Forged products are typically subjected to high workloads and complex operating conditions. Therefore, selecting appropriate inspection methods, controlling testing environments, ensuring the expertise of inspection personnel, analyzing and recording data throughout the process, and regularly calibrating testing equipment are all critical to quality assurance. Below are the commonly used inspection methods for forged products:
1. Visual Inspection: A preliminary check to detect surface defects. Forgings are examined with the naked eye or magnifying glass, focusing on surface cracks, porosity, inclusions, and forging defects. This method is fast and straightforward, making it suitable for initial screening.
2. Dimensional Inspection: Dimensional accuracy of forge products directly affects the fit and function of forged products, making precise measurements essential. Common tools include calipers, micrometers, and coordinate measuring machines (CMMs). For complex components, CMMs provide highly accurate dimensional data.
3. Hardness Testing: Used to assess material hardness and deformation resistance. Common hardness testing methods include Rockwell (HR), Vickers (HV), and Brinell (HB). Different methods are selected based on the material type, effectively reflecting wear resistance and strength.
4. Metallographic Analysis: A microscopic examination of the metal structure to evaluate grain size, phase composition, and inclusions. This analysis helps determine material uniformity, assess process effectiveness, and ensure the quality of high-performance alloys.
5. Non-Destructive Testing (NDT): Applied to detect internal defects in forged products. Common NDT methods include:
- Ultrasonic Testing (UT): Uses high-frequency sound waves to detect internal flaws such as cracks and porosity.
- Radiographic Testing (RT): Uses X-rays or gamma rays to identify internal structural defects.
- Magnetic Particle Testing (MT): Detects surface and near-surface discontinuities in ferromagnetic materials using a magnetic field.
- Liquid Penetrant Testing (PT): Uses penetrant liquids to reveal surface cracks and defects.
6. Tensile Testing: Evaluates the mechanical properties of forged products by measuring yield strength, tensile strength, and elongation to test the provides critical data on plasticity, strength, and toughness.
7. Fatigue Testing: Evaluate the fatigue failure that forging products may encounter during long-term use by repeatedly loading different cyclic loads. Such tests can determine the durability and safety of the product under actual operating conditions.
