Etek Aero, Prestwick Aerospace Centre

High Volume Inspection for Foundries Applications

Quality inspection using YXLON industrial X-ray and CT inspection systems enable high unit volume inspection of typical casting flaws such as porosities, pores and blisters, thermal cracking, dimensional changes, and inclusions

Typical foundry casting flaws can occur in all casting techniques that involve materials such as iron, aluminum, magnesium or zinc. These flaws include porosities, the formation of pores and blisters, thermal cracking, dimensional changes, and inclusions.

X-ray inspection offers the opportunity for:

  • Verification of blowholes and pores
  • Geometric measurement of inner structures
  • Wall thickness analysis

Quality inspection using YXLON industrial X-ray inspection systems enables high unit volumes to be checked with rapidity and certainty using YXLON inspection software. Cast parts with a deviating casting structure can be sorted out of the production process at an early stage. The possibility also exists to draw conclusions regarding casting quality based on the types of flaws found, and then increase productivity by initiating appropriate corrective measures.

YXLON industrial computed tomography (CT) is able to supply important supplementary information. For example, inner structures and remaining wall thicknesses can be precisely determined using CT, even in the case of complex components. Information like this is indispensable, particularly during prototype qualification.

For components bearing a relevance to safety, ascertaining remaining wall thicknesses following the casting process, or the finishing phase for series products, is of major importance. This measurement provides information about the material’s stability and thermal conductivity. Once a tomogram of a component has been made with YXLON industrial CT inspection systems, information is then available for a variety of analyses.

Quality piston inspection can prevent subsequent engine damage. Due to the great amount of stress placed on pistons, even tiny production flaws such as salt core residues in the cooling channel can result in substantial damage later on.

X-ray inspection offers the opportunity for:

  • Detection of inclusions and salt core residues
  • Verification of blowholes and pores
  • Cooling channel measurement
  • Comparison of actual vs. target situation

YXLON industrial X-ray and CT systems with our YXLON inspection technology make typically occurring anomalies visible, not only blowholes and blisters but also cracks and residues in the salt core, and inclusions of foreign materials.

The demands placed on modern spark-ignition and diesel engines are constantly growing. Not only must engines have a high power density, but they must also display low fuel and oil consumption. This means continuously operating pistons must be stable, while minimizing mass as much as possible. However, lightweight aluminum pistons for diesel-engine passenger cars can only be used when they have complex cooling cavities. If salt core residues remain in this cooling channel after casting, damage to the engine can occur.

A further increase in production process efficiency is possible by employing YXLON computed tomography (CT) inspection systems during initial prototyping. They enable the implementation of complete comparisons of actual vs. target situations and the analysis of cooling-channel geometries and remaining wall thicknesses.

Brake disks, calipers, pistons and linings are complex assembly structures. They are made of special combinations of materials to reduce weight without decreasing the level of stability and thermal conductivity. This lighter-weight construction design places particular demand on quality assurance.

X-ray inspection offers the opportunity for:

  • Inspection of material junction
  • Verification of casting quality
  • Detection of inclusions
  • Integration into the production process

YXLON industrial X-ray inspection represents an assured method for testing even complex structures, interfaces, and components precisely, during production. Material junctions, casting quality and shape retention are defined exactly and analyzed when needed.

Weight reduction of brake systems allows lower spring and shock-absorption quotients while enabling greater comfort, a more direct ‘steering feel’, and reduced fuel consumption as well.

YXLON offers industrial X-ray and CT inspection systems for both spot-check sample inspection and fully automatic systems that can be integrated ‘trouble-free’ into the production process. Flexible adaptation to the respective requirements make these systems just as suitable for X-raying thin-walled lightweight metal components as they are for inspecting gray cast iron several centimeters thick.

No matter the type of casting method utilized, small flaws can still arise during the production of engine blocks and cylinder heads. Since these can lead to engine breakdowns, strict quality controls ensure that defective pieces of machinery do not reach the delivery stage.

