CT Scanning Aluminum Charged Air Cooler for Leaks

CT Scanning Aluminum Charged Air Cooler for Leaks

CT scanning was used to nondestructively identify leaks in the seal area of this aluminum charged air cooler. A high exposure helical scan was used to capture a single, high resolution scan of the oblong assembly.

Helical scanning works by continuously rotating and raising the object with the part manipulator, creating a spiral dataset. The benefit of helix scans is that resolution is limited to the object’s greatest width, rather than it’s length. Additionally, CT artifacts like beam hardening are dissipated throughout the sample rather than concentrated in a localized, circular zone. Some drawbacks to helical scans are exceptionally large files (this was around 70gb), and spiral artifacts.

Helix_Scanning

Eddy Current Inspection Services of Cracked Steel Plates

Eddy Current Inspection Services of Cracked Steel Plates

Eddy Current Testing (ET) is a powerful & value-saving nondestructive method for ensuring product quality and providing failure analysis.

Recently, we inspected steel test bars using a 500 kHz pencil probe. This high-frequency setup concentrates eddy currents at the surface, making it ideal for detecting fine, surface-breaking flaws in ferromagnetic materials like steel.

During inspection, we identified a series of circumferential indications—micro-tears that could have easily gone unnoticed. Based on signal response and calibration, we were able to estimate the depth of the surface-breaking flaws to be approximately 0.02 inches, providing critical insight into the severity of the damage.

This video demonstrates the eddy current inspection of one of the test bars. Microcracking, undetectable to the naked eye, was identified following a jagged circumferential pattern around the part. These surface-breaking cracks were revealed through changes in signal amplitude and phase shift, with increasing phase lag behavior indicating crack depth and orientation. The observed responses are consistent with fatigue or stress-related discontinuities.

We can also use Eddy Current to map out defects for precise repair. By marking products as we probe (yellow arrow), we can determine point of origin and mark up all pathing. 3D microscopy was also used to evaluate surface quality in proximity to the crack.

Inspection isn’t just about identifying defects. It’s about providing manufacturers with the actionable insight they need to salvage high-value parts, reduce waste, and avoid production delays. With the right tools and expertise, inspection becomes an value saving investment.

CT Scanning Fuel Injectors for Injector Angles

CT Scanning Fuel Injectors

Over the years we’ve been asked to participate in many fuel injector studies because their features are so small and difficult to characterize. CT is a great solution, providing water tight, high resolution, exportable data for visual and dimensional analysis of critical features.

Injector angles matter because they directly affect how efficiently fuel mixes with air inside an engine’s combustion chamber. Ensuring design criteria is met improves combustion, power output, fuel economy, and emissions.

CT Scanning Steel Microfluid Assemblies for Cracks & Profiles

CT SCANNING MICROFLUID ASSEMBLIES

CT scanning is used to inspect stainless steel micro connectors and valves for internal weld defects and dimensional accuracy. It reveals voids, cracks, or misaligned welds that aren’t visible from the outside, while also confirming that tight tolerances are met. The process is non-destructive and ideal for quality control in precision manufacturing. Traditional methods require sectioning samples for internal evaluations, which could damage or eliminate critical areas of interest.

Crack in micro-weld

CT scanning revealed the linear, cracklike indication in the weld below, which was undetectable by visual inspection and dye penetrant. The scan provided exact location, length, and depth, allowing for targeted evaluation of the weld quality and potential failure risk. Early detection like this is critical in high-precision or pressure-sensitive applications, where even small defects can compromise performance and mission integrity.

Measuring Internal Profiles

Micro-CT scanning is effective for measuring intentional surface roughness in steel microfluidic components because it captures high-resolution, water-tight, internal and external surface data. This allows engineers to evaluate surface conditions that influence flow behavior, such as turbulence or adhesion, within tiny channels or chambers. Unlike tactile or optical profilers, micro-CT can measure roughness on complex, internal geometries where direct non-destructive access is impossible, ensuring the intended surface characteristics are consistently produced and maintained throughout the part and its production.

IIC Receives ISO/IEC 17025:2017 Accreditation

Industrial Inspection & Consulting LLC (IIC) is proud to announce its ISO/IEC 17025:2017 accreditation, affirming our commitment to excellence in testing and calibration services. This prestigious certification, granted by Perry Johnson Laboratory Accreditation, Inc., recognizes our technical competence in delivering precise and reliable results across a range of industries.

Our accredited services encompass both dimensional and non-destructive testing (NDT), including portable CMM, computed tomography (CT), ultrasonic testing (UT), penetrant testing (PT), magnetic particle testing (MT), and radiographic testing (RT). We utilize state-of-the-art equipment and adhere to stringent industry standards such as ASME 714.5, ASTM and MIL-STD, ensuring that our clients receive the highest quality assessments.

Operating from our state-of-the-art facility in Norton Shores, Michigan, IIC offers both on-site and in-lab services, providing flexibility to meet the unique needs of each project. Our team’s dedication to continuous improvement and adherence to international standards underscores our role as a trusted partner in delivering accurate and actionable testing solutions.

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IIC Launches X-RAY Authority

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Inspecting Microfluidic Mixers

Inspecting Microfluidic Mixers

Industrial CT scanning is a powerful tool for inspecting microfluidic mixers, especially in industries where performance and reliability are critical such as medical diagnostics, pharmaceuticals, biotechnology, and chemical processing. These mixers often feature complex internal channels and structures that are impossible to evaluate with traditional inspection methods without cutting or destroying the part.

CT scanning provides a fully non-destructive way to see inside a microfluidic device and verify that it was manufactured correctly. It could even remain in its sealed packaging.

For example, it can detect internal blockages, trapped air bubbles, or incomplete bonding between layers, all of which can compromise fluid flow or lead to device failure in the field.

In addition to assembly inspection, CT scanning is used for high-precision dimensional analysis. It allows inspectors to measure internal features like channel widths, wall thickness, and GD&T like flatness and concentricity with micron-level accuracy. This is especially important in devices where small variations can affect flow behavior, mixing efficiency, or the timing of chemical reactions.

CT Scanning 3D Printed Steel Tooling for Leak Paths

CT Scanning 3D Printed Steel Tooling for Leak Paths

One of our clients had issues with undetected internal leak paths within complex 3D printed steel tooling, compromising tool integrity and performance. Traditional inspection methods failed to reveal subsurface defects, prompting the use of industrial computed tomography scanning.

The high-resolution CT scans enabled non-destructive, full-volume analysis of the tooling, revealing internal porosity, profile deviations, and wear from water pitting. By visualizing and precisely locating these hidden defects, engineers have a better understanding for repair and corrective actions to mitigate future leakage risks. This application of CT scanning significantly improves quality assurance, reducing failure rates and increasing tool reliability.

This tooling and imaging is shared with permission by Grand Traverse Plastics.

Helical Scan 1 Steel Printed Tooling Wear Leakpaths
Helical Scan 1 Steel Printed Tooling