In order to ensure the quality of products, every step in the manufacturing process, from raw materials to products, needs to be carefully verified to avoid mistakes. Therefore we have established a series of standard operating procedure for quality control to verify each manufacturing process, aiming to provide our customers with the highest quality products.
Before putting into production, we will conduct pre-evaluation from various perspectives such as customer needs and manufacturing feasibility, and consider whether it is necessary to make modifications to the mechanical design based on the evaluation results. Our technical team can help customers transform intangible concept ideas into 3D models, parts, assemblies and more.
After the mechanical design is completed, the engineer will refer to the solidification simulation to predict various production parameters, and use finite-element simulation to calculate molten metal filling, stress field, shrinkage cavity, heat conduction and solidification process, providing accurate prediction, analysis, measurement and quantification of the most common casting defects to reduce scrap rate and improve product quality.
It is one of our most important core competencies to provide customers with alloy compositions that meet the requirements of international specifications. Our alloy products will be inspected by Spark OES (Optical Emission Spectrometer) before they are poured into the molds, and this step can be carried out only after the composition is confirmed to be correct. Imported forging materials will be confirmed through a portable XRF (Portable X-ray Fluorescence Spectrometer) analyzer after purchase.
For special superalloy materials, we will carry out the detection of gas content (N2, O2). Although there are no relevant regulations in international standards, based on our professional understanding of materials, even a small amount may cause defects in the alloy, which will damage the service life of the product.
Mechanical properties are one of the important indicators of material quality, which not only affects the performance of the product, but also affects the service life. We conduct tensile testing, macro- and micro- hardness testing on products applied to withstand high loading. For superalloy materials, we have a high-temperature tensile testing machine with a limit temperature of 1100 degrees (Celsius) to ensure the high-temperature mechanical properties of the product.
The microstructure of the alloy is an important factor affecting various properties. We conduct optical microscopy and scanning electron microscopy observation and microscopic element analysis for special-purpose products or failed samples provided by customers. Our laboratory is equipped with JCM-7000 SEM (Scanning Electron Microscopy), which includes secondary and backscattered electron images (SE and BSE), dimensional metrology tools, real-time 3D imaging and multifunctional EDS analysis. Through nanometer-scale metallographic observation, we can analyze the working history of materials from the microscopic scale.
Radiography testing is one of the methods for non-destructive detection of internal defects of materials. TCA possesses 320kV X-ray equipment to conduct X-ray inspection on important parts of castings to ensure product quality.
Several employees in TCA possess Level II radiography testing certificates issued by the society of non-destructive testing and certification of Taiwan.
Penetration testing (PT) is one of the non-destructive testing methods that use capillarity action to detect surface cracks or pores, and it is also a globally recognized testing method. It can detect surface defects such as cracks, gaps, pores…etc. Mainly use ASTM E1417 Type 1 (fluorescent type) and Type 2 (colorimetric type) two penetrants for testing, and check the surface quality of castings according to the required grade.
Several empoyees in TCA possess Level II penetration testing certificates issues by the society of non-destructive testing and certification of Taiwan.
In addition to traditional gauges, we perform dimensional measurements for our castings through optical 3D scanning. That is to superimpose and compare the 3D model scanned by the actual casting with the 3D model, and use automated software to find out where the dimensions do not match the tolerance. This dimensional test shows how far the casting in production deviates from the original design. Based on this analysis, our engineers can optimize the production to improve casting quality.
