Applications of Nondestructive Testing in the Automotive Manufacturing Industry

Release Date:

2021/12/11

Nondestructive testing (NDT) is a technique that, without causing any damage to the test object, exploits the changes in thermal, acoustic, optical, electrical, magnetic, and other responses induced by internal structural anomalies or defects to detect both internal and surface flaws in various engineering materials, components, and structural parts. It also enables the identification and evaluation of defect type, nature, quantity, shape, location, size, distribution, and their evolution. With the rapid advancement of modern sciences such as microelectronics and computer technology, NDT has likewise experienced swift development. I. Applications of Nondestructive Testing in the Automotive Industry

Nondestructive testing (NDT) is a technique that, without causing any damage to the test object, exploits changes in thermal, acoustic, optical, electrical, and magnetic responses—resulting from internal structural anomalies or defects—to detect both internal and surface flaws in various engineering materials, components, and structural elements. It further enables the identification and evaluation of defect type, nature, quantity, shape, location, size, distribution, and their evolution. With the rapid advancement of modern sciences such as microelectronics and computer technology, NDT has also experienced swift development.

I. Application of Nondestructive Testing Technology in Automobiles

(1) Ultrasonic Testing of Automotive Half Shafts

Fracture of the half shaft of Failure is primarily caused by high-frequency, low-stress fatigue damage, and the presence of internal defects in the workpiece is one of the major factors leading to fatigue fracture. Ultrasonic immersion testing can be employed to inspect both the raw material and the forged semi-finished products of the half shaft. During inspection, a transducer converts high-frequency electrical pulses into ultrasonic waves, which are then coupled into the half shaft via a coupling medium. When the incident wave encounters a defect—i.e., an interface between materials with different acoustic properties—it is reflected due to the difference in acoustic impedance. The reflected ultrasonic beam is subsequently converted back into high-frequency electrical pulses by the transducer; after amplification and processing, the location, size, and nature of internal defects in the half shaft can be determined based on the position, amplitude, and waveform characteristics of the reflected echoes. The advantages of this method include substantial acoustic energy penetration within the workpiece, which enhances flaw detection sensitivity and resolution, as well as stable, clear, and highly reproducible test waveforms. However, a drawback is the existence of a blind zone of approximately 5 cm at the workpiece surface.

(2) Magnetic Particle Testing for Detecting Surface Defects in Components

Magnetic particle inspection utilizes the focusing effect of magnetic particles to reveal surface and near-surface defects in ferromagnetic materials and components. This technique is widely employed for inspecting automotive parts such as crankshafts, camshafts, connecting rods, tie rods, and ball joints. The principle of magnetic particle inspection is that, when a material or workpiece is magnetized, any defects present on or near the surface generate a leakage magnetic field. This leakage field attracts the magnetic particles applied during the inspection process, thereby forming visible indications of the defects. The key to effective magnetic particle inspection lies in properly establishing a magnetic field on the test piece; given the wide variety of sizes and shapes of workpieces, it is essential to select the appropriate magnetization method.

(3) Laser Holographic Tire Inspection

Tires are multilayer structures composed of rubber laminated with fabric cords, nylon filaments, and other materials; during manufacturing, impurities can easily become entrapped at the lamination interfaces, leading to defects such as bubbles and delamination. These defects are difficult to detect using conventional inspection methods, resulting in defective products leaving the factory and creating potential safety hazards. Holographic technology leverages the principles of light interference and diffraction to record specific light waves emitted by an object as interference fringes, which can then be reconstructed under appropriate conditions to produce a realistic three-dimensional image of the object. The size of tire defects can be determined from the abnormal distortion patterns in the hologram, while the depth of the defect can be inferred from the spacing of these distortion fringes. Since defect depth is directly proportional to the fringe spacing—deeper defects are farther from the tire’s inspection surface and thus produce smaller surface displacements—the resulting fringe spacing will be larger, and vice versa. Because hidden defects beneath the tire’s surface vary in type and size, it is necessary to apply controlled loading to the tire so that defect characteristics and structural features manifest as localized surface distortions. As illustrated in Figure 3, this approach involves positioning the optical system on the inner side of the tire and placing both the tire and the optical setup inside a specially designed vacuum chamber for pressure reduction and load application, followed by photographic inspection. Moreover, during holographic reconstruction, the reconstructed interference fringes are highly sensitive to the viewing angle; even if the defect-related interference fringes have been recorded in the hologram, improper selection of the observation angle may prevent their detection, leading to missed defects. To address this issue, phase-holographic photography can be employed. This technique records both the phase hologram and the speckle shear map in the same hologram, enabling the measurement of an object’s three-dimensional displacement and its derivatives, thereby enhancing detection accuracy. This represents a further advancement in laser holographic inspection of tires.

