- 06/23/2025
- Report
- Technology & Processes
Detecting impurities at an early stage: Fraunhofer IZFP develops ultrasound system for aluminum melts
With the mobile measuring system “AloX”, inclusions in aluminum melts can be detected quickly, precisely and cost-effectively under real foundry conditions. The Fraunhofer IZFP was awarded the Joseph von Fraunhofer Prize 2025 for its work.
Written by & Editors EUROGUSS 365
Making critical inclusions visible
Ceramic particles, which only melt at over 2000 °C, remain as solid inclusions in the material if they are not detected and removed at an early stage. These impurities in the molten aluminum can lead to cracks or structural failure in the later component. Previous testing methods are either expensive, time-consuming or require special expertise. The new “AloX” system closes this gap.
Ultrasonic technology for the melt
Fraunhofer IZFP has developed a compact, mobile ultrasonic measuring system that is immersed directly in the molten aluminum during production. Based on the principle of a parking sensor, it emits signals that are reflected back by a reflector - particles floating past cause interference that can be reliably detected. This allows the quality of the melt to be assessed in real time and corrected if necessary.
Technology for extreme conditions
The implementation required specially developed components: The corrosive, 600-800 °C hot melt places high demands on the material and measuring system. The first prototype has titanium waveguides, an integrated cooling system and specially programmed evaluation software with a patented algorithm. The mechanism for changing the measuring heads is also patented.
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Broad application potential
The next generation of the “AloX 2.0” system has already been further developed and is ready for industrial use. The research team also sees potential for other areas of application, such as other molten metals, the production of adhesives and food production.
Contribution to the circular economy
Aluminum is considered a key material for the energy transition and lightweight construction, not least because of its good recycling properties. “AloX” helps to optimize the use of resources and ensure material quality, which is an important prerequisite for sustainable industrial production.
The detailed press release of the Fraunhofer IZFP can be found here.
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