X-ray Computed Tomography Measurements Research Articles

Data fusion of surface data sets of X-ray computed tomography measurements using locally determined surface quality values

Abstract. X-ray computed tomography as a measurement system faces some difficulties concerning the quality of the acquired measurements due to energy-dependent interaction of polychromatic radiation with the examined object at hand. There are many different techniques to reduce the negative influences of these artefact phenomena, which is also the aim of this newly introduced method. The key idea is to create several measurements of the same object, which only differ in their orientation inside the ray path of the measurement system. These measurements are then processed to selectively correct faulty surface regions. To calculate the needed geometrical transformations between the different measurements with the goal of a congruent alignment in one coordinate system, an extension of the iterative closest point (ICP) algorithm is used. To quantitatively classify any surface point regarding its quality value to determine the individual need of correction for each point, the local quality value (LQV) method is used, which has been developed at the Institute of Manufacturing Metrology. Different data fusion algorithms are presented whose performances are tested and verified using nominal–actual comparisons.

An interlaboratory comparison of X-ray computed tomography measurement for texture and dimensional characterisation of additively manufactured parts

This paper presents the results of the CT-STARR (CT-Surface Texture for Additive Round Robin) Stage 1 interlaboratory comparison. The study compared the results obtained for the extraction of areal surface texture data per ISO 25178-2 from five X-ray computed tomography (CT) volume measurements from each of four laboratories. Two Ti6Al4V ELI (extra-low interstitial) components were included in each of the CT acquisitions. The first component was an additively manufactured (AM) cube manufactured using an Arcam Q10 electron beam melting (EBM) machine. Surface texture data was extracted from CT scans of this part. The values of selected parameters per ISO 25178-2 are reported, including Sa, the arithmetic mean height, for which the values from the Nikon MCT 225 metrology CT measurements were all within 0.5% of the mean reference focus variation measurement. CT resolution requirements are discussed. The second component was a machined dimensional test artefact designed to facilitate independent analysis of CT global voxel scaling errors and surface determination errors. The results of mathematical global scaling and surface determination correction of the dimensional artefact data is reported. The dimensional test artefact errors for the XT H 225 commercial CT for length, outside diameter and inside diameter reduced from -0.27%, -0.83% and -0.54% respectively to less than 0.02% after performing mathematical correction. This work will assist the development of surface texture correction protocols, help define surface-from-CT measurement envelope limits and provide valuable information for an expanded Stage 2 interlaboratory comparison, which will include a more diverse range of CT systems and technologies, further expanding the surface-from-CT knowledge base.

Micro-voids quantification for damage prediction in warm forging of biocompatible alloys using 3D X-ray CT and RVE approach

This study aims to quantify the three-dimensional (3D) micro-voids for damage prediction in warm forging through non-destructive X-ray computed tomography (CT) and RVE approach. Typical biocompatible alloys, i.e., stainless steel 316 L (SS316L) and titanium alloy Ti-6Al-4V, were used as specimen materials in warm-forging a medical implant, i.e., a basal thumb implant. X-ray CT scanning was performed for both the preforms and forged components. Volumetric CT images were then reconstructed and the 3D micro-void distribution and evolution inside the materials were detected and analysed quantitatively. Furthermore, three typical local strain regions, i.e., the small tensile strain region (STSR), small compressive strain region (SCSR) and large compressive strain region (LCSR), were established as the 3D representative volume element (RVE) models for both SS316L and Ti-6Al-4V preforms. The spatial location, size and volume of each micro-void were obtained from defect analysis of the 3D CT images and considered explicitly for subsequent damage prediction. An improved thermo-mechanical coupled micromechanics-based damage (micro-damage) model, which considered the variation of volume fraction of micro-voids (VFMVs), was implemented into finite element (FE) package ABAQUS for localized damage prediction of the RVE models. The damage distributions of the RVE models at different strain levels were visualized and identified. Finally, the localized damage evolutions at both compressive and tensile deformations were predicted and found to match quite well with the findings acquired from CT scanning. Thus, the application of non-destructive X-ray CT measurement of micro-voids, incorporating the RVE approach, was able to play a significant role leading to a more reliable damage prediction in the warm forging process.

