DEFECTOPLATE

Innovative testing meets customer-specific solution

Steel and rolling mills are faced with increasingly tough quality requirements, which require verification through testing processes that are compliant with international standards or individual agreements. FOERSTER's DEFECTOPLATE test system is particularly suitable for verifying and assessing laminar discontinuities in heavy and thick plate with ultrasound.

The system features a modular concept, allowing tried-and-tested components to be adjusted to meet local requirements so as to generate the greatest possible functionality and process reliability. Depending on the production layout and requirements, various concepts can be applied to install the test systems either above the roller conveyor (test from the top) or integrated them in the latter (test from the bottom). Depending on concept, the entire plate is tested in one run or by testing in lines across the entire surface of the upright plate.

The raw data of laminar discontinuities in the material is recorded via ultrasound, pre-processed by the test electronics, and transmitted to the analysis software for assessment. The system also facilitates fully automatic assessments in accordance with various international standards and test standards defined by the system operator. If a plate does not meet quality requirements, repeated analyses can be performed in accordance with other standards on the basis of the stored test data without having to re-test the plate, which removes the need for handling the plate again.

Applications:

Automatic data storage for proving laminar discontinuities in the material across the entire width of the plate in one test run
High testing capacity of approx. 720 plates per day
Automatic and reproducible test documentation compliant with international and individually defined standards can be prepared thanks to the analysis software
Optional subsequent offline analyses based on various test standards can be performed with the analysis software. As a result, repeated inspection runs are no longer required and operation is simplified
Tested materials can be used to access premium markets and increase sales
Less production resources are required thanks to the use of the test system as process monitoring and optimization tool

Ultrasound electronics and equipment:	FOERSTER ultrasound electronics, FOERSTER analysis software
Sender / receiver test heads:	S1E1 / S1E3 / S1E4, 5 MHz
Test speed:	≤ 1,000 mm/s
Testing distance:	1 mm (at max. 1,000 mm/s)
Test sensitivity:	KSR2, KSR3
Dead zones: (benchmarks, depending on reflector size and depth)	Approx. 1.5 mm, both sides Untested edges (depending on system concept and design, deviating
Untested edges: (depending on system concept and design, deviating values may occur)	▪ Longitudinal edges with test ≤ 5 mm for cut plates / ≤ 15 mm for uncut plates ▪ Transverse edge without top / bottom testing ≤ 80 mm ▪ Transverse edge with top / bottom testing ≤ 5 mm (only for cut plates)
Materials:	Low-alloyed ferrite steel
Plate dimensions: (benchmarks, deviating values in accordance with customer-specific requirements)	Length 3,000 – 52,000 mm, width 900 – 5,400 mm, thickness 5 – 175 mm
Plate temperature:	Surface 5 – 120 °C, optionally up to 200 °C
Plate condition:	▪ Rough rolled surface free from contamination, oil, grease, paint, as well as loose particles and scale ▪ Preferably no warping and deformed edges (indentation and burring at the cut or residue from flame cutting) ▪ Restricted maximum tilt

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