Only a Shadow : Industrial computed tomography investigation, and method development, concerning complex material systems
The complexity of components fabricated in today’s industry is ever increasing. This increase is partly due to market pressure, but it is also a result of progress in fabrication technologies that open up new possibilities. One area where complexity has reached new heights is additive manufacturing and multi-material systems. While these complex material systems bring benefits such as improved mechanical properties, weight optimization, and sustainability, they also pose challenges for material integrity investigations and dimensional control.
Traditionally, internal features of components could be examined using conventional tools. However, with additive manufacturing, internal features can be fabricated that cannot be seen or measured with these tools. This necessitates the development of non-destructive inspection methods that can accurately measure these geometries. One such method is X-ray computed tomography, which utilizes the X-ray’s ability to penetrate materials and create 3D digital volumes of components. Measurements and material investigations can then be performed on these volumes without causing any damage to the original component.
Despite its potential, computed tomography in material science is not yet a fully mature method, and there are still uncertainties associated with its investigation technique. To address these challenges, a recent thesis presented by researchers focuses on investigating geometries fabricated by various additive manufacturing processes using computed tomography. The research also involves the development of a dual-energy computed tomography tool, aiming to enhance the measurement consistency of computed tomography when investigating complex geometries and material combinations.
Dr. Rebecca Thompson, a leading expert in additive manufacturing, emphasized the significance of this work: As additive manufacturing continues to revolutionize various industries, there is a growing need for reliable inspection methods. The ability to accurately measure and assess the internal features of complex components is crucial for ensuring their performance and quality.
The research team conducted comprehensive experiments using different additive manufacturing techniques, such as selective laser melting and fused deposition modeling. They then utilized computed tomography to analyze the internal structures and characteristics of the fabricated components. The findings provide valuable insights into the capabilities and limitations of computed tomography in handling complex material systems.
John Davis, a materials engineer involved in the study, explained, Our experiments revealed the capabilities of computed tomography in capturing intricate internal geometries. This method offers a non-destructive means to measure complex material systems, enabling us to evaluate their structural integrity and identify any potential defects.
This research marks a significant step forward in advancing non-destructive inspection methods for complex material systems. By fine-tuning and optimizing computed tomography techniques for additive manufacturing and multi-material systems, manufacturers and researchers can gain a better understanding of component performance and ensure the highest quality standards are met.
As industries continue to push the boundaries of complexity in their designs and manufacturing processes, the development and application of robust inspection techniques like computed tomography will be essential. The ability to uncover and analyze internal features without damaging the components opens up new possibilities for innovation and ensures the safe and reliable functioning of various products across industries.
In conclusion, the ongoing research and method development surrounding industrial computed tomography for complex material systems hold great promise for enhancing dimensional control and material integrity investigations. As additive manufacturing and multi-material systems become more prevalent, reliable non-destructive inspection methods become increasingly crucial. The findings from this thesis provide valuable insights into the potential of computed tomography and its role in ensuring the quality and performance of complex components in today’s industry.
Keywords: industrial computed tomography, complex material systems, additive manufacturing, non-destructive inspection, geometries, material integrity, dimensional control.
