Data-based quality assurance of foundry cores using resonance analysis

• Applicant: Professor Dr.-Ing. Philipp Lechner
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 524816579

Quality assurance is a central aspect of modern mass production in general and core production in particular. Quality assurance for core production and subsequent metal casting is comparatively complex compared to other mass production processes such as metal forming and machining. On an industrial scale, cores are currently inspected only visually before being used in the casting mold. Fine and closed cracks are often overlooked. Material defects such as increased moisture absorption can also not be detected in this way. These defects lead to scrap after casting, which can only be classified as such after a considerable consummation of resources. The aim of the present project is to investigate the methodological basis for non-destructive quality assurance of foundry cores. Core defects, which are caused either by the manufacturing process or subsequent storage, are often not detectable from the outside, which is why it is necessary to inspect the entire volume. Resonance testing in combination with modal analysis will be used for this purpose. Within the scope of the research project, methods will be developed not only to distinguish between good parts and scrap, but also to localize defects. For this purpose, the geometric as well as the material properties including their statistical distribution are characterized. This enables a spatially resolved quantification of the measurement uncertainty and finally a localization of defects in foundry cores. Ultimately, this leads to a decision whether a foundry core can be used reliably in the subsequent casting process or should be classified as scrap.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Wolfram Volk