1. Inspection and Repairs of Extrusion Press Components
by Al Kennedy
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2. Ideas presented here apply to extrusion presses and also other equipment
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3. Fatigue (n) fa-tēg′: Weakening or failure of materials under the action of repeated stresses
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4. Types of non-destructive inspection
visual
ultrasonic
magnetic particle
liquid penetrant
infrared thermography
eddy current
radiography (x-ray)

5. Types of non destructive inspection
visual
ultrasonic
magnetic particle
liquid penetrant
infrared thermography
eddy current
radiography (x-ray)

6. These high-tech tests require special knowledge and equipment
My expert: Ron Manganello,
Carlesa NDE:
Following examples are from Mr. Manganello

7. Visual Inspections The primary method used for extrusion presses
Look for:
loose or missing components
oil leaks
cracks

8. Visual Inspections

9. Visual Inspections

10. Ultrasonic Inspections
The most sensitive technology for detecting subsurface flaws
It can detect extremely small flaws such as cracks at great depths.
It can evaluate the thickness of an object to determine if there is corrosion.
Ultrasonic needs only one accessible surface

11. Ultrasonic Inspections
Indication of crack in tie-rod

12. Magnetic Particle Inspections
First magnetizes the surface
Colored magnetic particles are spread over the surface.
If there is a crack or other flaw, magnetic particles become attracted to and build up along the area of the defect

13. Magnetic Particle Inspections

14. Liquid Penetrant Inspections
Often used on materials where magnetic particle examination is difficult to use.
The surface is first cleaned, a red dye is placed on the area of interest, then a white developer is sprayed onto the surface.
The developer draws the dye into the surface defects.
If a colored dye appears, that indicates the position of the flaw

15. Liquid Penetrant Inspections

16. Liquid Penetrant Inspections

17. Examples of Common Problems with Different Components

18. Main Cylinders

19. Main Cylinders
Casting flaws –bubbles & impurities

20. Main Cylinders

21. Main Cylinders

22. Main Cylinders

23. Main Cylinders

24. Main Cylinders

25. Main Cylinders

26. Main Cylinders

27. Main Cylinders

28. Main Cylinders

29. Main Cylinders

30. Main Cylinders

31. Main Cylinders

34. Front Platens

35. Front Platens

36. Front Platens

37. Tie Rods

38. Tie Rods

39. Tie Rods

40. Ram Stems

41. Ram Stems

42. Ram Stems

43. Container Shift Cylinders

44. Container Shift Cylinders

45. SUMMARY
Non-destructive tests provide a good picture of the press’s condition
Repairs may be anticipated well in advance, to purchase long-delivery parts, and to avoid unplanned downtime
Results are cost savings and possible prevention of injury or death to workers
Tests require competent technicians and specialized equipment – may be in-house or consultants
Tests should include detailed records and documentation of results

47. ¡Gracias! alkennedy@usa.net www.alkennedy.net www.pressmaintmanual.com