Aluminum Safely Detect Inclusions With Ultrasound

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Researchers at the Fraunhofer Institute for Nondestructive Testing IZFP have developed AIoX, an ultrasound-based measurement system that, unlike previous analysis methods, detects existing inclusions in aluminum reliably, quickly, and cost-effectively. For the development of this innovative tool, the research team received the Joseph von Fraunhofer Prize 2025.

A research team from Fraunhofer IZFP has developed a new measuring system for impurities in the metal melt for clients in the aluminum industry—an important tool during the production process. "The purity of the melt, with a temperature between 1,110°F and 1,470°F, is extremely important for the final product. The ceramic particles present in the melt, for instance, only liquefy above 3,630°F and remain as inclusions in the finished component if not specifically removed. This can lead to cracks and holes and, in the worst case, component failure," explains Dr. Thomas Waschkies, Chief Scientist of Sensor Physics at Fraunhofer IZFP. He led the project from the start together with his colleague Andrea Mroß, who is now working in strategy and research programming at the Saarbrücken institute.

Aluminum: Central to Circular Economy And Climate Neutrality

Aluminum is the second most widely used metal in the world after steel and plays a significant role in climate neutrality, particularly through its use in lightweight construction. Additionally, it can be recycled with low energy consumption, making a significant contribution to the circular economy. There are already different measuring systems on the market for quality control of aluminum melts, but they are either expensive, require specially trained personnel to operate, or are highly time-consuming, allowing only for spot checks. The industry thus needs an affordable system that can be operated without special knowledge, delivers quick results, and can be used flexibly in foundries.

The system works analogously to a parking sensor in a car: the system submerged in the melt sends signals, which are reflected back by a reflector. If particles, i.e., impurities, pass by, interference signals are generated.

Andrea Mroß

Against this background, the idea for a mobile, ultrasound-based measuring system for aluminum melts was developed at Fraunhofer IZFP. The functionality of "AloX"—the project name combines "aluminum melt" and "oxide inclusions"—can be explained using an everyday example: "The system works analogously to a parking sensor in a car: the system immersed in the melt sends signals that are reflected back by a reflector. If particles, i.e., impurities, float by, interference signals are generated," explains Andrea Mroß. These allow for direct on-site intervention in production to ensure quality.

The challenge in developing the system mainly lay in the extreme conditions at the foundry site: The hot melt generates a very high thermal radiation, affecting not only the system itself but also the entire supporting structure. Additionally, aluminum melt is highly corrosive and attacks metallic materials. In close collaboration with the industry, the team eventually developed a first prototype: The measuring cart features a measuring unit with special ultrasonic waveguides and integrated cooling, as well as custom-developed software with a patented evaluation algorithm. The exchange mechanism for the titanium ultrasonic waveguides has also been patented.

Further Development for Industrial Use

Currently, the team is working on "AloX 2.0," which has been further optimized compared to the first version. One factor that has remained the same is that nearly all components are in-house developments by Fraunhofer IZFP. "From the ultrasonic sensors to the evaluation software and electronics to the mechanics of the housing: AloX is a complete package from a single source," sums up Andrea Mroß. The next step for the researchers is the broad industrial application of the system—initially in aluminum production. However, further applications are conceivable, such as for quality control of other metal melts or in the production of adhesives and food products.

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