Additive manufacturing

FALLSTUDIE: ADDITIVE FERTIGUNG

UMFASSENDE INSPEKTION EINES ALUMINIUM-RADTRÄGERS MIT KOMPLEXER BIONISCHER STRUKTUR. 

Herausforderung:

Die addi­tive Fer­ti­gung erfordert sorgfältig eingestellte Prozess­pa­ra­me­ter, die in iter­a­tiv­en Schrit­ten während des Pro­duk­ten­twick­lung­sprozess­es opti­miert wer­den. Eine schnelle und umfassende Rück­mel­dung über die Pro­duk­tqual­ität ist von größter Bedeu­tung für die Verkürzung der Entwicklungsphase. 

Mögliche Folgen:

Fehlende und unzure­ichend vali­dierte Prozessqual­ität kann zu hohen Auss­chussquoten führen. Ins­beson­dere bei sicher­heit­srel­e­van­ten Teilen des Fahrw­erks entste­hen zusät­zliche Risiken, die zum Aus­fall von Bauteilen führen kön­nen und das Risiko eines Unfalls schaffen. 

Vorteile einer CT-Prüfung:

  • Verkürzte Entwick­lungszyklen
  • Behand­lung der durch die FMEA iden­ti­fizierten Risiken
  • Reduzierung des Bedarfs an teuren Pro­to­typen durch zer­störungs­freie Prü­fun­gen für eine Vielzahl von Merkmalen.
Alu­mini­um-Radträger
Cases

Weitere Branchenbeispiele: 

Schwermetallguss 
Leichtmetallguss 
Automotive 
Addi­tive Fertigung 
Luft- & Raumfahrt 
Batteriesysteme 
Voriger
Näch­ster

Fragen Sie uns nach CT-Prüfung für Ihr Unternehmen! 

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    Automated inspection of hairpins

    Challenge:

    The stability of the hairpin joint is crucial for the reliability of electrically powered vehicles. Laser welding can be carried out according to different principles. However, this can affect the quality of the joint by process fluctuations resulting in undesired deviations.

    Possible consequences:
    Due to ambiguity in the quality of joints, high
    failure rates can occur.

    Advantages of a CT inspection:

    • Quality feedback within minutes
    • Statistically evaluable results thanks to Microvista's automatic analysis: 40 stators/day inspected
    • Only 165 €/part including an informative report.
    CT Scan exposing a burnt out battery

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    Pore analysis of a cylinder head

    Challenge:

    In order to achieve the highest possible ranges as well as low emissions, lightweight construction continues to be a primary goal in vehicle construction, regardless of the type of drive. Light metal casting is characterised by its ability to produce complex parts with a high degree of automation and recyclability. However, high technological demands are placed on the components, including mechanical load-bearing capacity under more complex stresses and simultaneous mass reduction.

    Potential consequences:

    A cylinder with poor quality leads to damage to the cooling system and ultimately to engine failure.

     

    Advantages of a CT inspection:

    • Visualisation of pores in the cylinder head and colour classification of the pores according to their volume is possible.
    •  The exact position of each pore and thus the potential risk it poses can be determined.
    Testing of wall thicknesses of an exhaust manifold.

    Challenge:

    The exhaust manifold is one of the most heavily loaded components of an engine. For this reason, the actual and desired condition of the wall thickness should be compared. Only with a sufficient wall thickness can the manifold withstand the shock-like inflow of exhaust gases and the resulting pressure front, as well as the many heating and cooling cycles in the long term.  

    Possible consequences of undetected deviations:

    The notch effect of blowholes can cause a crack in the manifold. Partial breakthroughs can also occur if the wall thickness is too small. This leads to a change in the pressure conditions in the manifold, which reduces engine performance and, at the same time, increases fuel consumption. In addition, there is a high noise level from the direction of the engine and a clearly perceptible exhaust smell in the interior.

    Advantages of a CT inspection:

    • Fast and automatic detection of relevant quality defects 
    • Avoidance of scrap refinement 
    • Detection of defect focal points through statistical evaluation of the results.
    CT Scan exposing a burnt pores in aluminium wheel
    Assembly inspection of lithium-ion batteries.

    Challenge:

    Due to production or assembly errors, the contact, insulation and electrolyte foil is damaged in some batteries.

    Possible consequences:

    A short circuit can be the result. This can lead to a high thermal reaction of the electrolyte. The resulting outgassing causes the battery to swell externally. Inflated, deformed, outgassed lithium-containing batteries can lead to explosions and fires.

    Advantages of CT testing:

    • Dismantling of batteries in small devices is not necessary for the test. The devices can therefore be used immediately after the test
    • By sorting out defective batteries, higher quality can be guaranteed, and prevention against legal disputes and negative press in case of a fire can be operated
    CT Scan exposing a burnt out battery
    Comprehensive inspection of an aluminium wheel carrier with complex bionic structure.

    Challenge:

    Additive manufacturing requires carefully set process parameters that are optimised in iterative steps during the product development process. Fast and comprehensive feedback on product quality is of paramount importance for shortening the development phase.

    Possible consequences of undetected defects:

    Missing and insufficiently validated process quality can result in high reject rates. Especially with regard to safety-relevant parts of the chassis, additional risks arise that can lead to component failure and create the risk of an accident.

    Advantages of CT inspection:

    • Shortened development cycles
    • Addressing risks identified by FMEA
    • Reduction of required expensive prototypes through non-destructive testing for a variety of features.
    Comprehensive inspection of an aluminium wheel carrier with complex bionic structure.

    Challenge:

    Additive manufacturing requires carefully set process parameters that are optimised in iterative steps during the product development process. Fast and comprehensive feedback on product quality is of paramount importance for shortening the development phase.

    Possible consequences of undetected defects:

    Missing and insufficiently validated process quality can result in high reject rates. Especially with regard to safety-relevant parts of the chassis, additional risks arise that can lead to component failure and create the risk of an accident.

    Advantages of CT inspection:

    • Shortened development cycles
    • Addressing risks identified by FMEA
    • Reduction of required expensive prototypes through non-destructive testing for a variety of features.
    A CT scan of insulation foam
    Assembly inspection of medical devices

    Challenge:

    To detect malfunctions, damage or collisions that cannot be traced after disassembly of the medical device. 

    Possible consequences:

    Blockages can cause some devices to malfunction during use.

    Advantages of a CT scan:
    Complete digitisation takes place without the application of force during the measurement, which makes it possible to measure, analyse as well as subsequently process filigree and soft components. The inspection takes place quickly and reliably in the assembled state. During the evaluation, the movements in the component can be recorded, whereby the blockage can be found.

    A CT scan of XXX XXX