Quality Control

 

The quality control segment of E.I.CO is consisted of three departments; quality control for incoming materials, quality control for the quality of the melt, and quality control of forged materials. All people involved in quality control have been certified and passed required training to conduct needed checking. State of the art instruments in this section allows a through quality control of the products throughout the production line.

 

a) Quality control of incoming materials

Samples are taken from all incoming materials including Ferro-alloys, additives, ingot mold etc in order to check the quality and making sure that the materials are used based on the needed standards.

 

 Radioactive testing

This test is performed in the scrap yard and prior to charging them into the melting furnace in order separate materials contaminated with radioactivity.

 

The melting area is also equipped with quantometery that control the chemical analysis of the melt. Samples taken from each melt is sent to the lab to make sure the composition is within the range specified by the engineering team. Depending on the needs visual and ultrasonic inspection of the produced ingots are performed in this area as well.

 

b) Quality control of semi-finished and finished parts

A variety of tests are performed on semi-fished and finished parts in the forging/pressing plant to meet the requirement set by customers. These tests as follows:

 

  1. Dimensional control

    Dimensional control are needed in various stages to check the diversion of dimension, tolerances, waviness, and asymmetric condition of the parts induced during the process,

    A 100% control is performed by experienced personnel. Tests are done with conventional equipment as well as electronic and laser ones together with ultrasonic testing is also performed. 

     

  2. Ultrasonic testing

    The quality control of E.I.CO.is equipped with several re-known ultrasonic instrumentation. The personnel working with these equipment are also certified internationally to perform these tests with the highest precision possible. Ultrasonic tests are performed with appropriate probes based the wave emitted in the samples. Analysis of the waves emitted in the samples gives an understanding of the internal condition of the forged products and the condition of possible defects. The tests are performed with the highest precision and results are compared with the international standards set for such products. 

     

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  3. Magnetic Particle Testing

    Two methods of Florescent Iron powder and Red Iron Powder are used for magnetic particle testing. The methods are suitable to find surface defects are defects close to the surface in Ferro magnetic materials. In this method whole or part of the sample is magnetized and the magnetic flow is passed through the sample. If a defect exists on the surface or close to the surface of the sample this results in emitted magnetic flow from the sample. By spraying very small Ferro magnetic particle on the surface cracks can be detected under ultraviolet waves.

    Even very small mechanical scratches are detectable by Yoke in such a method.

     

  4. Liquid Penetration Testing

    This one the usual tests of non-destructive testing and capable of detecting surface defects. This test is widely used by experienced personnel in the quality control department of E.I.CO.

     

  5. Hardness measurement

    The hardness measurement is done widely to control the quality of the products at E.I.CO. Heat treatment of hot work on steel usually changes its hardness and mechanical properties. Several stationary as well as portable hardness machines are used in the forging area to control the properties and the results are compared with the standards. Only after firm conformance with the standards the samples are sent to the next phase.

     

  6. Analysis of the products

    Both stationary and portable quantometers are used to check the analysis of the products throughout the production process. This is particularly the case for the forging and heat treatment plants.

     

    Certification

    The quality control department of E.I.CO., after carefully conducting the required testing and comparing them with the standards, issues quality certification based on EN10204. Depending on the needs of the customer this certification can be in two formats; 1) mentioning the results of the tests and the condition of the part, 2) mentioning the range of standards. All certificates of E.I.CO.contain a unique hologram consisting of the company's symbol. Certificates without such a hologram are not valid.

     

    Following are the type and number of equipment used for Quality control:

Equipment

Brand

Number of equipment

Ultrasonic Testing

Krautkramer

2

Portable Quantometer

Belek

1

Ultrasonic Testing

OLYMPUS

4

Portable Quantometer

ARUN

1

Hardness tester

Emcotest N3

1

Portable Hardness tester

EQUO TIP 2

1

Radioactive testing

EXPLORANIUM

1

Magnetic Yoke

Tiede

1

Hardness tester

Coppa

1

 

Management of the laboratories

E.I.CO. uses a highly professional and experienced team for its quality control department. It follows ISO /IEC 17025 standard for calibration, certification and validation.

