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Detection of quality features in hybrid cast components using NDT

Fast and safe testing of innovative multi-material concepts
: Leinenbach, Frank; Sukowski, Frank; Clausen, Jan; Straß, Benjamin; Wolter, Bernd

Bleicher, Christoph:
InCeight Casting C(hoch)8 2021 : Proceedings of the 1st Congress for intelligent Combining of Design, Casting, Computer Simulation, Checking and Cyclic Behaviour for efficient Cast Components, March, 2nd-3rd, 2021, Darmstadt
Stuttgart: Fraunhofer Verlag, 2021
ISBN: 978-3-8396-1703-8
Congress for intelligent Combining of Design, Casting, Computer Simulation, Checking and Cyclic Behaviour for efficient Cast Components (InCeight Casting C8) <1, 2021, Online>
Fraunhofer IZFP ()
hybrid; Multimaterial; NDT; casting; infiltration; adhesion; quality features; x-ray; ultrasound; eddy current; computer tomography

In lightweight construction, promising hybrid designs from different material classes and types are being used, which combine the individual advantages of the materials in the hybrid material produced by joining technology. At Fraunhofer IFAM, new types of manufacturing technologies for various material combinations have been developed up to production maturity, which are implemented in the casting process of the aluminum components. The combination of die-casting alloys and fiber materials or sheet metal structures opens up new potential for lightweight components, which are increasingly required for applications in a wide variety of Industries, like automotive and aerospace. An important point in the production chain is quality assurance. In addition to classic casting defects such as pores and cavities, a number of other potentially manufacturing defects have been identified that can occur especially in hybrid casting. Production errors that affect the mechanical component properties are mostly due to a poor connection of the insert material to the casting matrix. Inlay materials can potentially be fiber materials, semi-finished fiber composites with a thermoset or thermoplastic matrix, and metallic sheet or wire structures. The errors that occur can be divided into the categories of insufficient infiltration, geometric errors, outgassing of coatings, insufficient adhesion and classic casting errors. Since no processes have yet been identified that enable accurate and reliable quality testing of hybrid cast components with regard to the defects mentioned, the Fraunhofer Institutes IFAM, IIS / EZRT and IZFP have examined this aspect in more detail as part of the HyQuality - Hybrid Casting Production with Standardized Quality Assurance project in order to identify and evaluate potential test techniques and their possible uses. The aim of the project was to identify a test procedure for each of the defect categories mentioned above, which could reliably prove all existing defects in the component. This is a mandatory requirement for the industrial use of this technology. Furthermore, the identified testing methods should be able to be integrated in the production process. The focus was on the scanning and imaging methods: digital radioscopy, Computer tomography, ultrasound and eddy current testing. The non-destructive test results were validated in a destructive manner by means of metallographic examinations.