Electromagnetic detection and infrared visualization techniques for non-metallic inclusions in molten aluminum

The role of detecting non-metallic and weakly conducting inclusions in hot melts during the manufacturing process is of major importance. However, the key impediment to assessing melt cleanliness is the quantification of the level of inclusions. In this paper, we present the theory and practice in using a magnetic force-based detection system capable of monitoring small inclusions of micron-size dimensions. The idea is to force the non-conducting inclusions to a detection location (the free melt surface) by electromagnetic Archimedes forces. Further, an infrared (IR) imaging system can then be applied to detect their thermal signature. Finally, a novel image-processing algorithm is used to analyze the inclusion level on the measurement surface.