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X-Ray Refraction Techniques for Fast, High-Resolution Microstructure Characterization and Non-Destructive Testing of Lightweight Composites

X-ray refraction is based on optical deflection of X-rays, similar to the well-known small angle X-ray scattering, but hundreds of times more intense, thus enabling shorter measurement time. We show that X-ray refraction techniques are suitable for the detection of pores, cracks, and in general defects. Indeed, the deflected X-ray intensity is directly proportional to the internal specific surface (i.e., surface per unit volume) of the objects. Although single defects cannot be imaged, the presence of populations of those defects can be detected even if the defects have sizes in the nanometer range.We present several applications of X-ray refraction techniques to composite materials:- To visualize macro and microcracks in Ti-SiC metal matrix composites (MMC);- To correlate fatigue damage (fibre de-bonding) of carbon fibre reinforced plastics (CFRP) to X-ray refraction intensity;- To quantify the impact damage by spatially resolved single fibre de-bonding fraction as a function of impact energy in CFRP laminates.An example of classic high-resolution computer tomography of an impact-damaged CFRP will also be presented, as a benchmark to the present state-of-the-art imaging capabilities. It will be shown that while (absorption) tomography can well visualize and quantify delamination, X-ray refraction techniques directly yield (spatially resolved) quantitative information about fibre de-bonding, inaccessible to absorption tomography.

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Mobile Computed Tomography for Inspection of Large Stationary Components in Nuclear and Aerospace Industries

Mobile Tomographic Computer Aided Radiometry (TomoCAR) is based on the mechanical position control of an X-ray tube in front of an object and the application of a Digital Detector Array (DDA) behind it. Several hundred radiometric projections in small angle steps are acquired during the controlled movement of the X-ray tube along a preselected way. The tomographic or laminographic reconstruction allows the three-dimensional (3D) representation of flaws. A specially designed radiometric detector array with small internal unsharpness and high image contrast was used for visualization and sizing of planar and volumetric defects in austenitic welds in nuclear power plants. A German pilot study was successfully performed on the basis of the European network of inspection and qualification (ENIQ) guidelines. This was the precondition for several applications of TomoCAR in nuclear power stations in Germany and Switzerland.A versatile computed tomography (CT) system was developed on basis of the TomoCAR design for in situ inspection of large aircraft components under production conditions. A gate based planar computed tomograph was constructed and tested for inspection of the integrity of CFRP stringers, embedded in aircraft fibre composite shells. A probability of crack visibility >90% could be determined.

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Use of Alloy 59 for the Transport of Highly Corrosive Dangerous Goods

Alloy 59 (NiCr23Mo16Al) with a lot of chromium, molybdenum and nickel possesses excellent resistance not only to reducing but also oxidizing chemicals. Both the Nickel alloy 59 and the superaustenitic steel alloy 31 have already been used as shell materials for tank vehicles or tank containers. Use of these alloys allows the transport of a signifi-cantly more wider variety of chemicals and, especially, waste mixtures than the use of common aus-tenitic steels. Another advantage is the extension of test intervals of for transport tanks. In Germany the “BAM-List – Requirements for Tanks for the Transport of Dangerous Goods” is the basis for substance-related prototype approvals for tank containers designed for the car¬ri¬age of dangerous goods issued by the Federal Institute for Materials Re¬search and Testing (BAM). Com-patibility evaluations of selected metallic material groups as well as polymeric gasket and lining materials under the influence of approximately 7000 dangerous goods and water-polluting sub-stances are published in the BAM-List. Alloy 59 belongs to the group of metallic materials in the BAM-List. Due to the large number of dangerous goods in the BAM-List BAM, IKS Dresden and ThyssenKrupp VDM performed a comprehensive corrosion test programme with welded specimens of the nickel alloy 59 and the superaustenitic steels alloy 926 and alloy 31 in the period 2002 - 2010. Especially In particular alloy 59 and alloy 31 were exposed to a large number of corrosive sub-stances such as various mixtures of both nitric acid/sulphuric acid and nitric acid/phosphoric acid at 55 °C. Other corrosive test substances were different organic and inorganic halogenides, peroxyace-tic acid and molten substances. In the case of molten chemicals such as monochloroacetic acid the test temperature was increased to more than 100 °C. The test results presented in this paper are al-ready included in the 10th edition of the BAM-List and, therefore, available to the customer.

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Open Access