May 2024 - Industrial Inspection & Consulting

Investigating Failed Components using Industrial CT Scanning

FAILURE INVESTIGATION OF HUMAN SUPPORT SYSTEM (CHAIR)

Have you fallen and can’t get up?

Are you struggling to return something to Amazon?

Are you tired of finding 3500mm cubed voids in your products?

Do you wonder why everything is more expensive but doesn’t last as long?

Us too.

This case study explores the failure of a human support system (chair.)

Industrial CT Scanning is a powerful non-destructive imaging technique used to inspect the internal structure of objects. When applied to plastics to detect porosity, CT scanning provides detailed cross-sectional and 3D rendered images revealing the distribution, size, and shape of voids or pores within the material.

Everyone from manufacturers to law firms have used our services to assist with their fact finding, point of origin, or root cause evaluations.

We combine many hardware and software capabilities for the best possible evaluation of products. Because of the size of the chair we used a high accuracy laser scanner (Hexagon Absolute AS1) to capture the overall geometry of a still intact chair. We then created a coordinate system and aligned additional scans of the broken pieces in PolyWorks.

Once everything was aligned properly we imported the .STL mesh files into Volume Graphics to begin aligning the individual CT scans. The CT scans were acquired using our Nikon Microfocus X-Ray & CT cabinet. After the alignments were complete we extracted the volumetric porosity to find voids and cavitation as large as 3500mm³and found a significant concentration at the base of the chair.

Designing New Components Around Existing Geometry

DESIGNING NEW COMPONENTS FOR PERFECT FIT AND FUNCTION

Combining the power of the world’s best scanning hardware and software allows us to produce models with incredible accuracy. This case study focuses on acquiring high resolution, water tight geometry using laser and CT scanning technologies.

This helmet has several components with attachment features for accessories like lights, visors, and earmuffs. However, if you don’t have existing CAD, how do you effectively design new products?

The first step is to acquire water tight, high resolution data. Water tight data means no data is missing in the file. This is important for properly designing a product around all scenarios – if data is missing, you can’t understand proper fit and function. We scanned and segmented the attachment points and built a coordinate system to begin modeling visor attachment mechanisms.

Below shows the 2D sketches produced in Geomagic.

The final step of any reverse engineering project is to verify accuracy of the produced model. This verification takes the form of either Scan to CAD profile comparisons, or visual checks with 2D cross sections. The visor slides fit inside the tracks and the clips have curved tensioners to ensure tight fits into the slots.

What is Industrial X-Ray Imaging?

Industrial X-ray services are the unsung heroes of modern manufacturing, providing invaluable insights into the inner workings of complex components and materials. From aerospace to automotive industries, these services utilize X-ray technology to peer beneath the surface, uncovering defects, assessing structural integrity, and ensuring product quality with unparalleled precision.

THE HARDWARE

At the heart of industrial X-ray services lies advanced imaging technology that enables the creation of detailed, high-resolution images of objects’ internal structures. This non-destructive testing method allows manufacturers to scrutinize components without compromising their integrity, saving time and resources while maintaining product reliability.

1. X-Ray Source, 2. Part Manipulator, 3. X-Ray Detector

Whether it’s inspecting welds for cracks, detecting voids in castings, or analyzing composite materials for delamination, industrial X-ray services offer a versatile solution for a wide range of applications. With customizable inspection protocols and state-of-the-art equipment, these services can adapt to the unique needs of various industries, providing tailored solutions for quality assurance and defect analysis.

Moreover, industrial X-ray services play a crucial role in ensuring regulatory compliance, particularly in safety-critical industries where the integrity of components is paramount. By leveraging X-ray technology, manufacturers can uphold the highest standards of quality and safety, mitigating risks and enhancing customer trust.

In conclusion, industrial X-ray services represent a cornerstone of modern manufacturing, offering a glimpse into the hidden world of materials and components. With their ability to uncover defects, assess structural integrity, and ensure compliance, these services empower manufacturers to deliver products of uncompromising quality, driving innovation and excellence across industries.

CT Scanning Coronary Stents for Weld Evaluation

3um RESOLUTION CT IMAGING OF STENT WELDS

Coronary stents are a specific type of stent used in the treatment of coronary artery disease. These stents are implanted into the coronary arteries, which are the blood vessels that supply oxygen-rich blood to the heart muscle. Coronary artery disease occurs when these arteries become narrowed or blocked due to the buildup of plaque, which is made up of cholesterol, fat, and other substances.

Weld quality directly impacts the safety, efficacy, and longevity of coronary stents. Ensuring high-quality welds is essential for the successful treatment of coronary artery disease and the overall well-being of patients undergoing stent implantation.

Coronary stents often have welds as part of their construction. These welds serve several important purposes:

Joining Components: Stents are typically made from thin metal tubes or wire mesh. Welding is used to join these components together to form the desired stent structure. The welds ensure that the stent maintains its shape and structural integrity during deployment and once it’s in place within the artery.

