Patent ID: 8505397

Claim:
A method of characterizing aluminum oxide defects in aluminum castings comprising: creating an oxide image with a scanning electron microscope; comparing said oxide image with a standard oxide image stored in a database; if an aluminum oxide defect exists: topographically measuring said oxide image with said scanning electron microscope; determining a magnesium content in the aluminum oxide defect using energy dispersion spectrum (EDS) with said scanning electron microscope; classifying the aluminum oxide defect as an old oxide if the magnesium content is greater than 10 wt %; and classifying the aluminum oxide defect as a young oxide if the magnesium content is 10 wt % or less; if said aluminum oxide defect is old, enhancing filtration between a melting furnace and a casting mold; if said aluminum oxide defect is young, optimizing a location and geometry associated with a gating/riser system into which a liquid melt flows prior to casting.