Laboratory settlement for cut-up metallographic inspection of rolled threads Integration internship

Abstract

This final-year project aims to establish a metallographic inspection laboratory and define quality control procedures for aeronautical parts. The study begins by analysing the context and objectives of the project, particularly the needs of Dumoulin Aero, a company involved in aerospace manufacturing. It identifies the contributors and outlines the specifications and standards applicable to the inspection of metallic components. A functional analysis evaluates the materials involved, geometric constraints, manufacturing processes, inspection requirements, forecast volumes, and available space. Based on these parameters, the feasibility study confirms that the creation of the laboratory is realistic within the industrial context.

The project then explores the theoretical foundations of metallographic inspection, detailing each preparation step: sectioning, cleaning, mounting, grinding, polishing, and etching. Additionally, the inspection itself is discussed. It is carried out using a light optical microscope in both etched and unetched conditions. For each stage, suitable methods and equipment are selected according to material properties and the required observations. This ensures a coherent and well-justified choice of processes, which serves as a guide for selecting appropriate machines and consumables.

An experimental phase validates several theoretical decisions by applying them in practice, demonstrating their effectiveness for the specific inspection tasks at hand. Improvements to the procedure are proposed to enhance efficiency and reliability. The study ends with a detailed list of required equipment and consumables.

Finally, the project provides concrete recommendations for brands and suppliers, along with a cost estimation for the full laboratory setup. The proposed solution is adapted to the physical constraints and utilities available on-site at Dumoulin Aero, with careful attention paid to health and safety requirements. To support practical implementation, clear work instructions are provided, including troubleshooting advice for common preparation issues. A report template is supplied to assist operators in documenting their inspection results effectively. Additionally, a Python script is provided to assist in the generation of Data Matrices which are necessary during the identification of samples.