Model of Diagnosing and Searching for Incompatibilities in Aluminium Castings

An essential element of any industry is castings, which is determined by the technical conditions for their reception. However, conducting production in the foundry technology is burdened with many difficulties associated with, for example, the inability to control all of the parameters that may affect the casting quality. Therefore, it is essential to undertake improvement actions in this area. Efforts are being made to use non-destructive testing (NDT) as a part of quality control, but these methods are rarely combined in a single diagnostic run. As a part of quality improvement, it is also essential to identify the root cause of the problem. For this reason, it is justified to develop a model of diagnosing and searching for non-conformities, which would combine NDT tests and quality management tools. The model included the visual, ultrasound, and eddy current examination in the diagnostic part, and the Pareto–Lorenz diagram correlated with ABC method, histogram, and 5WHY method (asking five questions why). The study’s originality is manifested in the combination of several NDT methods with quality management methods in one model. Using integrally configured methods in the proposed model, it was possible to: reduce diagnostic uncertainty, characterize the critical group of non-conformities, and identify the root causes of the quality problem. The model is a new and universal method that can be implied in any foundry company in order to ensure the stability of the production processes. The application of the model contributes to an increase in the detection speed and enables the reduction of non-conformities in aluminium castings, thus increasing the quality level of the offered products.