Germany’s Fraunhofer Institute for Nondestructive Testing IZFP has introduced an innovative ultrasound-based measuring system capable of detecting inclusions in molten aluminum in real time. Named AloX, the system promises to enhance quality assurance and operational efficiency in aluminum production, offering a faster, low-cost, and mobile alternative to current testing methods.
Contamination in molten aluminum—especially non-metallic inclusions such as ceramic particles—can severely affect component integrity. Traditional analysis systems are often expensive, slow, and require highly trained operators. The Fraunhofer team, working closely with industry partners, has addressed these challenges by developing a real-time, in-situ inspection tool tailored to the harsh conditions of foundries.
“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,” said Thomas Waschkies, Chief Scientist for Sensor Physics at Fraunhofer IZFP.
Innovation Inspired by Everyday Tech
The core technology of the AloX system mimics a common automotive solution: the parking sensor. When immersed in molten aluminum, the system emits ultrasonic signals that bounce off a reflector. The presence of inclusions disrupts this signal, instantly identifying defects in the metal stream.
“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 Mross, one of the lead engineers on the project.
This real-time feedback enables on-the-spot quality assurance, significantly improving process reliability without halting production.
Engineered for the Foundry Floor
The AloX measuring trolley is equipped with special ultrasonic waveguides made of titanium, in-built cooling systems, and a proprietary software package with a patented analysis algorithm. The unit is built to withstand the extreme temperatures and corrosive nature of molten aluminum—conditions that have historically limited the use of sensitive instrumentation in these environments.
The system’s design also features a patented change mechanism for waveguides, further boosting durability and maintenance efficiency.
Toward Industrial-Scale Adoption
Currently, Fraunhofer IZFP is finalising AloX 2.0, a refined version of the prototype. With almost every component—hardware, electronics, software, and mechanics—developed in-house, the system is poised for broader industrial deployment, initially targeting the aluminum sector but with potential applicability in other molten metals and manufacturing domains.
“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,” said Mross.
As lightweight materials continue to drive sustainable manufacturing, AloX stands to play a pivotal role in enabling circular economy goals and climate-neutral production by ensuring the high purity of recycled and primary aluminum.
Reference: https://metrology.news/ultrasound-reliably-detects-inclusions-in-aluminum-production/
