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Quality Control of Incoming Goods: How to Avoid Mistakes

Quality control of incoming goods represents one of the most critical stages in the production process. When non-compliant materials bypass this stage, the consequences can be devastating for the entire production chain, which lead to additional costs and efficiency issues that cut into profits. In this article, we’ll explore the importance of using reliable and accurate measuring tools to catch errors early and maintain high production quality.

Issues with defective supplies

One of the most common issues in quality control is receiving supplies that do not meet the required specifications. This can happen for various reasons, such as size variations, defective materials, or issues in the suppliers’ production processes.  In these situations, a superficial or inaccurate inspection isn’t enough to identify discrepancies, which can jeopardize the entire production process.

For example, if a company that manufactures mechanical components receives a new batch of raw materials with the wrong dimensional tolerances, this can lead to a series of defective finished products. The result?  The entire production batch might be rejected, leading to higher production costs, wasted time, and a loss of customer trust.

 

Fears of faulty inspections

Quality control technicians often fear that they might not be able to identify defects in incoming materials. Uncertainty in measurements can lead to concerns that a non-compliant product might go undetected and end up in production, significantly increasing the risk of defective products.

This concern is further intensified by the pressure to perform inspections quickly. Rushing to speed up the process can result in less thorough checks or improper use of measuring tools.

Consequences of inaccurate measurements

The consequences of inaccurate measurements can be severe for the production cycle. If an error in inspecting incoming goods goes unnoticed, defective materials may enter the production chain, leading to a series of problems. Often, defects go unnoticed until the finished product is tested or, worse, when it is used by the end user.

Direct consequences include:

  • Production delays: Defects that are found out late can delay or even stop the production process, leading to costly repairs or replacements.
  • Increased costs: Additional expenses for returning or replacing defective materials if they aren’t identified early.
  • Customer dissatisfaction: Defective products can harm the company’s reputation and result in lost business.

 

The solution: Reliable measuring tools

To prevent these issues, it’s essential to implement an efficient quality control system sustained by highly accurate measuring instruments. That’s why SAMA Tools products play an essential role and ensure that every measurement is reliable, repeatable, and accurate.

Here are some key benefits of using high-precision measuring tools while inspecting incoming goods:

  1. Accurate Measurements: Designed to maximize accuracy and minimize errors, allowing for a thorough inspection and quick detection of anomalies.
  2. Long-Term Reliability: Delivers consistent performance with extended use; regular calibration ensures peak efficiency.
  3. User-Friendly Design: Easy to use and suitable even for less experienced staff, reducing operational errors and ensuring precise measurements.
  4. On-Site Training: Comprehensive training to quickly make your operators independent and productive.

Using our measuring tools can significantly reduce customer complaints and help detect non-compliant supplies before they enter production.

These photos show satisfied customers who have benefited from using SAMA Tools instruments and our personalized training courses.

Recap

Inspecting incoming goods is a critical part of the production process. Using accurate and reliable measuring tools is vital to ensure that all materials meet the required standards, while minimizing the risk of errors that could impact the entire process. Companies that invest in high-quality tools not only increase their quality control efficiency but also reduce error-related costs and improve customer satisfaction.

Looking to eliminate costs caused by supplies that are non-compliant?

See how our measuring tools can help you avoid errors. Join the many companies already benefiting from SAMA Tools products—read their reviews here!

Contact us now: 0584/392342 – 392453

sales@samatools.it

 

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Quality Control of Painting and Coatings in the Automotive Sector

Quality control in automotive painting and coating is an essential part of the production process, as well as in any industry, as it helps ensure the best possible results for both the manufacturer and the end user.

This is especially true of the automotive industry, where multiple components are assembled into one product, the automobile.

Therefore, quality control can take place in several production units, even within a single plant.

Here we will talk specifically about quality control in the production unit for auto body painting and the coating of its components.

Painting quality control before production

For the painting production unit, it’s of vital importance to execute quality control on the materials supplied by the supplier before they are applied.

In the automotive industry, the incoming materials are not only paints for car aesthetics, but also different types of coatings that provide protection to very important parts such as the chassis, for lasting durability.

For best results, there are specific material properties that need to be verified prior to application. Let’s see some of them.

Viscosity

Determining the viscosity of the paint is essential in the automotive industry as it is applied by spraying the nebulized paint with special nozzles.

In most cases, the paint viscosity is so low that it atomises, but not so low as to create problems like coating failure. This is why it’s crucial to check this parameter. It also has an impact on different performance standards such as:

  • Pressure
  • Flow
  • Coating speed
  • Coating film build up
  • Color matching
  • Chemical resistance

Viscosity also has a direct impact on the paint transfer and thus on the quality of the finished surface.

In any case, the production unit dealing with automotive painting should have the right equipment to control the viscosity of the paint.

Among the most suitable measuring instruments for these applications, we must certainly mention flow cups and rotary viscometers.

Digital rotary viscometers

 

PH

Although automobiles were initially made of steel to balance the cost between durability and workability, aluminum is more widely used nowadays, as it’s lighter in weight without sacrificing safety.

Specifically, the paint and coatings provide the corrosion protection of these metals. Therefore, a series of steps are employed to prepare the chassis and other car components for such protection.