II. Development Trends of Nondestructive Testing Technologies in the Automotive Industry

With the advancement of computer technology, nondestructive testing (NDT) has evolved toward faster, more standardized, digital, automated, and regulated practices. High-sensitivity, high-reliability, and high-efficiency NDT diagnostic instruments and methodologies are continually being developed. In recent years, General Motors has invested heavily in seamlessly integrating modern robotics, adaptive technologies, automatic control systems, computer science, and CAD/CAM with NDT, thereby advancing research on three-dimensional ultrasonic scanning imagery and technologies for reconstructing internal quality information within inspected components. This integration extends the NDT process throughout the entire lifecycle—from design and manufacturing to operation—significantly enhancing quality-control capabilities. Currently, NDT is primarily employed for quality inspection of finished products, including vehicle bodies and chassis, as well as welded, forged, and cast components; applications in this domain are both widespread and well-established. Beyond quality inspection, NDT should also fully leverage its strengths by aligning with the needs of automotive development and post-sales quality-tracking initiatives to drive product innovation. The future trend of NDT in the automotive industry involves establishing comprehensive quality-management systems, intensifying R&D and application of proactive in-process inspection technologies, and strengthening the development and application of NDT techniques tailored to new materials.

Applications and Development of Ultrasonic Testing Technology

Analyzing the Differences Between TOFD and Phased Array

Applications and Development of Ultrasonic Testing Technology

Analyzing the Differences Between TOFD and Phased Array

To further carry forward the spirit of Lei Feng and promote the volunteer ethos of “dedication, friendship, mutual assistance, and progress,” in accordance with the spirit of the Henan Provincial Association for Science and Technology’s “Notice on Launching a Centralized ‘i-Science Popularization’ Science and Technology Volunteer Service Campaign in the Spirit of Lei Feng,” Luoyang Weicheng Engineering Testing Co., Ltd. responded enthusiastically to the call and organized a science popularization event on the safe operation of forklifts. On March 4, our company meticulously planned and conducted an emergency response drill for special equipment—forklift accidents—and invited several nearby companies that use forklifts to observe the exercise. The purpose of this drill was to simulate real-world working conditions, specifically the sudden occurrence of an accident during the process of using a forklift to handle goods.

2024-03-05

The 10th Anniversary Gratitude Celebration of Luoyang Weicheng Engineering Testing Co., Ltd. Concludes Successfully

On the afternoon of December 29, 2023, Weicheng Testing Co., Ltd. held a grand gratitude celebration—“Our Ten Years”—inviting distinguished guests, including Mr. Jia Hong, Director and Vice Chairman of the Titanium-Zirconium Industry Development and Application Center of the China Equipment Management Association, as well as Mr. Lu Fusheng, Executive Deputy Director, Vice Chairman, and Secretary-General, along with clients and partners, to jointly witness this milestone occasion. The first segment of the event: A Decade of Development The event officially commenced at 2:00 p.m., with the company welcoming all attendees

2024-01-11

In 2023, Luoyang Weicheng Engineering Testing Co., Ltd. Successfully Held the “Intensive Training and Competition” — Gamma-Ray Radiographic Inspection Emergency Drill

On October 11, Luoyang Weicheng Engineering Testing Co., Ltd. held a large-scale training and competition—specifically, a γ-ray radiographic inspection radiation emergency response drill—under the theme “Everyone Talks About Safety, Everyone Knows How to Respond to Emergencies.” The event invited leaders from the provincial, municipal, and district levels to attend and observe. Prior to the start of the emergency response drill, Cui Songbiao, General Manager of Luoyang Weicheng Engineering Testing Co., Ltd., and Gong Aifeng, Deputy General Manager, extended a warm welcome to the visiting provincial, municipal, and district leaders and pledged that Weicheng Testing would consistently focus on enhancing its professional technical expertise and emergency response capabilities as key drivers for corporate safety management.

2023-10-19

Return to list

Address: Room 104, Building 9, Futong Intelligent Manufacturing Industrial Park, Jinye 1st Road, Yiyang County, Luoyang City, Henan Province

Phone:+86-379-66915081 +86-379-66915005

Email:lywcjc@lywcjc.cn

Fax:+86-379-66919852

Website:www.lywcjc.cn

WeChat

Yu Public Security Bureau Filing No. 41030602000129

COOKIES

Our website uses cookies and similar technologies to personalize the advertising shown to you and to help you get the best experience on our website. For more information, see our Privacy & Cookie Policy

COOKIES

required

These cookies are necessary for basic functions such as payment. Standard cookies cannot be turned off and do not store any of your information.

analyze

These cookies collect information, such as how many people are using our site or which pages are popular, to help us improve the customer experience. Turning these cookies off will mean we can't collect information to improve your experience.

Feature

These cookies enable the website to provide enhanced functionality and personalization. They may be set by us or by third-party providers whose services we have added to our pages. If you do not allow these cookies, some or all of these services may not function properly.

advertise

These cookies help us understand what you are interested in so that we can show you relevant advertising on other websites. Turning these cookies off will mean we are unable to show you any personalized advertising.