DIRA-GREEN

Enhancing the competitiveness of European Powder Metallurgy SMEs by an improved quality assurance tool based on latest digital radiographic achievements

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Dr. Gábor HalmiDr. Gábor HalmiSenior Research Engineer Senior Research Engineer & Project Coordinator& Project Coordinator

PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

DIRA-GREEN project• The DIRA-GREEN is part funded by the European

Union’s Seventh Framework Programme, managed by REA (Research Executive Agency) and started on 1st October 2011.

• The need of green part testing by monitoring porosity and identifying microscopic cracks came from the European Powder Metallurgy sector.

• Developments in digital radiography allowed the consideration of developing an effective non-destructive technique for Powder Metal (PM) parts.

2DIRA-GREEN - PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

DIRA-GREEN Concept

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Manipulator

Conveyer belt

Lead Chamber

Source

Detector

Sintering furnace Powder compaction

press

Parts to be inspected

Good parts to be sintered

Defected parts to be recycled

DIRA-GREEN - PM Sintering Short Course, 18th - 20th March 2012, Helsingborg,

Sweden

DIRA-GREEN Vision

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• DIRA-GREEN inspection tool is an integration of digital radiography, mechanical and control systems, for industrial use.

• The digital radiography subsystem includes an electronic subsystem capable of generating and measuring the signals.

• The mechanical system provides:• interface with production environment with careful handling and

transferring of sensitive PM green parts,• positioning for inspection in the lead chamber and • transfer good parts to sintering and scrap for recycling.

• The DIRA-GREEN inspection system high flexibility provided by the software control system, allowing reconfiguration within minutes. This enables sequential inspection of parts with various geometries and different ferrous and nonferrous materials.

• The data processing and evaluation system • makes failure recognition and classification and • allows collection data from defected parts to build up database for use

in ‘improvement cycles’.

• The DIRA-GREEN tool is capable of identifying defects before sintering, thereby reducing scrap, and saving time and energy.

DIRA-GREEN - PM Sintering Short Course, 18th - 20th March 2012, Helsingborg,

Sweden

• To design a unique inspection tool prototype for the assessment and quality control of internal defects in ‘green parts’ that is:

• reliable (resolution of 1% in density, and flaws of 0.5mm - the accuracy required by the industry according to EPMA),

• low cost (commercial price to be below €100.000), • cost effective (saves time, energy and material, fault detection in „green”

stage), • rapid (seven parts per minute), • easy to use (automated),

DIRA-GREEN Objectives

5DIRA-GREEN - PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

DIRA-GREEN Consortium

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Participant organisation name Country

MFKK Invention and Research Center Services Ltd. HU

EPMA EUROPEAN POWDER METALLURGY ASSOCIATION BE

AIPnD Associazione Italiana Prove Non Distruttive IT

ALTA LAB SRL IT

Gammatec Engineering GmbH DE

TOZ TOZMETAL TICARET VE SANAYI.A.S TR

MIMI MIMITALIA srl. IT

SINTER PRES SL SP

TPMA Turkish Powder Metallurgy Association TR

TWI LIMITED UK

EGE INOVEGE ARASTIRMA GELISTIRME PROJE DANISMANLIK SANAYI VE TICARET LIMITED SIRKETI

TR

IfU GmbH Privates Institut für Umweltanalysen DE

UBRUN BRUNEL UNIVERSITY UKDIRA-GREEN - PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

• Consortium of 13 industrial and academic partners from seven European countries.• The three year project valued at €3.1m

DIRA-GREEN Expected Benefits• The concurrent academic research leads to a greater understanding of

types, characterization and classification of green part flaws and digital radiography technology applied in P/M.

• The identified density map and size and location of defects will facilitate an ‘improvement cycle’ to optimize powder metallurgy mould and die designs.

• The availability of a reliable and attainable inspection tool for detecting ‘green part’ defects would result in

– substantial increasing of European P/M SMEs’ competitiveness, – by reduction costs associated with the production and control of the parts, and – by improvement of powder metallurgy parts reliability.

7DIRA-GREEN - PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

DIRA-GREEN Market Survey• The main principle of the project is to provide a system

that acts on the needs of SMEs, therefore please share with us your point of view about the inspection of green compacts.

• We are interested in the current technologies and the desired developments. This information will enable us to make a new design closer to your real needs!

• You can quickly fill the 11 questions on the project’s webpage in ENGLISH, GERMAN, HUNGARIAN, ITALIAN, TURKISH or SPANISH:

8DIRA-GREEN - PM Sintering Short Course,

18th - 20th March 2012, Helsingborg, Sweden

www.diragreen.eu