Quality November 2011

NOVEMBER 2011, VOLUME 50/NUMBER 11 WWW.QUALITYMAG.COM

MODEL BASED

DEFINITION PROMISES BIG DIVIDENDS p . 30 50 YEARS OF QUALITY: NONDESTRUCTIVE TESTING p. 18 ELIMINATE ERRORS IN VIDEO MEASUREMENT SYSTEMS p. 22 CMM MARKET: A LOOK AT THE FUTURE p. 26 ASSESSING AEROSPACE RISK MANAGEMENT p. 34

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TABLE OF

CONTENTS |

NOVEMBER 2011

|

Source: Airbus

QUALITY MAGAZINE

VOLUME 50

|

NUMBER 11

DEPARTMENTS

34

6

FROM THE EDITOR

Focus on Growth 8

INDUSTRY NEWS

Boeing Delivers First 787— Three Years Late Honda Recalls 100,000 Vehicles Global Manufacturing Execs Make Growth a Priority 14 FACE OF QUALITY

What’s Wrong with Strategic Planning?

FEATURES 50 YEARS OF QUALITY

18 A LOOK AT NONDESTRUCTIVE TESTING

16 OTHER DIMENSIONS

Conditions and Causes

This month 50 Years of Quality takes a look at how nondestructive testing (NDT) has been covered throughout the years. NDT became such an important topic for our readers that a special section called, NDT including Materials Test, launched in 2003.

QUALITY MEASUREMENT

22 ELIMINATE ERRORS IN VIDEO MEASUREMENT SYSTEMS Take a closer look at sources of error in video measurement systems and their comprehensive analysis.

QUALITY TEST & INSPECTION

26 CMM MARKET: A LOOK AT THE FUTURE Manufacturers are looking to build CMMs that are more reliable, efficient and suitable to various types of end users, which require significant R&D investments.

38 CASE STUDY

FEA Increases Notebook Reliability 47 CLASSIFIEDS 48 ADVERTISING INDEX

QUALITY SOFTWARE

30 MODEL BASED DEFINITION PROMISES BIG DIVIDENDS Inspection planning greatly enhanced with MBD and GD&T.

NEXT MONTH QUALITY MANAGEMENT

34 ASSESSING AEROSPACE RISK MANAGAMENT Realize the benefits of an aerospace risk management process and why it should be part of every organization’s culture.

2012 Quality Spending Survey Total Quality Management No Compromise Leadership Profile Tolerancing

NOVEMBER 2011, VOLUME 50/NUMBER 11 WWW.QUALITYMAG.COM

ABOUT THE COVER MODEL BASED

DEFINITION

In the long evolution of 3-D computer aided design (CAD), you would not think innovative progress is possible at this point. Take model based definition (MBD), for example. Surprisingly, there is significant activity in this area, and genuine value this technology can bring to the manufacturing table. Source: Hexagon Metrology

PROMISES BIG DIVIDENDS p. 30 50 YEARS OF QUALITY: NONDESTRUCTIVE TESTING p. 18 ELIMINATE ERRORS IN VIDEO MEASUREMENT SYSTEMS p. 22 CMM MARKET: A LOOK AT THE FUTURE p. 26 ASSESSING AEROSPACE RISK MANAGEMENT p. 34

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QUALITY | November 2011

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ONLINE TOC VISIT WWW.QUALITYMAG.COM FOR DIGITAL EDITIONS AND WEB EXCLUSIVE CONTENT

Why the Buzz on Metrology Software in 2011? Between 2003 and 2007, the majority of software vendors spent substantial amounts of money on research and development (R&D) and marketing aimed at increasing awareness among end users about the benefits of software enhancements. This has continued over the past three years, although the economic slowdown has had a negative impact on demand for new applications. End users have now become more aware of the cost-saving potential of software, and this is opening up new market opportunities for suppliers. Cost Savings Elusive for Lean-Leaning Manufacturers Lean manufacturing principles, widely touted by companies as an effective way to eliminate waste and boost the bottom line, often do not achieve targeted cost savings, according to a recent study. S. 1619 Will Not Improve U.S. Global Competitiveness On October 11, the Senate passed with a vote of 63-35 the Currency Exchange Rate Oversight Reform Act, S. 1619. The bipartisan bill, sponsored by Sens. Chuck Schumer and Sherrod Brown, would place new duties on imports from nations that devalue their currency in order to keep their export prices low.

Industry experts share their views on the latest in quality and manufacturing:

• Quality Remix

• Jim’s Gems: Weekly Updates!

• Learning with Lecky, Vision RoundUp and Perspectives in Vision

• Shifting the Paradigm

Nov. 16 at 2 p.m. EST: 3-D Optical Microscopy-Correlating Industrial Surface Metrology to Enhanced Product Performance Available On-Demand CAD-Based Inspection Using Contact Measurement Eddy Current Testing: Its Many Benefits and Applications

CONNECT WITH QUALITY: Connect with us to receive updates and to network with other industry professionals just like you.

• NDT: Key to Quality and NDT Round-Up

Podcasts are easy to listen to directly from your computer or downloaded as an MP3 file.

Videos show you the latest products and technology to improve manufacturing processes.

NOW PLAYING ON Q-CAST

NOW PLAYING ON Q-TUBE

The Importance of ISO 50001

If you missed Quality Expo, or want to

Calibration Management Software: Important Factors Manufacturers Need to Know AS 9100 Revision C–What You Need to Know The Importance of SPC to Quality Management Systems

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QUALITY | November 2011

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FROM THE EDITOR

FOCUS ON GROWTH LARGE MANUFACTURERS READY TO SHIFT GEARS.

W

GILLIAN CAMPBELL

hile the name of the game the past few years has been controlling and cutting costs, senior manufacturing executives are apparently loosening the death grip on their wallets, according the 2011 Global Manufacturing Outlook from KPMG International. The KPMG annual survey of 220 manufacturing executives—including 61 in the United States—from global companies with at least $1 billion in revenue found that businesses are cautiously optimistic on near-term prospects and are shifting their stances from cost containment to a focus on top-line growth as a priority in the next two years. During the past two years, in addition to cost containment, U.S. executives were most focused on customer relationships, process efficiencies and shared services. Looking at their top priorities for the two years ahead, 26% of the U.S. executives say they will focus on top-line growth, followed by 13% saying R&D and innovation, and 12% indicating customer relationships, according to the report. Seventy-nine percent of U.S. respondents were either very optimistic or optimistic about their company’s business outlook for the next two years. When asked to compare the primary focus areas of their growth strategies in the next two years with the two previous years, the survey revealed a shift in focus: 56% of manufacturers globally are planning to sell new products in new and existing markets during the next two years, up from 37%. This eagerness to release new products was evident at the recent Quality Expo, held Sept. 20-22 at Chicago’s McCormick Place. A bevy of new products was unveiled at the show, and I spoke with several marketing people whose companies plan to release new

products in the first quarter of 2012, a good indicator going into an IMTS year. It’s encouraging when one considers how many companies traditionally wait until IMTS to make a splash with new products. I’m also seeing more new product announcements come across my desk than in recent memory, a sure sign that more money is going toward product development—whether it’s brand new product or a tweaking of existing products. “Many companies emerged from the 2008-2010 downturn with significantly reduced cost structures, more cash and liquidity, and a laser focus on their customers and markets. These survivors have the mindset and strategy to define the standard of success in the next five years,” said Jeff Dobbs, KPMG’s global head of Diversified Industrials and a partner in the U.S. firm. Where do you think manufacturing is headed in the short and long term? Is the industry poised for growth or is this recent revival a response to pent-up demand that will eventually fizzle out? Share your thoughts with me at [email protected], or with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/ QualityMagazine.

Gillian Campbell, Editor [email protected]

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PEOPLE NEWS ROBERT W. GALVIN, 89, the former chief executive and chairman of Motorola Inc. who led the company as it pioneered the cellular phone, died October 11, in Chicago, his family said. Galvin shaped Motorola, a company founded by his father, into a multinational technology powerhouse with a strong presence in Europe, Latin America, China and other regions. Galvin, who attended Evanston Township High School and the University of Notre Dame, started working full time at Motorola in 1944. He succeeded his father, company founder Paul Galvin, in 1959. At that time, Motorola’s annual sales totaled $290 million. By the time Galvin stepped down as chairman in 1990, Motorola was a global company with $10.8 billion in sales. General Motors (Detroit) has retained former vice chairman ROBERT A. “BOB” LUTZ to provide counsel to the senior leadership team of the company. Lutz will be available to executives on a part-time consultancy basis. He brings a wealth of experience built over the course of more than 40 years in the industry, including two stints at GM. He also has been a senior executive at Ford, Chrysler, BMW and was CEO of Exide Batteries.

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QUALITY | November 2011

BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

BOEING DELIVERS FIRST 787— THREE YEARS LATE EVERETT, WA—After three years of production and design delays, Boeing delivered its first 787 Dreamliner to All Nippon Airways at a handover ceremony in Everett, WA, on Sept. 26. ANA signed delivery papers Sept. 25, and flew its new jet from Seattle to Tokyo on Sept. 27, the Associated Press (AP) says. The 787 is said to give to 20% fuel savings over other passenger jets, mainly because about half of its primary structure—including its fuselage and wings—is constructed from composite materials. Yet it travels at the same speed, Mach 0.85, as other wide-body planes. And it has the newest aviation technologies, including an on-board health-monitoring system that allows the Dreamliner to monitor itself and automatically send in maintenance reports to ground-based computer systems. In 2008, Boeing first revealed the Dreamliner, and said then that it had already taken 677 preorders. But at the time, the company said the first Dreamliner would fly by September of that year, and that the first passengers would be flying by May 2008. It would take Boeing until December 15, 2009, to get the plane into the sky. And only now will paying passengers be able to climb aboard. The Dreamliner issues began in September 2007, when Boeing delayed the first flight for a month because of “challenges with out-of-sequence production work, including parts shortages, and remaining software and systems integration activities.” Then, a month later, Boeing said it would slow down the program, for at least six months, “due to continued challenges completing assembly of the first airplanes.” A few months after that, the first flight was

again pushed back because of a series of supply chain problems. The delays did not end there. There was a 57-day machinists strike, which ended in November 2008 but also caused new supply shortages. There were additional problems with assembly. And then, in June 2009, the aircraft maker announced more delays “due to a need to reinforce an area within the side-of-body section of the aircraft.” Even after the Dreamliner’s first flight in December 2009, there were still new problems to contend with. In August 2010, India’s National Aviation Co., which operates Air India, said it wanted $840 million in compensation from Boeing because of the delays. Boeing said then that it was involved in negotiations with various carriers over delayoriented costs. And then, in November 2010, came the most biggest complication of all—an onboard electrical fire in a control panel. Airlines have ordered more than 800 of the Dreamliner. The plane is covered in lightweight carbon fiber instead of aluminum, and should give fuel savings and offer passengers greater comfort, the AP says.

HONDA RECALLS 100,000 CR-VS, CR-ZS IN UNITED STATES TORRANCE, CA—In the most recent of a series of recall announcements this year involving Honda cars sold in America, the automaker said it will recall 5,626 CR-Z hybrid sports cars from model year 2011. The recall affects CR-Z models that have manual transmissions, and the software that controls the vehicles’ electric motors needs to be updated. The affected cars’ problems involve the potential for the car to roll unexpectedly. When the gasoline engine

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has stalled with the integrated-motorassist (IMA) battery in a very low state of charge and the transmission is in gear, the electric motor can rotate in the direction opposite to that selected by the transmission. “If this occurs and the driver has not engaged the brakes, the vehicle may slowly roll in an unexpected direction (for example, backwards when the transmission is in a forward gear), potentially leading to a crash,” Honda says. A software update will add additional controls to correct the issue, Honda say, which has of yet not caused any reported injuries or deaths. Honda also said it would voluntarily recall 80,111 CR-V vehicles from the 2006 model year in the United States to replace the power

window master switch. The design of the power window master switch can enable residue from interior cleaners to build up, which can, over time, cause the electrical contacts to degrade and may lead to a fire in the switch, the automaker said. No injuries or deaths have been reported related to this condition. Honda urges all owners of affected vehicles to take their cars to an authorized dealer as soon as they receive notification of a recall from Honda. The recall announcements came within hours of a Honda spokesman in Tokyo stating that the company would recall about 960,000 Fit subcompacts and other models globally to repair defects, including the malfunctioning power window switches.

EXECS MAKE GROWTH A PRIORITY NEW YORK, NY—Large global manufacturers are setting their sights on top-line growth over the next two years fueled by new products, strategic acquisitions and alliances, innovation and increasing production capacity in highgrowth markets. Bolstering the growth agenda are stronger investments in supply chain risk management to mitigate the impact of continued market volatility, according to KPMG’s 2011 Global Manufacturing Outlook. The KPMG annual survey of 220 manufacturing executives, including 61 in the United States, from global companies with at least $1 billion in revenue, found that businesses are cautiously optimistic on near term pros-

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NEWS pects and are shifting from their previous emphasis on cost containment to a focus on top-line growth as a priority in the next two years. Looking at their top priorities, 26% of the U.S. executives say they will focus on top-line growth, followed by 13% saying R&D and innovation, and 12% indicating customer relationships. Throughout the past two years, U.S. executives were most focused on cost containment, followed by customer relationships and process efficiencies/ shared services. Seventy-nine percent of U.S. respondents were either very optimistic or optimistic about their company’s business outlook for the next two years. “Today, we’re seeing that despite an increasing set of cost challenges, manufacturers are realigning their business models to prioritize top-line growth,” says Jeff Dobbs, KPMG’s global head of Diversified Industrials and a partner in the U.S. firm. “Companies have learned they can survive the challenges of economic uncertainty, political instability and historic natural disasters with lean

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turers globally are planning to sell new products in new and existing markets over the next two years, up from 37%. As to where demand is expected, the United States ranks as the top market, closely followed by China, then India, with Brazil and Germany rounding out the top five. Slightly more than half see emerging markets as key to their growth strategies. Price volatility of raw materials and inputs remains the biggest challenge for 44% of executives, followed by increased competition and pricing pressure, and uncertain demand. In the United States, price volatility on key cost inputs, uncertain demand, and intense competition and pressure on pricing were seen as the top three challenges. To better manage volatility, 56% of manufacturers say they are reshaping their supply chain models. Standardization is one of the key strategies—55% of manufacturers plan to standardize their production process, while 45% will require standardized inputs. Further, just more than 40% said they will focus on cost

agile operating structures, enhanced risk management practices, and a focus on innovation.” In pressing ahead on the growth track, 39% of global respondents say they will grow through mergers and acquisitions (M&A), joint ventures and alliances; and 30% through increased production capacity, mainly in high-growth markets. U.S. respondents cite increased production capacity (36%), M&A, joint ventures and strategic alliances (31%), research and development (23%), and new sales offices (10%) as approaches to achieving growth for their companies. “Many companies emerged from the 2008-2010 downturn with significantly reduced cost structures, more cash and liquidity, and a laser focus on their customers and markets. These survivors have the mindset and strategy to define the standard of success in the next five years,” says Dobbs. When asked to compare the primary focus areas of their growth strategies in the next two years with the two previous years, the survey revealed a marked shift in focus: 56% of manufac-

QUALITY | November 2011

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reduction through a shortening of the overall product development life cycle. Nearly half of respondents say they will invest in technology to improve visibility across the supply chain, the single most important tool for managing risk. Other measures include helping suppliers develop risk management standards and assessing supply chain processes.

