurement is usually applied to measure any insulating layer applied on a metal substrate, such as paint and plastic layers. It is carried out by means of coating thickness gauges, such as our high accuracy digital coating thickness gauges which are capable of detecting insulating (enamel/paint etc.) and non-ferromagnetic (aluminum/zinc etc.) coatings over ferromagnetic substrates and insulating (enamel/ paint etc.) coatings over non-ferromagnetic substrates.

Coating thickness gauges use the magnetic induction measuring principle for ferrous base coatings and the eddy current measuring principle for non-ferrous base coatings. In addition to paint thicknesses measurement, these instruments can measure different types of coatings applied to sub-layers or resulting from galvanic baths such as anodizing, chrome plating, galvanizing, etc.

On the other hand, wet measurement is usually applied as part of the painting or coating application process, since it does not require the coating and varnish layer to be completely dry. This is especially useful for coating service providers, as it allows them to adjust immediately the coating layer as necessary without the need of post processing.

Common examples of wet coating thickness measuring instruments are our comb-shaped thickness gauges and rolling wheel wet film thickness gauges

What are the applications of coating thickness measurement?

As mentioned above, coating thickness measurement is essential for many industries.

Some of the sectors that commonly perform coating thickness measurement include, but are not limited to:

  •  Automotive.
  •  Aerospace.
  •  Marine sector.
  •  Commercial vessels.
  •  Mega yachts sector.
  •  Oil & Gas.
  •  Chemicals.
  •  Construction.
  •  Electronics.

Thickness gause fiels of application

Common activities in these sectors that require coating thickness measurement are:

Piping inspections in the oil and gas, and the chemicals sectors to avoid corrosion issues that may result in pipe failure, costly shutdowns and industrial accidents.

Checking the paint coating consistency on an aircraft or component in the aerospace industry for improved safety and performance.

Nautical and maritime maintenance, like in the case of bulkheads, tanks, ship hulls, and other coated components.

 Verifying the integrity of pressurized containers such as fire extinguishers, gas tanks, industrial boilers and others that depend on coatings for corrosion protection.

Maintenance inspections on bridges, especially those with metal structures, which are coated to withstand the hardest environmental conditions.

 

How to select a coating thickness measurement instrument?

Selecting the right coating thickness measuring instrument for your specific application is very important, since making a wrong selection may result in a total inability to obtain any value or obtaining false information.

Any of the aspects mentioned above means undesired consequences such as increased costs, customer dissatisfaction and loss of reputation.

To avoid all those problems, some aspects must be considered to select the right coating thickness measurement for your application:

  •  The coating type, whether it is dry or wet.
  •  The type of coating and material coated.
  •  The roughness of the coating. This also affects the type of probe to be used.
  •  The area measured and its location.
  •  The geometry of the part under test.

 

  • Coating thickness gauges

    Coating thickness gauges – SAWF, SAPIG548, SAWFR

At this point, it is also important to highlight that there are destructive methods to measure coating thickness. For example, our paint inspection gauge (P.I.G.) – SAPIG548 provides high accuracy measurements in the range of 2-2800µm on every substrate, like steel, non-ferrous metal, plastics, wood, concrete, plaster, among others with the aid of a built-in microscope allows you to measure the thickness of each layer. This instrument, thanks to its microscope, allows measuring both the total thickness of the coating and each single layer deposited on the substrate.

However, the integrity of the part is not kept, as this is a destructive test.

The fact is that, no matter your application, we have a coating thickness measuring instrument to cover your needs.

If you want to check the dry and wet coating thickness measuring instruments we offer to select the one for your application, just click here.

Of course, if you are not sure yet or have any doubts about measuring coating thickness, our recommendation is to contact us and one of our experts will gladly help you.