Appearance Inspection of Die-Cast and Cast Products | How to Identify Voids, Chipping, and Flow Marks
In the visual inspection of cast and die-cast products, defects such as chipping, burrs, and surface voids are often visible in 2D, while the depth of voids, dents, and the height of burrs require 3D inspection. The main difficulty lies in the roughness of the casting surface. The normal surface shines finely, which can obscure defects. Internal voids are not visible through optical means and require different methods. 【Key Points】 - Chipping, burrs, and surface voids are often defects that can be seen in 2D. - The roughness of the casting surface can conceal defects. - Internal voids are not visible through optical inspection. *For detailed explanations, please refer to the technical notes in the related links and the downloadable materials.*
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【Contents of this Technical Note】 ■ What are the appearance defects in cast and die-cast products? ■ The roughness of the casting surface makes inspection difficult. ■ Surface voids, chips, and burrs are assessed in 2D, depth in 3D, and internal voids require different methods. ■ The approach to capturing images is to smooth out the roughness before identifying defects. ■ Internal voids and shallow defects buried under a rough casting surface are not visible in appearance inspections. ■ A method to differentiate between detectable voids and buried defects using actual cast products. 【Consultation】 I will confirm whether it can be measured or captured with the work at hand using the actual item. Please consult with a photo.
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The technical notes can be read by anyone from the related links. We will discuss the costs of development and testing based on the details you provide.
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【Frequently Asked Questions】 Q. Can all nests be found in the images? A. Nests that are open on the surface can sometimes be detected depending on the lighting. Internal nests are not visible optically, so we consider combining with other methods. Q. Can AI find defects within the casting surface? A. It is a possibility, but if the defects are not captured in the way the images are taken, they cannot be found. We will decide on lighting that evens out the roughness before proceeding to AI training. Q. Is there a difference in difficulty between die casting and sand casting? A. Yes, there is. The casting surface of sand casting is rough, and the scattering of light is significant, making shallow defects more likely to be obscured. We will verify this with actual samples.
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We specialize in 2D and 3D inspection and measurement technologies using cameras. We possess a wide range of knowledge in optics, mechanics, electronics, and software, enabling us to provide technical support for both hardware and software. Not only do we have personnel with experience working as researchers at image inspection device manufacturers, major electronic component manufacturers, and universities, but we also have numerous successful implementations of developed products in actual production environments, making our ability to adapt advanced technology to on-site needs a strong point. Additionally, we are skilled not only in developing proprietary algorithms but also in using off-the-shelf products such as image processing controllers from Keyence and Omron, allowing us to excel in selecting and utilizing the most suitable equipment for specific needs. In recent years, while AI technology has garnered attention, there are cases where utilizing 2D and 3D technologies can be implemented more easily than AI, and cases where optical devices and mechanical jigs can improve performance and reduce software load. We offer services related to image systems, including "equipment selection," "implementation support," "performance improvement of existing equipment," "technology development," and "joint development," so please feel free to consult with us first.
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