Effects of magnification and sampling resolution in X-ray computed tomography for the measurement of additively manufactured metal surfaces

Recent studies have shown that X-ray computed tomography (XCT) can be used to measure the surface topography of additively manufactured parts. However, further research is necessary to fully understand XCT measurement performance. Here, we show how magnification of the X-ray projections and resolution of the volumetric reconstruction grid influence the determination of surface topography in the XCT data processing pipeline. We also compare XCT results to coherence scanning interferometry (CSI) measurements and find that by increasing the magnification of the X-ray projections, smaller topographic detail can be resolved, approaching the lateral resolution of CSI. Results show that there is an optimum setting for magnification, below and above which XCT measurement performance can degrade. The resolution of the volumetric reconstruction grid has a less pronounced effect, but in general, adopting higher or lower resolutions than the default leads to degraded repeatability in surface determination. The problem of determining sensitivity of XCT surface measurement as a function of setup parameters is complex, and it is not yet possible to provide optimal setup configurations that work regardless of object geometry. However, the methods presented here, as well as the results obtained, represent a useful contribution to good practice for XCT measurement of surfaces.

Three-dimensional study by synchrotron radiation computed tomography of melt distribution in samples doped to enhance contrast

AbstractThe three-dimensional distribution of melt in partially molten synthetic samples compositionally corresponding to diopside (90 wt.%)–anorthite (10 wt.%) and doped with PbO, WO3, MoO3, or Cs2O to enhance contrast was studied by X-ray computed tomography (CT) with synchrotron radiation. The heavy elements were strongly concentrated in the melt and contributed to an increase of the X-ray linear attenuation coefficient (LAC) of it. PbO was found to be compatible with silicate melt (>20 wt.% in solution) and incompatible with diopside crystals. Other oxides WO3 (∼10 wt.%), MoO3 (∼5 wt.%) and Cs2O (< 5 wt.%) are also soluble only in the melt. Such doping is useful not only for LAC control in X-ray CT measurements, but also for systematic control of the structure (wetting properties, distribution and connectivity) of partial melt. This technique gives basic information for discussion of the 3D distribution of partial melt having different wetting properties. As PbO was most effective in visualization of the diopside–anorthite partially molten system, CT images of the PbO-bearing sample were used for further 3D investigation of distribution. A distribution of dihedral angles at solid-melt-solid triple junctions ranging from 22 to 55° was observed with the 3D data. This range in angle distribution was probably caused by anisotropy of crystals and the result supports the argument that there is some limitation in a theoretical framework of stereology which estimates the 3D structure based on 2D observations. Investigators have begun to apply X-ray CT to the study of the 3D distribution of partial melts in rocks using synchrotron radiation. Our study on the effect of doping is one approach for developing a technique to investigate 3D melt distribution.

Simulating the influence of scatter and beam hardening in dimensional computed tomography

Cone-beam x-ray computed tomography (XCT) is a radiographic scanning technique that allows the non-destructive dimensional measurement of an object’s internal and external features. XCT measurements are influenced by a number of different factors that are poorly understood. This work investigates how non-linear x-ray attenuation caused by beam hardening and scatter influences XCT-based dimensional measurements through the use of simulated data. For the measurement task considered, both scatter and beam hardening are found to influence dimensional measurements when evaluated using the ISO50 surface determination method. On the other hand, only beam hardening is found to influence dimensional measurements when evaluated using an advanced surface determination method. Based on the results presented, recommendations on the use of beam hardening and scatter correction for dimensional XCT are given.

Staged thermomechanical testing of nickel superalloys produced by selective laser melting

The creep performance of additively manufactured components remains an issue before additive manufacturing can be put fully implemented. In this study, Inconel 718 two-bar specimens are produced by selective laser melting and subjected to a ‘staged’ creep test. Creep test was interrupted at critical junctures and X-ray computed tomography measurements performed at various extensions of the specimen. Periodic X-ray computed tomography measurements allow, for the first time, examination of the specimens during creep testing. Evaluation of specimen performance shows the number and size of pores within the specimen increasing over time as a result of classical creep mechanisms. Location and tracking over time of weak points are performed, allowing early estimation of sample failure points. This information is valuable to selective laser melting practitioners who seek to optimise the build strategy in order to minimise in-built defects.

In-situ X-ray nano-CT System for Polymer Electrolyte Fuel Cells under Operating Conditions

We developed two types of in-situ three-dimensional imaging systems on the basis of full-field transmission X-ray computed tomography (XCT) methods for polymer electrolyte fuel cells (PEFCs) under operating conditions at beamline BL36XU at SPring-8. One was for a wide field of view (more than 500 μm) to obtain the whole membrane electrode assembly (MEA) images, and the other was for nano spatial resolution (less than 100 nm) using a Fresnel zone plate as objective optics. We succeeded in in-situ three-dimensional visualization of an MEA in PEFC using both XCT measurement systems and show preliminary results.

Areal surface texture data extraction from X-ray computed tomography reconstructions of metal additively manufactured parts

Many applications that exploit the manufacturing flexibility of additive manufacturing (AM) produce surfaces, primarily internal features, which cannot be measured using conventional contact or line-of-sight optical methods. This paper evaluates the capability of a novel technique to extract areal surface data from micro-focus X-ray computed tomography (XCT) from AM components and then generate surface parameter data per ISO 25178-2. This non-destructive evaluation of internal features has potential advantages during AM product research and commercial production. The data extracted from XCT is compared with data extracted using a focus variation instrument. A reference dimensional artefact is included in all XCT measurements to evaluate XCT surface determination performance and dimensional scaling accuracy. Selected areal parameters generated using the extraction technique are compared, including Sa, for which the nominal difference between the value obtained using XCT and used the focus variation method was less than 2.5%.

Sensitivity of X-ray computed tomography measurements of a gas-solid flow to variations in acquisition parameters

Due to its high spatial resolution and non-invasive nature, X-ray computed tomography has become a popular method for determining the flow characteristics of multiphase flows. However, because many of the X-ray computed tomography systems used for non-destructive imaging of multiphase flows provide the operator wide leeway in the selection of imaging parameters, the potential exists for errors to be introduced into the measurements if the algorithms are sensitive to these changes. In this paper, a representative multiphase flow (specifically, a fluidized bed) is imaged with a wide range of X-ray tube electrical potentials, currents, and detector exposure times and reconstructed with a wide range of centers of rotation. The results of these tests show that while the raw CT intensities are sensitive to these parameter variations, once the measurements are calibrated to reference images (in this case through a void fraction calculation), the final results are insensitive to most changes. In the extreme cases where there is some sensitivity to the parameter changes, the causes and practical implications are discussed.

An investigation of internal flame structure in porous media combustion via X-ray Computed Tomography

X-ray Computed Tomography (XCT) measurements are performed to characterize the internal volumetric flame structure within a Porous Media Burner (PMB). X-ray attenuation measurements are obtained using a multi-zone silicon carbide PMB combusting a radiodense Kr/O2/N2/CH4 mixture designed to enhance X-ray contrast. Time-averaged tomographic reconstructions of the X-ray attenuation field are used to assess internal PMB flame structure. Several key internal physical phenomena are observed, including heat recirculation within the combustion region, spatial inhomogeneity within the reaction zone, and preheating of gas in the upstream porous section. Further, the theory of XCT measurements applied to combustion systems is developed and implemented to arrive at 3D implied temperature field measurements at high spatial resolution. Implied temperature results are shown to exhibit quantitative agreement with those of a known 1D volume-averaged model for porous media combustion as well as with standard thermocouple measurements. These results shed light on internal thermophysical processes within PMBs while demonstrating the significant potential of XCT in obtaining quantitative, spatially resolved field data within optically inaccessible combustion environments.

Sustained-release microsphere formulation containing an agrochemical by polyurethane polymerization during an agitation granulation process

In this report, a new solventless microencapsulation method by synthesizing polyurethane (PU) from polyol and isocyanate during an agglomeration process in a high-speed mixing apparatus was developed. Clothianidin (CTD), which is a neonicotinoid insecticide and highly effective against a wide variety of insect pests, was used as the model compound. The microencapsulated samples covered with PU (CTD microspheres) had a median diameter of <75μm and sustained-release properties. The CTD microspheres were analyzed by synchrotron X-ray computed tomography measurements. Multiple cores of CTD and other solid excipient were dispersed in PU. Although voids appeared in the CTD microspheres after CTD release, the spherical shape of the microspheres remained stable and no change in its framework was observed. The experimental release data were highly consistent with the Baker–Lonsdale model derived from drug release of spherical monolithic dispersions and consistent with the computed tomography measurements.

