QualiNet - Automated in- line inspection and quality control of net shape powder metallurgy components...

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Net shape parts of typically intricate and complex shape obtained by powder metallurgy (PM) are employed in several keymass industry sectors, especially automotive, aerospace and medical. Their use is growing rapidly in preference toconventional casting because the process produces parts in the precise final shape required with little or no machiningrequirement combined with fine grained (nano-micro scale), homegeneous microstructures of enhanced strength. Howeverthere is a lack of production quality control as little in-line inspection is performed. End-of-line inspection, not oftenperformed, leads to scrapping of 6-8% of components yet fails to detect micro sized defects, which can grow in service toproduce major in service failures and recalls. THE PROJECT VISION is an in-line quality control system (QUALINET) using3D microfocus x ray imaging with AUTOMATION INNOVATIONS (A) Detection and characterization of volume and surfacemicro-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 lineproduction, reducing energy consumption and carbon emissions, all by 8%. The benefit will be optimal for state of the artPM component lines including additive manufacturing by laser deposition, nano-powders and injection moulding.