Automotive Applications Division Features

Real-Time Microfocus X-Ray System
by Niamh Roche-Kelly, Ford Motor Co

Dunton Materials Technology Centre has commissioned the first 3D real time X-ray machine of its type to be used by Ford in Europe. It has replaced the traditional 'wet film' X-ray technique with a revolutionary system of the calibre that has applications in aerospace inspection technology.

The X-Tek real-time Microfocus equipment employs state of the art digital imaging to generate a live two dimensional image of any object placed in its metre-cube cabinet - test pieces may vary in size and technology from a microchip to an engine block casting.

Figure1. View inside the X-ray Cabinet

Test pieces are mounted on a motorised stage within the cabinet. The test piece may be manipulated through five degrees of freedom, enabling instant and optimum X-Ray examination. The system is capable of producing X-Rays up to 225 kV and up to 1 mA in intensity. Adjustments of camera and lens settings allow successful examination of a wide variety of material and component types. Figures 2 and 3 demonstrate how a variety of test pieces have been successfully X-Rayed in two dimensions.

Figure2. Crack in Spot Welded Steel

Figure3. Micro-Examination of Integrated Circuit

The system is equipped with a Computed Tomography, (CT), software package. A series of two-dimensional views are saved as the object is rotated through 360° . The CT software corrects the views for geometric distortion, outputting a series of attenuated image files. These attenuated image files are the building blocks for the volume file that is the final output. The volume file can be manipulated and rendered using Volume Graphics VMax Studio. This powerful software package includes tools to enable virtual sectioning of the object as well as measurement and location of internal flaws. Figure 4 below shows a rendering that was produced using this system.

Figure4. 3-D Rendering of a Cracked Rivet

The features of this X-Ray system include:

• Ability to examine thoroughly any object without contamination or interference
• Capable of X-Raying a very diverse range of materials and components
• Microfocus allows micro-examination of materials and components
• Real-time X-Ray imaging allows instant identification of apparent or potential structural flaws
• CT capability allows measurement and location of internal flaws

For more information about the Dunton Materials Technology Centre X-Ray System please contact nrocheke@ford.com.