PORTFOLIO HELPS METROLOGY SOFTWARE VENDORS STAVE OFF COMPETITION LONDON—Consumers of metrology software have upped the demand for higher product quality in order to streamline their production processes, thereby reducing costs, maintaining efficiency and ensuring profitability, says market research firm Frost & Sullivan. To achieve these goals, consumers have increased investments in the automation of production processes, where software also plays a key role. Metrology software developers are looking to cash in on this demand by producing flexible, reliable and accurate solutions. New analysis from Frost & Sullivan, World Metrology Software Market, finds that the market earned revenues of $254.4 million in 2009 and estimates this to reach $331.9 million in 2014. “The majority of software vendors had spent substantial amounts of money on R&D and marketing to raise awareness among end users about the benefits of software enhancements,” says Frost & Sullivan research analyst Prathima Bommakanti. “Eventually, end users are more knowledgeable about the costsaving potential of software, and this is opening up new market opportunities for suppliers.” Market participants are striving to keep pace with the evolution of end-user technologies by focusing on ease-of-use and advanced technological feature sets that can accommodate future demand. The need to stand out in the market has forced manufacturers to provide services and solutions that can restore customer confidence and renew demand. One of the top criteria for choosing a metrology software vendor is a service portfolio. “Without an extended service portfolio and qualified engineers, suppliers have limited scope of becoming leaders in the metrology software market,” notes Bommakanti. “Most key

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market participants have well trained and experienced in-house staff that can offer complete and customized service support to their customers.” Although the market is progressing steadily, manufacturers are still trying to shake off the effects of the global economic downturn. Some of the fallouts of the downturn were pricing pressure on vendors and the dip in demand for new applications.

The competitive landscape and the market maturity further compelled software vendors to place emphasis on maintenance contracts from the major customers. The situation will ease gradually, once customers start unfreezing their investment plans. The percentage of licenses is expected to increase as the pent-up demand is released and end users’ business plans are solidified.

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BUSINESS OPTIMISM INDEX REVEALS GLOOMY OUTLOOK AMONG MANUFACTURERS CHICAGO–U.S. manufacturing leaders are extremely pessimistic about the U.S. economy, according to Grant Thornton LLP’s most recent Business Optimism Index, a quarterly survey of U.S. manufacturing business leaders. Only 13% believe the U.S. economy will improve in the next six months, down significantly from 40% in May. At the same time, 40% believe the U.S. economy will get worse, up from 26%. In addition, only 21% of manufacturers say they will increase hiring and 35% say they plan layoffs. “Manufacturing has been one of the few bright spots in the economy since the end of the recession, generating more than 300,000 new jobs since December 2009, according to the National Association of Manufacturers,” says Jim Maurer, partner and practice leader of Grant Thornton LLP’s Consumer and Industrial Products Practice in Chicago. “Strong export growth in 2010 and the first half of 2011 helped increase revenues

and create jobs. However, the slowing global economy coupled with a lack of confidence in domestic and global economic policy has caused senior manufacturing executives to turn cautious as these are matters over which they have very little direct control.” The manufacturers that Gruenes speaks to regularly say they are focused on matters that they can control, with their top three priorities being reducing costs by improving their manufacturing processes; utilizing techniques such as lean manufacturing and Six Sigma; upgrading their production equipment and IT systems to enhance their efficiency; and re-enforcing quality and customer satisfaction. When asked what public policy initiative would make business leaders most optimistic about the country’s future, a job creation program was most popular (46%) with manufacturers, followed closely by deficit reduction (43%).

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QUALITY | November 2011

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rented garage near downtown Detroit, it began a journey that has taken Chevrolet to every corner of the planet. A hundred years and more than 209 million cars and trucks later, Chevrolet is one of the world’s-largest car brands, doing business in more than 140 countries. “For Chevrolet, the journey is just beginning,” says Chris Perry, vice president, global marketing and strategy for Chevrolet. “Chevrolet starts its second century with its best product lineup ever and strong growth in major markets in Asia, Europe and South America. “Our goal is to build on the foundation laid in our first hundred years to make Chevrolet a hometown brand in home towns around the world,” says Perry. Chevrolet is becoming GM’s global mainstream brand, the foundation of the company’s business in most major markets. In recent years, Chevrolet has expanded from its traditional markets in North and South America, and its list of Top 10 markets now includes China, Russia, Uzbekistan and India. The brand today sells more than 60% of its vehicles outside the United States. Last year, Chevrolet sold a record 4.26 million cars and trucks, and was the only global automaker in the top five to grow its market share. This year, Chevrolet is on track for the best sales year in its 100year history. New, globally designedand-produced models are behind Chevrolet’s record growth. For example, the Chevrolet Cruze is on pace this year to mark 1 million in total sales since its launch. Cruze went on sale in the United States last year, and is the nation’s best-selling compact car, surpassing all Asian, European, and U.S. competitors. A Malibu sedan will launch this fall in South Korea, along with a global midsize Colorado pickup in Thailand. A Sonic subcompact (Aveo in global markets) goes on sale this fall in the United States, followed by the Spark mini-car in 2012. Chevrolet was founded on building affordable cars and trucks with style, value and features not offered by competitors. For example, in 1955, Chevrolet re-engineered the V-8 engine in a way that made performance accessible to millions of new customers. The result was the small-block V-8. This spirit of innovation continues today.

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A new Malibu Eco model will include eAssist technology that improves fuel economy by approximately 25%. Last year, the first Chevrolet Volt extendedrange electric vehicle rolled off an assembly line near Detroit, combining electric power and a small rangeextending gas engine. The Volt and Malibu are part of Chevrolet’s global electrification strategy to reduce petroleum use and vehicle emissions.

Chevrolet was created in 1911 by auto pioneer and industrialist and William C. Durant and Swiss-born race car driver Louis Chevrolet. Durant believed Chevrolet should produce cars offering more value than the volume leaders of the time, most notably the Model T. Although both men had left GM by 1920, Chevrolet has stayed true to this vision.

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November 2011 | QUALITY

13

FACE OF QUALITY

WHAT’S WRONG WITH

STRATEGIC PLANNING?

THE PROBLEM MAY BE TOO MUCH PLANNING AND NOT ENOUGH EXECUTION.

M

JIM

any of us are involved in the annual seemingly endless ritual of creating a strategic plan. While it is a necessary and important management tool, many organizations spend a lot of time and resources on planning and not enough time and energy on execution. Many management teams will spend hours sequestered in conference rooms in deep discussions about their L. SMITH organizations, competition and markets. Staff and line personnel will typically spend countless more hours researching, compiling reports, putting together and delivering presentations. But to what avail? If we’re lucky, the strategies will be communicated down to the worker level; however, data suggests that this doesn’t happen in many cases, at least in a clear and meaningful manner. Mostly, the strategy is put into a nice binder and then put on the bookshelf. At the next appointed time, the binders are taken Strategic planning is too down, dusted and used important to delegate to staff. as review material for the next strategic planning cycle. However, organizations that do well seem to follow these simple fundamental concepts. • Senior managers accept full accountability. Strategic planning is too important to delegate to staff. No others in the organization will be better positioned to have the overall picture to set the direction of the organization. Senior management must remain intimately involved. • Strategic planning is a process. Strategic planning is not an exercise or event done once a year. A lot of effort goes into the plan, but the real work resides in the execution of the plan. In order to be a success, implementation of the plan needs to become part of the day-to-day operations. • Select the right team. Obviously senior management needs support, advice and counsel in order to be effective. It needs to include those who will be able to contribute to the content of the plan. These people also should be positioned to help drive implementation of the strategies within the plan. • Involve the organization. Have no doubt that senior management and their planning team are leading the effort. However, successful companies seek input from within and outside their organization. They seek input from a number of ways including, market research focus groups and surveys. Successful strategic planning teams will be armed with diverse data and information to create a more robust plan.

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QUALITY | November 2011

• Allocate enough time and resources. Strategic thinking and planning involves thoughtful discussion. Organizations that don’t allow enough time for their strategic sessions generally end up with inferior results, which will be very costly. • Encourage communication. The strategic plan needs to be communicated clearly to the organization. Employees need to know what to expect and how they can help with implementation. The mistake many organizations make is not repeating the plan and giving regular updates. Management should err on the side of overcommunicating the plan and progress toward meeting the milestones. • Link the strategic plan. The strategic plan must be cascaded throughout the organization in order to deploy and execute the outcome of the plan. Management and employees must have specific action steps (tactical objectives), linked to the plan, in order to implement the strategy. At the end of the day, it is the whole organization that will ensure deployment and implementation. • Measure the results. The old saying, “what gets measured, gets managed” is certainly true in this case. Management needs to monitor progress of the action steps at regular updates—a quarterly review, at minimum. It is one thing to develop the strategic plan, but quite another to implement the outcomes. This is where the real work resides and the organization needs to manage it as such. All employees must have clear and accountable objectives through which they are able to monitor their progress. In this manner adjustments can be made accordingly as everyone has his focus on deployment and implementation. • Remain flexible. Plans aren’t perfect. If something isn’t working, don’t just keep plowing ahead—make adjustments. Monitor and measure the changes to ensure positive change is taking place. So, what’s wrong with strategic planning? The problem rests with management’s approach and commitment, not with the tool. The solution is fairly simple as it rests with commitment, alignment and visibility. The strategic plan must be an active process with results cascaded for linkage. The corresponding actions are constantly monitored to ensure that decisions and results are in line with the strategy. Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at [email protected].

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n some recent columns I dealt with common mistakes that are made when calibrating gages. The columns dealt with the picky details, but often a look at the bigger picture can help you get to the specific details faster or alert you to a bigger, unseen problem that won’t go away no matter how much fiddling you do. I attended a presentation by a gage user that outlined HILL COX his experience with a high-tech thread gage calibration device he had spent a bomb on. No more reviewing reports as the machine spewed out the numbers and made the decisions. Calibration was done in a fraction of the time. When you’ve got hundreds of gages to do, this thing had to be the greatest invention since they put erasers on pencils. Or so this gage user thought. To prove his point, he quoted results from a batch of several hundred gages from different makers that the machine had “…when every measurement “calibrated.” It rejected every one. is identical, something is The fact that not one probably wrong…” of these gages was considered acceptable should have set off an alarm. Even the worst gage makers actually get some gages right, a thought that even the greatest skeptic will agree with. Others attending the presentation had already run tests on this device and found it inaccurate for gage calibration and were not surprised by its performance. The lesson to be learned here is that when every measurement is identical, something is probably wrong, and it doesn’t matter whether the device is accepting or rejecting everything. Repeatability of a process or calibration device is required to obtain reliable measurements—but you can have perfect repeatability of the wrong answer. Whether it’s gages or component parts measurements, when they all lean in the same direction compared to someone else’s readings, someone has got a measurement problem. Here are some elements to consider: • Resolution of the equipment is too coarse. • The temperature is off. • Incorrect setting masters are being used or correct ones are used incorrectly. • Worn contacts and/or anvils can put a consistent error into the readings. • Indicators and/or probes that are not correctly mounted on comparator stands will result in nonlinear response from them—all of the time.

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QUALITY | November 2011

• People problems can never be ruled out. • Measuring forces are different. • Check the batteries. To solve any mysteries in measurement you need to have something that is stable to start with or you’ll be running around in circles forever. Whether the readings are considered right or wrong, if they are repeatable, you can use a process of elimination to determine what’s going on. If they don’t repeat, there are a number of things that should be checked to stabilize whatever mess you’re trying to sort out. Here are some of them: • The instrument is physically damaged. • Contact points are loose on mechanical equipment. • Unstable power source to digital equipment. • Hands-on analog indicators are loose. • Normalizing times are not being observed when it’s a calibration dispute. • Check the batteries. Any one of these situations can cause unstable readings. It’s easiest to check the batteries. You should have spares on hand because they always go down on the night shift on a weekend when all local suppliers are closed. Switch those in the instrument with unused ones, and if the problem persists, you know that’s not the cause. Alternatively, you could put the instrument on an AC adapter to see if that will correct the problem. Yes, I know most battery-powered instruments have warning symbols to indicate a low battery situation, but this is often overlooked and may not be working properly. Air gages are another instrument that requires a stable supply but in this case, besides electrical power to a display system, a stable supply of clean, dry compressed air is required for them to work properly. Repeatability problems arise when the air is dirty and crud accumulates around the sensing jets. If the air is not dry, it can condense in the pneumatic side of the instrument putting water in the air circuit that will cause fluttering pointers, flickering digital displays and wrist-slashing frustration. I hope these notes will help you sort out these problems when they arise. Of course, I’ve left the most critical tip to the last: don’t forget to check the batteries. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

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November 16, 2011 | 2 PM EST The function of a wide variety of industrial manufactured components depends upon proper surface characteristics and preparation. For example: drill bits, medical implants, gears, surgical blades, clutch plates, shaft seals and brake pads depend not only on proper form such as shape, angle and geometry, but also on proper surface texture characteristics for optimum performance. 3D optical microscopy is inherently invaluable to the inspection of surfaces such as these due to the fast, non-contact capability to measure and quantify in gage capable fashion a range of relevant parameters for the surfaces. In this presentation, a variety of surface parameters for 3D analysis will be described and discussed, and a few specific examples from industrial applications will be presented.

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50 YEARS OF QUALITY

Take Another Look at

Nondestructive Testing This month 50 Years of Quality takes a look at how nondestructive testing (NDT) has been covered throughout the years. NDT became such an important topic for our readers that a regular special section, NDT including Materials Test, launched in 2003. NONDESTRUCTIVE TESTING THROUGH ANNIHILATION, MAY 2003 Annihilation. The word itself brings to mind destruction and conflagration. In the atomic realm, however, the rules are different. One company has developed a way to play by those rules. It has developed a way to test materials nondestructively based on the physics of the subatomic world. In this technology, particles are created only to be destroyed. The technology, called Photon Induced Positron Annihilation (PIPA), was invented by scientists at the U.S. Department of Energy’s Idaho National Engineering and Environmental Laboratory (Boise, ID) and licensed to Positron Systems Inc. (Boise, ID) for commercial use. PIPA can detect component fatigue and embrittlement of materials based on the amount of energy created when positrons and electrons annihilate each other. The technology can identify

18

QUALITY | November 2011

defective materials or determine the remaining “life” of materials. It can identify atomic lattice defects smaller than 10 microns in size and measurement uncertainties of less than 1%. Measurements using this technique have been performed on a variety of materials, including titanium, aluminum, stainless steel, iron, copper, polymers and composites. The system can penetrate materials to different depths depending on the material’s density. For example, it can penetrate 2 inches into stainless steel, 3.5 inches into titanium and 4 inches into aluminum, says Curt Rideout, chemical and nuclear engineer who serves as Positron’s military marketing and sales manager. If desirable, measurements can be taken from both sides of a test material or part, doubling the depth-detection capability. The technology also can produce cross-sectional analyses, and assembled parts can be tested and analyzed. For instance, a titanium strut inside of an aluminum airplane wing

can be tested without having tto o disasdisa di saasssemble the structure. PRESERVE THE IMAGE, AUGUST 2006 Visual inspection is the oldest of all inspection V techniques. Man has always trusted his eyes to assess the quality or fitness for purpose of objects ranging from artifacts and structures to precious stones and food. He also has always trusted his brain to provide him with analysis and management of the input data. However, as engineered products became increasingly complicated, it became necessary to devise other inspection methods. One of these is remote visual inspection (RVI), which still permits the human brain to make critical assessments but allows the eye to travel to previously inaccessible locations. Inspection, and specifically nondestructive testing (NDT) or examination, is a vital technology for the operation of any industrial plant and in the manufacture of any product. Inspection is carried out to assess the functional integrity of offshore oilrigs, nuclear power stations and aircraft. Inspection is carried out during the manufacture of capital and consumer products from children’s toys to auto|

Q UA L I T Y T E S T & I N S P E C T I O N

|

isual inspection is the oldest of all inspection techniques. Man has always trusted his eyes to assess the quality or fitness for purpose of objects ranging from artifacts and structures to precious stones and food. He also has always trusted his brain to provide him with analysis and management of the input data. However, as engineered products became increasingly complicated, it became necessary to devise other inspection methods. One of these is remote visual inspection (RVI), which still permits the human brain to make critical assessments but allows the eye to travel to previously inaccessible locations. Inspection, and specifically nondestructive testing (NDT) or examination,

When it comes to remote visual inspection, there has been an improvement in overall imaging quality as a result of fully digital data streams and improved optical and illumination technology, which, in turn, has led to a greater probability of flaw detection and improved inspection productivity. BY BRUCE A. PELLEGRINO

is a vital technology for the operation of any industrial plant and in the manufacture of any product. Inspection is carried out to assess the functional integrity of offshore oilrigs, nuclear power stations and aircraft. Inspection is carried out during the manufacture of capital and consumer products from children’s toys

to automobiles to ensure quality and fitness for purpose. There are many techniques available for such inspections. Radiography provides volumetric inspection of simple and complex geometry items by using high-energy radiation to penetrate the parts. Ultrasonic techniques, or sound waves

TECH TIPS

 Remote visual inspection (RVI) permits the human brain

 In its most basic form, an RVI system is made up of a

to make critical assessments but allows the eye to travel to previously inaccessible locations.

lens and an illuminating light source, connected to a light transmitting extension that ends in a viewing eyepiece.