In general, corrosion can be reduced through pH control and the use of corrosion inhibitors.

To check the pH in the paint production unit, manufacturers can rely on tools such as portable pH meters, thanks to which, they can test the pH anytime, anywhere, quickly and easily.

Conductivity

After electrodeposition, the accumulation of excess paint that adheres to the surface, but not bound to it is rinsed through an ultrafiltration unit, to ensure the uniformity of the surface.

However, this can create a water-stain contamination problem on the coated surface. To avoid this phenomenon, well-deionized water is used.  Therefore, conductivity must be constantly monitored to ensure positive results.

For this phase, it is essential to have a reliable conductivity meter.

Portable pH meters

In photo: portable pH meters

Quality control post-production

We have seen some critical aspects of quality control before painting the body and the car components. Now it’s time to see how to ensure high quality even after the end of production.

Once the paint and coatings are applied, colorimetric measuring tools must be used to ensure high quality results. Let’s take a look at some of these tools.

Spectrophotometers

The spectrophotometer is one of the most high performing tools for painting in the automotive sector.

Two objects, which are illuminated in the same way, may have the same color, under a given light source, but a different color, under a different light source. Therefore, two objects of the same color, but produced at different times and with non-identical products, can reflect light in different ways.

Spectrophotometers use the principle of combined spectroscopy, which is to separate light according to a certain wavelength range. This way, they carry out the complete spectrographic analysis of the color, covering the entire wavelength of the painted piece, confirming the spectral curves and the metamerism.  This allows one to verify that an entire production batch has the same color, guaranteeing repeatability and consistency.

If you are interested in light and color analysis, please read this article on our blog to learn more about spectrophotometers.

Color Difference Meters

This tool, also known as a colorimeter, allows you to measure color differences to check their uniformity. To find out more about color difference meters, click here.

Professional colour difference meter

Glossmeters

The glossmeter is an interesting tool for the automotive industry as it allows one to determine the gloss and brightness of the paint; two essential characteristics that makes the car much more appealing to the human eye.

If you’re curious about how it works, read everything you need to know about the glossmeter here.

Other indispensable tools for production include:  thickness gauges for paints and coatings and hardness and cross hatch testers to check the durability of coatings. The point is that quality control is a must in this industry.

Glossmeters

You can also learn more about this topic by reading our article about the 10 Instruments for First-Class industrial Coating.

The calibration of instruments in the automotive sector

Last but not least, we must remember about calibration. These tools must be calibrated to ensure accurate and reliable results, which is why we consider it a priority service for all our customers.

Why calibrate measuring instruments?

The calibration of the measuring instruments is absolutely necessary to be in accordance with the UNI EN ISO 9001, and more specifically with paragraph 7.6,  which deals with the management of the measuring equipment.

We have already explored this important topic.

Who is responsible for the calibration of the measuring instruments?

Calibrations can be performed both by independent laboratories that offer their services to different companies and by laboratories within the company itself, as long as they adhere to the same legal requirements as external laboratories.

Calibration banner

When is an instrument considered calibrated?

An instrument is said to be calibrated when it’s subjected to a sort of “photograph” which helps to define the metrological characteristics of the instrument itself. This service is optional when purchasing the instrument and takes place by means of comparing measurements with a reference instrument, called a sample.

S.A.M.A. Italia can assist your company’s needs, both by providing you with the measuring instruments mentioned in this article, and by providing our calibration services.

We can issue calibration reports with traceability to primary samples, or we can provide you with ACCREDIA certificates, in collaboration with the best accredited laboratories.

Do you have other questions about the differences between these two services? Don’t worry because our technicians receive dozens of requests like this every day and are always available to assist you.

If you want your instruments calibrated but you’re not sure if you need to receive a calibration report or a LAT certificate, contact us.  There’s no obligation.

Many of our customers often decide to leave their feedback.  Find out what they have to say about us.

 

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Sheet metal manufacturing and quality control

The manufacturing of sheet metal plays a crucial role in creating a wide range of everyday items, including car bodies and appliance parts.  In the context of a highly competitive market, precision, uniformity, and quality are paramount.

The ultimate goal is to deliver products of the utmost quality.

Considering this, it’s evident that quality control (QC) is a fundamental element in reaching ever-higher standards and satisfying customer requirements. Keep reading to learn more.

What is sheet metal?

When we talk about sheet metal, we refer to a sheet derived from a roll of metal.  The advantages certainly include a great adaptability to numerous surface finishes at all levels with very low processing costs. In fact, it does not require additional machining operations, which is why it is used in various sectors.

sheet metal production

Photo by Canva Pro

Sheet metal manufacturing: production

Sheet metal manufacturing usually involves a series of processes that include laser cutting, stamping, bending, among others.

A process like stamping is usually divided into subprocesses that are necessary to achieve the final product.

  • Bending
  • Hemming
  • Blanking
  • Ironing
  • Curling
  • Piercing
  • Cutting
  • Stretching
  • Drawing
  • Reducing/necking
  • Embossing

Of course, with the most recent developments in manufacturing technology, sheet metal manufacturers have taken their skills to the next level.

By using CNC machines, they can now achieve the very complex geometries required by many applications while complying with the tightest tolerance specifications.

