SGS provides brake disk testing
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SGS SA - Industrial Services product story
Edited by the Engineeringtalk editorial team
Jul 16, 2009
SGS Industrial Services has carried out the gamma radiation control of brake disks for IBRE.
IBRE develops and produces disk brakes and callipering systems in cast iron or steel, serving the rail industry, private networks and original equipment manufacturers (OEMs) all over the world.
SGS Industrial Services carried out gamma radiation control of brake disks for IBRE.
The company produces its brake disks by using a gravity cast technique (sand cast and silica binder comprised of two half-dies).
The gravity cast technique is a manufacturing process where molten material, such as metal, is poured into a mould that contains a hollow cavity of the desired item.
As opposed to injection techniques, the only pressure that makes the molten material fill the mould is its own weight.
The material then hardens within the mould, and the solidified part or cast is ejected or broken out to make a rough disk.
Casting is used for making parts that have complex shapes and are difficult or uneconomical to make by other methods, such as cutting from solid material.
The casting process is subdivided into two main categories: expendable and non-expendable casting (for plastic only).
It can be further classified by mould material, such as sand or metal, and pouring method, such as gravity, vacuum, or low pressure.
SGS Industrial Services has been in charge of brake disk testing for IBRE since 1988, carrying out gamma radiation control with Cobalt-60 for brake disks in accordance with European technical standards (for example, NFE EN 12 681) and reference images ASTM E446 and E186.
Cobalt-60 is a radioactive isotope of cobalt and is used in the industry to take images of welding seams and other structural elements for the detection of defects.
SGS uses gamma rays as the casts are very large and weigh about 150kg each.
After the production of a series of around 20-30 casts, two to three pieces are sent to SGS Industrial Services to be tested for defects.
These samples are exposed to gamma rays for 1.5 to three hours - depending on cobalt source - for radiography.
Subsequently, SGS experts analyse and interpret the resulting images, and if they find any flaws, extra samples may be tested to confirm the previous results.
Depending on the new results, IBRE may decide to scrap the entire series of casts.
The usual kinds of defects are sand inclusions, shrinkage cavities and blowholes.
If no defects are found by SGS, IBRE can continue with the brake disk operation process.
As the production of brake disks is on hold during the inspection period, it is very important that the SGS experts work very quickly.
SGS radiation control is on the critical path of IBRE's supply chain, which is why it is essential that operations be processed without delay, and that experts are able to interpret the results quickly and reliably.
Normally, the overall control process by SGS takes around two to 3.5 hours.
SGS not only identifies cast defects, but also deduces their causes.
The usual causes for the defects are: degassing issues, inappropriate temperature or incorrect speed of the flow.
For IBRE, it is very important and helpful to pinpoint and understand what went wrong in the production process in order to fix the errors and prevent further problems.
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