 Sometimes, a remote visual inspection and report will meet

 With its integrated PC operating system, today’s borescope

the relevant inspection requirements. Other times, RVI will be used to complement other nondestructive testing modalities or inspection and measurement instrumentation.

can be used to browse the Web and communicate through conventional e-mail and other electronic methods, as well being suitable for the running of application software.

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QUALITY | August 2006

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50 YEARS OF QUALITY mobiles to ensure quality and fitness for purpose. There are many techniques available for such inspections. Radiography provides volumetric inspection of simple and complex geometry items by using high-energy radiation to penetrate the parts. Ultrasonic techniques, or sound waves much like sonar, can be used to detect and size defects in materials. Eddy current techniques are used to identify near-surface or surfacebreaking defects. Very often the first stage, and often the last stage, in any inspection will be a visual inspection. Because of the complexity of much of today’s plant and equipment, very often this inspection has to be carried out remotely. QUALITY 101: NONDESTRUCTIVE TESTING, MARCH 2008 Nondestructive testing (NDT), or nondestructive evaluation (NDE), is a method of materials testing that assesses the characteristics of a component without altering or destroying it. NDT is important in the materials testing industry

where quick, dependable information on finished or raw material is needed. This may occur during the production stage, during the service life of a material or product, or as a diagnostic tool in the event of material failure. NDT is contrary to destructive testing such as stress or bend testing where critical material properties are determined through achieving specimen failure. While destructive testing is intrinsically more revealing, it is costly to a manufacturing operation due to material loss and, for obvious reasons, it is not suitable for in-service material testing. Application uses for NDT cover a comprehensive range of material and industries such as automotive, aerospace, construction and a multitude of manufacturing types. A classic example of NDT at work is testing for weld defects at manufacture and periodically during service life of the welded material. Other typical applications include crack detection in aircraft skins, surface flaws in pipes or bar, and evaluation of heat treating of product.

NDT also has become a valuable tool in the research and development field where quick, reliable data can provide vital information on materials. Typical types of NDT include ultrasonics, eddy current, rebound and ultrasonic contact impedance. Hardness testing by diamond or ball indentation also is—although sometimes arguably— considered a form of NDT, as in most cases the material only is indiscernibly affected. The force applied in a hardness test correlated either with the depth of indent or with area of indent provides a measurement of hardness. Typically the properties and usefulness of the material is not compromised. Microhardness testing is the best example of a nondestructive hardness test. Q UA LITY 1 0 1

 Shown here is a rebound test of round stock using the Leeb principle. Source: Wilson Instruments, an Instron company

sonic contact impedance. Hardness testing by diamond or ball indentation also is—although sometimes arguably— considered a form of NDT, as in most cases the material only is indiscernibly affected. The force applied in a hardness test correlated either with the depth of indent or with area of indent provides a measurement of hardness. Typically the properties and usefulness of the material is not compromised. Microhardness testing is the best example of a nondestructive hardness test.

COMMON NDT TESTS

Nondestructive Testing Nondestructive testing (NDT) is used in a multitude of industries to test a wide range of materials. BY BI LL O’NEIL L

N

ondestructive testing (NDT) (NDT), or nondestructive evaluation (NDE), is a method of materials testing that assesses the characteristics of a component without altering or destroying it. NDT is important in the materials testing industry where quick, dependable information on fi nished or raw material is needed. This may occur during the production stage, during the service life of a material or product, or as a diagnostic tool in the event of material failure. NDT is contrary to destructive testing such as stress or bend testing where critical material properties are determined through achieving specimen failure. While destructive testing is intrinsically more revealing, it is costly to a manufacturing operation due to material loss

22

and, and for obvious reasons, reasons it is not suitsuit able for in-service material testing. Application uses for NDT cover a comprehensive range of material and industries such as automotive, aerospace, construction and a multitude of manufacturing types. A classic example of NDT at work is testing for weld defects at manufacture and periodically during service life of the welded material. Other typical applications include crack detection in aircraft skins, surface flaws in pipes or bar, and evaluation of heat treating of product. NDT also has become a valuable tool in the research and development field where quick, reliable data can provide vital information on materials. Typical types of NDT include ultrasonics, eddy current, rebound and ultra-

Ultrasonic testing (UT) uses highfrequency sound energy to evaluate a variety of materials to produce vital information. It is typically used for flaw detection, dimensional measurements and surface thickness. A typical system would include a pulser/receiver, transducer and display device. The pulser produces high-voltage electrical pulses to the transducer, which in turn generates ultrasonic energy. The energy is introd introduced to and flows through the test piece in the form of waves. Flaws as a discontinuity on the are detected detec path, and the resultant electriwave pat cal signa signal is displayed on the display device. UT U is one of the more widely forms of NDT and has several used form advantages, including minimal mateadvantag rial preparation, instant results, high accuracy and access to only a single side of the workpiece. UT is used on steels, concretes, woods and composites. Eddy current testing uses the principle of electromagnetism as the basis for conducting examinations. In eddy current testing, a current is introduced to the material. Changes in the current based on the material provide valuable workpiece information, such as flaws and surface cracks. Eddy current testing also can be used to determine material hardness, as well as material and coating thickness determination. Rebound testing uses the Leeb principle. In this method, an impact device uses a spring to propel an impact body through a guide tube toward the

QUALITY | March 2008

022_QM0308q101.indd 22

UNCONVENTIONAL NDT, JANUARY 2009 Robert Nath, chairman, and Mike Giannini, business development manag-

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QUALITY | November 2011

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er of Magnaflux Quasar (Albuquerque, NM), say that when customers approach them with a specific problem, they look at the application and then make recommendations to the customer. “Sometimes our recommendation is based on the physical properties required, sometimes it’s the economics of it, sometimes a combination,” Giannini says. “When it is possible to test between two different methods, our job is to recommend the most reliable means of testing and the most economical way for the customer.” Also, the method used depends on the industry. Liquid penetrant is heavily used in aerospace, but not widely used in automotive, where magnetic particle and resonance inspection would be more common. If ferrous materials are involved, magnetic particle inspection may be a good fit. If the customer is looking at areas with no surface imperfection and the potential for failure in service, resonant testing would be a solution. Though Magnaflux Quasar’s customers come from various industries,

Giannini acknowledges that NDT is not widely known. “If you asked 10 people on street, ‘what is NDT?’ you would get blank stares,” he says. However, Giannini points out that almost everyone is affected by NDT technology. “Anybody who uses a vehicle for anything is made safer by these industries.” One recent example was an application for a high-end automobile engine manufacturer in Europe, for which Magnaflux successfully implemented resonant testing equipment. While the company has offered a magnetic particle method and liquid dye penetrant for more than 70 years, it began offering resonance testing equipment when it acquired Quasar in March of 2007. Unlike other testing methods, resonance testing equipment finds structural anomalies, and measures structural weaknesses and surface systems. Imagine driving to work, Giannini says, and the steering knuckle of the car breaks. “This would not be a good start to your day,” he says. These types of structural defects can be found with resonant testing, and it would take

two to three seconds to test the knuckle. These results cannot be found with any other method, Giannini says. Unconventional NDT “What we’re doing is making sure you make it back and forth to work without the steering knuckle giving out on you,” Giannini says, as the company deals with safety critical and warranty critical parts. According to the company, Quasar process compensated resonant testing (PCRT) provides effective resonance inspection in the presence of typical manufacturing process variations. Using PCRT, defective parts can be reliably rejected on the production line because the results correlate directly to part performance. The resonant frequency of a part is based on its stiffness and mass. The Quasar method measures several resonances for each part and uses a proprietary pattern recognition algorithm to compensate for the acceptable process variations, according to Magnaflux. Q |

QUALIT Y T EST & INSPECT ION

W

|

ith nondestructive testing (NDT) methods ranging from visual examination, liquid penetrant testing, magnetic particle inspection, ultrasonics and eddy current, there is likely an NDT method to fulfi ll the application requirements. Liquid penetrant testing may be the most widely used NDT method, and is often used in aerospace applications. But just because a method is popular, does not mean it is right for every application. In order to get the most out of nondestructive testing, it

Less commonly used NDT methods may be the best choice for the application. BY MICHEL L E BANGERT, SPECIAL PROJECTS EDITOR is essential to choose the right testing method. At its most basic, nondestructive testing is performed to reject defective parts. Conventional NDT methods, such as X-ray and magnetic particle inspection, identify defective parts by scanning for indications of a defect. In addition to these methods, process compensated resonant inspection and

phased array, though not the most commonly used, may be the right choice for a particular application.

RESONANT INSPECTION

Robert Nath, chairman, and Mike Giannini, business development manager of Magnaflux Quasar (Albuquerque, NM), say that when customers approach them with a specific problem, they look

TECH TIPS

 In order to get the most out of nondestructive testing, it is essential to choose the right testing method.

 Unlike other testing methods, resonance testing finds structural anomalies and measures structural weakness.

 Each company has different drivers—some are focused on speed, others on resolution or flexibility.

 Phased arrays allow operators to size defects precisely despite a structure’s complexity.

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QUALITY | January 2009

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MEASUREMENT

Over the years, the various sources of errors in video measurement systems have become well understood. Today’s high quality measurement systems minimize errors through careful design and construction, and provide effective compensation for residual errors through software calibration. Source: View Micro-Metrology

Eliminate Errors in

Video Measurement Systems Take a closer look at sources of error in video measurement systems and their comprehensive analysis. BY MUTHUKRISHNAN (KRIS) CHELLAPPA

N

oncontact video measuring systems have been in widespread use for more than 30 years. Over the years, the various sources of errors in these systems have become well understood. Today’s high quality measurement systems minimize errors through careful design and construction, and provide effective compensation for residual errors through software calibration. As the basic components of video coordinate measuring machine (CMM) systems—stages, optics and cameras— have become readily available as OEM assemblies, a host of new video CMM products have come on the market.

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QUALITY | November 2011

An accurate measurement system depends on much more than a simple combination of catalog components. In this article we’ll reflect on 35 years of lessons learned about the sources of errors in video CMM systems, and how to account for them. SOURCES OF ERRORS Errors in a video coordinate measuring system can be broadly classified into systematic errors and constant errors. Let’s look first at the systematic errors: • Straightness (or yaw) errors. When the X or Y stage moves nonlinearly, there is a shift in the perpendicular

direction dire rect c io on of motion relative to the axis of travel. In other words, as a stage moves in the X direction, it also is moving in the Y direction. Straightness errors are a function of the quality of materials and manufacturing of the stage ways and bearings. The straightness error for a well-made, cross roller bearing type compound stage is typically less than 40 microinches per inch of travel. • Abbe (or pitch) errors. Pitch error occurs when the axis of the measurement system is offset from the plane of the work piece and the motion of the work piece and measurement axis are not horizontal and parallel. The most common cause of pitch error is the combined weight of the stage and work piece deflecting the stage downward at each end of travel. This makes the stage move

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in an arc rather than a straight line. A high quality compound stage will exhibit pitch error less than 5-arc seconds over its full range. An ultraprecise compound stage suited for micron or submicron accuracy will exhibit less than 0.1 arc seconds of pitch per millimeter of travel. • Orthogonality errors. Orthogonality error is caused by an out-of-square condition between two or more axes. The extent of the error varies as a function of stage length and squareness. In order to measure and correct for stage orthogonality errors, an orthogonal external reference must be established. This is most often done using a theodolite mounted in a fixed location near the stage, and an L-shaped mirror made out of low TECH TIPS expansion quartz » Today’s measurement mounted on the stage. systems minimize errors The stage is then through careful design moved within this and construction. frame of reference and » Errors in a video coordiboth straightness and nate measuring system orthogonality errors can be broadly classified can be measured. into systematic errors and • Scale errors. Scale constant errors. errors are caused by » High accuracy begins with variation in the scale comprehensive underreader head and associstanding of the sources of ated electronics when error in measurement sysdetermining the positems, and their effect on tion on the scale. This is the overall accuracy and referred to as quantizauncertainty of the resulting measurements. tion error. Because the scale reader outputs

Achieving high accuracy and precision in video measurement systems requires much more than clever integration of components. Source: View Micro-Metrology

an analog signal corresponding to the location of ticks on the glass scale, the uncertainty in the scale location error can be taken as ±1 scale tick, as the worst case scenario. • Lead screw and coupling errors. Two types of errors are observed in the mechanical drive and servo control systems of stages. In the

first case, when we use a rotary encoder on the drive motor, we see a cyclical error in the rotary mechanisms (encoder, bearing and coupling combination) that constitute a type 1 error on the order of 1 arc minute per revolution. Using a linear type encoder instead of a rotary encoder can eliminate this type of error, however, there will still be a lead screw accumulative error of (typically of 50 microinches per inch) due to hysteresis.

