Non-destructive Quality Inspection For Hybrid Cast Components

2023 Author: Hannah Pearcy | [email protected]. Last modified: 2023-11-26 11:39

Hybrid construction is one way of combining the best properties of different materials. Useful combinations of different materials are, for example, CFRP and aluminum. So far, these components have been connected using adhesive or mechanical joining. Scientists at Fraunhofer IFAM have developed a connection solution in the form of a transition structure that can be integrated into aluminum components using die casting. The inserted connecting element, which can consist of heat-resistant glass fibers or titanium, leads to galvanic decoupling between the materials and thus reduces the corrosion behavior of the aluminum-CFRP material composite.

So far, however, there is no process that allows the non-destructive quality inspection of such hybrid components - which in turn is a prerequisite for industrial implementation. The Fraunhofer Institutes IIS / EZRT, IZFP and IFAM are therefore contributing their respective expertise to the project “HyQuality - hybrid casting production with standardized quality assurance” in order to jointly develop appropriate methods for this. The aim is to develop a production-integrated and non-destructive inline test that makes all types of defects in hybrid components visible and thus verifiable. In order to be able to precisely recognize the contact surface between fiber, wire or sheet reinforcement and the casting matrix and to be able to assess their quality, imaging technology that displays the material as high-resolution as possible isrequired. X-ray technology, computed tomography and thermography are three of the technologies that can be considered in this context. The aim of the development team is to evaluate all processes with a view to a production-integrated inline test for hybrid casting. In order to determine the suitability of each of the non-destructive testing methods and to make a scientific comparison, the samples and components produced in the project are subsequently destroyed. The results of the destructive test serve as reference results and are used for comparison with the results of the non-destructive test. (qui)evaluate all processes with regard to a production-integrated inline test for hybrid casting. In order to determine the suitability of each of the non-destructive testing methods and to make a scientific comparison, the samples and components produced in the project are subsequently destroyed. The results of the destructive test serve as reference results and are used for comparison with the results of the non-destructive test. (qui)evaluate all processes with regard to a production-integrated inline test for hybrid casting. In order to determine the suitability of each of the non-destructive testing methods and to make a scientific comparison, the samples and components produced in the project are subsequently destroyed. The results of the destructive test serve as reference results and are used for comparison with the results of the non-destructive test. (qui)The results of the destructive test serve as reference results and are used for comparison with the results of the non-destructive test. (qui)The results of the destructive test serve as reference results and are used for comparison with the results of the non-destructive test. (qui)