Wire Insights Podcast - Episode 9: Testing expertise for wire - Modern inspection solutions for premium wire quality

Intro

Host: Welcome to Wire Insights, the podcast from voestalpine Wire Technology. Here we talk about developments, technologies, and solutions that shape our industry - from materials technology to industrial applications. You will gain in-depth insights into current projects and their practical significance.

In this episode, we focus on a topic that’s crucial for wire production and the entire value chain: testing expertise for wire.

Why is wire testing so important? What technologies are used? And how does it influence quality, efficiency, and sustainability? We’ll give you an in-depth look - from proven methods to AI-powered solutions.

Testing expertise is a strategic lever for quality assurance. It enables the early detection of surface defects, ensures compliance with customer requirements, and reduces the carbon footprint by minimizing scrap.I’d like to welcome two experts: Stefan Brandtner and Claudia Gruber, both of whom specialize in measurement and testing technology.

Introduction and Overview

Host: Mr. Brandtner, let’s start with you. Would you mind introducing yourself briefly?

Brandtner: Certainly. I’ve been working in non-destructive materials testing for over 13 years, specializing in eddy current testing of cold- and hot-rolled wires. I’m currently leading two projects on inline surface inspection of hot-rolled wire. We rely on a modern eddy current system and our own AI-based inspection system, “Falconn.” This allows us to combine classic inspection technology with high-speed cameras and AI-assisted defect detection - a concept that is unique in the market.

Host: Thank you very much. Ms. Gruber, what does your role entail?

Gruber: My focus is on building expertise in inspection technology and developing innovative system solutions for implementation in production lines on the one hand, and for downstream quality inspection on the other. I am currently working on two projects: the transition of the compression test to an objective measurement method and the development of a hybrid inspection system for the wire drawing plant in Bruck an der Mur. The goal is to combine various technologies such as eddy current testing, optical systems, and data analysis to ensure the highest quality and process reliability.

Part 1 – The importance of testing expertise in wire

Host: Mr. Brandtner, why is wire testing so important?

Brandtner: Our wires form the basis for sophisticated end products - from the automotive sector to energy applications and the construction industry. Surface quality is crucial. Inline testing on hot wire allows us to monitor this quality directly within the process. The sooner we detect deviations, the faster we can react - this saves resources, reduces scrap, and lowers the carbon footprint.

Host: What does that mean in practice?

Brandtner: Without inline testing, surface defects would only be detected after the cooling conveyor. Until then, we’re producing scrap for minutes on end. With inline testing, we significantly shorten the response time. That means less material loss, lower energy consumption, and a significant reduction in CO₂ emissions.
Quality doesn’t start at the end of the production line, but within the process itself. When we detect defects early on, we not only avoid scrap but also ensure the stability of our customers’ processes - a crucial factor for customer satisfaction.

And importantly: We’re talking about 100% inspected wires. This doesn’t mean they’re flawless, but that every meter is checked and documented.

Part 2 – Technologies in use – From eddy current to AI

Host: Ms. Gruber, what technologies are used today for surface inspection?

Gruber: We rely on a hybrid approach: eddy current testing, optical inspection, and AI-powered image processing. Eddy current testing detects surface defects such as cracks and imperfections and provides corresponding depth information. However, it offers little to no insight into the type of defect. High-speed cameras capture the entire wire surface, and AI analyzes the images in real time, recognizes patterns, and classifies defects. This allows us to fill gaps that a single technology cannot cover.

Host: What are the advantages of this hybrid approach?

Gruber: It enables not only precise defect detection but also a thorough root cause analysis — a crucial step for continuous process optimization. By combining these technologies, we can, for the first time, visualize surface defects and trace their origin.

Host: How are you implementing this approach in practice?

Gruber: We are currently developing a prototype for the small-profile rolling mills at the wire drawing plant in Bruck an der Mur. There, we link inspection data in real time to avoid production interruptions and identify defect causes more quickly. The biggest challenge lies in real-time capability: At production speeds of around 1 m/s, images with a resolution of 20 µm per pixel must be processed within 0.3 seconds. This requires powerful IT systems and perfectly coordinated processes.

Host: How was the optical inspection system selected?

