[4B3] Bringing inspection into the light: automated fluorescent dye inspection of mass-produced metal parts
G Diamond, P Kubasiak and M Metodiev
Inspection Tech Ltd, UK
High-tolerance castings and forgings are often critical components in many industries that cannot afford to have manufacturing defects go unnoticed. We report on a fully automated fluorescent dye inspection system, which is operable under normal lighting/daylight conditions and can detect every indication on millions of parts without affecting production throughput rates. Currently, the dark-room conditions and enclosed inspection cells required for the dye penetrant inspection of cast components increase manpower, reduce floorspace and are the cause of severe production bottlenecks and low throughput rates at inline inspection points. Moreover, reliance on human inspection, attention span and skill levels are approaching their limit. The variation between human inspectors often results in quality standard inconsistencies and the failure to detect defects altogether. We present examples from the aerospace, automotive and medical prostheses industries of an automated NDT inspection system that: (i) removes the production bottleneck problem by enabling the inspection of parts to be performed under bright light conditions; and (ii) eliminates the need for a human inspector altogether with a fully automated software solution that can scan a part at least 10 times faster than a human inspector and can find every defect on millions of inspected components to provide full 100% quality audit and which reduces inspection costs by 90%. All captured images (pass or fail) are permanently stored and recorded for traceability of parts, even after they have entered service. If required, recorded images with indications can be mapped onto a 3D STL file of the part. Tolerances of less than 5 thousandths of an inch are repeatedly achievable and we present detailed results from extensive characterisation and Gauge R&R trials with a large aerospace castings manufacturer in the United States.
