Quality assurance
Robot sensor system inspects hybrid components
Scientists at Fraunhofer IZFP have developed a robot-assisted sensor system for the non-destructive testing of hybrid cast components that can be integrated into production processes for quality monitoring.
Intelligent sensor systems are of key importance in the quality assurance of lightweight components: in many industrial sectors, particularly in the aerospace and automotive industries, pioneering hybrid designs made of fiber composites and light metals are increasingly being used. However, material defects in the end product can lead to premature failure and thus impair safe use. Scientists at Fraunhofer IZFP have developed a robot-assisted sensor system for the non-destructive testing of hybrid cast components, which can be integrated into production processes for quality monitoring without great effort.
When time-consuming destructive testing methods are used, the quality inspection results in enormous costs due to the damage or destruction of the products. Moreover, process faults are often only detected when a considerable amount of scrap has already been produced due to the testing being limited to random samples. Non-destructive testing methods are therefore an alternative and, if implemented appropriately, a long-term replacement for destructive methods. The Fraunhofer Institute for Nondestructive Testing IZFP in Saarbrücken inspects components or parts during the manufacturing process without damaging the material itself or changing the surface and its properties.
Cognitive sensor technology for quality assurance
In the context of Industry 4.0, the automated use of intelligent, non-destructive sensor systems is an essential part of ensuring optimum product quality in production. The Fraunhofer experts have therefore presented a robot-supported sensor system for quality monitoring that can be easily integrated into production processes. The possible application of such systems is demonstrated using robot-assisted testing of hybrid casting samples. These are die-cast aluminum ingots that are reinforced by a metal insert on the inside. Robot-assisted eddy current testing can be used to verify quality features such as the position or integrity of the insert in the casting.
The advantages of robot-based testing with eddy current over conventional computed tomography testing lie in the uncomplicated testing with fewer necessary safety precautions and in the evaluation of relevant quality features. This saves resources, reduces costs and helps to strengthen the competitive position of producers. The Saarland Research Institute has decades of experience and expertise in the combination and automation of such non-destructive testing methods for production. as
You might also be interested in
From sensor to intelligent system
Sensors, measurement technology and artificial intelligence are merging to form intelligent systems. From June 9 to 11, 2026, Sensor+Test in Nuremberg will showcase the most important trends in a changing industry.
read more...Dr. Volker Frey becomes CTO
On May 1, 2026, there were personnel changes in the top management of the ifm group of companies. Dr. Volker Frey succeeds Benno Kathan as CTO, who has retired.
read more...Sales growth in a turbulent market environment
Thanks to innovations and a focus on strategic industrial markets, Sick was able to moderately increase its sales in the 2025 financial year. In a turbulent market environment, the company was able to maintain its position and gain market share with...
read more...Precise sensor technology for mobile machines
Compact singleturn Hall-effect encoder with IP65
The Megatron MP1612 is a wear-free Hall effect single-turn encoder with 12-bit resolution, IP65 metal housing and extremely compact design (Ø12 mm, depth 11.5 mm). Ideal for joysticks, AGVs and agricultural machinery.
read more...New impetus for ifm sales
Two new positions were filled at ifm at the start of 2026: Markus Wolf becomes Managing Director Sales Germany, Sven Quant takes over the position of Central Managing Director in the Process Sensors division within the ifm Group.
read more...Werner von Siemens Fellows 2025
Five research talents honored
Five outstanding research talents have been honored as Werner von Siemens Fellows 2025. The Werner von Siemens Ring Foundation recognizes researchers whose work has made an exceptional contribution to the advancement of science and technology in...
read more...Biodegradable label makes transportation conditions traceable
Researchers are developing a smart, compostable label that measures temperature and humidity and detects when limit values are exceeded.
read more...Digitization of the entire value chain
At SPS 2025, ifm will be demonstrating how the digitalization of the entire value chain can be implemented in practice. In an interview, Michael Marhofer, CEO of the ifm group of companies, explains which technologies are in focus, which industry...
read more...About AI, autonomous automation and cybersecurity requirements
The increasing importance of AI, autonomous automation and cybersecurity requirements are currently shaping many areas of industrial sensor technology. In this interview, Dr. Henning Grönzin, CTO of Leuze, explains the company's technological...
read more...