The testing and quality control department consisted of the following segments:

 

  • Sample preparation area

  • Heat treatment lab

  • Mechanical testing lab

  • Metallographic lab

  • Quantometery lab

  • Chemical lab

  • Calibration lab

     

    The following methods are used in the Quality control department of E.I.CO. to make sure of the soundness of the results of the testing:

  1. Participating in Proficiency Testing (PT) programs

  2. Calibration of the instruments affecting the quality in the calibration lab

  3. Continuously using reference materials certified by CRM for the validation of the equipment of the tests.

  4. Stability control of the testing equipment with secondary reference materials (with control graphs)

    E.I.CO. participates in Proficiency Testing (PT) tests based on an annual program. The results are then analyzed and put in the website for customer information.

     

    Quantometery lab

    Several quantometers are available at E.I.CO. for on-line measurement of the chemical composition from the melt as well as throughout the whole process. Services and Equipment in Quantometery Lab as follows:

     

Equipment

Standard

Testing

ARL 3460 & Spectra Lab

M8

ASTM E1086, ASTM

E415

Determining The

Chemical Composition Of

Steel

ON-MAT 8500

CS-MAT 6250

Bruker G8 & H-MAT 2500

ASTM E1019

Measuring O, N, C, S, H in

steel

 

Chemistry Lab

Chemical analysis is also measured in the chemistry lab that has the following equipment:

 

Equipment

Testing

XRF: Model AXIOS Panalytical

Atomic absorption: Model Shimadzu

Titration ferroalloy

XRF: Model AXIOS Panalytical

Atomic absorption: Model Shimadzu

Analysis of samples of unknown minerals,

slag, refractories etc.

Spectrophotometer: Model Merck

Testing water for drinking and industrial

applications, corrosion control

 

Sample Preparation Lab

In this lab raw materials send from the production plants and the engineering department are converted, by various cutting, milling and machining equipment, to different samples used for tensile, impact, analysis, microstructure etc testing.

 

Heat treatment Lab

The following tests are performed in the heat treatment lab:

Laboratory name

Test

Standard

Equipment

Heat treatment

Jominy test, various cycles for heat treatment of tensile and impact samples,

 

Jominy test standard of ASTM A255-02

-Salt bath furnace

-Furnace under vacuum

-Various small and large furnace

-Jominy test equipment

-Hardness measurement ofM40 075

 

Mechanical Testing Lab

This lab has a tensile testing machine of 1200 KN on rounded and flat specimens, an impact testing equipment capable of up to 450 J and down to -45°C and a hardness measurement instrument for Rockwell, Brinell and Vickers methods.

 

Laboratory name

Test

Standard

Equipment

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Mechanical testing

Tensile

ASTM E8M, ASTM A370,

ISO 6892-2

 

Tensile test machine ZWICK, Z1200Y, Freezer,

Three phases stabilizer

 

Impact energy

BS_ISO_148-1, ASTM E23

Impact tester: Roell

Amsler, Model RKP450

Owen Julaab, Model

FP50

Notch condition: U, V

 

Hardness

ASTM E10, ASTM E18

 

Hardness tester M40 075

 

 


 

Metallographic Lab

With a very experienced team, computerized microscopes the metallographic lab is capable of conducting the following tests: microstructural analysis, grain size measurement, decarburization depth, macro etching, sulfur-print, and micro-hardness. Services and equipment in the metallographic lab as follows:

 

Equipment

Standard

Testing

Light microscope

Nikon ME600 &

Olympus BX51M

With image analysis

Software

ASTM E3, E407

Microstructure

ASTM E112

Grain size

ASTM E45

DIN 50602

Inclusion content

ASTM E1077

Depth of

decarburization

ASTM E348

Micro-hardness

ASTM E381

Macro Etch

ISO 4968

Sulfur Print

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Contact us

(+9821)88841182-6

info@esfst.com