Aviva - 997 Intercoolers - Inspection

  • 31 March 2012

Aviva Instruments - 997 Intercooler Endtanks: Deburring & Inspection

In the previous Aviva update the endtank castings were received for inspection. The following steps were to delicately dress and deburr the parts. After ribbon sanding the casting gates and parting lines smooth, flattening the weldface and vibratory deburring, they reached their final surface quality and finish. More importantly, they were clean and ready for the next process: NC machining & welding.

With thin wall AL castings [3.10 mm], it is a challenge to accurately produce consistent thin walled features. Part warpage along flat and thin sections is a concern. As molten AL starts to cool once poured into the mold, it contracts and solidifies at different sections and times. Stresses that build up will often warp and distort the part while its cooling. With the tolerances specified in the Porsche 997 turbo IC Project, there is little room for design deviation when upgrading to a much larger inter-cooler system. The hoses, brackets, machining and fitment all depend on everything stacking up as intended.

We used a blue light scanner to develop a surface map of the physical part. The developed surface mesh of the physical part is compared to the reference 3D cad model. The software generates a color overlay of the parts identifying the the magnitude of the surface deviations. Features are also identified in the scan data through software fitments and compared to the critical features on reference model. This data is used to adjust and refine our machining fixtures and cutting operations.

Tools used:
ATOS III Blue Light Scanner
Polyworks V11 and 3D infotech solutions
Faro Platinum Arm

Images taken at delivery:

Post deburring:

Under the blue light scanner:

Blue / green is nominal.
Surface deviation map1:

Surface deviation map2: