Researchers at the Fraunhofer Institute for Nondestructive Testing IZFP have developed an innovative ultrasound-based measurement system known as AIoX. This system aims to detect inclusions in aluminum, a crucial process during production, ensuring the quality of the final product. The team behind this groundbreaking tool was awarded the prestigious Joseph von Fraunhofer Prize in 2025.
Aluminum holds a significant place in the global economy, especially in promoting climate neutrality through its use in lightweight construction and recyclability. While various quality control systems exist for aluminum melts, they often come with limitations such as high costs, specialized training requirements, or time-consuming procedures. This underscores the need for a more accessible and efficient solution for the industry.
The development of the ultrasound-based measurement system, named “AloX,” was driven by the necessity to address impurities in aluminum melts effectively. The system operates similarly to a parking sensor in a car, emitting signals that detect impurities in the melt. This real-time detection capability allows for immediate corrective actions to maintain product quality.
Creating AloX posed challenges due to the extreme conditions in foundries, including high temperatures and corrosive materials. Through collaboration with industry partners, the Fraunhofer IZFP team successfully designed a prototype featuring specialized ultrasonic waveguides, integrated cooling systems, and patented evaluation algorithms.
The ongoing development of AloX 2.0 aims to enhance the system’s performance and usability further. Almost all components of the system are internally developed by Fraunhofer IZFP, ensuring a comprehensive and cohesive solution for aluminum analysis. The team envisions broader applications beyond aluminum production, potentially extending to other metal melts and industrial processes.
As the demand for efficient and reliable quality control systems continues to grow across industries, the advancements in ultrasound technology exemplified by the AIoX system offer a glimpse into the future of nondestructive testing. By combining innovation with practical applications, Fraunhofer IZFP’s ultrasound-based measurement system underscores the importance of technological advancements in ensuring product quality and process efficiency.
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