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

粉末冶金(PM)获得的典型复杂形状的净形零件被用于几个关键的大规模工业部门，特别是汽车、航空航天和医疗。与传统铸造相比，它们的应用正在迅速增长，因为该工艺生产的零件具有所需的精确最终形状，几乎不需要加工，并结合了细晶(纳米-微米级)、均匀的显微组织和增强的强度。然而，由于很少进行在线检查，因此缺乏生产质量控制。不经常执行的生产线末端检查导致6-8%的部件报废，但无法检测到微小缺陷，这些缺陷可能会在服务中增长，导致主要的服务故障和召回。VISION项目是一个在线质量控制系统(QUALINET)，使用3D微焦点X射线成像(µXCT)，具有自动化创新(A)检测和表征烧结前和烧结后阶段的体积和表面微尺度缺陷。(B)决策：(1)部件验收或(2)送回回收或(3)送来治疗缺陷愈合的处方。QUALINET将消除浪费，增加生产线产量，减少能源消耗和碳排放，所有这些都将减少8%。对于最先进的粉末冶金组件生产线，包括通过激光沉积、纳米粉末和注塑进行添加制造，这一优势将是最佳的。包括合作伙伴、被许可方的利润和安装QUALINET销售系统的PM系统所节省的减少废物的估计ROI在欧洲经济区是111：1，在商业化的前5年是35：1。全球对网络技术的接受可以节省340 mpa的GB。

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.