Automated in- line inspection and quality control of net shape powder metallurgy components using microfocus three dimensional x ray computed tomagraphy imaging (Qualinet)

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Net shape parts of typically intricate and complex shape obtained by powder metallurgy (PM) are employed in several key mass industry sectors, especially automotive, aerospace and medical. Their use is growing rapidly in preference to conventional casting because the process produces parts in the precise final shape required with little or no machining requirement combined with fine grained (nano-micro scale), homogeneous microstructures of enhanced strength. However there is a lack of production quality control as little in-line inspection is performed. End-of-line inspection, not often performed, leads to scrapping of 6-8% of components yet fails to detect micro sized defects, which can grow in service to produce major in service failures and recalls. THE PROJECT VISION is an in-line quality control system (QUALINET) using 3D microfocus x ray imaging (µXCT) with AUTOMATION INNOVATIONS (A) Detection and characterization of volume and surface micro-scale defects at the pre and post sintering stages. (B) Decision making: (i) component acceptance or (ii) send for recycling or (iii) send with a prescription for defect healing treatment. QUALINET will eliminate waste, increasing line production, reducing energy consumption and carbon emissions, all by 8%. The benefit will be optimal for state of the art PM component lines including additive manufacturing by laser deposition, nano-powders and injection moulding. Estimated ROI comprising the profits of the partners, licensees and the savings in reduced waste from the PM systems on which the QUALINET sold system would be installed are 111:1 in the EEA and 35:1 over the first 5 years of commercialisation. Global acceptance of the net technolgy could save £340mpa.