Segment Coil Solutions for High-Precision Weld Seam Inspection

Our specialized Segment Coil solutions are engineered for the rigorous demands of longitudinal weld seam inspection in tubes and profiles. While encircling coils inspect the entire 360° volume, segment coils focus electromagnetic energy precisely on the Heat Affected Zone (HAZ). This targeted approach delivers superior signal-to-noise ratios, making it the industry standard for detecting cracks, fusion defects, and inclusions in ERW, TIG, and Laser-welded lines.

Technical Versatility & Specifications

These segment coils are designed to adapt to a wide range of production geometries and material properties:

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  Winding Configurations:

  • NA Windings: Combined Normal-differential and Absolute windings. This dual-channel approach is ideal for detecting both localized point defects and gradual longitudinal variations.

  • NO Windings: Normal-differential windings optimized for high-speed detection of small, discrete discontinuities without an absolute channel.

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• Diameter Range: We offer comprehensive coverage for test pieces ranging from 10 mm to 520 mm, with specialized configurations available for flat materials.

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•  Material-Specific Application:

  • Ferrite (Ferromagnetic) Materials: To eliminate permeability noise and ensure high-sensitivity inspection, segment coils are utilized within a specialized holder integrated with a Magnetizing Unit (MU) or high-strength permanent magnets.

  • Non-Ferrite Materials: Operated with our standard high-stability segment coil holder for non-magnetic alloys.

The Segment Coil Holder: Integrated Precision

In segment coil testing, the mechanical holder serves as the primary positioning and adjustment system, effectively acting as an integrated "adjustable table." Precision alignment is the foundation of a reliable signal, and our holders provide the necessary degrees of freedom:

• Vertical Height Adjustment (Z-Axis): The holder features an integrated vertical mechanism that allows operators to fine-tune the lift-off distance. This ensures consistent sensitivity and signal stability even in environments with production-line vibration.

• Multi-Axis Tiltable Option: Maintaining perfect parallelism between the sensor face and the weld seam is critical, especially for non-cylindrical profiles. The tiltable mechanism allows the sensor to follow the exact contour of the profile or compensate for tube rotation during the welding process.

• Compact Mechanical Fixture: By integrating these adjustments directly into the holder, the system remains compact and stable, ensuring the sensor remains centered on the weld seam throughout the production run.

Seamless Industry 4.0 Integration & Traceability

Our segment coil solutions are built to function as key nodes within a smart factory environment:

• Real-Time Data Visualization: These probes are fully compatible with EDDYWISE instrumentation and acquisition software, allowing for real-time visualization of the impedance plane and advanced phase-gate filtering.

• NDE 4.0 & Traceability: Inspection data can be synchronized with Manufacturing Execution Systems (MES) to provide full batch traceability. Many configurations include embedded chips for sensor data storage, meeting the strict audit requirements of the aerospace and automotive sectors.

For more information, please contact us today.