X-Ray & CT Scanning Archives - Page 2 of 6 - Industrial Inspection & Consulting

MyVGL Tutorial & Users Guide for CT Analysis

Become a CT Expert using MyVGL

In just a few steps you can become an expert CT analyst. This guide demonstrates the basic, step-by-step functions of the industrial CT industry’s standard software: Volume Graphic’s myVGL Viewer.

1. Download myVGL & Open File

myVGL is the free viewing app for projects created with Volume Graphics Software.

myVGL Download Page

With myVGL, you can view 3D objects (in voxel, point cloud, mesh, and CAD format), the analyses and measurements performed on these objects, and define your own measurements and imaging results!

2. ACTIVATE NECESSARY TOOLS

Navigate to the Window pane. To the right, click the “Tools” drop down to activate important sidebar options like Rendering, Scene Tree, and Bookmarks.

Rendering allows for contrast adjustment, Scene Tree shows the different files and tools within the project, and Bookmarks allow you to navigate between saved images.

3. NAVIGATION

Clicking the cursor navigation button in the upper left corner allows the user to navigate to a single location in all window views simultaneously. Hold Ctrl + Left Click any location.

In the Window menu the viewing panes can be modified or removed for optimal viewing of areas of interest. Quad View is standard which shows all three planar directions and a 3D render view in the bottom right. Additional options include Rotational View about an axis, or Unroll View which planarizes cylindrical features.

4. CONTRAST & RENDER ADJUSTMENT

Adjusting the contrast of the scan data is done in the Rendering window you activate earlier. The Histogram contains a variety of tools including a sliding bar. At the ends of the bar are upper and lower limit handles (1.1 and 1.2). Drag these to adjust the contrast. You can move both handles simultaneously by selecting and dragging 1.3. Location 2 shows the Gray Value rendering slider and Location 3 activites and deactivates the ability to adjust the Gray Value rendering slider.

Right clicking the 3D renderopens a menu with a variety of options including clipping tools. Clipping tools can be used to digitally section the part, and the sections are saved to be activated or deactivated in the upper right Scene Tree.

5. SLICE SETTINGS

Right click any viewing pane to open pane settings menu. Primary viewing tools including:

Thick slab – the slice thickness control which has parameters to define thickness, bring forward the highest density gray values in that thickness, slice averaging, and so on.
Slice step width – how far the viewer scrolls through each tick of the mouse. The small the value, the slower the scroll and more detail will be viewed.

6. MEASUREMENTS

A variety of measurement options are available in myVGL including basic dimensioning like distances, angles, and polylines. However, complex dimensional tools like profiling, wall thickness, CAD alignments, and coordinate systems are reserved for full Volume Graphics Cast & Mold licenses.

Indicators are used to mark areas of interest and recover their locations quickly. Calipers use rendered surface data to create tangible distance measurements.

7. IMAGING & REPORTING

In the Reporting panel measurements can be exported to Excel and images can be exported using the Save Image button. Images can be modified based upon the current state of the defined windows of the software or as defined in the Save Image pane.

2D slice videos can also be exported.

8. METROLOGY USING POLYWORKS

Visit our case study about dimensional inspection of these vacuum heads using PolyWorks Metrology Suite here.

Complex dimensional programs can be written for large batches of parts for GD&T and profile analysis.

Industrial CT Scanning Complex Electronics like Relays

INDUSTRIAL CT SCANNING COMPLEX ELECTRONICS

Aviation Relays are used in power distribution systems to control the flow of electrical power to different components and subsystems. Aircraft control systems, such as those for flight control surfaces, landing gear, brakes, and anti-ice systems, often rely on relays to activate and deactivate various functions.

The proper manufacturing of intricate components like these is paramount for the function of each related system it controls. Broken or pinched wires, shorts caused by FOD, and weld quality are all conditions that can be evaluated using Industrial CT Imaging.

Micro CT scanning offers the ability to render into 3D small geometries like copper windings to look for wire breaks, tang alignments, micro welds, and other geometries. Sometimes, areas of interest are only accessible using 3D characterization via CT scanning because the inspected surfaces are behind high density materials that cannot be adjusted adequately from just a 2D X-Ray perspective.

