What Non-Destructive Testing Methods Are Used in Forging?

What Non-Destructive Testing Methods Are Used in Forging?

Forged steel parts are celebrated for their strength and reliability, making them vital in industries like aerospace, mining, oil and gas, and heavy machinery. However, even the best forging process can introduce hidden flaws that compromise performance. That's where non-destructive testing (NDT) comes in—a critical step to ensure quality without damaging the part. At WALKSON, a trusted supplier of high-quality steel closed-die forging parts, we rely on advanced NDT methods to guarantee every component meets the highest standards. Let's explore the key techniques used in forging and why they matter.

1. Ultrasonic Testing (UT): Seeing Beneath the Surface

Ultrasonic testing uses high-frequency sound waves to detect internal defects like cracks, voids, or inclusions in forged steel parts. A transducer sends waves into the material, and any disruptions in the wave pattern indicate a flaw. This method is highly effective for WALKSON’s closed-die forgings, ensuring internal integrity aligns with standards like EN 10228. UT is ideal for thick or complex components, offering a non-invasive way to confirm quality deep within the steel.

2. Magnetic Particle Inspection (MPI): Spotting Surface Flaws

For ferromagnetic steel forgings, magnetic particle inspection is a go-to method. The part is magnetized, and fine iron particles are applied to the surface. If there’s a crack or seam, the magnetic field distorts, and the particles cluster at the defect, making it visible under UV light. WALKSON uses MPI to ensure our high-quality forgings meet stringent surface quality requirements, such as those in ASME Section V, making it perfect for parts like gears or shafts.

3. Dye Penetrant Testing (DPT): Highlighting Surface Imperfections

Dye penetrant testing is a simple yet powerful method for detecting surface-breaking defects. A liquid dye is applied to the forged part, seeping into any cracks or porosity. After a dwell time, a developer reveals the dye, exposing flaws to the naked eye. At WALKSON, we use DPT for our closed-die forgings where surface finish is critical, adhering to standards like ASTM E165. It’s especially useful for non-magnetic alloys or intricate shapes.

4. Radiographic Testing (RT): A Full Internal Picture

Radiographic testing involves passing X-rays or gamma rays through the forged part to create an image of its internal structure. Defects like shrinkage or gas pockets show up as shadows on the film or digital detector. This method is invaluable for WALKSON's high-stakes applications—like oilfield components—where internal soundness is non-negotiable. RT complies with standards such as ISO 5579, ensuring our forgings are flawless inside and out.

5. Eddy Current Testing (ECT): Precision for Conductive Materials

Eddy current testing uses electromagnetic fields to identify surface and near-surface defects in conductive materials. When an alternating current flows through a coil, it induces eddy currents in the forging; any irregularities disrupt the flow, signaling a flaw. WALKSON employs ECT for precision forgings, meeting standards like ASTM E426. This method excels at detecting small cracks or material inconsistencies in parts like turbine blades.

Why NDT Is Essential in Forging

Non-destructive testing isn't just a quality check—it's a safeguard. A hidden defect in a forged steel part could lead to failure under stress, endangering equipment, projects, or lives. At WALKSON, we integrate these NDT methods into our production process to deliver closed-die forgings that perform reliably in the harshest conditions. Our commitment to excellence ensures that every part leaving our facility meets global benchmarks and customer expectations.

WALKSON: Your Partner for Flawless Forged Parts

When it comes to high-quality steel closed-die forging parts, WALKSON stands out as a leader. Our advanced NDT techniques—ultrasonic, magnetic particle, dye penetrant, radiographic, and eddy current testing—set us apart, ensuring every forging is free of defects and ready for action. Whether you need components for mining, energy, or industrial applications, WALKSON delivers unmatched quality. Contact us today to learn how our expertly tested forgings can power your next project.