Sheet metal manufacturing: Every metal has a different use

The uses of sheet metal vary based on the type of metal being used.

It is certainly interesting to list some types and match them to the most suitable form of application.

What kind of metal is used to produce shop signs? What about the components of aerospace engines?

Let’s find out!

  • Carbon steel sheet is often used when corrosion is not a concern.  It can be used for anything from car bodies to store signs. The reason for its versatility is because it is relatively affordable and has superior tensile strength when compared with copper and aluminum.
  • Galvanized steel sheet is a form of carbon steel sheet metal that is frequently used in automotive parts and greenhouse equipment, buckets, irrigation pipe and marine vessels.
  • Stainless steel sheet is typically more expensive because it can withstand corrosion and is widely used in aerospace engine components, marine structures and vessels, pharmaceutical processing equipment and food handling equipment. Stainless steel sheet also has good aesthetic appeal that makes it popular for signage and appliances.
  • Aluminum sheet is lightweight and quite resistant to corrosion. Aluminum sheet is used for boat components, marine structures, cookware, automotive parts, and aerospace parts.
  • Finally, copper sheet is known for its electrical conductivity and is used in resistance welding equipment or certain types of battery systems. Because of its malleability and superior aesthetic qualities, it is also commonly used in home decor and other forms of artwork.

If you are interested in sheet metal production techniques, you can check out the free Masterclasses offered by the Italian company Dallan Spa.  They specialize in the production of profiling lines, punching machines and laser cutting of thin materials.

sheet metal processing

Photo by Canva Pro

Sheet metal manufacturing: Quality Control

However, to be competitive, sheet metal manufacturers can’t stop at basic processing. Especially when many of the parts they make will end up in important structural applications, including beams, cross sections, rail tracks, the body of different vehicles, and even the fuselage and airplane wings.

Among the things just mentioned, sheet metal manufacturers need to guarantee their products are strong and durable enough to cope with the operational demands of such applications.  They also have to make sure surfaces can resist exposure to extreme temperatures and harsh environments. Think of the components in the body of an airplane and you will get the idea.

How to make this possible?

Many people think quality control refers to identifying defective products and discarding them before sending a batch into the market.

However, according to ISO 9000:2015 section 3.6.2, quality is “the degree to which a set of inherent characteristics of an object fulfils requirements.” And this means that manufacturers must ensure that the parts are made to design specifications and will function properly.

Dimensional verification

Quality Control in the sheet metal industry usually involves the verification of dimensional properties such as straightness, flatness, circularity, concentricity, cylindricity, perpendicularity, parallelism, profile, and runout.

These dimensional properties are usually verified with measuring instruments such as calipers, micrometers, and the resulting measurements must fall within the expected tolerances.

But quality control in the sheet metal industry is not just about dimensional verification.

Destructive and non-destructive testing (NDT)

Manufacturers also need to guarantee hardness, strength, and durability. To do so, they need to verify those properties on the final product. This is generally done with destructive and non-destructive testing (NDT) control instruments, which include:

As mentioned above, surfaces must resist exposure to extreme temperatures and harsh environments, but metals are usually prone to change or lose their mechanical properties in these situations. We all have seen how corrosion attacks metal parts near the ocean.

dukometal sheet metal production

Photo by Canva Pro

Sheet metal manufacturing: corrosion resistance

Apart from using metals that may have a higher corrosion resistance, manufacturers can use some surface finish techniques like coating to improve these properties. Naturally, this also requires quality control to guarantee that it actually works.

Let’s look at the case of our customer Dukometal SA as an example.

Quality control for sheet metal coating: Dukometal SA

While Dukometal SA specializes in sheet metal manufacturing with stainless steels, they offer a powder coating service they call “Thermopowdering” which they use to provide an even higher level of quality.

Dukometal SA’s powder coating is a type of thermosetting powder coating typically applied by electrostatic spray deposition (ESD) and then cured under heat.

They offer specific advantages, such as:

  • Emitting little or no volatile organic compounds (VOC), unlike liquid coatings.
  • Creating a more durable finish than conventional paint.
  • Producing much thicker coatings than conventional liquid coatings without running or sagging.
  • They can be recycled, so it is possible to achieve nearly 100% use of the coating.
  • Capital equipment and operating costs for a powder line are generally less than for conventional liquid lines.
  • Horizontally and vertically powder-coated surfaces have a more uniform appearance than liquid coated items.
  • A wide range of specialty effects can be achieved that would otherwise be impossible with other coating processes.

Dukometal SA quality control

When it comes to the quality control of these types of coatings, several aspects must be considered.

The coating obtained needs to be tested for crack resistance and the stripping performance. This can be done with a Cylindrical Mandrel Tester which should be in compliance with standards ISO1519 / ASTM D522 / DIN53152.

Adhesion of the coating is also critical. This will ensure the metal is not exposed caused by coating peeling. Therefore, a cross hatch adhesion tester is recommended.

Coating thickness is verified with a coating thickness tester to guarantee the uniformity of the coating.

