X-ray Machine for Auto Parts

No. The X-ray based nondestructive testing method does not leave residual radiation on the test object, since X-ray is an electromagnetic wave. X-rays are emitted in the form of energy, and not matter. That’s why like an ordinary light bulb when there is electricity shut down, the electromagnetic wave of X-rays disappears without leaving any residue on the part.

The common defects in the castings include especially holes and inclusions. So, let us understand the differences between loose holes, slag, shrinkage holes, pinholes, and trachoma in the defect.

There are two categories of defects:

1. Inclusion type

• Slag: It occurs during the pouring process in the liquid metal in a timely manner without separation
• Trachoma: If the sand debris gets entrained in the liquid metal, trachoma is formed. Due to the sand formation, it remains in the liquid metal into the cavity before it already exists during individual pouring.

2. Hole-type

• Loosening: It is officially called shrinkage – a honeycomb defect due to inadequate shrinkage during the liquid metal solidification step.
• Shrinkage hole: This defect is more serious, where the hole is usually accompanied by the upper part of the shrinkage area. It gets concentrated into one or several larger holes.
• Pinhole: As per the formation mechanism, it is divided into many types. At times,
• Slag porosity phenomenon may take place due to the slag or sand containing gas material formation.

X-ray testing can be directly incorporated into the manufacturing line where it is possible to inspect every radial truck, bus tire, and many passenger cars tires.

• This X-ray inspection technique detects the anomalies such as spacing, position, and damage in steel wires.
• Other issues that can be detected by X-ray inspection test include:

– Foreign objects

– Defects or missing wires in the belt plies

– Shifts and distortions in the reinforcement plies

– Air inclusions

X-Ray based non-destructive testing can detect wheels defects such as:

• micro porosities to prevent the microsections formation
• foreign bodies
• clusters and blowholes
• prevent surface-breaking flaws on the finished wheel

All these testing results are well documented and archived to provide prompt direct solutions for enhancing the quality of the casting process.

There are chances of typical casting defects in all casting techniques that include materials such as iron, magnesium, aluminum, or zinc.

X-ray based non-destructive testing can detect automotive casting defects such as:

• Porosities like pores and blister formation
• Thermal cracking
• Dimensional changes as well as inclusions
• Blowholes

Yes, it is possible to inspect multiple parts simultaneously to reduce the overall cost of the work. But it depends on the customer’s objective as well as the resolution level to visualize the results effectively.

Brake disc sand hole typically refers to the surface and interior part of the brake disc. Either, there will be sand particles, commonly called a ‘sand hole’. Else there will be gas, hole, or impurity formation. They are referred to as grit.

This appearance of grit on the brake disc surface can be viewed or identified directly through our naked eye. But if it appears on the interior part, the object should be processed before getting exposed, or it can be detected with the help of X-ray based nondestructive testing equipment. Obviously, X-ray based non-destructive testing equipment is the best choice.

X-ray based non-destructive testing equipment follows the principle of X-ray transmission by taking real-time photographs of the interior parts to detect the inner structure of the brake disc. For detecting the brake disc sand hole, you need not expose the workpiece and process. The X-ray inspection method is the most convenient and efficient technique. There are few defects like a sand hole, sand grain, sand block, and sand mass in the brake disc, which require casting workers to detect them. Just detecting these defects in the brake disc is not enough. It’s mandatory to evaluate these defects in terms of count, size, area, and so on, in order to improve as well as promote the product quality.

The hood of an automobile engine is made up of magnesium alloy, which can be used as steering wheel frame, transmission case, seat frame, wheel hub, instrument panel frame, etc.

How should we ensure the quality of magnesium alloy parts? 

This is where X-ray based nondestructive testing machines play a significant role. X-ray based non-destructive testing equipment can be used to detect magnesium alloy parts, for any defects at a glance via real-time imaging. It can get connected with the production line of the factory, implement the complete automatic loading and unloading manipulator, decrease the manpower cost, understand the integration method of production, testing, and evaluation thereby improving the production efficiency. With maximum resolution, high definition qualitative imaging, automatic defect recognition, and the automatic evaluation function, this entire system can inspect the magnesium alloy parts automatically and thoroughly with 100% accuracy in real-time.

Before knowing the application of X-ray inspection to detect sand hole, it is mandatory to understand the formation of a sand hole in the castings.

A sand hole typically refers to a hole formed by impurities or gas on the surface or internal part of the casting. The appearance of sand holes on the casting surface is easily visible. But the sand holes on the internal part cannot be seen easily. Only when these internal and surface casting sand holes are detected, they can be rectified by grinding, welding, or scraping. This is where X-ray based non-destructive testing equipment solves the purpose.

