QualiNet - Automated in- line inspection and quality control of net shape powder metallurgy components...

Net shape parts of typically intricate and complex shape obtained by powder metallurgy (PM) are employed in several key
mass industry sectors, especially automotive, aerospace and medical. Their use is growing rapidly in preference to
conventional casting because the process produces parts in the precise final shape required with little or no machining
requirement combined with fine grained (nano-micro scale), homegeneous microstructures of enhanced strength. However
there is a lack of production quality control as little in-line inspection is performed. End-of-line inspection, not often
performed, leads to scrapping of 6-8% of components yet fails to detect micro sized defects, which can grow in service to
produce major in service failures and recalls. THE PROJECT VISION is an in-line quality control system (QUALINET) using
3D microfocus x ray imaging with AUTOMATION INNOVATIONS (A) Detection and characterization of volume and surface
micro-scale defects at the pre and post sintering stages. (B) Decision making: (i) component acceptance or (ii) send for recycling or (iii) send with a prescription for defect healing treatment. QUALINET will eliminate waste, increasing line
production, reducing energy consumption and carbon emissions, all by 8%. The benefit will be optimal for state of the art
PM component lines including additive manufacturing by laser deposition, nano-powders and injection moulding.

WITHIN THE CONSORTIUM: Creation of 180 jobs assuming one job per £100kpa of turnover.
OUTSIDE THE CONSORTIUM: (1) Creation of 90 further jobs along the supply chain to the consortium assuming a 50%
added value along the chain. (2) ECONOMIC BENEFITS FOR PM PLANT OPERATORS: Adding an O&M cost of
£13.5kpa it should last the plant life, typically 20 years and thus the cost of the system (CAPEX +OPEX) is £257kpa. Global
production of PM components amounts to £1m tonnes pa, valued at £2k per tonne. Assuming some 400 PM component
production plants globally (including MIM and additive manufacture) with an average of 8 lines per plant the production is
312 tonnes pa valued at average of £620kpa per line (with high value products as at LCT the turnover is £1.5m per line pa)
and the product wastage is 0.08 x £620k ~£50k pa per line. One system, shared between all lines in one plant (typically 8)
can thus save up to £375k per plant pa after discounting the system cost. The 5 year operator savings from the average 18
systems pa sold directly by the partners = £375k x 18 x (5+4+3+2+1) = £102m. If potential licensee sales are taken into
account the saving increases to £340. If the sales within the EEA are taken to be proportional to the EEA share of the
global PM market (37% from Q2 [REF 1], the EEA 5 year savings would be 0.37 x £340 = £126m and the 5 year profits of
the EEA licensees and the partnership, are taken at a similar percentage, would be (from Q2) ~ (£26m +£14.1m), ignoring
secondary markets but including maintenance services and partner royalties. EEA 5 year ROI would be (£126 +£26m
+£14.1)/£1.5m = 111:1 and sustainable thereafter at ~ 55:1 pa. For the UK with about 50% of the EEA PM market, the ROI
~ 28:1 pa. Global economic benefits from wide acceptance of the technology, assuming 400 plants worldwide, would be
400 x £388kpa = £155mpa. GLOBAL ENVIRONMENTAL /SOCIAL BENEFITS (i) An ~ 8% reduction in plant energy
consumption and carbon emissions means 8% less pollution. (ii) Avoidance of major product re-call costs, which improves
public confidence in PM reliant product. Greater acceptance of additive manufacture, still relatively a cottage industry.
Detailed Calculations can be found in Table A4, APPENDIX A1.