Emergency Nondestructive Testing for Drivetrain Components
A rapid-response nondestructive testing solution using magnetic particle inspection to identify and certify drivetrain components for a Tier 1 automotive supplier under urgent production conditions.
Challenge: Urgent Crack Detection in Drivetrain Components Using Magnetic Particle Inspection
A Tier 1 drivetrain supplier contacted Industrial Inspection Company with an urgent quality concern involving possible cracking in a precision-machined component. Operators on the client’s assembly line noticed a fine, dark line on a gear tooth and suspected it could be a crack. A second part showed a similar defect, prompting immediate concern over a broader issue. With the customer’s production schedule at risk, they needed a certified nondestructive testing partner that could respond immediately, verify the problem, and provide large-scale testing support to keep the line running.
Solution: Magnetic Particle Inspection and Rapid Turnaround Testing Services
Industrial Inspection Company mobilized its in-house Magnetic Particle Inspection (MPI) capabilities to inspect the parts using a multi-stage, precision process on our bench unit. Upon arrival, the suspect parts were prioritized and moved directly into the inspection area.
- Initial inspections confirmed that the gear teeth contained cracks
- Several hundred parts were delivered to IIC for rapid inspection, cleaning, repacking, and return delivery
- The parts’ geometry required a two-stage inspection process for full coverage
- Stage one: Oriented parts to maximize detection on gear teeth using two perpendicular magnetization directions
- Stage two: Rotated parts to inspect along the full length of the shaft for axial cracks
- Defects were only found on gear teeth; shafts were clear
- Post-inspection cleaning was performed to remove residual magnetic particles and apply corrosion protection
- All certified parts were safely repacked and shipped back to the client
Outcome: Crack-Free Parts Returned in 48 Hours to Avoid Downtime
Within just 48 hours, the suspected issue was identified, confirmed, and resolved. All parts were inspected, cleaned, and returned to the customer with full documentation and crack-free certification. The client was able to continue production with minimal disruption and now relies on Industrial Inspection Company for high-speed nondestructive testing and real-time quality control solutions for drivetrain and powertrain components.
