The forged components are placed into the test portal by means of a crane and then set in rotation.

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1 st Edition 2013 Contents ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars 1 ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars ECHOGRAPH 1090: Ultrasonic testing of laminated glass 3

The privately-owned company employs more than 2000 people and looks back upon a history of more than 500 years.

The scope of customers mainly comprises branches with highest quality requirements: The power industry including wind power systems, machinery and plant engineering, drive technology, press

1 1 st Edition 2013 Contents ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars 1 ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars ECHOGRAPH 1090: Ultrasonic testing of laminated glass 3 ECHOMETER 1076 TC: Waterways put to the test 3 ECHOMETER 1076 TC Data: Measurement of residual wall thickness of ship floors 4 In 2012 a testing system was delivered to BGH Edelstahl Siegen GmbH. The privately-owned company employs more than 2000 people and looks back upon a history of more than 500 years. At the facility in the town of Siegen open-die forgings and forged steel bars with unit weights of up to 32 t are produced. The scope of customers mainly comprises branches with highest quality requirements: The power industry including wind power systems, machinery and plant engineering, drive technology, press manufacturing and the offshore industry. FLUXA and KD-Check: Security for summer toboggan runs and water chutes 4 RMG 4015: Crack depth measurement in a pumped storage hydro power plant 5 DEUTROMAT UWE: Safe landing 5 expand international distribution network 6 Prof. Dr.-Ing. Volker Deutsch turned eighty 7 Typical component in the new 4,000 t press at BGH Edelstahlwerke Siegen GmbH New employees at 8 Fairs and trade shows 8 Contact Pruef- und Messgeraetebau GmbH + Co KG Otto-Hausmann-Ring Wuppertal Germany Phone ( ) Fax ( ) info@karldeutsch.de The testing system is designed for steel bars with diameters between 300 mm and 1,000 mm, lengths between 1.5 m and 10 m and unit weights of up to 35 t. The inspection surfaces are pre-turned and provide a roughness of 25 µm. The forged components are placed into the test portal by means of a crane and then set in rotation. Typical peripheral speeds are 0.15 m/s. The probes are touched down in 12 o clock position and driven in parallel to the part axis, thus yielding a helical scan track. Since two separate test stations are included the test mechanics needs to be designed for a load of up to 70 t. The double portal enables typical production quantities of 4,000 t per month. During the inspection by one of the stations further tasks can be carried out on the other station, such as manual post examinations, as well as service and cleaning work. Continued on page 2

directions for the detection of longitudinal flaws.

2 News from your partner for NDT Continued from page 1 Loading and unloading of such high unit weights heavily stresses the test mechanics. Therefore the roller systems were provided with absorber modules, area with TR-probes, straight beam insonification for the core region and angle beam insonification in both circumferential directions for the detection of longitudinal flaws. Further increase of the throughput was achieved by employing 8 identical probes two parallel electronic modules were installed in two separate carriers, with the shot sequence synchronization of the two units to be as precise as possible. The probes were mounted in link chains in circumferential direction. The flexible chains align themselves optimally to the surfaces of all relevant object diameters. The arrangement of the probes in circumferential direction also provides extremely short untested end zones and guarantees overlapping of the identical probes. Overlap is achieved at low speed and also at full motion speed in axial direction of the component. Testing of a large forged shaft with a total of 32 probes in two carriers which are moved pneumatically after charging. The base area of the testing system - weighing about 40 t - covers 5.3 m by 14.6 m. The system was completely put into service in the assembly hall of in order to check all performance characteristics prior to shipment. The construction focused on most efficient dismounting and subsequent reassembling at BGH Edelstahl Siegen GmbH. In November 2012 the testing system was successfully put into operation and approved. Probes and probe carriers For increase of throughput special probes were developed to enable scans with an extra wide test track and yet high sensitivity at the same time. for each inspection task, resulting in a total of 32 probes. The motion feed per revolution and per probe is 32 mm at full testing Carrier for 16 probes with water gap coupling speed, thus yielding 256 mm in total. Of course the achievable defect sizes, pulse repetition frequencies and testing speeds depend on the material properties. The ultrasound is coupled by means of a water gap between probe and object surface. A motorized gap adjustment allows for convenient operation of the testing system with respect to gap optimization according to different surface curvatures or object diameters. Furthermore wear and tear of the hard metal shoes is minimized. Test results and recording Typical specifications are DIN EN parts 3 and 4, SEP 1921, SEP 1923 and ASTM A 388. The test sensitivities are 0.8 mm FBH for the straight beam insonification in the near-surface region down to a depth of 50 mm and 1.5 mm FBH for the core region. A careful selection of the probes concerning roof angles of TR probes or near fields of the straight beam probes was necessary to ensure complete coverage between the near-surface region and the core. Calibration for the angle beam insonification under ±45 is executed with a surface notch of 2 mm depth, or by means of 6 mm side drilled holes. The test results are provided also in C-scan format. WD The four inspection tasks cover straight beam insonification into the near-surface Due to the very good sound conductivity of forgings so-called phantom echoes may occur. Therefore the probes controlled by Products» Ultrasonic Testing Systems» ALPT/RPTS 2