Sealing Edges: Welding can be used to seal the edges of the metal components, preventing them from unraveling or causing damage to the artery walls during insertion or deployment. This sealing helps to ensure the safety and effectiveness of the stent.

Reducing Material Weakness: Welding is often employed at points where different parts of the stent meet. These junctions can be weak spots if not properly reinforced, and welding helps to strengthen these areas, reducing the risk of failure or breakage.

Smooth Surface: Welding can be used to create smooth transitions between different sections of the stent, which can help to minimize irritation to the artery walls and reduce the risk of complications such as clot formation or restenosis (re-narrowing of the artery).

POROSITY IN STENT WELDS

Porosity in stent welds refers to the presence of small voids or air pockets within the welded region of the stent. This porosity can occur due to various factors during the welding process and can have significant implications for the quality and performance of the stent. Here are some key points regarding porosity in stent welds:

Reduced Mechanical Strength: Porosity weakens the welds, making them more prone to cracking, fracturing, or deformation under mechanical stress. This compromises the structural integrity of the stent and can lead to premature failure or breakage during deployment or while in place within the artery.

Increased Risk of Corrosion: Porous welds create pathways for corrosive agents, such as bodily fluids or environmental factors, to penetrate the stent material. This can accelerate corrosion processes, leading to degradation of the stent over time. Corrosion weakens the material and can result in structural failure, particularly in environments with high levels of oxidative stress.

Poor Biocompatibility: Porous welds may have rough or irregular surfaces, which can increase the risk of tissue irritation, inflammation, or thrombosis (blood clot formation) when the stent is implanted in the body. The presence of voids or air pockets within the welds can also serve as sites for bacterial adhesion, raising the risk of infection at the implantation site.

Compromised Drug Delivery (for Drug-Eluting Stents): In drug-eluting stents, where medications are coated onto the stent surface to prevent restenosis, porosity in the welds can affect the uniformity and integrity of the drug coating. This may result in uneven drug release or premature degradation of the drug layer, reducing the efficacy of the stent in preventing re-narrowing of the artery.

Difficulty in Inspection and Quality Control: Porosity in welds can be challenging to detect visually or with conventional inspection methods. This makes it difficult to ensure the quality and reliability of the stents during manufacturing. Advanced non-destructive testing techniques, such as X-ray and CT Scanning, may be required to identify and quantify porosity accurately.

CT Scanning PCB Components

X-Ray & CT Scanning PCB Components

Industrial X-Ray & CT scanning is used to non-destructively evaluate printed circuit boards.

2D X-RAY

2D x-ray allows our certified technicians to quickly inspect features like bond wire straightness, pin perpendiculariy, BGA porosity, trace defects, and capacitor cracks. Our high resolution systems are fully programmable allowing automated image acquisition including translations, rotations, and magnification changes.

3D CT SCANNING

3D CT scanning offers an additional viewing axis for inspection. With 2D X-Ray all geometry in the view is viewed simultaneously. With 3D CT we can navigate through a tangible inspection volume where a larger variety of digital tools are available. For example, precise component alignments can be created. Additionally, dimensions can be extracted like depth of discontinuities, volumetric porosity, wall thickness, and complex 3D GD&T like flatness or feature positions.

X-RAY IMAGING

CT IMAGING

VOLUMETRIC POROSITY & DATA EVALUATION

Porosity can be extracted, volumetrically quantified, and exported into Excel. Such values as total porosity percentage, individual pore volume, equivalent diameter, and XYZ positional data can be produced.

VIEWING FILTERS

Various viewing filters can be applied to the CT slice data. Instead of looking through a single slice of geometry, we can look at the highest density features across a specified length. For example, the bond wires below are imaged using a maximum density filter across a 2mm zone. If data is particularly noisy, an average min/max filter can be applied to help the inspector understand the geometry.

Reasons for Using a CT Scanning Laboratory

Are you searching "Industrial CT Scanning Near Me?"

Navigating Industrial CT Scanning: Local Challenges, Nationwide Solutions

In the realm of industrial CT scanning, there’s a prevailing wisdom: sometimes, the best solution lies beyond your doorstep. While the idea of sending your projects across the country may seem counterintuitive at first glance, a closer examination reveals the compelling reasons why clients should consider this inspection method. Let’s explore why bypassing local inspection options in favor of industrial CT scanning solutions can lead to superior outcomes.

Access to Cutting-Edge Technology

When it comes to CT scanning, not all facilities are created equal. While your local options may offer 3D scanning capabilities, they might lack the cutting-edge technology necessary for complex projects. By widening your scope to include facilities across the country, you gain access to state-of-the-art equipment and advanced scanning techniques that can uncover insights and nuances impossible to detect otherwise. From intricate aerospace components to delicate medical devices, investing in superior technology ensures unparalleled accuracy and reliability.

