Billet Ultrasonic Testing Systems

STARMANS DIO 2000 Automated Ultrasonic Device for Billets

Advanced Automated Ultrasonic Testing for Round & Square Billets

The STARMANS DIO 2000 Automated Ultrasonic Device for Billets represents cutting-edge inspection technology for comprehensive quality control of steel billets. This automated system delivers precise ultrasonic testing for both round and square billets through efficient linear movement inspection, ensuring superior defect detection in production environments.

Dual-Axis Detection Technology

Our immersion-based testing system utilises a two-cassette configuration for complete billet inspection:

• First Cassette: Longitudinal crack detection along billet length
• Second Cassette: Transverse crack detection across billet cross-section
• Complete Coverage: Comprehensive inspection in single pass operation

International Standards Compliance

Comprehensive Regulatory Conformity

The STARMANS DIO 2000 Billet Testing System complies with major international ultrasonic testing standards:

European Standards:

• EN 12668-1: Ultrasonic examination equipment characterisation and verification
• EN 12668-2: Ultrasonic probes
• EN 12668-3: Combined equipment specification and verification
• EN 10308: Non-destructive testing of steel forgings
• EN 583-2: Ultrasonic examination sensitivity and range setting

ASTM Standards:

• ASTM A 388: Ultrasonic examination of steel forgings
• ASTM E 428: Performance of ultrasonic pulse-echo testing

Plus additional international standards as required

Advanced System Architecture

Dual-Frame Mechanical Design

Versatile Configuration

• Round Billet Frame: Purpose-built rigid frame optimised for cylindrical billets
• Square Billet Frame: Dedicated frame designed for square cross-section inspection
• Durable Construction: Robust mechanical design for demanding production environments
• Immersion Rack System: Water-coupled inspection for optimal ultrasonic transmission
• Linear Movement: Efficient billet transport through inspection zones

Optional Marking Integration

• Automated Marking Device: Optional defect marking system available
• Real-Time Marking: Immediate identification of defective areas
• Quality Segregation: Automated sorting based on inspection results
• Production Integration: Seamless marking for downstream processing

Comprehensive Testing Capabilities

Multi-Mode-Mode Calibration

Flexible Validation

• Static Calibration: Stationary billet calibration for system verification
• Dynamic Calibration: In-motion calibration simulating production conditions
• Traceable Standards: Reference blocks for consistent performance
• Quick Validation: Rapid system verification between production runs

Complete Defect Detection

What the System Detects:

• Longitudinal cracks and fissures
• Transverse defects and separations
• Internal voids and porosity
• Inclusions and material discontinuities
• Seams and laps
• Pipe and center defects
• Manufacturing flaws

Advanced Electronics & Control

Modular Electronics Architecture

Reliable & Expandable

• Centralised Control: Integrated management of all device functions
• Ultrasonic Signal Processing: Advanced analysis of probe signals
• Module-Wise Design: Electronic components and UT cards organised in cabinet
• Scalable Platform: Modular architecture allows system expansion
• Industrial-Grade Components: Robust electronics for production environments

Siemens PLC Control System

Industrial Automation Excellence

• Touch Screen Interface: Intuitive operator control panel
• Network Integration: Seamless connection with company information systems
• Automated Operation: Continuous testing with minimal operator intervention
• Real-Time Monitoring: Live system status and performance tracking

User-Friendly Software

Comprehensive Control Features

Intuitive Operation

• Settings Management: Easy configuration of test parameters
• Real-Time Measuring: Continuous monitoring during inspection
• Data Monitoring: Live visualisation of ultrasonic signals and results
• Calibration Tools: Integrated calibration procedures and verification
• Quick Parameter Change: Rapid adjustment for different billet specifications
• User-Friendly Interface: Minimal training requirements for operators

Flexible System Adjustment

• Multiple Product Profiles: Save and recall settings for different billet types
• Rapid Changeover: Quick transition between round and square billet testing
• Custom Configurations: Adaptable parameters for specific quality requirements
• Remote Access: Network connectivity for off-site system management

Advanced Data Management

Comprehensive Record Keeping

Complete Documentation & Analysis

• Automatic Recording: All test results captured and stored
• Statistical Analysis: Advanced analytics for quality trends and process control
• Report Generation: Professional reports for quality documentation
• Large Database: Extensive data storage for historical tracking
• Custom Formatting: Records arranged according to customer specifications
• Print Integration: Professional report output capabilities

Information System Integration

Enterprise Connectivity

• Network Interface: Direct connection to company information systems
• Data Export: Automated transfer of inspection results
• ERP Integration: Seamless connectivity with production management systems
• Traceability: Complete inspection history linked to billet identification
• Quality Management: Integration with ISO quality management systems

System Advantages

Operational Excellence

Superior Performance Benefits

• Automated Operation: Continuous testing without constant operator presence
• High Throughput: Rapid inspection cycles for production environments
• Dual-Axis Detection: Complete crack detection in all orientations
• Consistent Quality: Eliminates operator variability in test results
• Reduced Downtime: Quick calibration and parameter changes
• Cost Efficiency: Lower inspection costs through automation

Quality Assurance

Enhanced Defect Detection

• 100% Inspection: Complete coverage of every billet
• Early Detection: Identifies defects before costly downstream processing
• Standards Compliance: Meets international quality requirements
• Documentation Ready: Complete records for customer certification
• Process Control: Statistical data for continuous improvement

Applications & Industries

Primary Markets

• Steel Mills: Production quality control for billet manufacturing
• Forging Operations: Pre-forging material verification
• Rolling Mills: Raw material inspection before rolling
• Metal Processing: Quality assurance for billet suppliers
• Automotive Industry: Critical component raw material verification
• Aerospace Manufacturing: High-quality billet certification

Billet Types

• Round billets (various diameters)
• Square billets (various dimensions)
• Steel alloys and grades
• Special materials (by specification)
• Continuous cast billets
• Ingot-cast billets