Challenges in non-destructive X-ray CT testing of riveted joints in the automotive industry

Abstract

Despite recent advancements, contemporary laboratory-based industrial computed tomography (CT) technology has not yet achieved the status of an efficient and economically viable in situ non-destructive method for examining riveted joints that are commonly used in the automotive industry. 2D X-ray or 3D CT systems can only reliably assess a rivet joint’s condition in rare, and favorable circumstances. Moreover, a comprehensive analysis to identify the obstacles preventing CT from efficiently capturing high-resolution, and contrast-rich scans of riveted joints in general is lacking. This work delves into the challenges and limitations of the technology that prevent operators from reaching the desired precision required for rigorous quality control. The study specifically addresses questions concerning in situ reachability and positioning of the sample structure, radiodensity and beam hardening, the relationship between spot size and power, and economic feasibility—all within the context of analyzing riveted joints in the automotive industry. Additionally, we provide an abstracted overview of the current industrial X-ray tube market, which informs our discussion on these specific aspects. Through a combination of experimental findings, analytical insights, and deductions, we shed light on the persistent difficulties in achieving resolutions comparable to macro-sectioning and microscopy, which are currently considered the gold standard in examining riveted joints. Our investigation further explores the potential of a photon-counting detector paired with a conventional, laboratory-based X-ray source. Furthermore, we investigate the use of a synchrotron beamline as an X-ray source in conjunction with a custom-designed detector optimized for such beam geometries. This detector employs scintillators coupled with optical magnification, functioning similarly to an X-ray microscope. Our findings and data collection conclusively reveal that commercially available CT systems still fail to meet the requirements for efficient testing, underscoring the urgent need for further research and development to enable widespread implementation.