Internal casting defects can compromise mechanical strength, leak integrity, and product safety. Digital X-ray NDT allows manufacturers to identify these flaws before machining, assembly, or shipment. Below are five of the most common defects found in die castings and iron castings—and how X-ray inspection reveals them.

1. Porosity

Gas porosity appears as rounded voids within the casting, often caused by trapped air, moisture, or poor venting. X-ray images show porosity as dark spots against a lighter metal background. High-resolution digital systems help quantify pore size and distribution for acceptance decisions.

2. Shrinkage Cavities

Shrinkage occurs when metal solidifies unevenly, leaving internal cavities. These irregular voids often appear near thick sections or hot spots. Radiographic inspection locates shrinkage before it causes leaks or structural failure in pressure-tight components.

3. Cracks

Hot tears and stress cracks may be invisible on the surface but visible under X-ray. Early detection prevents costly field failures, especially in automotive, aerospace, and energy applications.

4. Foreign Inclusions

Inclusions of slag, sand, or refractory material create density variations that show clearly in X-ray images. Filtering inclusions before shipment protects downstream machining tools and customer trust.

5. Cold Shuts and Incomplete Fill

Cold shuts form when molten metal fronts meet but fail to fuse completely. X-ray inspection confirms fill completeness and helps optimize gating and process parameters.

Micxy provides castings NDT X-ray inspection systems designed specifically for alloy and iron castings, with configurations from economical benchtop units to multi-axis rotary machines.