Shown is a typical arrangement of a precision compound stage. Source: View Micro-Metrology

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November 2011 | QUALITY

23

MEASUREMENT Hysteresis errors are minimized in two ways. First, by ensuring that the mechanical bearings have the required stiffness, and that there is no mechanical backlash in any part of the drive mechanism. Next, the servo motion control system must have very high resolution and enable the use of position maintenance in the closed loop control mode. CONSTANT ERRORS Next let’s examine five sources of constant errors. • Optics errors. Optical errors primarily impact field of view (FOV) measurements. There are several forms of optical errors associated with a lens system, namely distortion error (pin cusion and barrel distortions), chromatic and spherical

aberrations, coma, field curvature and vignetting. However, for optical measurement applications, distortion is the most important optical error to be considered. Distortion increases as the cubic power of the distance from the center of the lens. The amount of image error due to distortion will manifest in the active area of the image sensor. When a conventional VGA format camera is used, typically optical distortion has no more than a 10% effect on the individual pixel element intensity. In other words, the worst case error can be about 1∕ 10 of a pixel for the biggest lens. However, to take advantage of the larger field of view and greater resolution of advanced multi-megapixel format cameras, image distortion across the field of view must be minimal. Highest accu-

TYING IT ALL TOGETHER Having looked at the common sources of systematic and constant errors, we can insert typical error values into our area accuracy calculation to determine the overall E 2 area accuracy of a typical video measuring system: ASSUMPTIONS: • Pixel calibration value of 25.79 microinches for a system with a 10X objective lens • 20 microinch linear scales • Some of the errors are stated per unit length SYSTEMATIC ERRORS: (LENGTH DEPENDENT) “A” Straightness error: 40 microinch/inch Abbe error: 48.5 microinch/inch (based on 5 arc sec of angle and Abbe offset of 2 inches) Orthogonality error: 48.5 microinch/inch (based on 5 arc sec) Thermal error: 8.76 micro inch/inch/2 F (the temperature assumed to be maintained within ±2 F) CONSTANT ERRORS: “B” Scale error: 20 microinch X 2 locations Optical error: 1⁄ 10 of pixel X pixel value (2.58 microinches) Video error: ½ of pixel X pixel value (12.895 microinches) Calibration error: 4 micro inch OVERALL RMS ACCURACY IN THE MEASUREMENT OF A RING GAGE OF SIZE 0.107 INCH __________ =  L² [A] + [B] ______________________________________________________ =  0.107 ²[40² + 48.5² + 48.5² + 8.76²]+40.0² +2.58² + 12.895² +4² = 43.151 microinches or 1.079 microns Where L corresponds to the dimension measured. A and B correspond to the systematic errors and the constant errors, respectively. When the value of L is larger, as is the case for measurements of length in typical manufactured parts, the contribution of systematic errors (A) are substantial. Thus, the sources of systematic errors must be very carefully attended to in the design, construction and calibration of a video measuring system. As the value of L becomes smaller, as is the case when measuring micro parts, constant errors (B) become more significant, therefore the imaging optics, cameras calibration standards and image processing and motion control algorithms must be suited to this level of precision.

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QUALITY | November 2011

racy video measurement systems use optics that exhibit minimal distortion, typically fixed lens type systems with microscope objectives used as the front receiving lens. • Video errors. Video errors are contributed by the charge-coupled device (CCD) detectors or complementary metal-oxide semiconductor (CMOS) digital camera imaging sensors and by the edge-finding algorithms in the image processing software. The pixel arrays are arranged in rows and columns with a fixed spacing between each row and column, so there are active areas, as well as dead spaces on the detector surface. Hence, some information is lost due to chip geometry and spatial variation. In the case of analog cameras with frame grabbers, there is a pixel jitter, measured in nanoseconds, which may cause as much as 0.4 pixel error. The quality and stability of the frame grabber and camera must be carefully evaluated to minimize video errors. In digital cameras, there is no concern of pixel jitter. However, the light sensitivity of a CMOS chip tends to be lower and hence, subject to noise. Thus, the extent of potential error due to this sensitivity varies considerably depending on the make and model of the camera. While there are many multi mega-pixel digital cameras available, few have the S/N performance, pixel symmetry and thermal stability required for precision measurement. Therefore, digital cameras must be selected with great care. • Calibration errors. Calibration errors increase linearly from the center of FOV to the edges of interest. Also, the calibration errors will apply to two edges, if both are present in the FOV. From the calibration certificate for the standard used in vision systems, the maximum error of calibration varies from 70 nanometers to 100 nanometers. This calibration is usually traceable to NIST standards. • Computational errors. Precision may be lost due to the finite size of the word length (number of bits) used for image processing. Usually IEEE format for floating points, with a specified number of bits for mantissa and the remaining bits for exponent is used. This error is usually of the order

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BALL GAGE INSTEAD OF A CYLINDRICAL PLUG GAGE. Save time with the self centering spherical surface of the ball gage. When measuring a large number of holes it can be 100 times faster. Put one or two flats on the ball and find any out-of-round holes. Measure how parallel the space is between two surfaces and or the size. You can get into inside An orthogonal reference setup checks for orthogonality errors. Source: View Micro-Metrology

of 1∕16 of a pixel for a 4 bit exponent any attempt is made to carry out or 1∕64 of a pixel for a 6 bit exponent calibration or repeatability studies and hence may be ignored. Here it on the measurements. has been included for the purpose of completeness only. Nearly 30 years experience with • Errors due to temperature, pressure video measurement systems has shown and humidity. In applications with that achieving high accuracy and accuracies of the order of a micron, precision requires much more than it is essential to keep the temperature clever integration of components. Hig h controlled within ±2 F. Although accuracy begins with comprehensive well-designed measurement systems understanding of the sources of error are built from materials with low in measurement systems, and their and generally similar thermal coefeffect on the overall accuracy and ficients, where two dissimilar mateuncertainty of the resulting measurerials are physically connected, temments. With this understanding, we perature changes can induce stress can apply sound design and careful and deformation. At the micron level manufacturing techniques to produce even small changes in temperature systems with exceptional accuracy can have measureable impacts on and repeatability, which provide many both systematic and constant errors. years or reliable service. Q Ignoring thermal stress induced errors, the worst case error due to Muthukrishnan (Kris) Chellappa is a senior temperature deviations has been applications engineer with View Micro-Metrology estimated to be about 4.38 microa division of Quality Vision International Inc. inches per inch per degree F or (Rochester, NY). For more information, e-mail 4.38 microns per meter per degree [email protected], call (480) 295-3150 or visit F, assuming steady state condiwww.viewmm.com. tions and no transients. Therefore, it is advisQUALITY ONLINE able that the materials For more information on for which measurevideo measurement, visit ments are to be carried ww.qualitymag.com for out in the system be the following: thermally soaked in the • “Advanced Video same room for about 24 Measurement Solutions” Shown is a typical hours, preferably in a • Q-cast Podcast: scale and reader head controlled environment Video Measurement arrangement. Source: with temperature of • “Select the Right View Micro-Metrology about 68 F ±2 F, before Video System”

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diameters or inside spherical surfaces of rod end bearings.

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TEST & INSPECTION

Source: Mitutoyo America Corp.

CMM Market:

A Look at the Future Manufacturers are looking to build CMMs that are more reliable, efficient and suitable to various types of end users, which requires significant R&D investments. BY PRATHIMA BOMMAKANTI

I

mproved product quality, advanced equipment at a lower price than ever, and compliance with a myriad of standards affecting various industries across different countries: aren’t these the most significant demands of customers all over the world, irrespective of the industry and product type? End users’ requirements for coordinate measuring machines (CMMs) are very much in line with these demands. As such, reliability, repeatability, service, quality and compliance with standards are factors taking on new and utmost importance in this industry.

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QUALITY | November 2011

A CMM HERE AND A CMM THERE Due to the sluggish market growth, prices of CMMs are declining. This contraction in prices and the resulting decrease in profit margins have forced manufacturers and suppliers to identify opportunities for growth. One such opportunity is the increasing demand for services offered with the equipment. They include the delivery, installation, and equipment operation and maintenance, which now constitute a valuable source of income for suppliers of CMMs. However, with the recovery of the economy, manufacturers need to invest in

new technologies to generate products that are better suited to end-user requirements. This will be no easy task though, due to a lack of adequate monetary resources. Manufacturers are looking to build CMMs that are more reliable, efficient and suitable to various types of end users, which require significant R&D investments. CMM manufacturers need to provide products that are on par with the industry’s requirements in terms of price and quality. While they have always faced intense price competition from low-cost imports of Asian origin, such competition is expected to increase further in the future due to the price sensitivity of global end users and the increasing quality of the products being introduced in the market by Asian manufacturers. COMPETITIVE FACTORS The world CMM market is dominated by a few large companies, which have

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BENEFITS

involved in this industry. operations in most of the » CMM manufacturers need Competitive factors in key geographic regions. to provide products that are the CMM market include The top four companies on par with the industry’s price, accuracy, size, cuscontrol more than 75% requirements in terms of tomer relationships, softof the total market. This price and quality. ware, services, product is significant challenge » The world CMM market is differentiation, distribufor smaller regional comdominated by a few large tion, and research and panies, as well as entry companies, which have development efforts. barriers for potential new operations in most of the The level of imporentrants. While this is a key geographic regions. tance attached to each challenge from a competi» The highest revenue contribof the aforementioned tive standpoint, this also utors were the automotive attributes varies dependmay lead to stagnation in and aerospace industries, ing on the product segterms of the overall marwhich accounted for more ment and the end-user than 50% of the total market growth and technolket revenues in 2010. target. For example, ogy improvements. ease of installation and Key market participants use plays an important in the world CMM market role in the selection process of most include Hexagon Metrology, Carl Zeiss CMMs, whereas size and speed of IMT, Faro Technologies, Mitutoyo Corp., response play a vital role in the Wenzel, Metris, Mora, Stiefelmeyer, selection of bridge machines and ITP Group, Tarus, Helmel, Trimek, articulated-arm machines. Dukin, and Accurate and International Price is expected to continue to be Metrology Systems. one of the most important competitive The CMM market is a large one, factors in this market. Improvements not just from a revenue perspecmade in manufacturing and technoltive but also from the standpoint of ogy is enabling prices to reduce, and the number of competitors actively

this trend is set to continue throughout the forecast period. The level of importance attached to research and development activities varies by market segment. The articulated-arm machines segment is dynamic from a technology standpoint, and therefore, the R&D investments of manufacturers of such machines are greater than in other segments of the CMM market. Changes also have occurred in the gantry and horizontal-arm machines segments, but the core technology has remained the same. As a result, product differentiation and customer relationships assume significant importance to get the sale. END USER ANALYSIS The highest revenue contributors were the automotive and aerospace industries, which accounted for more than 50% of the total market revenues in 2010. These industries are driven by the need for customized solutions and extended support, as the lifespan of these machines are high.

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TEST & INSPECTION

The world coordinate measuring machines (CMM) market generated revenues of $1,436.0 million in 2010, increasing by 3.4% over 2009. In 2010, the gantry, bridge, horizontal and articulated-arm machines segments represented 8.9%, 53.7%, 17.8% and 19.6%, respectively, of the overall market revenues. Research indicates that this market is likely to generate revenues of up to $1,795.1 million at the end of the forecast period, at a compound annual growth rate (CAGR) of 4.6% from 2010 to 2015. Source: Frost & Sullivan

CURRENT TRENDS AND OPPORTUNITIES Over the years the usage of CMMs has expanded from quality control to process control. The end user’s wish of using dimensional measurement results as a means to check the process involved in the manufacturing of a given

product is one of the key factors that have led to the growing usage of CMMs. CMM manufacturers are increasing their focus on temperature compensation, high-speed data-gathering sensor technology and software improvements to introduce new machines that better address customers’ needs than existing solutions.

Traditional CMMs have had standard control packages with fixed capabilities. Computer numerical controls (CNCs) can be categorized as proprietary standard combinations of hardware and software. In order to build in a lot of flexibility in machines with room for upgrades and expansion for new applications, the

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software must be developed so that it can evolve with the needs of customers. Consequently, there has been an increase in the number of ISPs collaborating with the CMM vendors to offer best functional deliverables to the customers. Manufacturers also are focusing more on noncontact probing technology. Laser-based noncontact probes, which have great advantages in terms of the amount of data that can be acquired and the speed with which the data can be obtained, is highly accepted in the automotive and aerospace industries. Manufacturers are working on implementing advanced technologies to reduce errors while using noncontact probing technology. LAST THOUGHTS With several individual product segments near or past the stage of maturity, the growth rate in the CMM market is not expected to rise above the moderate 5% in 2011. Competition is expected to be fierce as large companies seek out strategic merger opportunities. The companies that will successfully

adopt cost-cutting measures, as well as manage to continue to improve the price-performance ratio of their product offering, are the ones that are most likely to succeed in this market. While there are a few factors that can upset the positive development of this market moving forward, the rapid rate of infrastructure development in emerging markets presents immense growth opportunities for manufacturers. If these opportunities are tapped at the right time, market participants can expect robust growth in the coming years. Q Prathima Bommakanti is a senior industry analyst, measurement & instrumentation at Frost & Sullivan. For more information, e-mail prathima. [email protected], call +442080902004 or visit www.frost.com.

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QUALITY ONLINE For more information on coordinate measuring machines, visit www.qualitymag.com to read the following: • “CMMs Create Flexible Feedback” • “Multisensor CMMs Add Flexibility” • “Portable CMMs Go to Source of Inspection”

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SOFTWARE & ANALYSIS

Model Based

Definition PROMISES BIG DIVIDENDS FOR QUALITY ASSURANCE Inspection planning greatly enhanced with MBD and GD&T. BY SHAUN WISSNER

I

n the long evolution of 3-D computeraided design (CAD), you would not think innovative progress is possible at this point. Take model based definition (MBD), a term and methodology long tossed around by software developers and the aerospace industry. Surprisingly, there is significant activity in this area, and genuine value this technology can bring to the manufacturing table. MBD “gold” lies in its ability to streamline product development into a drawing-free process based on an information-rich 3-D CAD model that fully defines and provides specifications for parts and assemblies. This

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next-generation approach to product design has several time and moneysaving ramifications, from simplifying manufacturing operations to greatly improved inspection processes. THE TALK OF MBD INSPECTIONS The transition toward 3-D CAD has accelerated in recent years as more and more design and manufacturing companies embrace solid and surface modeling techniques. However, 3-D models lacked GD&T (geometric dimensioning and tolerancing) information, so it was anyone’s guess as to the part’s allowable discrepancies.

Additionally, any change to the original design intent turned into a lengthy process of redesigning detailed prints—sometimes repeatedly—with each change consuming valuable time and introducing the potential for errors. All of these intricacies roll down to the desk of the quality inspector. In the quality assurance world, the main problem with the typical CAD model is that it required a separate blueprint to determine datum structure, key characteristics and tolerancing to create an inspection plan. This scenario occasionally requires access to the product designer to interpret some of the GD&T information, which is not exactly convenient for multinational corporations. Stir in the nagging question of whether the CAD data or the print is the most

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 Companies can leverage their CAD models for further improvements in the product development process, and at the same time, garner quality assurance gains through inspection software enhanced to take full advantage of MBD. Source: Hexagon Metrology

single CAD file and complete all the current revision, and you have a necessary steps to build and inspect a recipe for convolution. given part. MBD has arrived on the scene to Secondly, MBD solves human error alleviate this complexity, as several issues by transferring notes into CAD software packages inspection software. The now allow for embedded TECH TIPS traditional use of 2-D GD&T. All pertinent » Model based definition drawings to supply docuproduct information “gold” lies in its ability to mentation such as GD&T, and inspection planning streamline product developbill of materials and other data is incorporated ment into a drawing-free process based on an engineering configurainto one versioninformation-rich 3-D CAD tions has left companies controllable entity—the model that fully defines and exposed to the inherent 3-D CAD model. MBD provides specifications for risk of human error in consolidates component parts and assemblies. the interpretation of this datum structure and » In the quality assurance information. Model based revision levels, GD&T world, the main problem definition solely relies on interpretation, product with the typical CAD model 3-D digital data to define details and any other is that it required a sepaand supply specifications necessary dimensioning rate blueprint to determine for parts and product into the model. For quality datum structure, key characassemblies, giving plauassurance purposes, this is teristics and tolerancing to sible meaning to the term good news. create an inspection plan. paperless inspection. » As more companies use Lastly, and most sigBENEFITS ARE model based definition, nificantly, MBD delivers FOR REAL quality assurance departan automated mechaTo get a sense of what is ments will experience an nism for part program possible, it is worthwhile uptick in productivity, while creation directly from to study the inherent benengineers move even closer the 3-D design informaefits of an informationto preserving the original design intent of their parts tion. Inspection prorich CAD model. For and assemblies. grams change as design starters, MBD provides, modifications are made, for the first time, a forand dependencies also mal communications are updated automatically. When the vehicle between design and quality tolerance of one feature changes, the without the need for prints, so design program updates all associated features. intent is automatically available at the This capability is a valuable time saver, time of the part program creation. particularly on more complex parts. For With CAD software tools, component example, if a part contains 80 holes with manufacturers are able to receive a

similar tolerancing and that specification changes, a simple click will instantly update all associated dimensions without further operator intervention. NO LONGER JUST TALK In the natural scheme of progress, a few CAD-based inspection software platforms are keeping pace with MBD and capitalizing on the advantages of the new embedded GD&T data. Some systems provide the basic ability to create features, datum definitions and associated dimensions from a single mouse click. One inspection planning software takes it one step further by automating the inspection process based on design changes and embedded GD&T. The software can create full and sub inspection programs and control revisions all while using a program that is device neutral. It also can be used regardless of the measurement technology—such as touch, scan, continuous analog, vision and laser—employed. When this inspection software is dynamically linked to CAD, a change manager feature notifies the quality technician of updates or changes to the CAD model. These changes can be accepted or rejected, with the software automatically revising the inspection path based on the most efficient route to incorporate the required changes. Although the inspection routine of features and dimensions is automatically generated with emphasis on measurement efficiency, the technician can customize

