NON DESTRUCTIVE TESTING(MEMB453) SEMESTER 2, 2014/2015 MINI PROJECT : A VISIT TO SAPURA INDUSTRIAL BERHAD ASEAN AUTOMOTIVE STEELS SDN. BHD. UNIVERSITI TENAGA NASIONAL COLLEGE OF ENGINEERING DEPERTMENT OF MECHANICAL ENGINEERING

GROUP MEMBERS LECTURERPROF.MADYA DR. ABDUL AZIZ BIN MOHAMED 1. MUHAMMAD HASRUL BIN ROSLIME MOHD SOFWAN BIN MOHD SAFIENME MOHD EIZUWAR BIN ZULKEFLEEME SECTION : 01 2

Details of visit  Date :  Company’s Personnel : Ahmad Tajuddin Bin  Position : QA/QC Engineer 3

Introduction  Main Product: Stabilizer Bar  Conducted magnetic particle testing (MT).  Also expert in production high quality coil springs, link component and strut assemblies right up to design level integration.  Working closely together and co-designing with the respective car manufacturer's design team. 4

Objective of the visit.  To observe the result after NDT method is applied.  To be familiar with NDT method and make use of the knowledge learned in class.  To gain more understanding on NDT by observing the real life applications by the company. 5

Magnetic Particle testing (MT)  Longitudinal coil shot (MT), Wet method.  Wet method : -Able to examine discontinuities. - More sensitive to fine surface discontinuities. But is not sensitive enough ads the dry method for the detection of subsurface discontinuities.  During the fabrication of the car balancing bar, the process is more on bending and heating. So discontinuities may happen during that process. The main purpose of using wet longitudinal coil shot because they want to inspect the small crack happen in balancing bar. They have to follow certain standard give by their client. For example, Volvo set that their balancing bar need to withstand at least times bending before it can break. In order to make the client satisfy, they randomly pick and try the product. 6

Dry or Wet Detecting Media DRY  Iron particles  <200 microns (BS4069)  Colours vary for contrast against component  Hot components, root cut backs and sub-surface WET  Iron oxide  <100 microns  Colour contrast of fluorescent  Water or kerosene based  Concentration important 7

Particular NDT methods that had been chosen by the company. 8

Magnetic Particle testing (MT)  Advantages : Save more time in examine the product. Need less effort to clean it and also uncomplicated. It Easily examined small or large object. So they will not having problem when new product need to be tested. All the product produced by this company is a ferromagnetic material. Then they will not face problem to used this method. 9

Picture of Lectromax 10

Standards OHSAS (2007)  Key areas that will be assessed by OHSAS certification  Management systems in place  Planning and risk assessment  Staff training and awareness  Communication of safety management systems  Response to emergency situations  Monitoring and continual improvement ISO14001 (2007)  single site to large multi- national companies  high risk companies to low risk service organizations  manufacturing, process and the service industries; including local governments  all industry sectors including public and private sectors  original equipment manufacturers and their suppliers. 11

Eddy current testing (ET)  Use the principal of “electromagnetism” as the basis for conducting examinations.  Eddy currents are generated through a process called electromagnetic induction.  When alternating current is applied to the conductor, a magnetic field develops in and around the conductor.  This magnetic field expands as the alternating current rises to maximum and collapses as the current is reduced to zero.  If another electrical conductor is brought into the close proximity to this changing magnetic field, current will be induced in this second conductor.  Eddy currents are induced electrical currents that flow in a circular path. They get their name from “eddies” that are formed when a liquid or gas flows in a circular path around obstacles when conditions are right. 12

Eddy current testing (ET) Advantages of eddy current inspection include:  Sensitive to small cracks and other defects  Detects surface and near surface defects  Inspection gives immediate results  Equipment is very portable  Method can be used for much more than flaw detection  Minimum part preparation is required  Test probe does not need to contact the part  Inspects complex shapes and sizes of conductive materials 13

How NDT can help in relation to the component parts been manufactured ? 14

 At Sapura Automotive Steel, visual inspection and leak testing are powerful and easy NDT methods.  In addition, modern equipment and materials allow for these other, more accurate and rapid testing.  Sapura NDT experts are trained to visually check for many types of problems including surface rust, scaling (paint lifting away, showing a rough not-clean surface), and signs of cladding buckling (bumps when looking down a straight line or putting a straight edge up to the head box apron). 15

 Testing is needed not just on cast iron surfaces but also on stainless steel. If a stainless part is not kept clean there will eventually be some visible surface corrosion and pitting.  Fortunately corroded stainless only requires surface cleaning and conditioning to be renewed.  In addition, structures and different assemblies of stabilizer are made from various materials, such as aluminum alloy, steel, titanium and composite materials. In the present trend of NDT application on aircraft, about 60-80% of NDT is performed on the airframe, structure, landing gears and the rest carried out on engine & related components. 16

Is the materials related to the NDT recyclable? 17

 Preventive support can spare significant cost as far as downtime, damage, lost chance, and lost income.  Two extremely essential non-destructive testing methods, magnetic particle testing (MT) and eddy current testing (ET) might be handy in distinguishing manufactured abandons in parts before they go into administration where they could fall flat and recognizing administration identified surrenders that emerge from harm being used.  What we don't perceive is the impact it provides for environment and if the material utilized is recyclable. 18

Conclusions  The visit was a very successful one, as we have learned a lot about the NDT testing that takes place in the companies in Malaysia. Hence although it was a short visit, the group had a lot of fun and all took part in learning while the Magnetic Particle testing and the liquid penetrant testing was being conducted. We have solemnly shown utter gratitude to the person in charge, Ahmad Tajuddin Mohamad, and the staff. Hence, in conclusion it can be said a better learning was done and the group’s knowledge about Magnetic Particle testing and the liquid penetrant testing has enhanced. 19

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