The X-ray based non-destructive testing equipment manufactured by Uni X-ray technology can effectively detect sand holes in castings. At first, this equipment can precisely detect the internal structure of the casting through the X-ray transmission principle. The defects like a sand hole, shrinkage cavity, and cracks can be easily viewed on the computer screen. Hence, it’s possible to improve the quality of the product by promptly finding out the abnormality in the casting production process.

Not only the inspection quality but also the mechanism of this equipment is too convenient. It is enough to keep the test piece on the machine tray. Within a few seconds, the entire result about the quality of the test piece can be viewed via the computer screen. This efficient and intuitive result can improve the casting production by finding the cause of the issue in every step, and rectifying it at the right time. Checking the cause of the issue includes analysis of the size, area, defects, etc. Hence, it is possible to improve the product quality and affordability by drastically lowering the negative effects to the minimum level.

Thus, X-ray based non-destructive testing equipment manufactured by Uni X-ray technology is extensively used in the assessment of automobile parts, pressure vessels, engineering parts, steel cylinder, aluminum iron castings, and other industries.

The quality of the wheel usually depends on the method of its manufacturing and prompt inspection.

Wheels are manufactured in two forms: Steel wheels and light alloy wheels including magnesium alloy and aluminum alloy. The lower version of automotive models or trucks uses steel wheels, while most of the family cars are integrated with aluminum alloy wheels.

According to the range of expenses, there are varied methods of wheel manufacturing like gravity casting, low-pressure casting, as well as forged wheels. The cost of forging is anyway costlier than the ordinary casting, which suits the high-end modification market. Since the low-pressure casting has high durability and a higher yield rate, it is suitable for mass production. Hence, many car manufacturers prefer this method of manufacturing.

Depending on the manufacturing method, it’s possible to estimate the quality and rate of the wheel. Irrespective of the manufacturing method, an inspection of the manufactured wheels is mandatory to ensure its quality. This is where the X-ray based NDT method plays a significant role.

There are numerous factors that affect the value of castings, like meager control of raw materials, unreasonable structure design, unreasonable procedure plan, improper production operation, etc. All these factors may produce a variety of defects in castings, such as bubbles/pores, inclusions, cracks, and loose.

X-ray based nondestructive testing is the most preferred method to detect internal defects in castings so that it can improve production efficiency and avoid material wastage. Cracks in the castings can be viewed as light-colored lines in the final X-ray inspection image. Similarly, inclusions are viewed as a dark block, and loose as a light-colored nebulous (hazy) form.

The quality of the car can be assessed in four stages during the entire production process.

1. Pre-production inspection

Our automotive X-ray machine can generate precise metrology data during pre-production by validating the conformity of the component with original designs to confirm its quality. In order to satisfy PPAP requirements, we find highly precise dimensional data for auto parts with complicated internal and external geometries, thereby validating the function of multi-material assemblies. 

2. Production inspection

We deliver offline inspection solutions during the production phase that can confirm the quality of automotive parts before they reach their final destination. This step is perfect for high-value component applications as well as performance racing. The inspection with automotive X-ray machine during the production phase can be conducted at random or specific intervals to recognize the defects, confirm dimensions, as well as validate production steps. This phase can also inspect profile complex surfaces and detect out of tolerance features in production parts.

3. Part Sorting

For warranty, quarantined, or recalled automotive parts, our high-speed X-ray based NDT inspection services can reduce uncertainty by providing a traceable and repetitive inspection. We provide confidence to our manufacturers to go ahead with their projects, isolate suspect parts, and reintroduce valid parts back into the production phase. the offline X-ray machine is considered as another option for part sorting and inspection in lower volume.

4. Failure Investigation

The automotive X-ray machine is a vital tool for failure analysis of automotive components and assemblies. As a non-contact nondestructive testing method, X-ray inspection reveals internal failures without damaging the component and preserving its natural condition. Our automotive X-ray machine not only saves your expenses but accelerates the complete inspection process by instantly delivering qualitative data for failure analysis.

The quality of the auto parts castings typically includes internal quality, external quality, and service quality.

• External quality – refers to the roughness of the casting surface, shape deviation, size deviation, weight deviation, and defects.
• Internal quality – refers to the mechanical properties, physical properties, chemical composition of the casting, metallurgical organization along with the internal defects such as the presence of cracks, holes, inclusions, segregation, and other conditions within the casting.
• Service quality – refers to the strength of the castings in varied conditions, including corrosion resistance, wear resistance, heat and cold resistance, shock absorption, fatigue, and other properties like weldability, machinability, and other technological properties.

Varied inspection methods including X-ray, γ-ray, eddy current and ultrasound can check and determine the internal quality of the castings. With the help of the ray detection effect, it’s possible to predict the size, shape, type, and distribution of internal defects in the castings.