Gruber: We evaluated various providers and decided to collaborate with the Fraunhofer Institute for Physical Measurement Techniques. Fraunhofer possesses extensive expertise and has already developed an optical wire inspection system. Together, we were able to design an inspection system that meets our requirements and integrates seamlessly into the hybrid inspection approach.

It is particularly important to us that the entire wire surface - even for profiles with internal grooves - is monitored seamlessly. To achieve this, we use six cameras arranged circumferentially. Another key aspect is the synchronization of image recording with eddy current testing. This allows us to detect periodic anomalies and define appropriate follow-up actions.

Host: Mr. Brandtner, you are working on a similar project. Why was it necessary to develop this in-house?

Brandtner: There is no system on the market that meets our requirements in the rolling mill. Thanks to our expertise in digitalization and process technology, we were able to develop a customized solution in collaboration with external partners. For us, in-house development means independence and the ability to tailor systems precisely to our processes and quality goals.

Long surface defects such as scratches or longitudinal cracks cannot be reliably detected using conventional eddy current differential measurement, which is used worldwide in such processes. Falconn supplements this inspection with AI-supported, camera-based defect detection that provides seamless image recording of the entire wire surface using high-speed cameras. This generates enormous amounts of data, which are processed in a dedicated storage system with a capacity of two petabytes. There is currently no comparable concept on the market.

Part 3 - Benefits for customers and the market

Host: Ms. Gruber, how do customers benefit from this inspection technology?

Gruber: Our customers benefit from stable processes and reliable surface quality. Defective areas are detected early and corrected internally before the product is shipped. This reduces downtime and lowers costs.

Digitalization also enables a digital twin of the product — seamless documentation for traceability and quality assurance. At the same time, we secure our leadership in quality, reduce scrap, and lower energy consumption. This is not only economically sound but also an important contribution to sustainability.

Brandtner: Our task is to fully meet customer requirements. Absolute flawlessness in wire up to 20 kilometers in length is not always possible. What matters is adhering to defined limits and knowing the exact location of defects. With this information, we can often adjust problematic areas internally. For customers, this means stable, fail-safe processes and thus a clear cost advantage.

Some customers must stop their equipment at every defect, remove the section, and restart. Every stoppage causes production downtime and additional costs.

Part 4 - Digitalization and the future

Host: Ms. Gruber, you briefly mentioned digitalization and digital twins — what role do these topics play?

Gruber: Digitalization plays a central role. Testing systems provide measurement data, and production facilities provide process information — these must be consolidated. With the help of AI, we can detect anomalies, identify causes, and provide recommendations for action in real time. This is the path to predictive quality and, in the long term, to autonomous processes.

A key component is the product’s digital twin. It not only enables seamless internal quality assurance but also offers our customers new possibilities — from traceability to integration into downstream production processes.

Host: What does the future look like?

Brandtner: The next step is the full integration of AI into defect detection. Our goal is not only to identify defects but also to automatically determine their causes. This opens new possibilities for predictive maintenance and targeted process optimization.

Gruber: In the long term, the focus is on connectivity along the entire value chain — from steel production to drawn wire. A consistent data model makes it possible to ensure quality, use resources more efficiently, and sustainably improve the carbon footprint.

Outro

Host: Testing expertise is more than just a technical step — it is a strategic lever for quality, efficiency, and sustainability. Today we heard how voestalpine Wire Rod Austria is setting new standards with innovative solutions: from eddy current technology to AI and hybrid testing systems. Many thanks to Stefan Brandtner and Claudia Gruber for their valuable insights.

For more information, visit the voestalpine Wire Technology website or contact us directly. Thank you for listening and seeing you in the next episode of Wire Insights.

It ensures that surface defects are detected early on and that no defective products enter downstream processes. This guarantees consistency and quality for customers.

Inspection takes place directly during production. Deviations are detected immediately, allowing for a quick response and minimizing waste.

Modern systems combine eddy current testing, optical systems such as high-speed cameras, and AI-based data analysis to accurately detect and classify defects.

Every meter of wire is inspected and documented. This ensures complete transparency regarding the product's quality.

Customers benefit from stable processes, lower risk of downtime, and consistently high surface quality - which ultimately reduces their own costs.