Copper Billet Defect Inspecion (IUT) - Defects Problem Solver In-line Automated NDT Solution

The Problem: High Defect Rates in Copper Strip Manufacturing

According to Zhang and Zheng (2016), surface defects account for 79.2% of quality complaints in precision copper strips, with physical defects contributing 67.4%. One manufacturer reported a 5.44% scrap rate, costing millions annually.

The consequences are severe: pinholes degrade conductivity in electronics, cracks in automotive heat sinks risk thermal runaway, and for IC lead frames (C19400 strips), internal stress-induced warping or poor surface adhesion disrupts chip integration. A semiconductor client rejected entire batches due to etching defects, resulting in contractual penalties and delayed deliveries.

These quality issues aren't new to the copper strip industry. To transform high-complaint operations into no-complaint manufacturing, we focus on prevention at the source: copper billet inspection before strip formation. By eliminating physical defects in raw materials, we dramatically reduce downstream defect rates.

Our core system is a sophisticated mobile scanning platform featuring a powerful 6-probe A-scan ultrasonic configuration. This multi-probe setup ensures rapid, comprehensive coverage with detailed inspections across the entire billet surface. The water-immersed ultrasonic transducers identify internal defects by detecting prominent waveform changes caused by wave reflection differences.

Key Features & Capabilities:

• Unmatched Customization & Engineering: This is the cornerstone of our service. We don't just sell a machine; we deliver a solution. Our engineering team works directly with you to modify and design the mechanical scanning system, fixtures, and software to perfectly match your specific component. Your unique inspection challenge is our blueprint for innovation.
• Advanced 6-Probe A-Scan Technology: Our system's six A-scan ultrasonic probes work in concert to provide a detailed, multi-point analysis of the material's internal structure. This allows for the precise detection, localization, and characterization of flaws such as internal cracks, voids, porosity, and inclusions with exceptional reliability
• Optimized for Plate-Like Components: While originally designed for high-demand applications like copper strip billets, our solution is expertly adapted for any flat or plate-like metal part. The mobile scanning mechanism ensures 100% inspection coverage, essential for industries where material integrity is non-negotiable
• Total Quality Assurance & Process Control: Integrating a Desisen custom IUT system provides definitive, actionable data for your quality control. By catching defects early, you safeguard your production processes, prevent costly material waste, and ensure your final products meet the most rigorous industry standards.

"Our clients come to us with unique inspection needs that standard equipment cannot solve," states a Desisen technical lead. "Our strength lies in our ability to listen, engineer, and build a truly custom IUT machine that fits their workpiece and workflow perfectly. We provide not just a product, but a partnership in quality."

From aerospace-grade aluminum plates to high-purity copper strips, Desisen's highly customizable IUT systems deliver the confidence and precision required in today's competitive manufacturing environment.

Support and Services:

Technical Support and Service

We provide technical support and service to ensure our customers are satisfied with their Portable Eddy Current Flaw Detector. We offer both on-site and online support for all of our products.

On-site Support

Our on-site support team is available to help with any installation, troubleshooting, or maintenance related issues you may have with your Portable Eddy Current Flaw Detector. Our technicians can come to your location and help with any questions or problems you may have.

Online Support

Our online support team is available 24/7 to help with any questions or issues you may have with your Portable Eddy Current Flaw Detector. We have a live chat feature on our website, as well as an online ticket system for more in-depth issues. Our team is always available to help.

So why under water? Immersion Ultrasonic Testing Explained

Reduce noise / disturbance from the air

During the rolling process, the surface of a Copper Strip Billet may have minor roughness, oxidation layers, or unevenness. With traditional contact testing (where the probe touches the part directly), these microscopic air gaps would severely disrupt the ultrasonic signal, causing significant noise and erroneous readings. By immersing the billet in water, the fluid fills every micro-gap, ensuring that the ultrasonic energy is transmitted into the copper stably and uniformly. This results in a clean, reliable, and repeatable inspection signal.

Contactless, Extend life expectancy of the probes

 In a in-line inspection environment, direct contact would cause rapid wear on both the transducer and the billet surface. This is not only costly but also leads to constantly changing test sensitivity as the probe degrades. Immersion UT is a non-contact method. The transducer maintains a fixed distance from the workpiece while moving through the water, eliminating wear and tear and ensuring high consistency throughout the entire inspection process.

Higher resolution, higher sensitivity

Immersion testing readily allows for the use of focused transducers. These probes act like a magnifying glass, concentrating the ultrasonic energy at a specific depth within the copper billet. This dramatically increases the sensitivity and resolution of the inspection, enabling the precise detection of minute internal defects such as inclusions, porosity, and micro-cracks—all of which are critical-to-quality control points for producing high-grade copper strips.