The properties of powder coatings need to be determined before, during and after the temperature induced curing step to understand how a certain formulation will work with a specific processing step, as well as the actual application of the finished part. Therefore, Dukometal SA relies on our portable pH and conductivity meter to verify anywhere and anytime they need it.

sama dukometal instruments

Instrument calibration

It is also important to keep all these instruments calibrated, otherwise false results could mislead the quality control inspections.  This is why we not only provide our calibration services to Dukometal SA but also to all our customers.

Calibration banner

We’ve come to the end of this article on sheet metal manufacturing and quality control.  If you’ve found it interesting, you can share it with your colleagues and on social media. Content is even more useful when it is shared with others.

For all your measuring needs or our calibration services, you can call to speak with our technicians, or email us, if you prefer.

We are here to assist you.  Contact us now.

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The role of force gauges in quality control

In order for manufacturers to be competitive, they need to set high-quality standards and their products must go through a series of tests to verify that such standards are met, before the product is put on the market. But what role does the force gauge play in quality control?

Before we answer this question, let’s go into some detail about the force gauge itself.

What is a force gauge?

A force gauge is a measuring instrument designed to register and display the value of the force applied to certain element. There are different types of force gauges and they are normally classified as analog or digital or are based on the type of force they are capable of measuring. The types of force usually measured by a force gauge include push or compression force, pull or traction force, and torque force.

Analog force gauges

Analog force gauges, also called mechanical force gauges, generally operate with a load cell or spring to covert the magnitude of the force being measured into a calibrated force value that is displayed by a needle on a graduated dial indicator.

Our SAMA Tools analog force gauge is a fine example of a versatile instrument in this category.

Digital force gauges

Digital force gauges use a load cell or gauge strain that converts the value of the force applied, into an electrical signal that can be quantified, calibrated, and digitized directly onto the display.

While analog force gauges are very durable and versatile, nowadays digital force gauges are commonplace, since they provide a series of added advantages.  Some of the most common advantages are:

  • The ability to sample, record, and store data of the measured values over time.
  • To provide measurements of the total average, as well as peak force values.
  • To rapidly measure changing force values such as those measured during an impact test.

You can see some of the digital force gauges that are available to get a better idea.

force gauges

Why measuring force?

The measurement of the force applied to a piece allows one to identify the value of the force that causes the piece to break altogether or the breaking down of the material.   Therefore, force gauges are essential when performing tensile strength tests, compression tests, leak tests and any other test used to evaluate a dynamic stress cycle of a piece or material.

From the description above,  it is clear that force gauges are useful for many applications in various industries but are especially useful in quality control. To answer the question we asked at the beginning, here are the most common applications of force gauges for quality control.

Applications of a force gauge for quality control

As mentioned above, force gauges are commonly used for traction or tensile testing, compression and torque testing. These tests are useful for determining the:

  • Peel force for sealing bags.
  • Pull force for crimping wires.
  • Compression force of springs.
  • Ergonomics of products such as door handles, computer keyboards, bottle caps, and any other items that require the application of force by human hands.
  • Checking the opening or closing force of gates, doors or windows.
  • Testing the bonding strength of adhesives.
  • Testing strength and load capacity of different elements for safety purposes.
  • Verifying and calibrating torque wrenches.
  • Verifying the fatigue and stress resistance of the material.

As you can see, force gauges can be applied in many situations and will help determine whether the product or the element being tested complies with the quality and safety standards. Therefore, any quality control department should have a force gauge on hand.

Force test

 

Force gauge calibration

The correct calibration of the force gauge is essential in ensuring accurate measurements.

If you’re wondering how often a force gauge should be calibrated, you can read all about it in our other article here.

S.A.M.A. Italia provides calibration services on force gauges and other measuring instruments of all brands.

Below, you can also read an array of positive feedback left by our loyal customers worldwide.

Ask us for a quote for the calibration of your measuring instruments now and we’ll get back to you A.S.A.P. (fast service is one of our many strengths).

In conclusion

While using a force gauge is generally very simple and intuitive, it’s important to have the right tools and skills in order to successfully meet the specific requirements of your application.

S.A.M.A. Italia offers a wide variety of force gauges to meet your every need. Regardless of the industry or type of test you need to perform, you’ll find the right force gauge for you.

Our mission is to help customers achieve the required quality standards.

How do we do it? Thanks to our experience, we are able to analyze your specific needs and requirements and offer advice on the right measuring tools, which can make the difference.

Read the feedback from our many satisfied customers, here.  We’d be thrilled for you to become one of them.

Therefore, if you need help identifying the most suitable measuring instruments for your specific needs or if you need your tools calibrated (even instruments of other brands), don’t hesitate to contact our technical department.

You can reach us at 0584/392342 – 0584/392453 or write us at sales@samatools.it.

 

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Coating Quality Control on Commercial Vessels and Mega Yachts: MCR Marine


The quality control (QC) of the coating on commercial vessels and mega yachts is a very important process to ensure that both desired aesthetics and performance are achieved.

In fact, this is true for the entire marine sector, including new constructions and refits of ships, yachts, offshore structures and accessories.

Obviously, coatings are very important for commercial vessels and mega yachts since they are exposed to a very corrosive environment. So, maintaining the highest performance level is essential for the integrity of the vessel, along with its aesthetics.

How is the quality control of coatings performed?

