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

由粉末冶金（PM）获得的典型复杂形状的净形零件被应用于几个关键的大众工业部门，特别是汽车、航空航天和医疗。与传统铸造相比，它们的使用正在迅速增长，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，并且具有细晶粒（纳米-微米尺度）、均匀的微观结构，强度增强。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%的组件报废，但未能检测到微尺寸的缺陷，这些缺陷可能在服务中增长，从而产生重大的服务故障和召回。PROJECT VISION是一种在线质量控制系统（QUALINET），使用3D微聚焦x射线成像（µXCT）和自动化创新(A)在烧结前和烧结后阶段检测和表征体积和表面微尺度缺陷。(B)决策：(i)部件验收或（ii）送去回收或（iii）送去治疗缺陷的处方。QUALINET将消除浪费，提高生产线产量，降低能源消耗和碳排放，所有这些都将减少8%。对于包括激光沉积、纳米粉末和注塑成型的增材制造在内的最先进的PM组件线来说，这一优势将是最佳的。估计的投资回报率包括合作伙伴的利润、被许可方的利润以及安装QUALINET销售系统的PM系统减少浪费的节省，在欧洲经济区为111:1，在商业化的前5年为35:1。全球接受净技术可节省340mpa英镑。

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.