Metal-based objects and components surround us and are essential in every application. However, they are manufactured after a massive process where they are machined and shaped so that the metal may be put to purpose.
No matter how much care is taken while manufacturing metal-based components, one thing that cannot be 100% eliminated is the chance of failure or defects. In some way, there will be at least one such component out of a considerable volume with imperfections.
There are many ways in which metal casting may be inspected, and it is imperative to inspect them before supplying them to the industries. If you are looking forward to learning about these methods of inspecting the metal castings, you are at the right place; let’s read through them below.
What is Metal Casting?
Numerous metals are extracted and then processed because of their exemplary quality. They serve different applications. When manufacturing them, there are multiple machining processes or processes where they are molten and then molded.
Aluminum casting products are, for instance, manufactured by pouring molten metal into molds, and then once solidified, they can be used. Similarly, the different methods apply to different kinds of metals.
Common Defects in the Aluminum Casting Products
It is common to have certain defects in aluminum casting products, it comprises some repeated defects that are usually found or prone to be present due to the surrounding impact or the processes. Some of the common deficiencies found in aluminum casting products are as follows:
Issue of Voids
The issue of voids is quite common in the process of metal casting, and this is because when the molten metal is left for cooling, the casting loses its volume, and due to this, voids take place. Hence, the size and layout might need to be revised in certain aspects.
Casting Surface
The casting surface may also get some defects if the mold has dust particles or any spots present. This could end up solidifying along with the metal and impact the product’s surface.
It could cause cracks and appearance, which looks awful on the surface of the manufactured part and hence needs to be eliminated.
Therefore, it is suggested to keep the mold clean in the first place, and after it has solidified, the part must be examined thoroughly.
Measurement Defects
Since the castings are left for cooling, which causes them to shrink a little, sometimes the difference after shrinking in the product is tolerable. Still, sometimes when precise dimensions are required, this could be a problem, as there is no way to add back material.
Errors of Chemical Compositions
Many external factors may impact the product subjected to the casting process. The speed at which the metal is poured, the temperature maintained in the surroundings, variations it suffers, and the combination of the metal composition play an important role in causing defects in the design.
Aluminum Casting Inspection Methods
Once the aluminum casting products are manufactured, it is essential to ensure that the process of inspection has been carried out to remove the defective pieces, and for this, some of the common inspection methods are as follows.
Inspecting Visually
An expert carries out the inspection process for aluminum casting at all times. They know the techniques and have the vigilance to carry out this task. The first way to inspect is by visually assessing the component. The experts check out that there are no cracks in parts, holes, voids, and any tearings that cause distortion or bends in the element.
By visually assessing these parts, the components are subjected to compression with the plan and quality standard to check whether the part meets it.
Assessment of Mechanical Properties
It is essential to ensure that the component’s mechanical properties are up to the mark. The component that doesn’t have the proper mechanical properties, but it won’t be able to fulfill the purpose for which it is manufactured.
To assess these properties, different tests are conducted. The hardness test allows for determining whether the component has the required strength, which helps evaluate its resistance against wear and tear.
Tensile testing is also a process where the manufactured component is tested against destructive methods, ensuring it has enough strength and long-lasting durability. Similarly, the component is also subjected to some force to test the maximum load it can handle without being damaged.
Verification of Dimensions
There is a standard that the manufacturers follow for the dimension testing of the different components. It is essential to ensure the measurements are accurate and comply with the standards before the complaint is processed further or sent to the clients.
There are many methods of verifying the dimensions of composers using gauges and micrometers for measurement.
Chemical Analysis
When aluminum casting is manufactured, it is not 100 percent aluminum used in the components. A composition is created by adding some other metals in a smaller quantity.
It is essential to ensure that the composition of the metals added is accurate, and for this, an inspection is carried out before the part is manufactured by making a sample.
Why is Aluminum Casting Inspection Significant?
Every client expects to have a quality product manufactured and to ensure the quality of the product, the manufacturers need to test and inspect their components.
There are chances of defects in components made using different casting processes; some may be obvious, and some are hidden. These must be identified and matched against the standards provided by the client so that the product which appears to be the final one is quality oriented and doesn’t feature any chance of failure upon usage.
In the case of aluminum, the casting product fails due to defects, and the application for which they will be used will also end up failing.
Trained engineers are capable of identifying these defects and devising strategies to test components. At Sunrise Metal, before we dispatch the products to our clients, we ensure our team of engineers does this job. Our prime concern is delivering a quality product; hence, we always provide testing practices that are in place for your projects.