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Defect analysis

CT analysis of component defects

Today, production processes of leading industrial companies are very sophisticated. This also applies to foundries, which use special casting processes to manufacture components made from various materials for their customers. Foundry practice, however, shows that hardly any cast component is completely free from defects. Typical defects are porosity, cavities, inclusions and cracks. These defects can be reliably detected via CT scan, displayed in 3D and evaluated with state-of-the-art CT analysis software.

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Microvista carries out such defect analyses on a daily basis and provides exact data and detailed test reports depending on the specific needs and issues of the client. These data can be used by the component manufacturer or supplier for a comprehensive evaluation of the detected defect and for classification of the component with regard to compliance with specified quality features. In addition, defect analysis based on CT scanning provides more information on the existing defects and prevents that every defect leads to n.i.o. classification of the component. This, defect analysis nearly eliminates the risk of producing or delivering defective parts.

CT scan analysis of pores and cavities in a component

Where compliance with quality characteristics as stipulated by requirement specifications or component specifications is concerned, the nature of the component material always plays a crucial role. Microvista uses CT scanning for non-destructive testing of components of different sizes and made from various materials. Once the scanning data are available, porosity analysis is carried out. Then a test result is drawn up, which documents porosity analysis results in a clear manner that leaves no room for interpretation.

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In addition to porosity analysis, the client can request to be provided with his scanning data complete with free-of-charge viewer software to be able to assess component porosity on his own. In a web conference, it is possible to clarify further issues of the porosity analysis with the member of the engineering department, who has carried out the component evaluation. This way, CT porosity analysis provides the client with precisely the data that enable him to make the “right” and cost-optimal decisions.

Detection and representation of component cracks via CT scan

Contrary to pores, cavities and inclusions, cracks in a component mostly are the result of previous mechanical, thermal or corrosive stresses. Experience shows that cracks are most frequent in cast components and joints (welded joints). For surface crack verification, suitable procedures such as magnetic particle testing or dye penetrant testing are used. For crack detection within components, various standard procedures like ultrasonic or eddy-current testing can be applied. However, in comparison to the aforementioned procedures, CT radiography offers the advantage that detected cracks can be shown in a three-dimensional representation, which clearly portrays their size, location and progression.

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Apart from optimal resolution for the size and position of the component, it is the user’s experience that is particularly important in crack detection through CT scanning. Microvista employees in this specific area of responsibility have an extensive know-how of error patterns which might occur in crack detection and are therefore able to distinguish between real cracks or so-called false errors or artefacts. The results of crack detection are either documented in a test report or in a data package which comes complete with viewer software for independent assessment.

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