ECHOGRAPH 1090: Ultrasonic testing of laminated glass Due to safety reasons front shields of airplanes, trains and cars are manufactured as laminated glass.

Damped echo sequence: Good bonding As an ultrasonic flaw detector the ECHO- GRAPH 1090 is recommended, together with the high frequency and broadband probe DS 6 PB 4-14.

RW Front shield of a car When the probe is coupled to the glass surface the echo sequence from the first glass layer can be evaluated.

put to the test The Wasser- und Schifffahrtsverwaltung des Bundes (Federal Waterways and Shipping Authority) is responsible for federal waterways and the control of shipping traffic.

3 ECHOGRAPH 1090: Ultrasonic testing of laminated glass Due to safety reasons front shields of airplanes, trains and cars are manufactured as laminated glass. At least 2 panes of glass are joined by means of adhesive plastic foils. For quality assurance a flawless adhesion must be proved. This task can be solved with the aid of ultrasound. Damped echo sequence: Good bonding As an ultrasonic flaw detector the ECHO- GRAPH 1090 is recommended, together with the high frequency and broadband probe DS 6 PB Long echo sequence: Lack of fusion damped echo sequence. A faulty adhesion leads to a strong reflection yielding a long undamped echo sequence. RW Front shield of a car When the probe is coupled to the glass surface the echo sequence from the first glass layer can be evaluated. If the adhesion is good, the sound is absorbed by the plastic foil and this results in a strongly Products» Ultrasonic Testing Instruments» Instruments» ECHOGRAPH 1090 ECHOMETER 1076 TC: Waterways put to the test The Wasser- und Schifffahrtsverwaltung des Bundes (Federal Waterways and Shipping Authority) is responsible for federal waterways and the control of shipping traffic. Around 13,000 employees make sure that all federally owned water routes and shipping sites with related constructions (locks, weirs, bridges, culverts) are in sound condition. Regularly all structures are revised in order to ensure proper functioning. Culverts, for example, are underpass tubes for waste and drinking water, groundwater or oil-pipelines underneath roads, embankments, tunnels, rivers, or other water routes. Often such passages contain straight tubes from one side to the other. If steel pipes are used they need to be protected against corrosion by means of coating. Water culvert of the Huenxe Creek at the Weser-Datteln canal Revisions need to cover the examination of coatings as well as the determination of the remaining wall thickness in order to judge the stability and water leak-tightness. For some time now, the waterways and shipping authority in the town of Duisburg- Meiderich uses the wall thickness gauge ECHOMETER 1076 TC Basic for this purpose. TC is short for Through Coating and denotes the capability of the gauge to measure the wall thickness of coated material without the necessity to remove the coating beforehand. By means of the probe DSE 8.3/15 PB 5C it is possible to determine wall thicknesses between 2 mm and 28 mm under a coating of up to 4 mm. Since the culverts need to be examined along their entire length, operation sometimes is extremely tough. Narrowness, darkness and wetness are big challenges for the inspector and the instrument. Because of its robustness and easy operation the ECHOMETER 1076 TC is the optimal solution for this task. Ki Products» Wall Thickness Gauges» Gauges» ECHOMETER 1076 TC 3

News from your partner for NDT ECHOMETER 1076 TC Data: Measurement of residual wall thickness of ship floors Similar to regular examination of cars by technical inspection agencies, also ships must

The check is carried out in a dry dock, following a specified measuring grid. Especially the ship floor is tested from the outside because it is permanently exposed to water.

After removal of loose rust the wall thickness can be measured by Measurement on a roughly cleaned ship floor placing a transmission/receiver probe directly on the steel surface.

