Surface Crack Detection Built for Today’s Steel Manufacturing Challenges

In precision-driven industries like steel and metal manufacturing, every flaw matters—and so does every dollar. As bar and rod producers face mounting quality expectations and leaner operations, testing systems must work harder, faster, and more reliably than ever.  

The CIRCOFLUX DA is FOERSTER's next-generation AC magnetic flux leakage (ACMFL) system for surface crack detection in hot-rolled ferromagnetic steel bars. This turn-key solution is designed to improve speed, sensitivity, and efficiency, bringing measurable improvements to quality teams and production lines.  

Why Advanced Flaw Detection Matters Now  

The landscape for non-destructive testing is shifting. In the U.S., the number of active black bar producers has stagnated, and those remaining must do more with fewer operators, tighter tolerances, and higher quality standards.

At the same time, technological gaps in older test systems make it harder to meet these demands. FOERSTER invested in a new standard of surface inspection that leverages decades of global expertise and recent strategic growth. With the acquisition of Prüftechnik, we’ve strengthened our footprint in magnetic flux leakage testing, ensuring our customers benefit from a unified, future-ready product line supported by a global NDT leader.  

How CIRCOFLUX DA Improves NDT Efficiency and Quality   

Higher Throughput and Less Downtime   

When inspection slows down, so does production. The CIRCOFLUX DA is built to keep pace with demanding operations, offering faster line speeds and easier transitions between test runs. 

• Supports test speeds up to 4 m/s   
• Automatic diameter adjustment capability allows size changeovers in ~1.5 minutes   
• Reduces setup and changeover delays for multi-size bar production   

Greater Flaw Detection Sensitivity   

Missing a small defect today can mean big problems tomorrow. The CIRCOFLUX DA delivers the sensitivity and resolution needed to catch critical flaws early and consistently without overwhelming your team with noise.    

• Detects surface flaws as small as 0.1 mm deep   
• Adjustable minimum flaw length detection starting at just 4 mm   
• Integrated high-resolution C-Scan supports clear visualization and traceability   

Lower Total Cost of Ownership   

Routine maintenance and scrap losses add up quickly. The CIRCOFLUX DA minimizes both with a durable, low-maintenance design that helps you get more value from every bar tested.   

• Inductive signal and magnetizing transmission = no brushes, fewer parts to replace 
• Wear shoes that last up to 1.5 years   
• Shorter untested ends (20 mm) mean less material waste and more yield  

Key Takeaways: What You Need to Know  

Whether you are planning an upgrade, optimizing existing lines, or exploring ways to meet tighter QA specs, here is what the CIRCOFLUX DA brings to your operation:  

• If you're running high-speed black bar lines, the CIRCOFLUX DA gives you the sensitivity and speed to keep up without increasing costs.  
• If you're facing tighter quality specs, this system delivers consistent, documentable detection at a resolution older models can’t match.  
• If you're evaluating equipment upgrades, the CIRCOFLUX DA supports both new installations and future migration from DS-generation systems—with full FOERSTER support from design to integration.