Aluminum Casting defect in X-ray inspection Application

Release: 2023-03-20, Update 2023/08/31, M.P.

In aluminum die casting and other metal casting processes, Cavities may occur inside metal casting parts. The cavities created in casting and die casting are called "Shrinkage Cavities", "Gas Porosity," or "Blowholes" and are among the most common defects. Since casting holes results in defective products, it is necessary to determine the blowholes' location and size to take preventive measures. The shrinkage cavities cannot be visually inspected, and an X-ray system is needed for such shrinkage cavity inspections in aluminum casting.

Aluminum die castings have complex shapes, and it is difficult to determine whether they are cast cavities by X-ray radiographic images taken from a single direction. Therefore, an X-ray inspection system that can observe from many different directions is necessary. In addition, since aluminum die-cast is a metallic material and many samples are large, an X-ray tube with a high voltage is necessary.

The horizontal model of our X-ray inspection systems has a turntable stage, so the workpiece can be rotated 360 degrees for observation simply by placing it on the object. The Computed Tomography (CT) imaging function is effective for more detailed shape observation. The ability to observe 3D images and cross-sectional images from three directions enables observation of internal structures that could not be seen without grinding or cutting, as well as dimensional measurement and comparison with design values by converting to Stereolithography (STL) data.

The horizontal X-ray inspection system μRay8700 is equipped with a 130kV microfocus X-ray tube and a high-resolution, large area 6-megapixel Flat Panel Detector (FPD), enabling wide-field, high-resolution X-ray radiographic images of Shrinkage Cavities in Aluminum Casting.