Quality Control

Purpose: Measures dry-film coating thickness on pipes and fittings for coating-process control and corrosion-protection consistency.
Typical use: Verify the gauge and probe, check zero/reference foils, clean and dry the surface, then take readings at representative positions.
Key checks: Measuring location, reading stability, coating condition and batch traceability.
Precautions: Avoid contaminated surfaces, unsuitable curved areas and uncured coating. Use only equipment within its calibration or verification period.
Record: Batch, instrument ID, locations, readings, inspector, date and disposition.

Purpose: Verifies the chemical composition of prepared cast-iron samples to support material identification and melt control.
Typical use: Select the approved program, verify the instrument with a suitable reference sample, prepare a clean flat surface and perform multiple valid burns.
Key checks: Sample identity, surface preparation, reference validity, repeatability and comparison with the approved composition range.
Precautions: Trained personnel only; keep the spark area clean and reject contaminated, porous or overheated burn spots.
Record: Heat/batch, sample ID, instrument ID, results, operator, date and disposition.

Purpose: Measures material hardness as a supplementary indicator of material consistency and mechanical behaviour.
Typical use: Select the specified method and test force, verify with a certified block, prepare a flat stable surface and take readings with correct edge and indentation spacing.
Key checks: Scale, specimen support, surface condition, repeatability and approved requirement.
Precautions: Hardness does not replace required tensile or performance tests. Avoid scale, unsupported thin sections and unsuitable curved areas.
Record: Batch, method/scale, instrument ID, locations, readings, inspector and disposition.

Purpose: Provides a controlled accelerated-corrosion environment for comparative evaluation of coating quality and process consistency.
Typical use: Prepare and identify specimens, position them without contact, confirm chamber conditions, run the approved exposure cycle and evaluate visible changes.
Key checks: Exposure time, solution, temperature, collection rate, orientation, blistering, rusting and peeling.
Precautions: Salt-spray hours do not directly predict outdoor service life. Prevent cross-contamination and apply only the acceptance criteria in the relevant specification.
Record: Batch, coating system, method, chamber ID, conditions, photos, observations and disposition.

Purpose: Evaluates coating or component stability during controlled hot-water exposure when required by the applicable specification.
Typical use: Identify specimens, verify bath temperature, immerse to the prescribed depth, maintain the approved time/temperature, condition after removal and inspect.
Key checks: Actual temperature, exposure time, immersion depth, sample spacing, blistering, softening, cracking, peeling or deformation.
Precautions: Use heat-resistant PPE and suitable lifting tools. Test temperature and duration must follow the approved method for the relevant product.
Record: Batch, bath ID, method, temperature log, start/end time, photos, observations and disposition.

Purpose: Measures specified mechanical properties of prepared specimens or finished components, including tensile behaviour or ring-crush performance where applicable.
Typical use: Confirm machine range and fixture, verify the load system, measure and align the specimen, apply load at the specified rate and review the curve and failure mode.
Key checks: Specimen geometry, alignment, loading rate, peak load, calculated result and failure location.
Precautions: Use guards and keep clear of the loading area. Test terminology and acceptance criteria must match the applicable product standard.
Record: Batch, dimensions, method, machine/fixture ID, curve, result, operator and disposition.

Purpose: Assesses the durability of selected pipe, fitting, joint or coating assemblies under repeated temperature changes when required by the test plan.
Typical use: Assemble the test piece as specified, check connections and sensors, set approved temperatures, dwell times and cycles, monitor the test and inspect after completion.
Key checks: Assembly, actual conditions, cycle count, leakage, cracking, blistering, delamination, deformation and joint condition.
Precautions: Hot water, pressure and thermal expansion are hazards; use guarding and pressure relief and never open while hot or pressurised.
Record: Component batches, assembly details, equipment ID, cycle log, photos and disposition.

Purpose: Conditions samples under controlled temperature and relative humidity for comparative evaluation of coating, material or component stability.
Typical use: Identify and photograph samples, verify chamber sensors, arrange for free airflow, run the approved program and inspect after conditioning.
Key checks: Setpoint versus actual conditions, duration, spacing, condensation and specified appearance or performance changes.
Precautions: This chamber alone does not prove acid, alkali or wastewater resistance; those claims require the corresponding chemical test method. Avoid overloading and protect against hot surfaces and condensate.
Record: Batch, chamber ID, program/log, photos, observations and disposition.

Purpose: Quantitatively determines carbon and sulfur in prepared iron samples to support melt control and traceable chemical analysis.
Typical use: Check reagents and gas, verify with suitable certified reference materials, weigh and prepare the sample, run blanks/samples as required and review repeatability.
Key checks: Sample identity and mass, reference validity, blank value, repeatability and approved composition range.
Precautions: Trained personnel only; follow oxygen, combustion and reagent safety requirements. Stop if verification falls outside approved control limits.
Record: Heat/batch, sample mass, analyzer ID, reference/blank results, C/S results, operator and disposition.

Purpose: Monitors moulding-sand properties such as moisture, compactability or strength, permeability and active clay where applicable, helping maintain mould consistency and reduce casting defects.
Typical use: Collect a representative sample, prepare it by the approved method, perform the specified measurements and compare results with process-control limits.
Key checks: Sampling point/time, preparation, moisture loss, equipment verification, repeat readings and production-batch linkage.
Precautions: Methods and limits depend on the sand system. Test promptly, prevent contamination or drying and confirm questionable readings before process adjustment.
Record: Line/mixer, batch, sampling time, results, equipment ID, adjustment and follow-up.

Purpose: Examines prepared metal microstructures to evaluate graphite morphology, matrix condition, inclusions and microstructural discontinuities where required.
Typical use: Select a representative specimen, cut without overheating, mount if needed, grind and polish, etch when required, examine at suitable magnifications and capture representative images.
Key checks: Sampling location, preparation quality, magnification, field selection, traceability and classification by qualified personnel.
Precautions: Poor preparation can create misleading features. Use PPE and ventilation for etchants and never treat one field of view as representative of an entire batch.
Record: Heat/batch, location, method, microscope ID, magnification, images and conclusion.