There is a very important preparation and painting process before a commercial vessel or a mega yacht is ready to set sail, and it includes a quality control step.
The quality control of the coating on commercial vessels and mega yachts involves the measurement of paint thickness applied. This thickness can be measured both dry (DFT) and wet (WFT).

Dry coating thickness measurement is performed during quality control and maintenance inspections. On the other hand, wet coating thickness measurement can be performed during the preparation and painting process since it does not require the coating to be completely dry as the name suggests.

The most common coating thickness measurement instruments are coating thickness gauges. They are used to measure dry layers applied on a metal substrate, such as paint and plastic layers. A good example of these instruments are the high accuracy digital coating thickness gauges.

Coating thickness gauges work on both ferrous (magnetic) and non-ferrous (non-magnetic) metal parts. Depending on the material, the instruments will use either the Magnetic Induction or the Eddy Current measuring principle.

However, for wet coating thickness measurement, different types of gauges are used, which include the comb-shaped thickness gauges and the rolling wheel wet film thickness gauges.

Thickness gauges for thickness measurement of paint applied.

In the picture above SA8850, SAWF and SAWFR

Quality control at MCR Marine

MCR Marine Srl is a company which is formed by a group of professionals who specialize in the coating and painting industry, and provide technical support before, during and after preparation and painting on commercial vessels and mega yachts.

The service they offer not only covers the painting of the vessel, but also the preparation and coating of accessories. In addition to the sectors mentioned above, MCR Marine is able to provide assistance to the entire marine sector.

MCR Marine Srl provides two main ways to guarantee the quality of their services:
• Certified Inspectors by the major world bodies: Frosio, Nace, RMCI.
• Quality control tools and instruments properly calibrated according to the highest standards.

How calibrating quality control instruments helps MCR Marine Srl?

As we mentioned above, MCR Marine Srl prepares and paints commercial vessels and mega yachts.

Quality control is essential in their activities.

By using the right tools for the verification and evaluation of different activities such as material hardness and coating or painting thickness, they can guarantee high-quality results to their customers.

However, as with any other tool or instrument, measuring instruments need to be periodically calibrated to ensure the values obtained are really accurate.

If quality control is performed with measuring instruments that are not calibrated, the operator might make mistakes, such as requesting extra coating which can result in delivery delays or even worse, sending vessels to the customer with deficient coating which may result in premature failure.
So, how do the experts of MCR Marine make sure their tools and instruments are properly calibrated to match their high-quality standards?

quality control

Above: Photos of a Quality Control Department (Canva.com)

SAMA Tools calibrating services: The best option

Apart from counting on SAMA Tools as the provider of their tools and instruments for the quality control for the preparation and painting process of the commercial vessels and mega yachts, MCR Marine periodically sends their instruments to our headquarters for calibration.

Shore analog hardness testers – SA6410

In the picture aboce Shore analog hardness testers – SA6410

One of the instruments, we calibrate for them is the shore analog hardness testers – SA6410 a non-destructive instrument used to measure hardness of parts made of rubber, plastic, stucco, sponges and similar materials. Other tools and instruments, we calibrate for MCR Marine Srl are coating thickness measurement instruments.
MCR Marine relies on our calibration services because we help them comply with the UNI EN ISO 9001 standards.

Moreover, in case the adjustment of the instrument is required to fulfill calibration requirements, we offer such adjustments, as a specialized separate service to guarantee their needs are covered.

Through this specialized service, the experts at MCR Marine have always been able to guarantee above satisfactory results to their customers. Working closely together has allowed us to develop a strong relationship that we are looking forward to maintain for a long time.

In the video above: High accuracy digital coating thickness gauges – SA8850

Now it’s up to you!

We strive to provide our customers with the best solution for their specific needs. Customer satisfaction is our top priority and we would be delighted to have you on board with us.

So, if you need help with calibration, or would like advice on the best instrument for your specific case, do not hesitate to contact our technical department.

You can call us at 0584/392342 – 0584/392453 or, alternatively, book a video meeting.

 

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Flaw detections: Inspection methods for quality control

Flaw inspections represent the daily lives of Quality Assurance (QA) and Quality Control (QC) professionals, who work with flaw detectors every day in order to perform accurate inspections.

When trying to detect defects, the inspector usually focuses on finding alterations or irregularities on the sample tested.

When talking about metal part inspections, common flaw inspectors look for irregularities on the material structure.

Such irregularaties may or may not affect the usability of the product, depending on the results of the evaluation and the criteria established for product acceptability.

What types of defects can be detected by performing flaw inspections?

The most common and relevant defects that can be detected by a flaw inspections can be superficial or deep cracks, porosity on the surface and material crystallizations.

Any of these defects can be found alone or in combination on the same inspected part, which is why flaw inspections are important for quality assurance and quality control.

What are the causes of the defects found with flaw inspections?

The defects described above can have different causes.

Flaw inspections help detect those defects and evaluate them to identify the possible causes.

The most common causes include:

  • Congenital causes, meaning they are inherent to the material formation.
  • Casting process issues.
  • Heat treatment issues.
  • Hot working issues.
  • Mechanical fatigue.

What are common flaw inspection methods?