MBD provides a formal communications vehicle between design and quality without the need for prints, so design intent is automatically available at the time of the part program creation. Component manufacturers are able to receive a single CAD file and complete all the necessary steps to build and inspect a given part. Source: Hexagon Metrology

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November 2011 | QUALITY

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SOFTWARE & ANALYSIS

This inspection planning software automates the inspection process based on design changes and embedded GD&T. Source: Hexagon Metrology

the measurement report to suit the desired requirements. It is a simple process to import CAD data and select feature control frames

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QUALITY | November 2011

or other linear dimensioning from the 3-D model. Each dimension selected will add the most up-to-date features and tolerancing to the inspection plan

based on the designer’s intent, eliminating interpretation by the inspector. The software uses PTB certified algorithms for ASME Y14.5-1994, ASME Y14.5– 2009 and ISO standards to ensure the highest level of measurement acceptance accuracy. This is done automatically when the initial plan is created. The inspection software also ensures common datum features referenced by multiple feature control frames are not duplicated in the inspection routine, which keep inspection time efficient while maintaining accuracy. This is a paradigm shift in the process as ensuring throughput and accuracy has always been the responsibility of the quality technician. In essence, model based definition shifts that burden from the technician to the software. With the software’s tools, the measurement path can be optimized automatically. The software groups inspected features by proximity and probing angle, minimizing probe rotations and tip changes. Multiple measurement plan default parameters can be set by the inspector to

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clarify the number of points taken and their locations for various customer or internal inspection requirements. Also, after the plan is imported the real-time functionality can be utilized to either step through the measurement plan making changes on the f ly, or spot edit known areas of concern or key characteristics. Since efficiency equates to speed, and speed requires safety, another advancement takes advantage of the software’s inherent bounding box. Parts that are round or irregularly shaped—for example, turbine blades, steering control arms and prosthetics/implants—are are contained within the bounding box, as well. When this ‘force field’ is activated, advanced algorithms will direct the probe tip to automatically clear the part. This requires the probe to safely back away from the part and fixture before moving to the next feature or completing a probe head rotation. WHERE DO WE GO FROM HERE? Using the unstoppable force of 3-D information, MBD continues on a path to reach its full potential. Companies can leverage their CAD models for further improvements in the product development process, and at the same time, garner quality assurance gains through inspection software enhanced to take full advantage of MBD. By embedding all relevant information within the CAD model, an organization should expect to save time and reduce the potential for human error. MBD promises to reduce the workload of inspectors by assuming some of the grunt work associated with change revisions. Although inspectors will still need to finesse the results by applying their specialized knowledge of metrology best practices, fixturing, customer requirements and the application of GD&T, a large percentage of the time spent adjusting inspection routines to match revisions will be eased as the software assumes that responsibility. As more companies strike MBD gold, quality assurance departments will experience an uptick in productivity, while engineers move even closer to preserving

the original design intent of their parts and assemblies. With all of this progress, it is not hard to imagine a world where quality technicians are streamlining part inspections without breaking a sweat. Q Shaun Wissner is a software marketing specialist at Hexagon Metrology's Elgin, IL, facil-

ity. For more information, e-mail Shaun. Wissner@ hexagonmetrology.com or visit www.hexagonmetrology.us.

QUALITY ONLINE For more information on computer-aided design, visit www.qualitymag.com to read the following: • "CMM Software Solves Scanning Problems" • "Computer Inspection Aids Six Sigma Efforts" • eXtra: “All About Software Upgrades”

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November 2011 | QUALITY QLT11114OPTI.indd 1

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MANAGEMENT

Source: Bombardier

Assessing

Aerospace Risk Management Realize the benefits of an aerospace risk management process and why it should be part of every organization’s culture. BY ROGER RITTERBECK

R

isk is an undesirable situation or circumstance that has both the likelihood of occurring and a potentially negative consequence. Risks are present throughout an organization and can be internal or external. Internal areas in an organization where risk could present a significant impact can include contracts, design, supply chain, planning and production. Internal risks have a high probability that they can be controlled. Conversely, external risks, such as natural disasters and economic, political and social risks, are generally difficult to predict or control. Risk management is a repetitive process to identify, assess, reduce, accept and control risk. The process should be systematic, proactive, comprehensive and cost effective while taking into

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QUALITY | November 2011

account the business, cost, technical, quality and schedule constraints. Each key process owner should identify risk and mitigate appropriately. WHY HAVE A RISK MANAGEMENT PROCESS? Risk management is now required by the AS 9100 standard. Let’s look at the benefits of an aerospace risk management process and why it should be part of every organizational culture. Organizations need a risk management process in order to reduce the odds of something harmful happening to the business. This involves focusing on risk to meet customer requirements and preventing product nonconformity escapes. The absence of an aerospace risk management process can result in known, unknown and unknowable/

unforeseen problems for the customer and stakeholder concerning cost, schedule and technical performance of programs, in particular for programs concerning the quality and delivery performance of products and services. BENEFITS What are the benefits of an aerospace risk management process? Process benefits of risk management can: • Increase the likelihood of achieving objectives • Encourage proactive management • Raise awareness of the need to identify and treat risk throughout the organization • Improve the identification of threats • Comply with relevant legal and regulatory requirements • Improve financial reporting and governance • Develop stakeholder confidence and trust • Establish a reliable basis for decision making and planning • Improve organizational controls

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TECH TIPS » Risk management is a repetitive process to identify, assess, reduce, accept and control risk. » A formal program describes the organization’s attitude and approach toward risk, how it conducts risk management and the level of risk it is prepared to accept. » The organization must begin by formalizing objectives and policies, as well as establishing a risk management plan supported by top management.

PURPOSE OF THE PROGRAM A formal aerospace risk management program describes the organization’s attitude and approach toward risk, how it conducts risk management and the level of risk it is prepared to accept. A risk management program: • Helps an organization identify risk • Helps an organization reduce occurrences and impacts of risk • Helps an organization understand significance and severity of risk • Promotes organizational behavior focused on risk management • Increases effectiveness of product delivery to customers • Creates a process for who, what, when, where, how and how much • Helps organization bring out hidden risk knowledge so it can be managed Risk management should encompass all areas of business performance and should be exerted at all levels of an organization. RELATING TO AS 9100 How does risk management relate to the AS 9100 quality standard? Risk

management is a requirement of the AS 9100 quality standard. The standard requires an aerospace quality management system that takes into account

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• Effectively allocate and use resources for risk treatment/handling • Improve operational effectiveness and efficiency • Cost of risk management is typically less than the cost of issue management • Enhance health and safety performance, as well as environmental protection • Improve organizational learning and resilience • Product and service benefits of the organizational management of risk • Reduce the likelihood of delivering nonconforming product or services to customers • Reduce the likelihood of delivering late product or services to customers • Increase the likelihood of business success, for example, meeting schedules and budgets • Reduce the probability and consequences of potential failures

the identification of various risk related to organizational circumstances in regard to its needs, business objectives, product range, applied processes and the size of the organization. There are several sections in the AS 9100 standard where risk and risk management are identified: • 3.2 Special Requirements: Those requirements identified by the organization or its customer(s)

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MANAGEMENT that have high importance in being achieved, thus requiring their inclusion in the risk management process. Factors used in the determination of special requirements include product or process complexity, past experience and product/process maturity. • 3.3 Critical Items: These include such things as safety critical items, fracture critical items, mission criti-

cal items, etc. A risk management process must be implemented to control these matters. • 3.4 (7.2.1, 7.2.2, 7.3.3) Key Characteristics: These are attributes or features which may create a risk to product fit, form function, performance, service life or produce ability and use of the product throughout the product life. The risk associated with key characteristics needs to be

managed through the risk management process. • 7.1.1 Risk Management Link to Project Management: The standard says: “The organization shall plan and manage product realization in a structured and controlled manner to meet requirements at acceptable risk, within resource and schedule constraints.” Any project management program must include risk management.

Risk management is a repetitive process to identify, assess, reduce, accept and control risk.

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QUALITY | November 2011

• 7.1.2 Risk Management: The standard says: “The organization shall establish, implement and maintain a process for managing risk to the achievement of applicable requirements, as appropriate to the organization and the product.” This should include: a) Assignment of responsibilities for risk management b) Definition of risk criteria, for example, likelihood, consequences, risk acceptance c) Identification, assessment and communication of risk throughout product realization d) Identification, implementation and management of actions to mitigate risk that exceed the defined risk criteria e) Acceptance of risk remaining after implementation of mitigating actions • 7.2.2 Product Risk: The organization has to ensure that risks have been properly identified, such as new technology, short delivery time frame, resources and change in source of supply. • Supply Chain Risk: The organization has to manage risk when selecting and using suppliers. • Preventive Actions: The organization must establish preventive actions including risk management, such as error proofing, failure mode effect

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analysis and product problems by external sources. WHAT SHOULD WE DO NOW? Organizations should develop and implement a process defining how risk management will be accomplished. A methodology must be developed by which risk management tools and documentation can be managed. Most importantly, the organization must ensure all personnel are aware of and use the system. The organization must begin by formalizing objectives and policies, as well as establishing a risk management plan supported by top management. The following are basic components of an aerospace risk management process: • Risk Identification. Identify and define the problem or opportunity, as well as risk issues—decide on the people, expertise, tools and techniques needed to work the issue—perform a stakeholder analysis—indentify using risk ID checklist and document risk. Risk identification should be performed by a cross functional team representing all affected functions of the organization. Risk identification should be a continuous process and included in the organization’s decision making processes. • Risk Assessment. Analyze the content of the issue from an overall organizational perspective and ensure the entire issue is understood. The analysis should include the likelihood, consequence, severity and customer impact. Risk criteria needs to be established at this point so the organization can determine what risk must be mitigated and what risk the organization can live with. • Risk Management Process. Once risks that fall outside of the acceptance criteria are identified, mitigation actions should be implemented. The organization should set desired results for the mitigation actions and select a strategy to address the situation. Maintain status of action items until the actions are complete. Verify that objective evidence of completion of the actions exist, and monitor for effectiveness. If the actions prove to be ineffective, define and execute new actions. • Risk Management Culture. The organization must foster a culture

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of risk management. To do this, risk management processes and actions should be communicated throughout the organization. The focus on risk management needs to be a top down approach, supported by top management. Organizations should: a) Promote risk management learning by employees b) Promote learning by experience from issues that arise

c) Include risk management in demonstrating management leadership d) Support innovation in a structured risk management environment. Q Roger Ritterbeck is an aerospace product manager at QMI-SAI Global (Cleveland, OH). For more information, call (800) 247-0802, e-mail [email protected] or visit www.qmi-saiglobal.com.

November 2011 | QUALITY

37

CASE STUDY ter. Abaqus from Simulia, the Dassault Systèmes brand for realistic simulation, has been an essential tool for FEA since the IDC first opened its simulation technology center. “With Abaqus, we’re able to be more innovative, more quickly and produce higher-quality products,” Xin says. Engineers use Abaqus early in design process to verify product strength, choose between different versions, and identify and improve problem areas. The process involves preprocessing from computer-aided design (CAD) to meshed model; establishing loads, boundaries and part interactions; running the analysis; and creating the reports.

FEA INCREASES

NOTEBOOK RELIABILITY Finite element analysis takes place at the concept, development and failure analysis stages.

A

senior manager at the Lenovo Innovat Lenovo (Morrisville, NC) a great tion Design Center (IDC) in Beijing. deal of design effort goes into Engineers at the IDC analyze all of ensuring that portable does not mean Lenovo’s products, ranging from PCs breakable. It is a measure of how seriand notebooks to cell phones and servously engineers take this task that two ers. Finite element analysis (FEA) recent designs for the takes place at the concept, ThinkPad X300 and the BENEFITS development and failure T400 were code-named » Engineers use Abaqus early analysis stages. FEA Kodachi and Shinai, in design process to verify simulations at Lenovo respectively—both the product strength, choose include modeling drop, names of Japanese martial between different versions, shock, vibration, static arts swords. and identify and improve pressure and motherThinkPads are widely problem areas. board strain. known for their perfor» Using Abaqus has reduced The IDC also performs mance and durability as the product development computational fluid well as looks—a legacy cycle by at least two weeks dynamics thermal and airthat Lenovo has continfor every project. flow acoustic simulations. ued since it purchased the » All of the simulations at the Realistic simulation laptop brand from IBM in Lenovo IDC yield the same of notebook comput2005. “Our aim is to creresult: high-performance, ers began at the IDC ate a high-quality, reliably quality products that in 2007 and became a strong notebook while undergo less prototyping, formal checkpoint in the keeping cost and product reach production faster at a smaller cost and perform product development development time down,” reliably for users. process shortly thereafsays Dr. Zhifeng Xin,

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QUALITY | November 2011

FLEXIBLE ANALYSIS, RIGID RESULTS FEA is particularly central to eliminating flex, an objective vital to making the ThinkPad more reliable. A number of forces—such as carrying a closed notebook one-handed—can potentially deform the laptop frame and bend the motherboard, which could damage the soldered connections or the liquid crystal display (LCD). “Notebooks face demanding loads and forces even when they’re just being carried from place to place,” says Xin. “It’s important for the covers to be stiff enough, with minimal deformation, so that the rear cover will protect the display, while the base cover protects the motherboard.” During recent work on a new model, simulation of flex was instrumental to the goal of reducing weight without loss in strength or rigidity. A base cover that used carbon fiber reinforced plastic (CFRP) with an aluminum shield would offer support to the motherboard. The LCD screen would be protected by a rear cover with CFRP and graphitefiber reinforced plastic (GFRP). Analysts simulated the physical tests that were performed on a magnesium LCD frame, an LCD panel assembly, a rear cover made of PC/ ABS and a CFRP base cover with its aluminum shield in place. “We applied loads of 400 to 3,200 grams, and we compared the resulting deformation to physical test results,” says Xin. “In each case, simulation had a close correlation with real-world behavior during physical testing.” In a whole machine analysis, engineers evaluated the performance of

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Analysts simulated the physical tests that were performed on a magnesium LCD frame, an LCD panel assembly, a rear cover made of PC/ABS and a CFRP base cover with its aluminum shield in place. “We applied loads of 400 to 3,200 grams, and we compared the resulting deformation to physical test results,” says Dr. Zhifeng Xin. “In each case, simulation had a close correlation with real-world behavior during physical testing.” Source: Simulia

laying-up composite CFRP for the rear cover; this type of composite material could enhance much of the strength for the entire machine. “In this instance,” Xin says, “the nonlinear

capabilities of Abaqus were valuable to us because of the complex performance properties of the materials, complex geometry deformation and complex contact behavior.”

