RESONANT

ACOUSTIC METHOD
DELIVERS DEFECT-FREE PARTS
The resonant acoustic method offers the
capability of 100% part inspection in a
high-volume production environment.
Richard Bono and Scott Sorensen
The Modal Shop Inc.
Cincinnati, Ohio

he resonant acoustic method is a whole

part inspection technique that measures
the structural integrity of each part to detect flaws on a component level. Capabilities include materials ranging from ductile iron to
powder metal to ceramics, and part sizes ranging
from less than an ounce up to 50 lb (23 kg). The technique is easily automated to eliminate human error,
with fast throughput providing cost-effective 100%
inspection with minimal disruption to production.
The nondestructive testing resonant acoustics
method (NDT-RAM) is now the standard in-line inspection on production lines for powder-metallurgy
and cast parts. It is a simple, effective solution to the
challenge of achieving zero parts per million defects.
Resonant inspection principle
The principle of resonant inspection is simple:
every part has a unique resonant vibration signature,
or pattern, that reflects its structural integrity. A deviation from the expected signature of resonances
can indicate the presence of a flaw. For example, consider a bell or tuning fork. When you strike either
part, it vibrates and emits a sound. An instrument
that rings true produces a consistent sound, which
correlates to the structural integrity of the instrument.
This is the basis for NDT-RAM technology. When
struck by an impactor, parts such as gears, brake anchors, and rotors emit many resonant frequencies
as part of their structural response. This unique,
measurable signature of resonances is compared
with and analyzed against both a good and bad
product. Just as a cracked bell will not ring true like
a structurally sound bell, if a part such as a gear is
cracked, lacks the correct density, or misses other
characteristics of a structurally sound product, the
flaw will be exposed when its resonant signature
deviates from what has been identified as good
product. Figure 1 graphically shows the steps in the
RAM inspection process.
The resonances of a structure are a function of
part geometry and material properties, and are defined by mass, stiffness, and damping ability. These
ADVANCED MATERIALS & PROCESSES/JULY 2008

Fig. 1 Steps in the Resonant Acoustic Method (RAM) testing process include
from left to right: Impact the part, measure the response, process the data, and
quantify the results. An industrial instrumented impact hammer taps each part
with a measured and repeatable force. The impact causes the part to ring; audible
and inaudible vibrations are measured by the microphone. A smart digital
controller performs a Fast Fourier Transform (FFT) on the measured data, and
NDT-RAM software compares results to acceptable limits and accepts or rejects the
part accordingly.

Typical structural defects detected by RAM inspection

Powder metallurgy parts
Cracks
Chips
Voids
Hardness
Inclusions
Heat treatment
Decarb
Oxides
Contaminants
Missed operations

Ductile iron
Cracks
Nodularity
Porosity
Hardness
Inclusions
Heat treatment
Cold shuts
Stresses
Contaminants
Missed operations

Ceramics
Cracks
Chips
Voids
Sizing
Inclusions
Delaminations
Pits
Agglomerates
Contaminants
Missed operations

resonant frequencies can be measured in most rigid

materials, including most metals and ceramics.
NDT-RAM systems detect frequency shifts that can
be caused by imperfections such as cracks, porosity,
and voids, as well as variances in nodularity (ductile
cast irons), dimensions, geometry, weight, density,
and manufacturing processes. Typical flaws and defects adversely affecting structural characteristics
are given in the table for powder metallurgy, ductile iron, and ceramic parts.
Quantitative analysis
RAM tests the entire part for both external and
internal flaws. It provides an objective, quantitative
analysis that eliminates errors involving human interpretation and judgment through proven dynamic
measurement equipment.
In operation, a dynamic sensor captures the
sound waves, and a high-speed analog-to-digital
converter translates the sound into measurable data.
The structural resonance of a defective part shifts,
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Fig. 2 Parts template in NDT-RAM software used for evaluating

parts against known good samples.

and the shift is identified when compared with predefined

data. In effect, NDT-RAM listens to the structural response
of a part and evaluates it against the statistical variation from
a control set of good parts to screen anomalies.
The criterion for the predefined data is established by experimental analysis of a statistically significant sample set.
The resonant signatures of both good and bad products are
captured to provide objective, measurable variables for comparison. Templates are established for each part type. An
example of a template is shown in Fig. 2. The NDT-RAM
system is programmed with these templates, and requires
minimal human interaction for operation or maintenance.
Because no special part fixturing or preparation is needed,
parts can be tested as fast as one per second, keeping pace
with automated production lines.
Comparison with other methods
Traditional NDT techniques focus on detecting and diagnosing defects. They are based on visual techniques or imaging to scan for any indication of defects. Scanning methods
include magnetic particle testing (MT), ultrasonic testing
(UT), eddy current/electromagnetic testing (ET), dyepenetrant testing (PT), and X-ray/radiographic testing (RT).
These methods often are manual and require subjective
interpretation by an operator. Although diagnosing and/or
imaging specific defects are applicable when evaluating an
individual part or system, they are not appropriate for highvolume, 100% manufactured part inspection. In these cases,
it is of primary importance to detect whether a part is nonconforming, rather than why. Identifying the type of defect
itself is secondary to identifying the nonconforming parts.
Therefore, an end-of-line "go/no go" objective inspection
such as by NDT-RAM is preferred over that of a slower subjective diagnosis.
After defective parts have been sorted with NDT-RAM,
complementary visual or imaging nondestructive testing
techniques provide a means for subjective diagnosis on the
smaller subset of parts. This is useful to determine the root
cause of a defect and ultimately improve the product design or production process.
One of the benefits of RAM is that it is easy to justify financially. It has a low overall cost of ownership because it
does not require additional materials to operate; no solutions, chemicals, or films are needed. It aids in profitability by
achieving zero defects and lowering overall production costs
by reducing variances in the production process.
Because it is fast enough to test 100% of the parts, the
system works as a process monitor in addition to part quality
ADVANCED MATERIALS & PROCESSES/JULY 2008

