HD scan: A breakthrough for cast quality investigation and casting process optimization

The main strength of HD scan lies in automated evaluation, which is controlled by advanced software. This enables the automatic generation of reports with objective results and provides easy access to statistics for further analysis and comparison. Artificial Intelligence (AI) technologies are integrated for tasks such as crack estimation, enhancing the convenience of the evaluation process.

The features of HD scan analysis are constantly evolving, with new features and functions being developed to meet the customer’s needs. The introduction of a cloud solution allows customers to access the latest software version, always updated with the most comprehensive set of functions. Additionally, the cloud offers a database feature that stores results, statistics, and images of customer samples in a customer-specific database. This database facilitates the comparison of different samples and the extrapolation of data for further evaluations. Access to this database is limited to the owner, so each customer can only see his or her own data.

The cloud solution serves as an alternative to traditional desktop software. The desktop software does not require internet access and can operate in a closed system, installed on a specific computer. Customers have the flexibility to choose between the cloud and the closed desktop solution, depending on their preferences and requirements.

The digital information acquired through the HD scan can be directly leveraged for product optimization. To facilitate this, additional casting process information is necessary. Customers have the option to utilize their own casting process models or seek assistance from SMS.

While casting process optimization is distinct from the core HD scan software, the quality data essential for optimization is derived from the HD scan evaluation. This data extraction can be performed at any time by exporting the evaluated statistics to a separate file. The extracted statistics comprise various calculated parameters, which, in combination with casting models or other analyses, provide insights into process challenges and can help to develop suitable countermeasures. For example, the origin of the crack within the caster can be determined by recalculating the distance between a crack tip and the surface of a cast product. Consequently, the corresponding casting segment can be monitored and adjusted as required.

Additionally, the 3D visualization capability of the HD scan offers a significant advantage for investigating crack propagation. The macrostructure representation in the HD scan can assist in assessing the impact of Soft Reduction and other process parameters.

The utilization of HD scanning technology, which allows for the examination of multiple internal layers within a sample, as opposed to the single surface layer visible through traditional macro-etching, offers a wealth of information regarding internal quality. This advancement enhances the reliability of measurement results and provides a more detailed perspective on flaw distribution and potential "problem zones." Several characteristic examples have been published previously. A recent investigation demonstrated the impact of this technology on optimizing casting processes, particularly in addressing internal cracks. As previously noted, estimating the origin of cracks is crucial for the development of countermeasures and the prevention of cracks in cast products. This involves measuring the distance between the internal crack and the surface of the casting product. In a specific customer case, results obtained from traditional macro-etching were misleading, as they suggested longer crack depths, leading to an erroneous focus on later casting segments. 

The comparative analysis of the results of HD scan and traditional techniques using hundreds of examples from different customers has shown a significant improvement in the volume of information with the new technology. Imagine the analysis as with magnetic resonance imaging (MRI). This opens new possibilities for further process optimization and research areas for investigation. 

The HD scan LAB units are mobile laboratories that can be deployed outdoors on site at the customer’s premises, requiring only an electrical connection. These units are a modification of a smaller HD scan unit housed in a construction container, including a comfortable workspace, window, heating, and air conditioning. The primary objective of this modification is to facilitate the easy relocation of the HD scan system between commissioning sites, providing rapid feedback on casting quality. This modification can be rented monthly. The HD scan LAB was successfully presented at the SMS Caster Fair in India in 2024, and a further unit is available in the USA.

After numerous customer requests, a third modification of the HD scan was developed: HD scan Mini, a laboratory unit like the HD scan LAB, but without the container and workplace. Designed for use in any laboratory, whether in the factory or at a specialist company, this smaller unit is ideal for customers with low sample throughput or for complementary research and development activities. We would like to point out that the HD Scan LAB can only be rented at locations on the European mainland. SMS thus offers tailor-made solutions to meet a wide range of customer requirements effectively.