Surface modification of cellulose nanofibers with alkenyl succinic anhydride for high-density polyethylene reinforcement

Hydrophobic cellulose nanofibers (CNFs) were prepared by surface modification using alkenyl succinic anhydride (ASA). The hydrophobicity of CNFs was varied by changing the degree of substitution (DS) from 0 to 0.83. Modified CNFs were mixed with high-density polyethylene (HDPE) using a twin-screw extruder and the resulting composites were injection molded. The tensile properties initially improved with increasing DS up to ∼0.3–0.5, and then decreased with further substitution. The tensile strength and modulus of 10wt.% HDPE/CNF composites containing 8.8wt.% ASA (DS: 0.44) were 43.4MPa and 1.97GPa, respectively. These values were both almost 70% higher than those of composites containing unmodified CNF, and 100% and 86% higher, respectively, than those for pure HDPE. X-ray computed tomography measurements showed that CNFs modified with a DS of 0.44 were dispersed uniformly within the resin matrix, whilst unmodified CNFs and those modified with a DS of 0.77 agglomerated within the composites.

An X-Ray CT Validated Laboratory Measurement Method for Air Voids Distribution Over Depth in Asphalt Pavement: A Step Toward Simplified Oxidation Modeling

Recent efforts relating pavement failure to binder hardening have resulted in a pavement oxidation model. A key parameter, the diffusion depth, the ratio of binder volume to accessible air void surface area, is determined via X-ray computed tomography (CT). Toward an alternative determination, in this work volumetric techniques were employed to measure total air voids of core slices over the pavement depth. Because the 0.4-inch-thick slices are insufficient to meet standard method specimen size requirements, precision was evaluated and alternative maximum theoretical specific gravity methods were compared. A vacuum dryer increases efficiency without oxidizing the binder. Air void distributions compare favorably with X-ray CT measurements.

Procedure and reference standard to determine the structural resolution in coordinate metrology

A new procedure and reference standards for specifying the structural resolution in coordinate metrology traceable to the SI unit the metre are proposed. With the definition of the structural resolution, a significant gap will be closed to complete ‘acceptance and verification tests’ of the coordinate measuring systems (CMSs) which are specified in the ISO 10360 series dealing with tactile sensors, optical sensors, and x-ray computed tomography measurement systems (CTs). The proposed new procedure uses reference standards with circular rounded edges. The idea is to measure the radius of curvature on a calibrated round edge structure. From the deviation between the measured and the calibrated radius, an analogue Gaussian broadening of the measurement system is determined. This value is a well-defined and easy-to-apply measure to define the structural resolution for dimensional measurements. It is applicable to CMSs which are based on different sensing principles, e.g. tactile, optical and CT systems. On the other hand, it has a physical meaning similar to the classical optical point-spread function. It makes it possible to predict which smallest details the CMS is capable of measuring reliably for an arbitrary object shape. The theoretical background of the new procedure is given, an appropriate reference standard is described and comparative, quantitative measurement data of CMSs featuring different sensors are shown.

A new method of performance verification for x-ray computed tomography measurements

Through its ability to measure otherwise inaccessible internal structures, x-ray computed tomography (CT) has become a useful tool in the field of dimensional metrology. However, the lack of international standards for performance verification and the determination of metrological characteristics has so far prevented it from becoming a standardized measurement technology. This paper considers how a test object comprising a dismantleable tetrahedral assembly of four calibrated alumina spheres can be employed to assess the metrological performance of an industrial-type CT system. The measurement accuracy was characterized in terms of sphere size, separation and form errors. In all cases, sub-voxel accuracy was achieved, with errors as small as 1/10 of a voxel being obtained. Good measurement repeatability was demonstrated even upon dismantling and reconstructing the reference object. The tetrahedral test object offers a simple robust solution for the verification of metrological performance with great versatility and adaptability.