AM 40

QUALITY | November 2011

Engineers also evaluated two alternatives for the array of CFRP: horizontally vs. vertically orienting the fibers. The analysis found that horizontal lay-up of the fibers resulted in smaller deformation. The engineers also were able to prove out the strength of a joint line for combining CFRP and GFRP. Due to composite CFRP being limited by part geometry shape, the rear cover is made of both CFRP and GFRP through the patented joint method. ANALYSIS WEIGHS ALTERNATIVES The Kodachi (ThinkPad X300) project proved that the simulation tool has the ability to provide accurate results, allowing engineers to predict the strength of the structure and offer suggestions to CAD designers, on the project codenamed Shinai (ThinkPad T400s), for example. Analyzing deformation of the closed notebooks under a press load revealed that the light emitting display (LED) stress was much lower than in the Kodachi design. During press load on the rear cover of the whole machine, the Kodachi LED contacted the track-point—the cursor tracking button in the ThinkPad keyboard—potentially creating as much as 8.4 MPa of stress. By contrast, the LED on the Shinai contacted the palm rest on the base, yielding a much lower stress of 2.2 MPa. The analyses also showed that four areas on the magnesium frame of the

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Kodachi design exceeded specifications for material yield strength and created deformation of the rear cover of 5.8 millimeters, resulting in higher overall deformation than on the Shinai, which only exceeded specs of material yield strength in one area. The data from the simulation guided revisions to the Shinai frame, helping the development team speed up the project schedule. “Because of our work with Abaqus,” Xin says, “we were able to fix the Shinai design quickly and easily.” In both cases, FEA results were quite similar to physical test results.

(and physically tested) for flex, and the Ball Grid Array (BGA) components are modeled undergoing strain to confirm that the solder joints will perform well. “As always, nothing validates a simulation like its close conformity to realworld testing,” Xin notes. “The pushpoint tests of the motherboard, and the strain tests for the BGA, were based closely on our physical prototype testing, and they yielded similar results.”

All of the simulations at the Lenovo IDC yield the same result: high-performance, quality products that undergo less prototyping, reach production faster at a smaller cost and perform reliably for users. Simulia, a Dassault Systèmes brand (401) 276-4400 www.simulia.com

FEA GETS IN TOUCH WITH KEYSTROKE FEEL Keyboard design is a strong selling point for the ThinkPad. The notebooks have long been known for their sturdiness and their pleasing signature feel—the physical response of keys being pressed. In the case of a new keyboard, the engineers wanted to reduce the thickness of the assembly (thereby making the overall notebook slimmer) but still keep their traditional keystroke feel. “‘Feel’ may sound like a vague term,” Xin says, “but with FEA, it is actually quantifiable.” To confirm that the feel remained the same from the old keyboard to the new, engineers simulated the effects of keystroke pressure on the original dome-shaped rubber spring, the central component that provides each key with its resistance and springback. Because the rubber dome was axisymmetric, they were able to model a 2-D half-section of the spring and run the analysis on that. The nonlinear simulation enabled the engineers to establish values—on a feeling chart— for how far the rubber dome traveled downward (compressed) as keystroke force increased. (Typical typing force is between 0.6 to 1.2 Newtons.) The engineers then used Abaqus to evaluate a new rubber dome design for the thinner keyboard in order to match the keystroke behavior of the old rubber dome. “The feeling chart of the new simulation showed close correlation with the old one,” Xin says, “and both simulations matched up well with data from physical testing.” These are just some of the simulations a Lenovo ThinkPad undergoes on its way from design to reality. The motherboard itself also is analyzed

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November 2011 | QUALITY

41

2011

CASE STUDIES SPECIAL A DVERTISI N G SEC TI O N This Case Studies Special Advertising Section features manufacturing companies with real-world challenges using quality equipment, software and services to solve their problems and improve their processes. These problem-solving stories describe myriad manufacturing challenges and how the correct application of a supplier’s product or service made the difference, providing quantitative benefits to quality and manufacturing issues. The suppliers in this special section present these real-world problems and solutions to help Quality Magazine subscribers who may have similar experiences.

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Buck Bicek 5820 Middaugh Ave. Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086 [email protected] REGIONAL SALES MANAGER

Steve Scheinpflug

This index is provided as a reader service. The publisher assumes no liability for errors or omissions.

155 N. Pfingsten Rd., Ste. 205 Deerfield, IL 60015 Phone: (847) 405-4025 Fax: (248) 283-6587 scheinpfl[email protected]

48

QUALITY | November 2011

QUALITY (ISSN 0360-9936) is published 13 times annually, monthly except semi monthly in November, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: QUALITY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to QUALITY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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DEPARTMENTS 4NDT

Editor’s Note Uncertainty

5NDT Source: Magnum Quality Resources

Industry News

IBCNDT Advertising Index

NDT TRAINING

8NDT

Are You Ready for Certification? More and more companies are requiring laboratory certification as a prerequisite for doing business and certification provides the customer with documented assurance that a quality system is in place.

IN THE NEXT ISSUE Laser Sensing Technology GigE Cameras

PHASED ARRAY

Cables and Connectors

10NDT Phased Array Training

CCD Cameras

Time and again, training has proven to be the limiting factor with phased arrays. One of the main objectives to improve training is to illustrate that certification is a key.

NDT RENTALS

16NDT In A Down Economy, Look to NDT Rentals What is the solution for an NDT service company when they require an inspection tool but do not have the capital? NDT equipment rental companies have been delivering the answer.

OFF TOPIC NDT Nondestructive Testing at...Legoland Some of the biggest theme parks in the United States rely on nondestructive testing in-house to ensure safety.

CT MARKET ANALYSIS

18NDT CT: Making Up for Lost Time Although the medical industry has traditionally been the largest driver for X-Ray inspection systems, the first use of X-Ray was intended for an industrial application.

ABOUT THE COVER In a poll conducted by Britain’s Science Museum, X-Ray was recognized as the most important modern scientific achievement of the 20th century. Source: www.photos.com

Source: MFE Rentals, Inc. 2 NDT ● NOVEMBER 2011

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Uncertainty

Darryl Seland Editor in Chief [email protected]

One only needs to look at the roller-coaster ride of the Dow Jones and other economic indicators to see why there is so much worry over the economy, not just in the United States, but globally. This worry and uncertainty has lead many companies to “sit on a pile of cash,” unwilling or unable to justify capital spending until economic conditions become more clear. The latest potential monkey wrench to the global economy is the European debt crisis.

T

Over the last year-and-a-half, unemployment and government belt-tightening in me Greece, Ireland, Portugal and Spain—the Gr Greece of attempting to gain control over res result the potentially crippling debt obligatheir tions—are threatening the stronger econotio tions mies of The European Union and beyond. Europe’s economic powerhouses, France and Germany, are being hurt by decreased business orders from these indebted countries, restraining their economies as well. In fact, European stocks fell sharply after German financial giant Deutsche Bank reduced its profit forecast for the year due to exposure in the debt problems of these countries. Investors were further scared off when speculation that French-Belgian investment bank Dexia could be the region’s first large bank to need a government rescue as a result of the current debt crisis. And the potential fallout does not end with Europe. Emerging economies like China and Brazil rely heavily on European exports. The United States has major banking and trading interests in Europe, a region whose banks are said to be “the most interconnected in the world” with a currency, the Euro, that is one of the largest reserve currencies in the global economy. A growing number of analysts and key financial figures have predicted that Europe is headed for recession, one of which is Goldman Sachs, forecasting that both France and Germany will slip into recession. The situ-

4 NDT ● NOVEMBER 2011

NDT SPECIAL SECTION

ation prompted Federal Reserve chairman, Ben S. Bernanke, to warn Congress that “the recovery is close to faltering” and could force the U.S. into a new recession unless the government took further action. However, Greece has repeatedly said that is has no plans to default and will make good on its debt. Chancellor Angela Merkel has pledged that Germany plans to fully support Greece. The idea that these officials could be downplaying a potential crisis aside, there is an element of perspective here, for both the observed and the observer. As has been said, it depends on how you look at it. Adding to the already murky waters, for example, some have said that U.S. banks could lose as much as $1 trillion if the current situation “were to lead to a full blown financial crisis.” Others have said, “[The U.S.] could lose close to nothing.” It is like Schrödinger’s cat. We will not know the extent of the risk to economies and individual companies until we look inside the box, meaning we won’t know the effect Greece defaulting or a European recession will have on the rest of the world until it happens. This month, NDT Magazine offers a potential solution for those NDT companies feeling the same uncertainty about the economy and unable to justify capital expenditures in the current climate—NDT rentals. Find out what you need to know about the rental market in Dylan Duke’s feature article, “In A Down Economy, Look to NDT Rentals.” Enjoy and thanks for reading! www.ndtmag.com

TÜV Rheinland Opens NDT Laboratory BOXBOROUGH, MA — In an effort to expand its presence in the southern United States, TÜVRheinland Industrial Solutions, Inc. (TRIS), a subsidiary of TÜV Rheinland North America Holding Inc., has commissioned a new nondestructive testing laboratory in Decatur, AL. Equipped with a variety of nondestructive testing equipment incorporating technologies such as computed radiography, ultrasonic testing and others, the new 8,000-square-foot facility will feature a start-up staff of seven, with employment expected to double or triple within the first few years. “As a company, one of our goals is to significantly grow the business we do in America’s south,” says Andy VanAusdall, director of sales for TRIS. “Our new lab’s dual offering of both labbased and on-site inspection services

www.ndtmag.com

should greatly facilitate our meeting this objective.” Situated on the Tennessee River, 25 miles west of Huntsville and 80 miles north of Birmingham, Decatur is well positioned to serve the many automotive, aerospace, metalworking, high technology and other manufacturers located nearby, making it fast and easy to ship products to the laboratory for NDT inspection. The region’s numerous chemical and petroleum processing facilities, and their extensive networks of piping and pressure vessels, are well within reach of the laboratory’s field testing capabilities. “Along with our traditional manufacturing and processing customers, we can now work with state and federal transportation departments and railroads to field-test the integrity of bridges and rails,” continues VanAusdall. “Our

NDT SPECIAL SECTION

NOVEMBER 2011 ● 5 NDT

extended capabilities and partnership with our sister company, TUV Rheinland Rail Sciences, has greatly expanded the scope of services each of our companies can offer to its clients.” The new laboratory is located at 35 Refreshment Place in Decatur and will be managed by Blake Whiteside, operations manager for TRIS.

West Penn Accelerates Test-Process Development in Wake of FAA Approval of Phased Array Ultrasonic Testing NEW KENSINGTON, PA—West Penn Testing Group, a provider of nondestructive testing and material testing services, reports completion of FAA approvals for phased array ultrasonic testing (PAUT). According to Albert Fletcher, director of sales of West Penn Testing, “The titanium-billet-phased-array group, made up of jet-engine OEMs, titanium-billet manufacturers and aerospace forgers,

has passed a crucial milestone with the approval last month of PAUT. After a three-year effort, the aerospace industry now has an alternative to multi-zone ultrasonic testing.” Fletcher says that as a result of the FAA approval, West Penn has sped up its program to develop test protocols that meet the requirements of individual OEM customers. “We have the trained people in place and the schedule to install the additional equipment well underway. Now, as we begin to receive the detailed testing requirements from various jet-engine OEMs, we can adapt our process to satisfy the demands of specific customers.” West Penn reports that a number of tasks must be completed before high volumes of titanium billets can be run through the PAUT process. These tasks include certification of the process for each jet-engine OEM and its suppliers, further equipment-manufacturer evaluations and selection, and

final approvals for testing procedures related to data capture, manipulation, analysis and reporting. “It is possible these issues can be resolved during the first half of 2012,” says Fletcher. “In any event, by that time West Penn will be in a position to conduct a high rate of titanium billet inspections.” For more information, visit www. westpenntesting.com

MoviTHERM Awarded NDT NASA Contract HOUSTON, TX—The NASA Johnson Space Center in Houston, TX has awarded MoviTHERM Advanced Thermography Solutions a contract for an infrared non-destructive test (NDT) system for the purpose of testing advanced composite structures and materials. The NDT test system uses a thermal camera from FLIR Systems and various thermal excitation sources. Halo-

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6 NDT ● NOVEMBER 2011

This revision provides updated training and certification requirements for Level I, II and III personnel. New content on: • Guided Wave and Ground Penetrating Radar as Methods • Radiological Testing Method which includes; • Radiographic Testing • Computed Radiography • Computed Tomography • Digital Radiography • Ultrasonics, Time of Flight Diffraction and Phased Array as Techniques • Additional Example Questions

See this publication and more at ShopASNT online at www.asnt.org/shop/ Phone FAX Mail

(614) 274-6003, (800) 222-2768 for US and Canada, (614) 274-6899 The American Society for Nondestructive Testing P.O. Box 28518, Columbus, Ohio USA 43228-0518

NDT SPECIAL SECTION

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phased array ultrasonic testing in aerospace, waveform-capture DGS ultrasonic testing in energy, and new materialstesting requirements for implant components in the medical manufacturing sector, it is critical for West Penn to develop strong leaders who can stake out

a competitive position for the company in important market segments.” According to Campbell, since DeChellis joined West Penn Testing in 1997, the company’s workforce has tripled in size and the number of plants in the West Penn network has grown from one to three.

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DeChellis Named President/ COO at West Penn Testing NEW KENSINGTON, PA—West Penn Testing Group, a provider of nondestructive testing and material testing services, has appointed James C. DeChellis, formerly vice president/COO of West Penn, to the role of president and COO. West Penn Testing reports that advances in numerous nondestructive testing technologies, as well as changes in the regulatory environment of multiple markets, have created a need for the company to respond. “Bringing new technologies and capabilities on line is challenging,” says N. David Campbell, West Penn’s chairman and CEO. “In light of the progress of www.ndtmag.com

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Are You Ready for

CERTIFICATION? More and more companies are requiring laboratory certification as a prerequisite for doing business and certification provides the customer with documented assurance that a quality system is in place. By Nick Cirenese If expansion into new markets is part of a company’s plan for growth, it may be faced with new p or additional demands on its quality program to o facilitate that growth. More and more companies, fa for example, are requiring laboratory certification fo as a prerequisite for doing business. Certification provides the customer with documented assurance that a quality system is in place and being checked periodically by a third party to ensure conformance. Among the standards many businesses may be required to meet are ISO9001, ISO 17025 and NADCAP (National Aerospace and Defense Contractors Accreditation). ISO 9001 is an important standard to companies whose work is considered production since high-volume inspection work is often judged on the same criteria as manufacturing operations. Most non-destructive testing (NDT) laboratories need to be certified to ISO 17025, the laboratory accreditation standard that correlates well with the types of inspections and tests performed by NDT organizations. NADCAP is important because a large amount of NDT work is currently 8 NDT ● NOVEMBER 2011

NDT SPECIAL SECTION

done on aerospace and defense related products. Contemplating certification to one or more of these current standards starts with a review of a company’s training program.

Training, Competence and Awareness Employee training is essential for NDT laboratories regardless of which of the many NDT tests they perform. Operating the equipment, performing the tests and evaluating the results are all part of the daily inspection process. Most important, some NDT tests require a high level of skill and expertise when it comes to interpretation of results, such as in radiography and ultrasonic testing. Both training and evaluation for employee competence are absolutely essential. When implementing a quality program for the first time, no matter which one, this is a good place to start.

