Non-destructive testing of iron castings

Iron casting - opportunity and challenge for lightweight construction

Lightweight construction does not automatically mean "light metal", because light metals cannot be used at high temperatures and pressures. With thin-walled iron or steel castings and innovative, bionic design, components are created that can compete with functionally equivalent elements made of light metal. 

Mass savings and high mechanical properties are accompanied by significant technological challenges. Those who are ahead of the game here can also enter the competitive market for lightweight safety components. Process monitoring based on meaningful inspection data enables high quality and ultimately more profit. Non-destructive testing of iron castings with CT can help here.

CT-Aufnahme eines Turboladers
CT Image as a cross section of turbocharger

Typical problems with iron casting.

Cracks in components

Use the magnifying glass to observe the crack in the component in 3D:

Zerstörungsfreie Prüfung von Eisenguss

Crack in a 2D view:

Riss im Krümmer durch CT sichtbar

Pores in components

Use the magnifying glass to observe the pores in 3D:

Zerstörungsfreies Lolo

Pores in a 2D view:

Pore im Eisenguss

Process for non-destructive testing of iron castings

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.


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.

Identify differences between simulation & reality

A constructor's imagination and the results of the simulation do not always match the reality.

Cross-sectional areas of ducts must be within specified tolerances, otherwise the hoped-for performance remains behind the expectations.

Querschnittsmessung mit CT
Cross-section measurement

Iron - not easy for CT systems 

Wall thickness plays an important role in non-destructive testing of iron castings with CT, as can be seen here.

Total attenuation coefficient of X-rays with the energy of 400 keV:
0,74 cm -1 (for comparison Al: 0.25 cm-1)

For a high-quality inspection, the ratio should be I/I0 ≥ 10-5!
Ablauf CT-Scan
Mögliche Wandstärke beim CT-Scan