CT Testing for Die-Cast Parts: Non-Destructive Defect Detection

Have you ever encountered a situation where a project entered mass production only to reveal consistent internal defects? This leads to increased production costs and extended lead times. Implementing CT testing early in the project eliminates this concern.

What Defects Can Be Detected Using Industrial CT Scanning?

Gas Porosity

Gas porosity primarily results from trapped gas within castings. During the die casting injection process, gas may become entrapped in the molten metal solution. 

If this gas isn’t expelled before cooling and solidification, it remains trapped in the final casting.

Though minuscule, these pores cannot be overlooked. Their presence significantly compromises the casting’s corrosion resistance and adversely affects airtightness and mechanical properties.

CT testing enables non-destructive inspection of internal porosity in die-cast parts. Identifying porosity during initial trial production allows optimization of die-casting parameters, thereby reducing production costs.

Shrinkage

Shrinkage primarily results from internal defects caused by uneven cooling during metal solidification. Similarly, shrinkage compromises the mechanical properties and structural integrity of die-cast components. Industrial CT scanning identifies shrinkage voids within castings, facilitating optimized cooling channel design.

Impurities

Despite refining raw materials during the die casting material processing stage, residual impurity metals or flux agents may occasionally remain. During the first article inspection of die castings, identifying impurities within castings using CT scanners enables early detection of issues arising from the material processing stage.

The Benefits of Using Industrial CT Testing for Die Castings

1. Non-destructive

Inspecting die-cast parts with industrial CT provides insights into their internal structure without damaging the components. This non-destructive nature significantly reduces inspection costs. CT testing plays a vital role both in early project stages and in final product quality control.

2. High Clarity

Images obtained from industrial CT scans of die-cast parts feature high resolution. Porosity, often difficult to detect with the naked eye, becomes clearly visible in CT scans. From the images, you can pinpoint the exact location, size, and shape of bubbles.

3. No Shape Limitations

CT scanning imposes no specific constraints on the shape or size of die-cast parts. Consequently, even highly complex die-cast components can yield accurate scan images.

4. Creation of 3D Models

Unlike X-ray testing, CT scans produce three-dimensional rather than two-dimensional results. Utilizing these scans enables the creation of 3D models for die-cast parts.  

5. Cost-effective

Using CT to detect internal defects in die-cast parts reduces development and inspection costs. This rapid inspection method lowers overall production expenses by enhancing efficiency and shortening turnaround times.

Conclusion

While internal defects in die-cast parts can compromise corrosion resistance, airtightness, and mechanical strength, CT testing leaves no room for these issues to hide. If you’re looking for a manufacturer with stringent quality control for die-cast components, contact Sunrise today！