General Training Requirements NDT labs that are not seeking formal quality system certifications may find ASTM E 1212-04, Standard Practice for Quality Management Systems for Non-destructive Testing Agencies, useful as a guideline for developing a Quality Management System. Paragraph 7.3 spells out the requirements for employee selection and training. It states that, “a training program shall be maintained to ensure employees develop and retain skill competence.” It continues by saying that, “NDT personnel shall be qualified in accordance with a nationally recognized NDT personnel qualification practice or standard such as ASNT-CP-189, ASNT/SNTTC-1A, NAS 410 or a similar document.” The www.ndtmag.com

American Society for Testing Methods (ASTM), which provides testing methods for almost every industry, provides guidance for all accepted NDT techniques and test methods.

American Society for Non-Destructive Testing and Other Sources The American Society for Non-destructive Testing (ASNT) is the primary source of training requirements for NDT personnel. Non-destructive testing encompasses more than 30 test methods and techniques, most of which come from ASTM. ASNT provides training guides and certification for most of them. There are several commercial schools and organizations, as well as community colleges and aviation schools around the country, that provide NDT training and certification. These programs can be easily located on the Internet and in magazines and other periodicals. Today, as in the past, the U.S. military provides training and releases hundreds of qualified technicians into the civilian job market every year.

ISO/IEC 17025-2005 and ISO 9001:2008 Requirements Many customers require that their sources for NDT inspections have laboratory accreditation to ISO 17025. Unlike ISO 9001, which is focused on organizational quality and excellence, ISO 17025 is all about individual competence and proficiency. Because of the unique requirements for demonstrating competence in this standard, employee training takes on a whole new meaning and a new set of guidelines if accreditation is required. And these same requirements extend to both trainees and contract employees, which means that work performed by a trainee, an experienced employee or a person contracted to perform the work, all must show the same level of training and competence. The ISO 17025 standard requires that the organization ensure the competence of all personnel who operate equipment, perform tests, evaluate results and sign test reports. In a typical NDT lab, that’s just about everybody. And competence only can be achieved through documented training and documented work www.ndtmag.com

Employee training should be the cornerstone of any program designed to achieve certification to international standards such as ISO17025 or Nadcap. Source: Magnum Quality Resources

experience. ISO 17025 spells this out by stating that personnel performing specific tasks shall be qualified on the basis of education, training, experience and demonstrated skills. The ISO 17025 standard specifically calls out non-destructive testing as a technical area where personnel performing specific tasks must hold certification. Laboratory assessors with access to Level I, II & III training requirements spelled out in the American Society for Nondestructive Testing (ASNT) training guides will want to see either certification of employees or internal training that conforms to the same requirements in the ASNT guide. Additionally, ISO 17025 requires NDT labs to formulate goals for education, training and skills of NDT personnel. This includes a certain amount of planning and documentation. The

standard goes on to say that personnel responsible for opinions and interpretations should have training, experience, qualifications and: • a relevant knowledge of the technology used for the manufacture of products and materials being tested. • knowledge of the way the products or materials are used or intended to be used and the defects and degradation that may occur during use or service. • knowledge of the general requirements found in applicable legislation and standards. • an understanding of the significance of deviations found with regard to the normal use of the items, materials or products. Finally, ISO 17025 requires NDT labs to evaluate and document the effectiveness of all training actions and keep

NDT SPECIAL SECTION

NOVEMBER 2011 ● 9 NDT

detailed training records and certifications for all employees engaged in testing activities. ISO 9001, while not as stringent as ISO 17025, still requires evidence of a training program, training performed, measurement of the effectiveness of the training and an evaluation of the competence of each employee.

Safety: Several NDT methods and techniques contain potentially harmful attributes. Gamma rays, dangerous chemicals and work in confined spaces all need to be addressed as necessary.

NADCAP Requirements NDT labs that plan to go beyond ISO certification and seek NADCAP certification face even more stringent requirements. National Aerospace Standard NAS 410 Revision 3 spells out a complete set of training and training documentation requirements for NDT. NADCAP training requirements for NDT levels I, II and III, and the required documentation, are the most stringent. NADCAP (through NAS 410) spells out very specific training, testing and evaluation requirements. Likewise, NADCAP documentation requirements also are very strict and demanding.

Structuring Your NDT Training Program Getting started is the most difficult part of any program. A solid and effective training program should start with these first basic steps. Job Descriptions: Both ISO standards require written job descriptions for every job category. Job descriptions, when done well, are a guideline for what training may be required to fill the job requirements listed. Training requirements, training performed and employee evaluations should all closely follow what is documented in the job description. Long Range Planning: What is the purpose of your training program? Are you seeking ISO or NADCAP certification? These are questions that should be asked up front. The types of training, and the degree of documentation, needs to match long-term plans right from the start. 10 NDT ● NOVEMBER 2011

Resources: What training resources are needed? Where can they be obtained? Will it be in-house training or training by consultants or professional trainers? What kind of reference materials will be needed? What will be on hand for training and who will control it? Equipment Training: Don’t forget to train employees on the correct ways to use equipment. Safety concerns and calibration requirements are all important. Theory: NDT training always requires discussion on theory. Why do materials exhibit the properties they do? What is magnetism and how does it work? NDT technicians need this training and all ASNT training programs are loaded with it. Performing the work: The most obvious element is how to perform the work, including how to read a specification. Often times, specifications include several options, known as methods within techniques and techniques within methods. Watch out for these because NDT customers are often very specific as to the technique and/or method they have specified. Quality: Product quality requirements, process quality requirements and the organizations goals for quality and quality certifications.

NDT SPECIAL SECTION

Achieving laboratory certification to any of the standards discussed here as required by current or future customers can be a daunting task. Getting management buy-in to the process of upgrading a laboratory’s skill set and competence is essential. Fortunately, there a lot of resources out there to help. A well-planned and executed training program will pay off in both the short and long run. NDT Nick Cirenese is a principal at Magnum Quality Resources in Sterling Heights, MI. [email protected]

References Relevant standards for laboratories seeking certification include: • ISO/IEC 17025:2005— General requirements for competence of testing and calibration laboratories. • ISO 9001-2008—American National Standard for Quality Management Systems-requirements. • ASTM E 1212—Standard practice for Quality Management Systems for Nondestructive Testing Agencies. • ASTM E 1316—Standard Terminology for Nondestructive Testing • ASNT SNT-TC-1A—Recommended practice for personnel qualification and certification in Nondestructive Testing. • ANSI/ASNT CP 105—Qualification and Certification of NDT Personnel • ASNT IRRSP—Certification for Industrial Radiography and Radiation Safety Personnel. • NAS 410—National Aerospace Standard • For more information, visit www. astm.org and www.asnt.org www.ndtmag.com

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PHASED ARRAY

Training Time and again, training has proven to be the limiting factor with phased arrays. One of the main objectives to improve training is to illustrate that certification is a key. By Michael Moles

A

As a ssupplier in phased arrays, Olympus NDT organizes AUT training courses on phased org organ arra and related subjects. These courses are arrays comprehensive, but are primarily aimed at comp lower end of the market, i.e. portables the lo l and instruments. The rationale is that nd related re higher-end instruments typically require specialized, well trained operators, while limited application instruments require “go/no-go” interpretation. This leaves a large market for portable phased array instruments requiring general training and certification. One of the main limitations of training is the requirement to be “certified.” Not surprisingly, certification means different things in different countries. Europe and Asia are working on harmonizing EN 473 and ISO 9712, while North America is working on a different approach. With the U.S., the dominant player in North and South America for NDE training and certification, ASNT has modified the ISO qualifications accordingly. The ASNT-modified ISO 9712 document is reduced, compared with the original

12 NDT ● NOVEMBER 2011

NDT SPECIAL SECTION

ISO document, and the differences between the ASNT ISO version and the global ISO 9712 are illustrated. ASNT is also looking at a new phased array approval process, which would use standard headings, formats and questions for training, but it is unclear when this will be approved. Conveniently, the Nuclear Research Commission has also required improved certifications (i.e. with a blind examination), and the ASME NDE (ANDE) program was developed accordingly. Hopefully, this will introduce North America to global certifications for NDT training. This would resolve one of the major issues facing manufacturers–a globally accepted phased array certification program. However, time and again, training has proven to be the limiting factor with phased arrays. One of the main objectives to improve training is to illustrate that certification is a key. Specifically, there are two main factors to look at for training, though as a viewer, not as a regulator: • Classroom hours, and • Certification specifications. Both written and practical exams require blind tests. Ensuring that all operators have globally recognized certification works reasonably well in Europe, Asia, Australasia and maybe Africa where ISO 9712 (3) and its related codes—EN 473 (4), PCN and CSWIP—are functioning. However, this leaves us with limitations in North America, where ASNT (American Society for Non-destructive Testing) is dominant. www.ndtmag.com

North American Certifications ASNT has two types of certifications: one is the well-known company certifications, which have their uses (5). To quote, “Employers are responsible for administering the visual acuity, practical and any job-specific examinations required by their written practice to complete the certification process.” This type of certification is company-specific and cannot be transferred by the operator on changing jobs. The other certification is the ASNT Central Certification Program (6) or ACCP, which is exam-based and transferrable. Neither certification includes advanced techniques like phased arrays and Time-Of-Flight Diffraction (TOFD). Thus there is a hole in North America’s advanced (read: phased arrays) NDT certifications, which is covered elsewhere in the world. According to the ASNT web site, the ACCP Level II UT meets the ISO requirements (though which version of ISO is not clear). ASNT is developing a Body Of Knowledge (BOK) for phased arrays, supplied by one of the Olympus NDT Training Academy Members. This is work in progress, though apparently the outline has been published. ASNT has developed their own version of ISO 9712 (7), with local adaptations – as permitted by the World Trade Organization. Here, we have some interesting modifications, for example, reducing the required hours for Level II Phased Array training from 80 to 40. In reality, these changes may not be globally acceptable, as Non Tariff Barriers (NTBs) may be erected to eliminate North American manufactured products in export markets.

North American Nuclear Certifications There are also nuclear-specific qualifications, in both Europe and North America. In Europe, we have the ENIQ (European Network for Inspection Qualification) (8). This is more of a general framework, with each country having qualification rights to regulate NDE procedures and techniques. ENIQ allows judgment in assessing the need for and extent of physical trials in demonstrating adequate performance. www.ndtmag.com

Minimum Training Requirements

NDT Method

Level 1 (hours)

Level II (hours)

ET

40

40

MT

12

8

PT

4

8

RT

40

40

UT

40

40

VT

8

16

National Explanatory Note: The Training hours in this table have been modified to reflect current national NDT certification requirements used by the majority of U.S. industry. Arbitrarily increasing these hours to reflect the ISO 9712 training hours, without technical justification, would result in an excessive burden on industry. Source: Reprinted from ASNT ISO 9712-2008 (7) with permission from the American Society of Nondestructive Testing. All rights reserved. No further copies can be made without written permission. Extract from ISO 9712 (3). Source: ASNT

Level 1 hours a d e

Level 2 hours a b d e

AT

40 c

64 c

ET

40 c

40 c

IT

40 c

80 c

A – Basic knowledge

8

16

B – Pressure method

14

28

C – Tracer gas method

18

36

MT

16

24

PT

16

24

RT

40 c

80 c

ST

16

24

UT

40 c

80 c

VT

16

24

NDT Method

LT

(a) Training hours include both practical and theory courses. (b) Direct access to Level 2 examination requires the total hours shown for Level 1 and Level 2. (c) In case of national regulations concerning the duration of a week of work, the 40 hours are equivalent to the legal duration of a week of work. (d) Training duration may be reduced by up to 50% when the certification sought is limited in application or technique. (e) A reduction of up to 50% in the total required number of training hours may be accepted by the certification body for candidates who have graduated from technical college or university, or have completed at least two years of engineering or science study at college or university.

NDT SPECIAL SECTION

NOVEMBER 2011 ● 13 NDT

Extract from ISO 9712 (3). Source: ASNT Extract from ASME ANDE certification rules (9). Source: Reprinted from ASME 2010 BPVC, Section V and Section XI, by permission of the American Society of Mechanical Engineers. All rights reserved. No further copies can be made without written permission.

Level I

Level II

Level III

40/40

40/40

40/0

GENERAL NOTES: (a) To certify a candidate directly to Level II with no time at Level I, the total hours of training required for Level I plus Level II shall apply. (b) To certify a candidate directly to Level III with no time at Level I or Level II, the total hours of training required for Level I plus Level II plus Level III shall apply. (c) Industrial or academic training courses covering the topics listed in 9.0 of Supplement 1 may be credited toward the training required for Level III personnel. (d) The hours of instruction devoted to each subject in Supplement 1 shall be determined by the NDE Instructor.

TABLE VII-4220-1 INITIAL TRAINING HOURS (CLASSROOM/LABORATORY)

Extract from ISO 9712 on different product sectors (3). Source: ASNT A.2 Product sectors (a) Castings (ferrous and nonferrous materials) [c]. (b) Forgings (all types of forgings: ferrous and nonferrous materials) [f]. (c) Welds (all types of welds, including soldering, for ferrous and nonferrous materials) [w]. (d) Tube and Pipe (seamless, welded, ferrous and nonferrous materials, including flat products for the manufacture of welded pipes) [t]. (e) Wrought products, except forgings (plates, bar, rods) [wp].

In the USA, ASME has recently supported another type of qualification, through ANDE (ASME Non-destructive Examination). ANDE does not use ASNT as a certification body, but uses the ASME certification instead from Section XI Article VII 4000 on Qualification Requirements (9). Thus, for a direct-toLevel II candidate, 80 hours of classroom training would be needed (plus experience, of course). ANDE is developing a Body Of Knowledge, which will cover all techniques, e.g. UT, EC, MT, PT, and phased arrays as well. Perhaps the main question for ANDE certifications is: “Will they be 14 NDT ● NOVEMBER 2011

acceptable outside the North American nuclear industry?” In contrast, the qualification requirements for (non-nuclear) ASME Section V Article 4 for AUT inspections (10) reads: “Only qualified UT personnel trained in the use of the equipment and who have demonstrated the ability to properly acquire examination data, shall conduct production scans. Personnel who analyze and interpret the collected data shall be a Level II or III who have documented training in the use of the equipment and software used. The training and demonstration requirements shall be addressed in the employer’s writ-

NDT SPECIAL SECTION

ten practice.” (Reprinted from ASME 2010 BPVC, Section V and Section XI, by permission of the American Society of Mechanical Engineers. All rights reserved. No further copies can be made without written permission) In ASME Section V, the assumption is that ASNT will perform this certification. There are differences between ENIQ and ANDE. Specifically with ENIQ, there is no qualification of equipment and probes by themselves. As each inspection procedure is case-by-case, a manufacturing company cannot develop a general inspection process to get its equipment qualified. Only service companies can run qualification of their NDT system, which includes procedure, manpower, instrument and probe. With ANDE, there is the possibility/probability of getting equipment approved by EPRI to go onto their acceptance list. As such, the direct involvement of an inspection company per se is not essential.

And Where Now? So, where does certification stand in North America? Reading this article, it sounds like North America is in major disarray, but in practice things are not that bad. Specifically, Olympus has been encouraging the introduction of ISOrelated phased array training courses into North America, with some success. Lavender International is introducing PCN courses (ISO-related) for phased arrays and for TOFD; Davis NDE and Eclipse Scientific are also introducing ISO-related courses. In addition, other companies outside North America, like Global School of NDT and Jubail Industrial College, are developing ISO courses. Given that it has taken years to get EN 473 and ISO 9712 to settle minor differences (11), our progress can be considered as reasonably brisk. However, the situation will be more comfortable when all trainers can offer globally-acceptable phased array certifications, most likely based on the ISO model. Not surprisingly, there are issues with the ISO approach as well. For example, ISO breaks down components into several sectors. www.ndtmag.com

The other issue, from one perspective, is the number of hours appropriate for training. For example, when Olympus started training, it ran a two day course only–called “Introduction to Phased Arrays”. Naturally, this course was not planned for qualifications, but proved woefully inadequate in terms of certification. This course was really only useful for engineers and managers, to get an idea of what phased arrays could do. Training courses have now expanded to 40, then 80, hours– many in keeping with ISO, PCN and other certifications. In fact, some training companies are even offering (private) courses of three or more weeks.