Microfocus CT Scanning of Fossils

MICROFOCUS CT SCANNING OF FOSSILS

The oldest fossils are billions of years old. Traditional ways of examining fossils often employ destructive techniques which can compromise these timeless specimens. Industrial computed tomography (CT) scanning offers a non-destructive alternative that enables detailed examination of fossils’ internal and external structures. This case study explores how we can assist the field of paleontology with our microfocus CT scanning capabilities.

CT technology generates datasets by measuring the differential absorption of x-rays. Changes in material density and thickness cause differences in x-ray attenuation.

Depending on how a fossil was formed, there may be enough difference in material density for x-ray/CT to differentiate fossil from sedimentary rock.

The relative density is dependent on a variety of factors, including the types of minerals present in the fossil, the type of surrounding rock, and the conditions of fossilization. Each fossil and rock pairing can be unique, so the density comparison can vary.

CT generates a 3D model by compiling thousands of 2D x-ray images. This means the 3D model has internal data and we are able to ‘slice’ through the test piece and look at it from any direction.

Using a high-end software for analysis and visualization of our microfocus CT data, we are able to perform a variety of measurements and analysis. We can generate videos for easy viewing and dissemination. We can create .stl models for 3D printing.

And in the case of these ammonites, the best part is we can do all of this analysis while the fossil remains undisturbed within the nodule.

The application of industrial microfocus CT in fossil analysis allows for the detailed examination of internal structures without compromising the integrity of valuable specimens. By providing high-resolution, three-dimensional insights, micro-CT enables us to uncover previously inaccessible information about these ancient organisms. Contact us today to see how we can help with your fossils!

X-Raying & Grading Aluminum Castings

CERTIFIED RADIOGRAPHY OF CASTINGS

X-ray inspection is a non-destructive testing method, meaning it allows for the examination of castings without causing damage to the parts. This is especially important for expensive or critical components where destructive testing methods would be impractical or cost-prohibitive. X-ray examination allows for the detection of part flaws or defects like gas porosity, shrinkage cavities, cracks & hot tears, inclusions, and voids.

Industrial Inspection offers a roster of technicians certified per the American Society for Nondestructive Testing (ASNT / SNT-TC-1A) and National Aerospace Standards (NAS-410). Our technicians have x-rayed everything from infrastructure pipework, automotive components, and rocket manifolds.

CONNECTORS
TOOLS & DEVICES
FASTENERS & COVERS

COMPRESSOR WHEELS
HEAT SINKS & BRACKETS
PUMP HOUSINGS

CONTROL ARMS
STEERING KNUCKLES
OIL PANS

TURBOPUMPS
TRANSMISSION HOUSINGS
WHEELS

There are a wide variety of standards and gauges used for digital radiography depending on the material type, thickness, and customer driven requirements for sensitivity. Industrial Inspection has a robust library to respond to almost any requirement and, for niche requirements, can order custom gauges within days.

We use industry standard software for image processing, evaluation, and grading. To the left is a casting being compared to ASTM E2422 Digital Reference Images for a gas hole in proximity to the edge of a machined surface.

Below is x-ray imaging of a transmission housing before and after contrast adjustment. Penetrameters are used to qualify a technique for adequate penetration through various material thicknesses, and software is used to adjust brightness and contrast to look for defects not seen in the raw image.

Measuring Volume of Tubes & Beakers

MEASURING TEST TUBES & VIALS FOR WALL THICKNESS AND VOLUME

CT scanning plays a pivotal role in assessing the wall thickness and volume of glass components, offering critical insights for manufacturing processes and product quality. Glass, known for its brittleness and susceptibility to defects, requires meticulous inspection to ensure structural integrity and performance. CT scanning provides a non-destructive means of examining these components, offering precise measurements of wall thickness and volume with unparalleled accuracy. By detecting variations in thickness and identifying potential flaws, CT scanning enables manufacturers to optimize production processes, enhance product reliability, and uphold stringent safety standards. The comprehensive evaluation provided by CT scanning ensures that glass components meet the highest quality requirements, ultimately contributing to safer and more durable end products.