Specialized Expertise

CT scanning is as much an art as it is a science. It requires a deep understanding of materials, meticulous attention to detail, and years of hands-on experience. While a local facility may boast competent technicians, truly exceptional results often stem from specialized expertise. A multi-method inspection lab aggregates the best talent from across the country, ensuring that your projects are handled by seasoned professionals with a track record of excellence. Whether it’s deciphering complex scans or troubleshooting unexpected challenges, tapping into this wealth of expertise can elevate the quality of your outcomes.

Rigorous Quality Standards

In industries where precision is paramount, quality control is non-negotiable. CT scanning facilities adhere to rigorous quality standards and certifications, providing clients with the assurance that their projects are in capable hands. Industrial Inspection maintains industry-specific certifications like NAS410 & ASNT, ensuring quality at every stage of the inspection process. By entrusting your projects to reputable facilities with a proven commitment to excellence, you mitigate the risk of errors, delays, and costly rework.

Unbiased Third-Party Validation

In today’s global marketplace, transparency and accountability are essential. Sending your projects to a third-party CT scanning facility across the country offers an added layer of credibility and objectivity. Unlike in-house scanning solutions, which may be susceptible to bias or conflicts of interest, external facilities provide unbiased assessments based solely on empirical data. This impartial validation not only enhances the credibility of your products but also instills confidence among stakeholders, from clients to regulatory agencies.

Future-Proofing Your Investments

Using a national CT scanning lab isn’t just about meeting current needs—it’s about future-proofing your investments. By aligning yourself with cutting-edge technology and top-tier expertise, you position your business for long-term success and innovation. As industries evolve and technologies advance, having access to best-in-class scanning capabilities ensures that you remain at the forefront of your field. Whether it’s staying ahead of regulatory requirements or pioneering breakthroughs in product development, the benefits of forward-thinking investment extend far beyond immediate gains.

Conclusion

In the dynamic landscape of industrial CT scanning, proximity should never be a barrier to excellence. By embracing the advantages of nationwide solutions, clients can unlock a world of possibilities for their projects. From access to cutting-edge technology and specialized expertise to rigorous quality standards and unbiased validation, the benefits of sending projects across the country are clear. In an era defined by innovation and competition, choosing the right CT scanning partner isn’t just a decision—it’s a strategic imperative.

CT Scanning Tube Welds for Lack of Penetration

IMAGING STEEL TUBES FOR WELD FLAWS

Inspecting tube welds in aerospace, defense, and nuclear applications is not just important; it’s absolutely essential for ensuring safety, preventing environmental contamination, maintaining operational efficiency, complying with regulations, mitigating risks, assuring quality, and ensuring long-term performance.

Tube welds are critical components in various systems such as piping, reactors, and steam generators. Any flaws or defects in welds could compromise the structural integrity of these systems, leading to catastrophic consequences.

Industrial CT scanning is used to evaluate welding processes by offering higher certainty, variable data compared to 2D X-ray or micro-sectioning.

CT Scanning Glass Components for Wall Thickness Evaluation

INDUSTRIAL CT SCANNING GLASS COMPONENTS

WALL THICKNESS EVALUATION

Industrial CT Scan of Suture Needle

MEASURING NEEDLES USING MICRO-CT SCANNING

Industrial’s micro-CT scanning systems are able to resolve down to 3um resolution for the inspection of the smallest manufactured products like needles, fine drill bits, micro-springs, and gears.

The below imaging demonstrates a suture needle. It’s geometry and surface topography can be measured or visually reviewed for defects.

Digital X-Ray or CT for Fuel Injector Sort?

X-Ray or CT for sorting?

Every sort we receive starts with the same question – is digital radiography or CT scanning the optimal method for this project? This sort focuses on a batch of fuel injectors with pinched wires.

Radiography can be a very fast (less expensive) inspection method with a single frame shot taking just 88 milliseconds. However, if the geometry is complex, sometimes it is not possible to characterize defects in a 2D view.

CT scanning can be a longer process (more expensive – 360 degrees of x-ray shots + data processing) but offers a 3D perspective. This perspective allows a tangible characterization to the inspection method, allowing for higher certainty evaluations.

2D Radiography

Because the two wires are in line with each other it is not possible to rotate the sample without the tangs blocking the areas of interest. Rotating the sample 90 degrees also did not work because the copper winding is behind the wires which reduced penetration. If the part configuration were different radiography could have quickly sorted this batch of parts.

3D CT Scanning

High resolution, high speed CT scanning was the method chosen for sorting this batch of parts. The below views are best effort results from the R&D portion of the project to prove capability. The defective sample was used as a representative quality indicator (RQI – a gauge used to prove the process.) We used this RQI to then adjust parameters for speed to improve run rate and reduce cost. Ultimately, we were able to reduce resolution and batch scan three samples at once in a three minute scan. Parts were serialized, sorted, and returned to the customer with accompanying serialized imaging.

Month: May 2024