Different industries have different inspection methods to ensure quality. Here you will find three of the most common non-destructive flaw inspection methods which are used.

ultrasonic flaw inspections

In the picture above Ultrasonic flaw detector – SAFD500

UT Ultrasound Control

This non-destructive flaw inspection method takes advantage of the principle of using sound waves at very high frequencies, usually higher than those heard by the humans ear, to identify and verify defects while keeping the integrity of the sample.

Moreover, it is possible to obtain results by inspecting from only one side of the sample with the use of a probe. The operation consists of accurately measuring the time it takes for an ultrasound pulse to pass through the thickness of the inspected part, being reflected on the opposite surface, and finally returning to the probe.

During this process, if the ultrasound beam encounters a defect, there is an early reflection of the signal, which therefore highlights the discontinuity. The ultrasound check allows the identification of both surface and depth defects, including:

  • Flaws on the surface finish which may not be visible to the human eye.
  • Corrosion on the material.
  • Non-metallic inclusions.
  • Congenital discontinuities in the material.
  • Discontinuities resulting from casting processes.
  • Material cracks.
  • Defects resulting from wearing or production processes.
  • Defects deriving from hot working.
  • Defects deriving from heat treatment.
  • Fatigue failures that occur during activity.
  • Welding defects.

The main applications of UT ultrasound control for flaw inspections include, but are not limited to:

  • The metallurgical industry.
  • Welding inspections.
  • The aerospace industry.
  • The shipbuilding industry.
  • Sectors that require non-destructive inspections.

In addition, UT ultrasound control is a very versatile flaw inspection method, as it can be applied on many different materials, including:

  • Steel
  • Cast Iron
  • Aluminum
  • Copper
  • Brass
  • Zinc
  • Gray Cast Iron
  • Spheroidal Iron

Check out our versatile ultrasonic flaw detector models:

Ultrasonic flaw detector

In the picture above, the operator is using the Ultrasonic flaw detector – SAFD500

PT Penetrating Liquid Method

Another non-destructive flaw inspection method is the one known as liquid penetrant inspection, which takes advantage of the penetration capabilities of a highly capillary liquid.

The idea is to make a very thin liquid flow into the superficial defect, and then drawing it out with an agent called the developer. After applying the contrast varnish spray, what was initially invisible becomes visible in normal light (in the case of visible liquids) ot through the use of a Wood lamp (in the case of fluorescent liquids). Fluorescent liquids are employed, for example, for the inspection of complex samples and / or cables not accessible to natural light.

To properly apply the PT penetrating liquid method, the following steps are necessary:

  1. Cleaning the surface by removing any contaminants such as grease, dust or any other kind of particles.
  2. Applying the chosen penetrating liquid and waiting for capillarization into the material.
  3. Removing the excess of penetrating liquid by means of water or a type of solvent.
  4. Applying the developer.
  5.  Inspecting the surface.
  6. Cleaning with corrosion protective solutions.

The main advantages of using the PT penetrating liquid method include:

  • Responsiveness to small surface defects.
  • Parts with complex geometries can be easily inspected.
  • Large areas and volumes of parts and different materials can be easily inspected at low costs.
  • The defect is visually indicated on the surface.
  • It is a portable, convenient, and inexpensive process.
  • Relative size, shape, and depth of the flaw can be revealed.
  • It is easy to perform this flaw inspection method, so there is no need for a special training.

Penetrating liquids have many fields of application and our products can be used to detect discontinuities on any type of non-porous material.

In regards to metallurgy, two applications are of particular interest: in the welding processes, to detect any process flaws (crater cracks, shrinkage cracks, porosities, slag cracks, marginal incisions) and when checking elements which are subjected to stress, to detect discontinuities due to repeated and prolonged punctual stress over time.

AC_DC magnetic detector - SAYK390

In the picture above, the AC_DC magnetic detector – SAYK390

MT Magnetic Particle Detection Method

This is another non-destructive flaw inspection method, in which a magnetic field is applied to the sample tested. Any indications present produce a variation of the flow lines of the generated field that are visible by means of magnetic powders.

The magnetic detection can be performed with magnetic liquids and fluorescent magnetic liquids.

The principle of operation is that the presence of discontinuities such as cracks and other defects disrupts a magnetic field created on the subject of inspection. So, applying a liquid containing magnetic particles on the part under such conditions will make those magnetic particles  gather and accumulate in the area by the discontinuity on the material.

Due to its operation principle, this method is mainly used to detect flaws on ferromagnetic materials such as:

  • Iron
  • Nickel
  • Cobalt
  • Some alloys

There are different tools used to implement this flaw inspection method.  Some are as follows:

There are many facilities that offer Magnetoscopic Training (MT) for operators, in accordance with UNI EN ISO 9712:2012, such as Bureau Veritas, which issues the certificate of attendance training.

This is a prerequisite for taking the exam to be certified according to the specific level.

Final considerations about flaw inspections

In this article we have highlighted what flaw inspection is, and the importance it plays in preventing the breaking of various types of pieces that we can find everywhere, around us.

All over the world, many have experienced  several cases of negligence in material checks, which have caused even fatal damage.

To make sure that this does not happen again, the work of QA and QC professionals is essential to prevent such damage by means of flaw detectors and many other inspection methods.