A Mechanical Aging Mechanism in Lithium-Ion Batteries

Cycling at different C-rates, as well as storage aging is performed with five different types of commercial 18650-type Lithium-ion cells. X-ray computed tomography measurements show strong deformations of the inner part of the jelly rolls for three different cell types without center pin after cycling at rates in the range of 3.6–16.6C. For cells cycled at 1C, this deformation is less pronounced, whereas it is totally absent for stored cells. The consequence on capacity loss of the cells was investigated by Post-Mortem analysis with unrolled electrodes, as well as scanning electron microscopy imaging with cross-sections of 18650 cells. In order to investigate the reason for the jelly roll deformation, we conducted in-operando temperature measurements in the middle of the jelly roll and at the cell surface during discharge with 16C for one selected cell type. Finally, the effect of a center pin on jelly roll deformation is tested by X-ray computed tomography imaging for two different cell types after cycling.

Correlating Gas Transport Parameters and X-Ray Computed Tomography Measurements in Porous Media

Gas transport parameters and X-ray computed tomography (CT) measurements in porous medium under controlled and identical conditions provide a useful methodology for studying the relationships among them, ultimately leading to a better understanding of subsurface gaseous transport and other soil physical processes. The objective of this study was to characterize the relationships between gas transport parameters and soil-pore geometry revealed by X-ray CT. Sands of different shapes with a mean particle diameter (d 50) ranging from 0.19 to 1.51 mm were used as porous media under both air-dried and partially saturated conditions. Gas transport parameters including gas dispersivity (α), diffusivity (D P/D 0), and permeability (k a) were measured using a unified measurement system (UMS). The 3DMA-Rock computational package was used for analysis of three-dimensional CT data. A strong linear relationship was found between α and tortuosity calculated from gas transport parameters ( ), indicating that gas dispersivity has a linear and inverse relationship with gas diffusivity. A linear relationship was also found between k a and d 50/T UMS 2, indicating a strong dependency of k a on mean particle size and direct correlation with gas diffusivity. Tortuosity (T MFX) and equivalent pore diameter (d eq.MFX) analyzed from microfocus X-ray CT increased linearly with increasing d50 for both Granusil and Accusand and further showing no effect of particle shape. The T UMS values showed reasonably good agreement with T MFX values. The k a showed a strong relationship when plotted against d eq.MFX/T MFX 2, indicating its strong dependency on pore size distribution and tortuosity of pore space.

Feature-based analysis for quality assessment of x-ray computed tomography measurements

This paper presents an approach to assess the quality of the data extracted with computed tomography (CT) measuring systems to perform geometrical evaluations. The approach consists in analyzing the error features introduced by the CT measuring system during the extraction operation. The analysis of the features is performed qualitatively (using graphical analysis tools) and/or quantitatively (by means of the root-mean-square deviation parameter of the error features). The approach was used to analyze four sets of measurements performed with an industrial x-ray cone beam CT measuring system. Three test parts were used in the experiments: a high accuracy manufacturing multi-wave standard, a calibrated step cylinder and a calibrated production part. The results demonstrate the usefulness of the approach to gain knowledge on CT measuring processes and improve the quality of CT geometrical evaluations. Advantages and limitations of the approach are discussed.

Non-destructive quantification of cereal roots in soil using high-resolution X-ray tomography

One key constraint to further understanding plant root development is the inability to observe root growth in situ due to the opaque nature of soil. Of the present non-destructive techniques, computed tomography (CT) is best able to capture the complexities of the edaphic environment. This study compared the accuracy and impact of X-ray CT measurement of in situ root systems with standard technology (soil core washing and WinRhizo analysis) in the context of treatments that differed in the vertical placement of phosphorus fertilizers within the soil profile. Although root lengths quantified using WinRhizo were 8% higher than that observed in the same plants using CT, measurements of root length by the two methodologies were highly correlated. Comparison of scanned and unscanned plants revealed no effect of repeated scanning on plant growth and CT was not able to detect any changes in roots between phosphorus treatments that was observed using WinRhizo. Overall, the CT technique was found to be fast, safe, and able to detect roots at high spatial resolutions. The potential drawbacks of CT relate to the software to digitally segment roots from soil and air, which will improve significantly as automated segmentation algorithms are developed. The combination of very fast scans and automated segmentation will allow CT methodology to realize its potential as a high-throughput technique for the quantification of roots in soils.