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Our customers place ever higher demands on the production and technical safety of their induction equipment. This means, of course, that we keep developing and standardizing our test procedures. The test procedures listed below are performed by Foundry Service GmbH, either as a standard or as an optional procedure.

MATERIAL STRUCTURE TEST

For each coil to be repaired, a material structure test of the copper profile is run by an independent institution. Of course, this applies also to newly installed copper profiles, for in those cases, too, we must be sure that only flawless copper profiles have been used. The results of the tests are much more than a mere appraisal. For the thorough analysis is an opportunity to draw conclusions as to the reasons for the wear of the coil. That knowledge, coupled with the long-standing experience of the operator, makes it possible to say in concluding whether repair measures of the past were not performed properly or whether the copper profile material has been damaged.

ENDOSCOPIC EXAMINATION

For an impression of the cooling channel and its soldered and welded joints, all copper hollow profiles may be examined with an endoscope to detect cross-sectional changes and deposits or tears inside the profile. 
The endoscopic cooling channel examination is recorded on video, and the customer can view and comprehend any point of the examination.

X-RAY

The necessary radiographic test of weld seams is conducted with the help of X-ray films and an X-ray tube. This is done particularly for vacuum coils and it is performed by an external service provider that is extremely reliable. The films put on the weld seam are exposed to X-rays, which renders a meaningful evaluation of the quality of the weld seam and the interior state of the weld seam. With X-ray technology, especially pores and tears in the weld seam can be detected. The radiological findings are documented in a test report.

HOT COMPRESSION TEST

Under operational conditions, hot compression strength tests are performed for all crucible furnace coils after cleaning of the metal. In that way any capillary cracks may be localized that cannot be found in the cold pressure test. 
The test is run at a water temperature of ca. 80°C and a pressure of 15 to 20 bar for twelve hours and documented.

Helium-Leckraten-Test

After the repair, all induction coils are subjected to a vacuum leak rate test. During this test step, even smallest leaks as well as any capillary cracks that were not detected during the hot compression test are localized through the use of helium. 



Another material structure test will be run for any sites localized by this procedure, to make sure that this is only a local porous site in the material.

HIGH-VOLTAGE TEST

During the final inspection of the induction coil the dielectric strength of the insulation is checked with a high voltage detector. The test spectrum is performed up to 6,000 V, according to manufacturer specifications and recorded.

FINAL INSPECTION

Upon completion of all repair measures and tests, the crucible furnace coil is checked in conclusion. According to our acceptance protocol all relevant data, such as the dimensional stability, the construction of the insulation, the pre-drying of the flat coating of the coil and the delivery condition are recorded. 
Because we are convinced of our quality, we give you a 12 month guarantee for all jobs performed by us.

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