Megacasting: Handtmann renews quality control

Handtmann has modernized its quality control for automotive components. With the introduction of modern measuring technology and testing procedures, the company aims to implement comprehensive series monitoring of its components manufactured using the megacasting process.

Specifically, Handtmann hopes that the new technology will enable it to ensure the quality of particularly large components from the die-casting process and quickly identify any deviations. The company also wants to provide full data transparency for each component. "Handtmann has set itself the goal of combining the latest supplier technologies with megacasting. The changed requirements for the components and the increased customer demands in terms of quality and safety confirm our strategy," said Heiko Pfeiffer, Co-CEO of the Light Metal Casting Group.

For the inspection chain, the responsible company, Albert Handtmann Metallgusswerk GmbH & Co. KG installed a ZEISS OMNIA GC 200-180 X-ray system from ZEISS Industrial Quality Solutions. The X-ray system is designed for automatic defect detection in large aluminum alloy components using ADR Automated Defect Recognition technology and can both detect and report deviations. In addition, the system's software contains all the important libraries for acceptance standards and thus enables testing according to customer-specific requirements. Typical components that are tested with the OMNIA GC are car rear ends, battery frames for electric vehicles and other structural components. These components must meet high safety and performance requirements.

Handtmann has also invested in a ZEISS ScanBox 5130 optical measuring system in order to carry out rapid series monitoring and analysis measurements. The device works in parallel with the production process. Whereas previously random samples were taken from ongoing production, sometimes sawn up and checked in a separate measuring room, the robot-guided, optical 3D scanner can now be used. With this ScanBox, heavy cast components with large dimensions of up to 3.5 metres can be inspected and fully digitized within 30 minutes. The measurement results and the resulting findings are sent online to the specialist department in real time using data-driven solutions.

The Handtmann Group of Companies decided to invest in the first megacasting die casting machine in 2022 and invested a sum in the double-digit millions. The process, which is in high demand in the USA and Asia, is still new in Europe. Handtmann is one of the first European suppliers to use megacasting in series production.

Featured photo: Handtmann