CT SCANNING TO MEASURE WALL THICKNESS

CT scanning is used for evaluating wall thickness in a wide range of materials and structures. By utilizing X-ray technology to penetrate objects, CT scanning generates detailed 3D images that allow for precise measurements of wall thickness. This non-destructive technique is invaluable for industries such as manufacturing, aerospace, and automotive, where ensuring structural integrity is paramount. This image demonstrates a total mapping of the thickness of the tube with variable results from .75mm to 2.55mm.

VOLUME OF GRADUATION MARKS

CT scanning offers a precise and non-destructive method for measuring volume in objects with complex geometries. We were able to segment, virtually cap, and extract volumetric measurements of the tube at various graduation marks.

The nominal “as-marked” volume states 100ml and the measured volume equals 100.533ml – a deviation of just 0.5% of the volume. However, sub-sections like section 5 have a deviation of 27%.

Industrial CT Scanning Battery Cells

In the race towards a sustainable future, battery technologies have emerged as frontrunners, promising cleaner, greener transportation. Central to this revolution are lithium-ion battery cells, the lifeblood of many electronics. Ensuring the safety and reliability of battery cells is paramount, presenting a unique challenge for manufacturers. Enter CT scanning, a game-changing technology offering unprecedented insights into battery cell integrity.

Traditional inspection methods often fall short when it comes to assessing the intricate internal structure of battery cells. However, CT scanning changes the game by providing a non-destructive and highly detailed examination of each cell. With its ability to penetrate solid materials and generate 3D images of internal features, CT scanning offers a comprehensive view of battery cell health.

LOOKING FOR DEFECTS

When it comes to ensuring the safety and reliability of battery cells, detecting defects is paramount, and CT scanning offers an unparalleled solution. By leveraging its capability to penetrate solid materials and produce detailed 3D images of internal structures, CT scanning enables manufacturers to meticulously inspect battery cells for defects such as delamination, voids, cracks, or foreign particles. This non-destructive technique allows for early detection of potential issues, ensuring that only cells meeting stringent quality standards are integrated into electric vehicles or energy storage systems. Ultimately, CT scanning plays a pivotal role in safeguarding product quality, enhancing safety, and advancing the development of clean energy technologies.

SORTING CELLS

CT scanning has emerged as a transformative tool for sorting battery cells with unparalleled precision and efficiency. By harnessing its ability to generate detailed 3D images of internal structures, manufacturers can swiftly identify and categorize battery cells based on various parameters such as size, shape, and internal defects. This level of precision not only streamlines the sorting process but also ensures that each battery cell meets stringent quality standards before integration into electric vehicles or energy storage systems. Ultimately, CT scanning enables manufacturers to optimize production workflows, enhance product quality, and uphold safety standards, thereby driving advancements in clean energy technologies.

Volumetric Porosity & Cracks in PCB Housing

INVESTIGATING A FAILED LED HOUSING

This LED housing has failed. It was sent to us to try to locate the point of failure, which is equivalent to finding a needle in a haystack. The point of failure is seen in one of the two images below. Can you spot it before moving to the next section of the post?

point of failure

While porosity calculations are interesting, typically an individual joint has a 20% porosity tolerance which can usually be gauged visually. Porosity is not the failure of this part.

If you look near the yellow arrow you’ll see a vertical, linear indication or fracture in the component. During evaluation the inspector uses multiple viewing directions for each component to find such small points of failure. If this crack were perpendicular to the viewing direction it likely would not have been found.

Industrial CT Scanning of Spark Plugs

INDUSTRIAL CT SCANNING OF AEROSPACE SPARK PLUGS

When precision and safety are paramount, the significance of CT scanning for spark plugs cannot be overstated. These small yet vital components play a crucial role in the functioning of aircraft engines, making their integrity and reliability essential. CT scanning offers a non-destructive method to scrutinize these intricate parts, providing engineers with detailed insights into their internal structure and potential defects. By meticulously examining spark plugs through CT scanning, aerospace professionals can identify any anomalies early on, ensuring optimal performance and safety of aircraft engines. Thus, integrating CT scanning into aerospace spark plug inspection protocols not only enhances reliability but also reinforces the commitment to air travel safety.

The below image is a focus scan with improved resolution allowing us to characterize fine details like voids and gaps in the insulation and cracks in aluminum oxide.

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.

Play Video

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.

Category: X-Ray & CT Scanning