The void and pore analysis of castings using computed tomography (CT) is a powerful quality control method in the foundry and automotive industries. Since castings are often susceptible to small voids and pores that arise during the manufacturing process, it is crucial to detect these defects at an early stage. Such defects can significantly affect the mechanical strength and service life of the component, which poses a high risk, especially for safety-relevant components.
Functionality of void and pore analysis with CT
Computer tomography allows castings to be completely X-rayed and reconstructed as three-dimensional volume models. X-rays are sent through the component and a complete image is generated from a large number of angled images. This enables the precise recording of the internal structure of a component, including the position, size and shape of cavities and pores.
CT analysis works with extremely high resolution and thus enables the representation of the smallest defects down to the micrometer range. The 3D data obtained in this way is then evaluated using special software that automatically detects and analyzes pores and cavities. The defects are examined according to critical parameters such as volume, number, distribution and distance from the surface. This provides valuable information for quality assessment and helps to check the cast parts for possible weak points.
Advantages of CT-based void and pore analysis
- Non-destructive testing: Unlike conventional testing methods, the castings do not have to be damaged or cut to detect defects.
- High precision: The detailed 3D representation makes even the smallest pores and cavities visible, which could often be overlooked with other methods.
- Quantitative analysis: CT analysis enables a quantitative assessment of defects. Parameters such as volume, diameter and surface distance can be precisely determined and documented.
- visualization and traceability: The results can be visualized as 3D models, which ensures clear documentation and traceability.
- optimization of manufacturing processes: The analysis results provide valuable data that help improve the casting process. Areas that repeatedly exhibit defects can be specifically optimized to increase quality in the future.
areas of application and significance
CT void and pore analysis is particularly relevant in industries where structural integrity and component reliability are critical. In the automotive, aerospace and mechanical engineering industries, CT technology is increasingly used to ensure that castings are free of potential weak points that could lead to failure or defects. CT analysis also plays a key role in optimizing casting processes, as precise defect analysis enables manufacturers to better understand the causes of casting defects and to adjust the manufacturing process accordingly.