X-ray inspection offers the opportunity for:

  • Verification of blowholes and pores
  • Geometric measurement of inner structures
  • Wall-thickness analysis
  • Comparison of actual vs. target situation

X-ray technology has been used successfully for years during production, both for spot-check sample and for 100% inspection. With YXLON industrial X-ray and CT inspection systems, casting core ruptures and shifts, inclusions, and porosities and blowholes can all be verified with certainty.

In addition to low levels of pollutant emissions and fuel consumption, modern engines must display a high performance and low weight. This is achieved through the use of aluminum and magnesium alloys as well as through the innovative combination of construction techniques and manufacturing processes.

At the research and development phase, YXLON industrial computed tomography (CT) inspection systems can be used to ensure that new materials and production technologies are being utilized and implemented with quality assurance. Typical tasks here are shape capturing, a comparison of the actual and target situations, initial prototyping, and the measurement of geometric relationships in inner and outer structures.

Specialized YXLON industrial CT inspection systems are used more frequently in research and development departments.

Chassis parts such as integral subframes, suspension arms, steering knuckles, swivel bearings, steering gear housings, and damper brackets all bear a relevance to safety and must be 100% inspected.

X-ray inspection offers the opportunity for:

  • Blowhole and pore verification
  • Geometric measurement of inner structures
  • Wall thickness analysis
  • Comparison of actual vs. target situation
  • High throughput – integration into the production process

Independent of the manufacturing process involved, inspecting quality using YXLON industrial X-ray inspection systems is a fast and proven method to detect flaws like blowholes, porosities or deviations in form during production.

The chassis is subjected to stresses that are highly dynamic and occur abruptly. This is why the assemblies must exhibit a high degree of long-life fatigue strength. Demand also exists for chassis parts to weigh as little as possible at minimized manufacturing costs. Weight is reduced through a modified forming or deployment of materials, while strict quality controls make certain stringent specifications issued by automobile manufacturers are adhered to.

Modular, modern vehicle platforms require high production volumes. Therefore, X-ray inspection systems must be integrated into the production process so they can readily inspect these volumes. YXLON offers different X-ray inspection systems to accomplish this and are coordinated to meet respective production requirements.

YXLON computed tomography (CT) inspection systems are used for the production of prototypes as well as for spot check sample inspection as inner structures can only be measured precisely using CT. YXLON X-ray inspection systems either with our CT-option or YXLON inspection technology are deployed in the subsequent production process.

NON DESTRUCTIVE TESTING

Inspection Systems

Our world class Imaging Division offers a range of innovative and cost effective equipment for industrial X-ray and CT for non-destructive parts inspection.

SUPPORT & TRAINING

Service & Maintenance

We have a team of equipment and process specialists capable of providing 24/7 rapid-response, ‘frontline’ support and training to compliment your own technical personnel.

Etek Aero, Prestwick Aerospace Centre

Featured Products

We offer a broad range of cutting-edge X-ray and CT products designed to support all your industrial inspection needs. Whether your component is measured in micrometers or meters, we have a system that fits.

YXLON FF35 CT x-ray inspection system for the aerospace industry

YXLON FF35 CT

High Resolution Industrial CT System for a Wide Sample Spectrum

YXLON MU2000-D x-ray inspection system for the aerospace industry

YXLON MU2000-D

Robotic System for Industrial X-ray Inspection of Turbine Blades

YXLON MU60 AE | X-ray and CT Inspection System for the Aerospace and Foundry Industry

YXLON MU60 AE

X-ray and CT Inspection System for the Aerospace and Foundry Industry

YXLON CT Compact x-ray inspection system for the aerospace industry

YXLON CT Compact

Industrial X-ray and CT Inspection System for Large Aerospace Parts

Why choose Etek Aero

With our team of experienced and factory trained service engineers, Etek Aero provide a world class service that focuses on quick response times and putting customers first.

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