Researchers from the Fraunhofer Institute for Nondestructive Testing IZFP have been awarded the prestigious Joseph von Fraunhofer Prize 2025 for their development of AloX, an innovative, ultrasound-based system capable of detecting inclusions in molten aluminum with speed, accuracy, and cost-efficiency.
The AloX system is set to transform quality control in aluminum foundries by providing a mobile, real-time method of identifying contaminants—without the need for time-intensive procedures or highly specialized training. The award acknowledges the technology’s significance for industrial efficiency, safety, and its contribution to sustainability goals in metal processing
Aluminum's Role in the Circular Economy
As the second most widely used metal globally, aluminum is central to the transition toward climate neutrality and a circular economy, particularly due to its lightweight properties and ease of recycling. However, contamination during the smelting process—especially from ceramic particles that don’t melt until around 2,000°C—poses a major challenge. These particles, if not removed, can remain as inclusions in components and compromise structural integrity.
“The purity of the molten metal, whose temperature ranges from 600 to 800 degrees Celsius, is hugely important to the final product later on. For example, any ceramic particles that may be present in the melt don’t liquefy until they get to a temperature of 2,000 degrees or more, and they remain in the finished component as inclusions if they aren’t deliberately removed. This can lead to cracks and holes, and thus in the worst case to component failure,” explained Thomas Waschkies, Chief Scientist for Sensor Physics at Fraunhofer IZFP, who co-led the project with Andrea Mross.
Smart Detection in Harsh Environments
The development team tackled considerable engineering challenges, including extreme temperatures and corrosive environments in foundries. Leveraging close industry collaboration, Fraunhofer IZFP created a mobile measurement trolley equipped with custom ultrasonic waveguides, advanced cooling systems, and proprietary analysis software. The core technology relies on ultrasound signals similar to automotive parking sensors, which are disrupted by the presence of particles—indicating contamination in the melt.
“It’s a lot like a parking sensor in a car in that the system, immersed in the molten metal, transmits signals that then bounce off a reflector. If any particles — meaning contaminants — float by, there is a disruptive signal,” said Andrea Mross, now part of the institute’s strategic research programming team.
Toward Industry Adoption
The Fraunhofer team is currently advancing AloX 2.0, which features further enhancements for broader industrial application. Almost all components—from ultrasonic sensors to electronics and software—have been developed in-house.
“From the ultrasonic sensors to the analysis software, electronics and the mechanics of the housing, AloX is an all-in-one package from a single source,” Mross added.
While the initial deployment targets aluminum production, the research team sees future applications in other molten metals, as well as adhesives and food manufacturing, where real-time contamination detection is equally critical.
