We have a similar problem. For these problems has been developed by our engineers EDM machines. We can offer you such an EDM machine. With her help of this year we have already done more then 100 different defects in different samples, which were put on nuclear power stations of Ukraine for the certification of systems of nondestructive testing.
Dear Mr. Charlie Belt,
Our company has more than 10 years, performs work in the field of NDT (see www.ndef.com.ua) primarily for the NPP of Ukraine.
About 3 years ago we started laying the test samples for the Qualification of NDT system of the reactor pressure vessel in accordance with the requirements of ENIQ.
Our production of test samples are sufficiently large mass (up to 2000 kg). In this regard, for the production of defects in their use of commercial EDM is not effective. Commercial EDM are usually stationary and place them in a test sample weighing 2 tons is very difficult. In addition, the cost of EDM is high enough. Therefore, we decided to develop its own EDM which is mobile and is intended only for manufacturing defects in test samples. With own EDM we have produced / finalized more than 10 large-sized test samples (more than 100 defects). For this EDM we have developed our own original electronic part which is based on digital technology.
If you are interested, we can meet your goals to develop and produce a similar device.
Mr. Yermolenko does not speak for PH Tool Reference Standards when he states that "the production of defects in their use of commercial EDM is not effective." PH Tool has designed and built application-specific EDMs for over 30 years for our in-house machining of precision notches, holes, pits, etc for NDT. While the company does not sell the machines, it is in the business of providing this service to the international NDT community. Calibration samples weighing 2 tons are "standard practice" for well-equipped standards makers.
In my message I just wanted to emphasize that in our case (in Ukraine) the use of commercially available EDM machines for manufacturing defects in the large test samples was difficult. The main factors - cost + specifications existing EDM.
For example, next year we will work on burning-out defects on the sample, which is the lid of the reactor pressure vessel. Weight of sample - 90 tons. All work on burning-out defects we plan to execute directly on the ground NPP, because the transportation of such samples is very difficult (in our conditions).
When I lived in Houston Tx, we used a company called Scan Systems for EDM's, here is their link http://www.edmnotches.com/ Talk to Tommy Buck, I believe they were going to market a portable EDM machine but not sure if they did this or not but talk to Tommy about this as they may help you.