4 News from your partner for NDT ECHOMETER 1076 TC Data: Measurement of residual wall thickness of ship floors Similar to regular examination of cars by technical inspection agencies, also ships must prove their reliability of operation in stipulated intervals. An important criterion at ships is the remaining wall thickness of the ship hull. The check is carried out in a dry dock, following a specified measuring grid. Especially the ship floor is tested from the outside because it is permanently exposed to water. At all measurement points the minimum wall-thickness matching the ship size must still be available. The ECHOMETER 1076 TC Data is well suited for this task. After removal of loose rust the wall thickness can be measured by Measurement on a roughly cleaned ship floor placing a transmission/receiver probe directly on the steel surface. There is no need to remove adherent paintings or coatings. In this case the gauge uses a 5 MHz probe and is set to the multiple echo method, thus avoiding false thickness values caused by the coating. The instrument features a coupling monitor, background light and a data memory to store wall thickness readings which later can be transmitted to a PC by means of the software tool icom. The operating function minimum-value automatically records the smallest thickness value during the dynamic scan of a measurement location. The red holster reliably protects the gauge against damages in rough outdoor environments. KS Products» Wall Thickness Gauges» Gauges» ECHOMETER 1076 TC FLUXA and KD-Check: Security for summer toboggan runs and water chutes The company Josef Wiegand GmbH & Co. KG from Rasdorf in Germany produces summer toboggan runs and water chutes. With more than 350 plant constructions the company is the global market leader for summer toboggan runs. penetrants with the KD-Check test system (RDP-1, PR-2, SD-1). With the aid of surface crack testing by qualified inspectors Regular nondestructive materials testing ensures untroubled leisure activities on summer toboggan runs The technical rules for steel constructions are specified in the quality standard DIN EN Since its introduction in 2012 the extent of nondestructive testing of all weld seams specified therein has widened considerably. From design type EXC2 of steel constructions (i.e. materials up to S700, stairs and handrails in public and industrial areas) complementary magnetic particle or dye penetrant testing is demanded in order to detect irregularities at the surface of welding seams. The company Wiegand meets the challenge of increased requirements by the purchase of test systems and by the qualification of employees: During the last months six staff members successfully have passed the training courses MT1 (magnetic particle crack detection) and PT1 (dye penetrant testing) at. Welds on ferritic steel constructions are tested with a DEUTROPULS yoke in combination with black FLUXA magnetic particles and white background painting. Water chutes, in particular, are made from stainless austenitic steel. Testing on this material is executed by means of red dye Hand magnet with flexible poles for matching object surfaces the usual high safety standards at the company Wiegand now are being improved on the shop floor already. Thus a secure leisure time pleasure is guaranteed for the guests also in the future. MR Products» Penetrant Testing» Testing Agents» KD-Check 4

During a scheduled examination of a generator shaft with the magnetic particle method a multitude of cracks was detected The magnetic particle testing on the generator shaft indicates a multitude of

5 RMG 4015: Crack depth measurement in a pumped storage hydro power plant In the German town of Gemünden am Main the company E.ON Wasserkraft GmbH operates a pumped storage hydro power plant, which provides the electric power for the train operation of the railway company Deutsche Bahn AG. During a scheduled examination of a generator shaft with the magnetic particle method a multitude of cracks was detected The magnetic particle testing on the generator shaft indicates a multitude of surface cracks in the hammer head notches in the so-called hammer head notches. Via these notches the four poles of the generator are connected to the shaft of the generator. Cracks with depths up to 3.0 mm are allowed to be reworked according to the manufacturer s specification. High centrifugal forces occur because of the high rotating mass of the rotor (total weight 220 t, 500 rev/min). If a hammer head would break down, a complete damage of the generator combined with a long downtime of the power station would be the consequence. The depths of cracks in all hammer head notches were evaluated using the crack depth meter RMG This was helpful for the operators, who are responsible for grinding the cracks and subsequent repair works. Additionally, all-clear could be given regarding the maximum depth of the existing cracks. The measurements were difficult, because relevant regions were not directly visible. Here the sensor could only be positioned by means of a mirror. In addition, a UV-LED hand lamp was necessary to make the cracks visible for inspection. Top view of the generator shaft After repair works all notches were subjected to examination with magnetic particles. No remaining cracks were found. Thus, the results of the crack depth measurement could be verified afterwards. MR Products» Crack Depth Gauge RMG 4015 DEUTROMAT UWE: Safe landing Our customer bmt aerospace with production sites in Belgium, the United States and Romania is specialized in gear drives, gear components, gear wheels and gear rods for the aerospace industry. Among other components mechanics for landing flaps of various aircraft types are produced in the Belgian plant Oostkamp. The main component assembly, which provides an elongation of the wing for landing approach, contains a curved gear rod with the related bevel. Both components have to be examined with magnetic particles to detect all surface cracks. Because of increasing requirements and many special demands of the mainly North-American customers a new crack detection system was purchased to meet the Nadcap audit objectives and the according specifications. By the end of 2012, delivered a customized machine for this task on the base of the well-proven DEUTROFLUX UWE series. The device offers the inspection with alternating current and alternating field as well as full-wave direct current and direct field. For this purpose corresponding rectifiers were installed. As well, a reconnection device for various combinations of the current flow is provided together with a respective security monitoring unit. With deeply penetrating direct fields also cracks just below the surface can be detected. In this case however, the inspection must be carried out in two steps and the demagnetization of DC fields is complex. To be continued on page 6 5