References

Conclusions

8. http://safelife.jrc.ec.europa.eu/eniq/

The phased array training programs, like Olympus NDT’s, have been very successful. Ideally, the industry could benefit from seeing all courses using the same certification. There is a significant difference between ISO-controlled certifications and ASNT-company certifications–for both global acceptance and for content. In other words, there is a mish-mash of certifications, but we are slowly iterating towards acceptable, transportable certifications–probably ISO 9712. NDT

9. ASME Section XI Article VII-4000 “Qualification Requirements”, 2010, p. 277.

Michael Moles is with Olympus NDT.

For more information, visit http://www.olympus-ims.com/en/training-academy/

3. ISO/DIS 9712: 2005. “Non-destructive Qualification and certification of personnel”.

testing

–

4. EN 473: 2009, “Non-destructive testing - Qualification and certification of NDT personnel - General principles”. 5. http://www.asnt.org/certification/levelii/ndt_about.htm 6. http://www.asnt.org/certification/levelii/index.htm 7. ANSI/ASNT CP-106 (ISO 9712:2005, Modified), “Nondestructive Testing – Qualification and Certification of Personnel”, 2008 Edition.

10. ASME Section V Article 4 Mandatory Appendix VI, “Ultrasonic Examination Requirements for Workmanship Based Acceptance Criteria”, 2010. 11. h t t p : / / w w w . n o r d i c i n n o v a t i o n . n e t / a r t i c l e . cfm?id=1-834-685

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NDT SPECIAL SECTION 3/7/07 9:44:26 AM

NOVEMBER 2011 ● 15 NDT

IN A DOWN ECONOMY, LOOK TO

NDT Rentals What is the solution for an NDT service company when they require an inspection tool but do not have the capital? NDT equipment rental companies have been delivering the answer. By Dylan Duke

T

The gguys in Washington might be saying the recession is over, but try telling that to the strugre recess businesses and the 9.1% unemployed. The g gling fact is, fa is times are tough for businesses. One does not have to be an economist to know that, in a n h economy, businesses have less capital to d down invest, especially when banks are lending at an all time low. What is the solution for an NDT service company when they require an inspection tool but do not have the capital? NDT equipment rental companies have been delivering the answer. Many businesses are not aware of the advantages a rental company has to offer a business and how it can help a company grow. NDT rental companies provide a quick solution to any business in a capital crunch or with an inability to obtain a loan from the bank. Why tie up much-needed capital when, for a fraction of the cost of ownership, a business can rent almost any NDT tool? Rental companies offer the ability to rent a tool daily, weekly, 4-weekly or even long-term. The rental frees up capital tied to owning the equipment while still getting to use that equipment. Not in a capital crunch and the bank is the company’s best friend? An operation may still need the service of a NDT rental company. On the

16 NDT ● NOVEMBER 2011

NDT SPECIAL SECTION

day of the job, how many times has a technician realized the equipment is out of calibration, deep discharged or does not function? I have heard too many of these sad stories. All of these issues result in lost time and revenue. With a NDT rental company, the equipment is calibrated, fully charged and ready to go, saving on calibration, maintenance and other hidden costs of ownership. What about the age of the company’s existing equipment? Every year manufacturers come out with the latest technology. It is only a matter of a few years before NDT tools are considered outdated. Customers might not want outdated equipment on the job site or have seen competitors showing off their new tools. This forces the purchase of the latest equipment. NDT rental companies always have the latest NDT tools on the market, allowing the job to get done with the best tool on the market at a fraction of the cost of ownership. What about inventory? Inventory is always in issue with NDT companies. How many NDT tools are on hand, where is the equipment located and who has it right now? Unfortunately, sometimes these are difficult questions to answer. I have heard many stories about how UT

TECH TIPS ● Equipment can be rented daily, weekly, 4-weekly or even long-term. ● Lost or incorrect inventory costs time and money. ● Many NDT rental companies can ship equipment overnight or deliver the same day.

www.ndtmag.com

gauges spring legs and “walk off ” job sites. Or inventory was incorrect and fewer tools were available then thought. Lost or incorrect inventory costs time and money. Rental equipment eliminates the need for tracking inventory. It frees up time and money for other important issues. Still need to be convinced that rental might be a valid option? How about when booking an unexpected job? Many rentals result from unexpected work at the site. For example, a company is contracted to do one job but the customer is now requesting more work be done. Not owning the right equipment to complete the extra work could jeopardize the contract. For a fraction of the cost of ownership, a business can rent One call to an NDT rental almost any NDT tool. Source: MFE Rentals, Inc.

company and the equipment can be shipped overnight or delivered the same day. NDT rentals are a great way of doing business. It results in freed up capital for more important jobs. Rentals can assure that the latest and greatest equipment can be on the job site, calibrated, fully charged and ready to go while saving on calibration and other costs. Rentals free up the time and money associated with keeping an inventory and make it easier to handle the unexpected workload. For these reasons, and a few more, the NDT rental market is a key in a struggling economy. NDT Dylan Duke is vice president of MFE Rentals, Inc., in Pasadena, TX.

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NOVEMBER 2011 ● 17 NDT

COMPUTED TOMOGRAPHY Making Up for Lost Time Although the medical industry has traditionally been the largest driver for X-Ray inspection systems, the first use of X-Ray was intended for an industrial application. By Nikhil Jain

T

The use u of X-Ray inspection techniques for nondestructive applications dates back almost no nonde 100 with the invention of high vacuum 10 years y tubes. Although the medical industry has XX-Ray traditionally been the largest driver for X-Ray tr tradit inspection systems, both in terms of technology in inspec and implementation, it is interesting to note that the first use of X-Ray by Wilhelm Conrad Rontgen was intended for an industrial application. Rontogen’s discovery that X-Rays could pass through human tissue, but not through materials of higher density, soon led to a revolution in the world of science and medicine. It was not until 1912, about 17 years after Roentgen’s discovery, that the use of X-Rays broadened to include industrial applications with the invention of high vacuum X-Ray tubes designed by William Coolidge. This trend continues today with the capabilities of X-Ray inspection systems reaching

18 NDT ● NOVEMBER 2011

NDT SPECIAL SECTION

new heights and its use becoming more frequent and commonplace for industrial applications ranging from materials research, maintenance and repair, manufacturing and quality control. Technological advances in hardware, such as tubes, sources and detectors, as well as upgrades in software, have significantly improved the productivity and user-friendliness of X-Ray inspection systems. In a poll conducted by Britain’s Science Museum in 2009, in which nearly 50,000 votes were cast, X-Ray was recognized as the most important modern scientific achievement of the 20th century on a list of the top ten greatest achievements in science, technology and engineering. With rapid advances in manufacturing technologies, material research and precision engineering, the industrial X-Ray inspection industry has had to evolve to accommodate the needs of its expeditiously developing customers. The growing need for increased productivity, quality and accuracy at lower costs has led to the industry witnessing a paradigm shift from analog to digital X-Ray technology. Led by advancements in the medical field, X-Ray technologies such as computed radiography (CR), digital radiography (DR) and computed tomography (CT) have seen accelerated development over the past few years. Amongst these three technologies, CT has witnessed sluggish demand since its introduction www.ndtmag.com

for industrial application. This article will provide a basic understanding of CT, factors currently driving its adoption and an outlook for the future.

CT: Back to the Basics CT is a radiographic inspection method that utilizes a computer to generate a three-dimensional image of the internal structure of an object under test. A general CT process consists of acquisition, correction, reconstruction and viewing the result or post-processing. Acquisition consists of rotating the test object, 360 degrees, on a turntable to procure a set of high resolution radiographs. This set of radiographs then undergoes geometrical correction to account for a few non-linearities introduced by the imaging device. Reconstruction is the most important part of the CT process, wherein the set of individually corrected radiographs are combined to obtain the three-dimensional image. The reconstruction of the radiographs is done with the help of advanced software that also displays the final image. This image can be processed further to obtain the desired result.

Lukewarm Industry Acceptance Initially, in the late 1980s, when CT systems were first used for industrial applications, the main hindrance for its widescale market adoption was price. CT

inspection systems are among the most expensive nondestructive techniques, with prices ranging from $90,000 to as high as $2 million. The prices are directly related to the capabilities of the system. Entry level CT systems equipped with a 130 kV tube are usually available for less than $100,000, while a 450 kV CT system could cost between $500,000 and $2 million. Although prices of CT inspection systems have dropped, the reduction has not been significant enough to be affordable to the lower tier of end-user industries such as automotive, manufacturing and electronics. Also, CT has been described by many experts as a cumbersome, slow and difficult-to-use technique. For the most part, dependence of CT on the computational powers of a computer can be held responsible. CT is a very data-intensive process, as a result of the detailed level of its analysis capabilities. This makes CT inspection a relatively slow technique and not suitable for production environments. To put things in perspective, a typical CT configuration acquires 720 projections to produce 512 cross-sectional images, each 512 by 512 pixels. Hence, there are nearly 100 billion calculations, each requiring several basic math operations. An advanced CT configuration often-used is 1,440 projections and 1,024 cross-sectional images, each with 1,024 by 1,024 pixels,

Others 12.0%

Power Generation 16.7%

Electronic 20.2%

Automotive 23.3%

Aerospace and Military 16.7%

● CT inspection systems range from $90,000 to as high as $2 million. ● An advanced CT configuration oftenused requires 1.5 trillion calculations. ● The CT inspection system market was valued at around $150 million in 2010. ● The market is expected to grow at a compounded annual growth rate (CAGR) of 8 percent.

requiring 1.5 trillion calculations. The shear volume of calculations places significant burden on the computer. As a result, acquiring a CT image could take a number of hours. Since the time taken to obtain an image is usually not of critical importance in the medical field, CT has become a standard form of X-Ray. However, for industrial applications, there are severe constraints on time and costs and CT had fallen behind in comparison with other X-Ray technologies. In the past few years, however, advances in computer technology and the reconstruction software have helped reduce the time needed for obtaining a CT image. But, the process is still sluggish in comparison with the productivity gains

North America 35.1%

Rest-of-World 8.1%

Asia Pacific 22.6%

Oil and Gas 2.6%

Aerospace and military applications lead the end-user market for computed tomography inspection. Source: Frost & Sullivan

www.ndtmag.com

TECH TIPS

Europe 34.2% Geographically, North America and Europe represent the majority of the global end-user market computed tomography inspection. Source: Frost & Sullivan NDT SPECIAL SECTION

NOVEMBER 2011 ● 19 NDT

Complex manufactured components in the aerospace industry, used for safety critical applications, require high-end inspection techniques. of DR and CR, which limits the number of applications it can be used for.

Potential Applications Previously restricted to laboratory environments, advancements in software have resulted in CT systems moving out of the realm of R&D applications and into more non-traditional markets. Currently, CT is being used extensively in homeland security, for inspection of baggage at airports. It is also being used by the military for missile inspection and small-scale failure analysis. The aerospace industry is utilizing the benefits of CT for crack analysis in components and turbine blade inspection. With considerable improvements in scan speeds, CT systems are expected to be made available for productionline inspection applications. Although, constraints in current instrumentation limit the use of CT in production line testing, within the next five years, conformance with quality standards and 100 percent automated inspection at production line speeds is within the realm of possibility. An important niche in this industry is expected to be 4-D computed tomography, a technology that is an integral part of the medical imaging community. Bringing the time dimension into consideration, 4-D CT is expected to enhance real time monitoring capabilities. Also, the ability of 4-D CT to capture a full range of motion of critical internal structures will propel this technology in the future.

Market Overview Although, CT systems were introduced into the field of industrial inspection

20 NDT ● NOVEMBER 2011

more than a decade ago, it’s only in the past five years that this segment has really come into prominence. A highly successful imaging technique in the medical field, it was only a matter of time before CT systems became an essential part of the nondestructive testing market. CT systems are currently a high growth area for X-Ray inspection systems with rapid changes and enhancements in technology compared to other industrial imaging techniques. These advancements in technology have rapidly improved the speed, cost and user-friendliness of CT systems, which in the past were meant only for highend laboratory applications. Frost & Sullivan research into the global CT inspection system market for industrial applications valued it at around $150 million in 2010. The market is expected to grow at a compounded annual growth rate (CAGR) of 8 percent. This is considerably impressive since the overall global X-Ray inspection systems market is expected to grow at five percent CAGR. From an end user perspective, aerospace is the highest revenue generator. Complex manufactured components in the aerospace industry, used for safety critical applications, require high-end inspection techniques. Components with complex shapes such as turbine blades, rotor blades and fuel nozzles cannot be effectively inspected for f laws and cracks by ordinary NDT inspection tools. Several aircraft components are subjected to harsh environments and are expected to have a shelf life of more than 20 years. Powerful inspection tools that are used throughout the life cycle of the product right from materials research, optimi-

NDT SPECIAL SECTION

zation of the production process and maintenance and repair is essential for the aerospace industry. The use of CT systems in the electronics end-user segment is growing. The integration of microfocus and nanofocus tubes with CT systems enables the inspection of components such as printed circuit boards (PCBs), integrated circuits (ICs) and high-density BGA chips. Microfocus/nanofocus X-Ray inspection has become the most widely-accepted method in controlling the quality of board assemblies, and in analyzing the defects associated with hidden solder joints such as insufficient reflow, faulty paste print, extraneous voiding and bridging.

Conclusion As with other X-Ray techniques, technological advancement is driven by the medical industry. The shear size of the medical industry—and its willingness to embrace newer technologies—results in high R&D investment to eradicate f laws in the technology. The NDT industry is a direct beneficiary of these advancements. The technology developed for medical applications of course has to be tweaked to suit the harsh environments the X-Ray system is subject to in production environments. Another factor that has contributed to the popularity and growth of CT as an inspection technique has been the effort taken by X-Ray instrumentation vendors to promote the capabilities of this technique and improve awareness of the end-user. There have been several product introductions with enhancements and refinements to existing CT capabilities from leading CT vendors such YXLON, North Star Imaging, phoenix X-Ray, Nikon Metrology and Dage. Considering the various advantages of CT, it is expected to expand significantly over the next five years, in terms of technology, application and revenues. NDT Nikhil Jain is Measurement & Instrumentation Research Associate for Frost & Sullivan. E-mail: [email protected].

www.ndtmag.com

Advertiser

Page

Phone

Web Address

American Society For Nondestructive Testing

6NDT

(800) 222-2768

www.asnt.org

Applied Test Systems Inc.

15NDT

(724) 283-1212

www.atspa.com

Carestream Health

1NDT

CSC Force Measurement Inc.

15NDT

(800) 866-FORCE

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Gradient Lens Corp.

7NDT

(800) 536-0790

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NDT Systems

5NDT

(714) 893-2438

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Olympus NDT

IFCNDT

(800) 225-8330

www.olympus-ims.com

Proceq USA, Inc.

IBCNDT

(724) 512-0330

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Spectronics Corp.

3NDT

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Yxlon International

BCNDT

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www.yxlon.com

www.ndt.carestream.com

This index is provided as a reader service. The publisher assumes no liability for errors or omissions.

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