The application is high pressure die cast aluminum engine blocks. We perform x-ray checks on sections of the casting to check for gas and shrinkage porosity in critical leak path areas. A large effort is being placed into moving this porosity with parameters and design, but the cost involved in this x-ray examination process is heavy. Castings must be cut in order to get a good x-ray image around the steel liners. The cost is incurred both in cutting blades(going through steel and AL) as well as internal scrap.
Could anyone recommend another practice that would be non destructive yet still define exactly where the porosity is located?
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