News from your partner for NDT Continued from page 5 A low frequency coil is necessary to demagnetize the parts after the test with direct field so the permissible remanence value of 3 Gauss is not

Two cages, stacked one on the other, are moved on a conveyor belt through the Multiple components are moved in up to two stacked stainless steel cages through a low frequency demagnetization coil low

All part-specific inspection plans are stored in the parameter memory. All changes to the inspection plans are recorded in a table.

After every inspection lot the results are transferred to the bmtnetwork, including the data on operator, components, date and results.

6 News from your partner for NDT Continued from page 5 A low frequency coil is necessary to demagnetize the parts after the test with direct field so the permissible remanence value of 3 Gauss is not exceeded. As requested by bmt the demagnetization is executed for multiple components at the same time using transport cages. Two cages, stacked one on the other, are moved on a conveyor belt through the Multiple components are moved in up to two stacked stainless steel cages through a low frequency demagnetization coil low frequency coil, thus obtaining an optimal result. Also with regard to the documentation of the test results the machine shows some special features which were realized via a Siemens touchscreen. All part-specific inspection plans are stored in the parameter memory. All changes to the inspection plans are recorded in a table. The magnetization values are selected according to the respective inspection plan. After every inspection lot the results are transferred to the bmtnetwork, including the data on operator, components, date and results. Regular system checks with reference objects have to be confirmed by the operator, thus ensuring a system operation with all required verifications. KS Customized crack detection system with demagnetization tunnel for aircraft components Products» Magnetic Particle Testing» Stationary Test Benches» UWE 600/900 expand international distribution network New strategic partners overseas: In the last year we kept on extending our international distribution network with the aid of Dr. Michael Maass (International Sales). We are proud to have won the company All Int Tech S.R.L. in Argentina as a sales partner for our complete product portfolio. After intensive in-company training in Wuppertal Christian Binder is available for all inquiries. He speaks four languages: Spanish, German, Portuguese and English. Also in Asia we could extend our sales and service network: In Thailand we trained 10 staff members of our partner NDT Instruments (Thailand) Co., Ltd. and presented ourselves with a shared exhibition booth on the most important industrial fair of Thailand, the METALEX. In Korea our long-time representation Chunsung now gets support from the company JSNT in the area of ultrasonic inspection systems. Furthermore we complemented our international sales net in the USA by winning the company BERCLI as strategic partner. Christian Binder of our Argentinian representation All Int Tech S.R.L. and Dr. Wolfram Deutsch during the training in Wuppertal Mr Uthai (left) and a part of his team of NDT Instruments (Thailand) The team around Dr. Deborah Hopkins (Founder and CEO) and Wayne Johnson (Engineering Director) has many years of experience in nondestructive 6

Longtime technical competence in nondestructive testing: The representation of in the USA is managed by Dr. Deborah Hopkins and Wayne Johnson.

takes over the technical consultation and sales in Mexico with a staff of seven employees.

AL The staff of our Mexican agency Test S.A. de C.V. Agencies Worldwide Prof. Dr.-Ing.

Already as a doctoral candidate at the University of Hanover the young Volker Deutsch joined his father s company in 1961.