inspection, and insures against quality-related expenses while functioning as a process control monitor. If the system starts failing multiple parts, it allows manufacturing personnel to adjust the
upstream process before a large number of faulty
parts is produced and must be scrapped.
Nodularity testing
One common application for NDT-RAM is testing
ductile iron for acceptable levels of nodularity. Cast
iron contains a high carbon content, and during solidification of the metal, the carbon content can form
irregularly shaped graphite flakes that disrupt the
crystalline structure, causing cracks and brittleness.
In ductile iron, the graphite forms spherical, rounded
nodules that inhibit the formation of cracks and provide enhanced ductility and machinability. The
higher the nodularity, the higher the ductility. Figure
3 illustrates the difference in microstructure of ductile iron with high nodularity (93%) and poor nodularity (55%).
Very often, part designers specify a minimum
level of acceptable nodularity (typically >85%) to
ensure proper ductility. This can be especially important in safety-critical automotive parts such as
brake and suspension components. The traditional
inspection technique for testing this is ultrasonic
(UT), which measures the velocity of sound waves
passing through material. Rounded graphite nodules do not impede the acoustic energy, while flaky
graphite particles do.

Fig. 3
Microstructure
of ductile iron
with high
nodularity
(93%), left, and
poor nodularity
(55%), right.

Thus, higher ultrasonic velocity correlates with

higher nodularity. However, UT is a localized test
that looks only at one specific section of a part, and
it requires a coupling liquid bath for testing.
With NDT-RAM, resonant frequency correlates
directly with nodularity, and no coupling agent is
required. Lower nodularity levels result in reduced
resonant frequency characteristics. Resonant inspection detects these shifts in resonant frequency characteristics, resulting in cost-effective, reliable, highvolume automated inspection. Additionally, because
resonant acoustic inspection is a volumetric technique, it checks the entire part for nodularity (as
well as for other flaws such as cracks and voids).
Sinter brazing
Sinter brazing is a common joining process for
powder metallurgy parts, as it allows production
of complex components via conventional PM technology. The technique involves assembling multiple
parts prior to sintering, adding a braze compound,
and sintering at temperatures above the melting

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Fig. 4
Examples of
sinter-brazed
powder
metallurgy parts
with braze-plug
locations marked
by red circles.

point of the brazing alloy.

When processed properly,
sinter brazing is very costeffective and produces a very
strong joint. Several examples of brazed powder metal
parts are shown in Fig. 4.
Certain defects are common
among sinter-brazed PM
parts, including subcomponent misalignment during
initial assembly and incomplete braze material infiltration. Inadequate infiltration is typically caused
by an improper braze alloy or damaged braze pellets (for example, a slug with 50% of its material
chipped away).
Another root cause of poor sinter brazing is
missing the braze pellet altogether. Other process
variances that can lead to inadequate braze joints
include improper furnace settings and dew point.
All of these defects can result in poor joints, reduced part strength, and ultimately part failure.
With RAM, resonant frequency shifts are measured
for an accurate, reliable 100% inspection. By comparing these measurements to visual and destructive separation pull-force evaluations, it can easily
and reliably detect poor sinter-brazed joints. The capability of automating NDT-RAM makes it superior to subjective visual inspection or inefficient separation-force testing.
Ceramic parts
Ceramic parts ranging from ceramic washers and
filters to personal body armor plates are also suitable

for NDT-RAM. Typical structural defects in these components include cracks, chips, and delaminations.
Ceramic parts are manufactured in a similar
manner to powder metallurgy parts: Ceramic powders are pressed into a green compact and then subjected to a sintering process. Density gradients and
non-uniform shrinkage can cause distortion or
stresses that can lead to fracture or other structural
defects during the process. Shock or vibration to
green parts during handling prior to sintering can
also lead to significant structural defects.
As a result, 100% part inspection via resonant inspection is often necessary, particularly with safetycritical parts or in medical equipment components.
In the case of personal body armor, plates are often
destructively tested by shooting them with a projectile. If a sample set from a production lot stops
the bullet, then the samples are discarded and the
remaining production units from that lot are accepted. On the other hand, if just one of the lot
sample plates is damaged by the projectile, the entire
lot is rejected. Given the high cost of the plates and,
more important, the value of human life that they
protect, a reliable and effective 100% inspection
method is critical.
With RAM, every part can be tested. Structural
defects or anomalies induce measurable resonant
frequency shifts that are detected readily, again resulting in reliable and cost-effective inspection.
For more information: Scott Sorensen, The Modal Shop
Inc., 3149 East Kemper Road, Cincinnati, OH 45241; tel:
800/860-4867, or 513/351-9919; ssorensen@modalshop.
com; www.modalshop.com.

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