We provide the tools and equipment required to cover each of the flaw inspection method mentioned above. If you want to check out the flaw inspections instruments we offer, just click here.

Instead, if you’re still not sure or have any doubts about any of the flaw inspection techniques we have described here or any of our instruments, we recommend that you contact us and one of our experts will gladly assist you.

 

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Optimize processes for continuous improvement: “Mejora”

Different industries need to control different aspects of their processes. Some of the most common ones are:

  • Vibrations.
  • Temperature.
  • Pressure.
  • Friction and wear.
  • Corrosion and abrasion.

What does control of the continuous improvement process mean?

Speaking about controlling processes for continuous improvement means focusing on one important step of a common methodology that search for perfection.

Here is the theme we will deal with if you continue reading this article.  First we will talk about the phase of data collection and analysis as no process can be improved if there is no information about it. Even better if it is possible to monitor the process for long periods and under different conditions.

How is controlling processes for continuous improvement possible?

As it was mentioned above, controlling processes for continuous improvement requires collecting data, which means that measuring instruments take an important role.
Some of these instruments can be directly installed in the production line and others require to be handled, usually by operators from the quality control or maintenance departments who report their findings for continuous improvement purposes.

Measurement and control instruments are divided into two main categories:

  • Non-destructive testing instruments.
  • Destructive testing instruments.

From these two categories, non-destructive instruments are increasingly gaining popularity, and they are especially useful when controlling process for continuous improvement.

The reason is that, as the name suggests, these instruments allow the performance of tests, measurements and checks that do not alter the integrity of the sample being analyzed. This results in a more cost-effective improvement process.

controlling process for continuous improvement

Continuous improvement with Mejora de Procesos Industriales S.A.C.

Mejora de Procesos Industriales S.A.C. is a company that partners with the most prestigious brands around the world to help their customers with the selection, configuration, installation and commissioning of equipment and instruments used in controlling processes for continuous improvement.

Their customers fall mainly in the following sectors:

  • Mining.
  • Energy generation.
  • Oil and gas.
  • Water treatment.
  • Industrials.

Of course, before partnering with any brand, they perform a rigorous study of the quality and the reliability of the equipment and instruments provided by the company owning the brand.
In addition, they make sure only the latest technologies that allow accurate control and measurement of physical and chemical parameters are the ones they represent for the customers in the sectors mentioned above.

This said, we are proud to be one of the group of partners that Mejora de Procesos Industriales S.A.C. represents. We work closely together so that they can offer their customers the best non-destructive testing and measurement instruments used when controlling processes for continuous improvement.

Among the instruments offered by Mejora de Procesos Industriales S.A.C. in representation of S.A.M.A Italia s.r.l., we want to highlight the following:

Vibration meters vibration meter sa6380

Rotating machines and other equipment operating in a production line or servicing different facilities in an industrial plant usually generate vibrations which can be considered normal.
Controlling vibration levels is very important, since any vibrations going out of the normal range of operation may result in a catastrophic failure, which means unexpected downtime and financial loss.

Moreover, controlling vibrations may improve the efficiency of the machinery which means an improvement in the whole process.
Our SA6360 and SA6380 models allow their customers to measure different parameters related to vibrations such as:

  • Acceleration
  • RMS velocity
  • Displacement

Measurements can be made on the 3 axes simultaneously and the portability of the design allows for an easy operation while on the field.

Infrared thermometers

Almost any single process in a production plant requires a specific temperature range for optimal results. Therefore, controlling processes temperatures to the most accurate possible levels is essential to achieve the desired improvements.

Installing equipment that is fixed within the process is a common practice, although it may not be the most cost-effective solution for many applications. Therefore, using a hand-held thermometer is a better option in such cases.

However, many times the temperatures are so high that it would be dangerous for an operator to take temperature measurements with a contact thermometer. Other times, the point of measurement is not easily reachable. Here’s where infrared thermometers are essential.

We offer four models: SA350 – SA652 – SA960 – SA1450

And all of them provide the following benefits:

  • Easy to use thermometer.
  • Response time is almost immediate.
  • Safe contactless measure.

infrared thermometer

Ultrasonic thickness gauge

This is a very important tool for quality control and maintenance processes. It consists in measuring the thickness of a piece in detail. By using this tool, the operator can obtain results by measuring from one side only with the help of a probe, thus eliminating the need for complicated and hazardous activities such as going inside a vessel.

With an ultrasonic thickness gauge, it is easy to detect problems that may reduce the efficiency of the process, for example:

  • Material loss due to corrosion and erosion.
  • Structural and welding problems on ships hulls and other components.
  • Damage resulting from splitting materials.
  • Defects on the surface finish of a finished product.

Mejora de Procesos Industriales S.A.C. provides their customers with our ultrasonic thickness gauge – SA8812 which allows them to measure the thickness on different materials, including:

  • SteelThickness gauge kit
  • Cast Iron
  • Aluminum
  • Copper
  • Brass
  • Zinc
  • Quartz Glass
  • Polyethylene
  • PVC
  • Gray Cast Iron
  • Spheroidal Iron

Through coating ultrasonic thickness gauge

Mejora de Procesos Industriales S.A.C. offers their customers this variation of the ultrasonic thickness gauge which allows accurate measurements of coated parts.
The main benefit is that the instrument is capable of discriminating the coating applied over the metallic substrate, thus avoiding the need from removing part of that coating which would mean increased operational costs.