7 Longtime technical competence in nondestructive testing: The representation of in the USA is managed by Dr. Deborah Hopkins and Wayne Johnson. testing and provides technical support and sales with the focus on ultrasonic testing. The company Tecnica Test S.A. de C.V. takes over the technical consultation and sales in Mexico with a staff of seven employees. partner Senior Miguel Saldamando Flanagan is convinced of our large product portfolio and sees great opportunities in the Mexican market, especially in the area of magnetic particle testing. AL The staff of our Mexican agency Test S.A. de C.V. Agencies Worldwide Prof. Dr.-Ing. Volker Deutsch turned eighty On December 13 th, 2012 the long-standing managing director of the company Pruef- und Messgeraetebau GmbH + Co KG celebrated his 80 th birthday. Already as a doctoral candidate at the University of Hanover the young Volker Deutsch joined his father s company in The company was founded in 1949 and provided products for nondestructive materials testing. Measurement of coating thicknesses, ultrasonic testing and surface crack detection methods are still in the focus today. Already during his doctorate Volker Deutsch was able to provide many Volker Deutsch (standing) at ultrasonic testing of railway axle wheel sets (1965 appr.) ideas for the development of products. Very soon the company founder Ing. Karl Deutsch entrusted responsibility to his son. The plant engineering and construction department expanded and a worldwide sales network was installed. Therefore he used to be on business trips to Eastern Europe, South America and China already in the 1970s. His capability of explaining complex issues in a comprehensible manner was the base for many presentations and publications in technical journals and over 20 specialist books. From 1982, Prof. Dr.-Ing. Volker Deutsch was a honorary professor at the University of Dortmund and presented lectures on nondestructive testing in the faculty of Mechanical Engineering. He knew well how to lead and motivate his more than 100 employees, who in general worked for the company for many years and partly still do today. Being locally involved he was a member of the committee on international trade of the local chamber of commerce and industry. Also he used to be shareholder and chairman of the board of the W-Tec, which is a centre for technology and start-up companies in Wuppertal. After 40 years at Prof. Dr. Deutsch handed the business management over to the next generation. Today the expanding enterprise is successfully Prof. Dr.-Ing. Volker Deutsch managed by his two sons: Dr. (USA) Wolfram A. Karl Deutsch as managing director of the two sites in Wuppertal and Olaf Deutsch (MA) as business administration manager of the branch office in Beijing, China. His daughter Dr. iur. Elke Herbsthofer owns the publishing house Castell-Verlag in Wuppertal, where all printed matters of the company are published. On the occasion of his big birthday two further books were added (one NDT book and a crime thriller). WD 7

News from your partner for NDT New employees at Since October 2012, Karina Windus supports our sales office in Wuppertal as skilled industrial business management assistant with experience in sales,

Being qualified for stock management Sascha Schäfer strengthens the team in stock / goods receiving and materials supply / shipment for our Works 2 and the new storage building since February of this

8 News from your partner for NDT New employees at Since October 2012, Karina Windus supports our sales office in Wuppertal as skilled industrial business management assistant with experience in sales, marketing and purchasing. Being qualified for stock management Sascha Schäfer strengthens the team in stock / goods receiving and materials supply / shipment for our Works 2 and the new storage building since February of this year. Fairs and trade shows September 16-21, 2013 SCHWEISSEN & SCHNEIDEN International Trade Fair Joining, Cutting, Surfacing Messe Essen Hall 4.0, booth B110 Essen, Germany October 14-17, nd testxpo International Forum for Materials Testing Zwick Company, Metallinsel Ulm, Germany All current dates can be found on our homepage under the topic Dates, Events NDT instruments, sensors and systems The privately-owned company has been involved in the development and fabrication of NDT instruments since its foundation in More than 50% of the products are exported worldwide. Digital and analog ultrasonic flaw detectors, wall thickness gauges, coating thickness gauges, crack depth gauges, ultrasonic testing systems, instruments and accessories for magnetic particle testing, and penetrants are part of our product range. Characterised by continuous innovation and product reliability, the trade marks ECHOGRAPH, ECHOMETER, DEU- TROFLUX, LEPTOSKOP, FLUXA, KD- Check and RMG are well-recognised. Application experience, theoretical knowledge and manufacturing know-how spanning more than six decades as well as the standard compliant quality management guarantee state-of-the-art instruments and accessories and a leading position with regard to quality, reliability and economy also for the future. 8 DIN EN ISO 9001 certified

Company Profile Product Groups

Company Profile Product Groups Definitely Tested! Instruments, Sensors and Systems for Non-Destructive Material Testing Ultrasonic, Magnetic Particle and Penetrant Testing Wall and Coating Thickness Gauges, Crack Depth Gauges Company