SERVICE SPECIALIST FOR INDUSTRIAL COMPUTED TOMOGRAPHY

Industrial CT in the automotive industry

Inspection of components using industrial CT has been an integral part of quality assurance in the automotive industry for many years. Manufacturers know that rapid feedback in the event of deviations in product quality saves costs. In times of lightweight construction, transition to electromobility and increased efforts to reduce CO2, this is even more true.

Microvista's service helps to overcome a wide range of challenges, e.g. when it comes to systematically identifying and eliminating the causes of defects or when batches cannot be released due to potential defects.

Prevention is often better than aftercare. With our fast and reliable CT service, you have everything in view. This foresight saves you time and money in relation to the entire production process.

Experts in powertrain testing

Practical example: combustion engine powertrain

combustion engine powertrain CT scan

Challenge:

Remaining of inorganic binders in cavities

Possible consequences:

Functional impairment due to adhering core residues in cooling channels (failure of pumps and auxiliary units due to detachment of these possible)

Advantages of CT testing:

Non-destructive testing can be implemented even on a completely assembled engine for acute damage limitation or preventively in case of suspicion (FMEA).

combustion engine powertrain 3D

Challenge:

High technological requirements for wall thicknesses and the mechanical load capacity due to more engine power and simultaneous mass reduction

Possible consequences:

Not achieving machine capability (risk of overheating and wall penetration under load).

Advantages of CT testing:

Dimensional inspection of individual and critical features with fast OK/NOK evaluation.

combustion engine powertrain CAD target actual comparison

Challenge:

Ordering a new production batch after a long time - does the mold really fit the current CAD?

Possible consequences:

Lost production (detection of missing contour only in final assembly)

Advantages of CT testing:

Fast detection of unwanted deviations and other deficiencies through CAD target/actual comparison (need-based maintenance of core boxes and molds possible)

Prax­is­beispiel: Antrieb­sstrang E‑mobilität

stators

Challenge:

Prevent impermissibly thin walls in the cooling jacket

Possible consequences:

Breakthrough at full load and risk of field failure occurrence.

Advantages of CT testing:

Rapid detection of defect focal points to stabilize production processes through fully automated and cost-effective CT evaluation 

hairpin and laser welding

Challenge:

High mechanical stress of laser joints (e.g. welding of hairpins or of contacting systems)

Possible consequences:

Field failures with possible recalls caused by systematic deviations

Advantages of CT testing:

Process reliability and stability through regular random sampling inclusive of fast automatic determination of the most important quality parameters

computed tomography scanning automotive industry

Challenge:

Holey short-circuit rings and shrink-funks on their connecting rods in asynchronous motors

Possible consequences:

Malfunction in use 

Advantages of CT testing:

Inspection of the mechanical stability on the metal sheet package 

Inspection of structural components

The manufacture of structural components is technologically challenging, because hybrid structures are created, e.g. from different metals and fiber composites, using sophisticated joining techniques.  Here, it can happen that mechanical characteristic values are not achieved and, as a result, malfunctions occur on critical components. An inspection with CT can provide feedback for process improvement and sort out defective parts. 
Strukturbauteile

Assembly and joint control

Your product is non-functional and you can't find the reason? You are unsure whether the assembly was done correctly? Disassembly is not permitted, unsuitable for analysis or too costly? 

Without disassembly can be checked completeness, proper fit and sufficiently good joint.

CT image of an assembly control

Too many or too few screws, seals, etc. were used during assembly of subassemblies. You do not know whether e.g. loose screws are included in the finished assemblies?

Industrial CT in the automotive industry helps to sort out defective assemblies quickly and cost-effectively so that blocked lots can be released at short notice.

assembly control CT image

Process of a non-destructive test

Serial testing

Ablauf Serienprüfung bei Microvista

*Note: Scanning within 24h only by appointment and depending on the number of parts.

Complicated components in high-quality end products? Major damage due to quality defects that far exceed the manufacturing costs of a component? Safety-relevant components that require 100% inspection?

In these cases, a fast, low-effort inspection such as industrial computed tomography is required. Due to ready-made process and automation modules, high levels of maturity in the inspection process are realised extremely quickly and at low cost.

Sampling

Ablauf einer Bemusterung mit CT

*Note: Lead time by arrangement, usually < 3 days for standard tasks. 

Need for inspection in case of acute problems in production? Customer returns? Qualification of product changes?

Reliable information on the condition of the product, inclusions, voids or other properties must be available quickly in order to react in time and draw the right conclusions. Expertise in the planning and execution of the CT scan as well as in the subsequent analysis are crucial for this.