Our SAUT310D-SW model is frequently used in nautical and maritime maintenance operations, and it is also very useful for the pressurized containers sector.

Final considerations

We offer a wide variety of non-destructive testing tools and measuring instruments apart from the ones highlighted here.
We strive to provide our customers with the best solutions to cover their needs, and we support them with certified high-quality tools.

Mejora de Procesos Industriales S.A.C. trusts us to be the best alternative for their customers, giving us the responsibility to support their reputation as a provider of high-quality tools used when controlling processes for continuous improvement.

If you need help with non-destructive testing tools and measuring instruments, or would like advice on the best instrument for your specific case, do not hesitate to contact our technical department.

You can call us at 0584/392342 – 0584/392453 or, alternatively, book a video meeting with us!

 

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Quality Control in the Hazelnut Production: Sarilar Case Study

There is more to it than sorting for quality control in hazelnut production.

An important aspect is making sure the highest quality is obtained by checking moisture levels.

Maintaining a constant moisture level in the production of hazelnuts,  helps to ensure that the product is neither too wet nor too dry.

This is the only way to ensure a delicious tasting product!

Therefore, the producer can  provide a high-quality product while being highly profitable, and the food processing industries will be able to obtain hazelnuts with adequate properties to make delicious end products.

quality control hazelnuts

How is controlling the levels of moisture in the hazelnut production possible?

There are different things a producer must do to achieve and maintain those desired levels of moisture.

A common practice among hazelnut producers is to have a quality control lab where the levels of moisture are measured by means of a moisture meter, more specifically a grain moisture meter like our SA7825G model.

Measuring moisture accurately allows the producer to determine the relative humidity (RH) in percentage values. These values can then be compared with the quality standards to make sure the product has the desired moisture level.

quality control hazelnuts Sarilar Moisture control with Sarilar

Sarilar Dis Tic Ltd Sti is a Turkish company devoted to providing their customers with the highest quality hazelnuts.

To accomplish their mission, they have evolved from a simple unprocessed hazelnut trading business into a high-tech processed hazelnut manufacturer. Their current factory is capable of selecting, calibrating and cracking the nuts without any human hands involved.

Some of the staff from the  SAMA Tools Group visited the factory to see the whole production process first-hand. Emre Sari, our contact within the company, proudly gave us a tour to show us how they work.

Their facilities are obviously equiped with a quality control lab. In their lab, they take check their hazelnuts with sizes ranging from 9 – 11 mm., 11 – 13 mm., and 13 – 15 mm.

To guarantee high quality hazelnuts they rely on our SA7825G grain moisture meter .

Besides trusting SAMA Tools instruments to control the moisture and quality of their hazelnuts, Sarilar has taken the role of a supplier, providing SA7825G grain moisture meters to their customers so they can use them to check the quality of their final products.

5 benefits of monitoring the humidity in hazelnut production.

quality control hazelnut Sarilar Turkey

At this point, it is clear that controlling the level of moisture of the hazelnuts is significantly important for the quality of the product.

Now, the question is how is the quality of a hazelnut affected by having the wrong moisture levels. And this can be easily explained by the following benefits that are also obtained when the levels are controlled:

  • Bacteria and other sanity issues are avoided.
  • Reduced waste.
  • Reduced energy consumption.
  • Downtime reduction.
  • Quality certified product.

Therefore, we can conclude that having the wrong moisture levels would make Sarilar and its customers less efficient and less profitable while having a product with a lower quality. This could also result in a reduced competitiveness and possible loss of reputation, hence the importance of having accurate moisture measures.

SAMA Tools Grain Moisture Meter: The solution

Saralir has chosen our grain moisture meter, the SA7825G model, because it offers them and its customers the possibility to perform a non-destructive test to measure the relative humidity on hazelnuts.

The instrument, however, is able to determine relative humidity on many other grains including rice, coffee, cocoa, linseed, peas, semolina, barley, clover, grain, flour, beans, wheat and sunflower seed.

This makes it a great solution for the customers in the food industry who process different raw materials.

In addition, the test complies with the highest standards, having the following characteristics:

  • Simplicity – this test does not require the operator to have a lot of experience. Almost anyone can perform it.
  • High accuracy – the difference between a hazelnut cracking because it is too dry or containing to much water is very small.
  • Verifiability – as it can be calibrated and compared to any standard.

Regarding the final characteristic, we provide a calibration service which includes laboratory test reports and/or ACCREDIA calibration certificates for our own instruments or equipment already possessed by our customers.

You can learn more about this service by clicking here.

Grain moisture Meter - SA7825G

Final thoughts

Apart from moisture meters, we offer a wide variety of non-destructive testing tools for different purposes.

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.

Sarilar is a good example that customer’s satisfaction is our main goal, and we would be more than happy to see you becoming one of them.

So, if you need help with moisture measure and control, or would like advice on the best instrument for your specific case, do not hesitate to contact our technical department.

You can call us at 0584/392342 – 0584/392453 or write at sales@samatools.it

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