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In the dynamic landscape of modern manufacturing, advancements in technology are constantly reshaping the way products are designed, produced, and inspected. As industries undergo transformative shifts such as the rise of electric vehicles (EVs) and additive manufacturing, the demand for innovative inspection solutions becomes paramount. One such breakthrough is the emergence of high-energy computed tomography (CT) technology, revolutionizing the inspection process by providing unparalleled detail and insight into complex assemblies.
Traditionally and due to wide availability, low-energy x-ray CT imaging (sub-600kV) is a common choice for industrial parts. Typically, capable of resolutions in the single-digit micron range, this granular detail can easily show fine features such as the individual layers in the latest batteries, but as the complexity and performance standards of modern assemblies continue to escalate, the limitations of traditional methods become increasingly apparent. The shift towards EVs, with their intricate battery modules and large electric motors, underscores the need for more sophisticated inspection capabilities. Large and complex assemblies, such as those found in an Electric Vehicle Battery, require a much higher energy source to penetrate its dense composition.
High-energy computed tomography is a versatile tool that offers comprehensive visibility across the entire manufacturing chain. Unlike low-energy X-ray CT imaging, which is commonly used for industrial parts and offers granular detail but struggles with thick and dense parts, high-energy CT overcomes these limitations. By utilizing a state-of-the-art 9MeV linear accelerator (LINAC), companies are able to achieve unprecedented levels of accuracy and clarity in their scans. The result is higher image quality with reduced noise, reduced scatter and beam hardening artifacts that, negatively impact the image fidelity of a part.
Also, Read About How Computed Tomography Transformed NDT
What sets high-energy CT apart from its predecessors?
The answer lies in its ability to penetrate dense materials with remarkable precision, revealing defects, voids, cracks, and other imperfections that may elude conventional inspection methods. From verifying proper assembly to identifying defects and verifying metrological data, high-energy CT offers a comprehensive solution for ensuring quality and safety across the supply chain.
Moreover, high-energy CT accelerates the product development cycle by streamlining processes from design to product release. By providing detailed insights early in the development phase, manufacturers can address potential issues proactively, saving both time and money. This enhanced speed and precision not only drive efficiency but also facilitate innovation, empowering manufacturers to push the boundaries of what's possible.
One of the key advantages of high-energy CT is its ability to inspect fully assembled components, such as large electric motors, battery modules, and transmissions, without the need for disassembly. This NDT approach not only saves time and resources but also minimizes the risk of damage to delicate components. In a single scan, materials ranging from iron and aluminum to steel, copper, plastics, and epoxy can be visualized with exceptional clarity, providing a comprehensive view of the entire assembly. Additionally, it is worthy to note that we are currently scanning battery modules up to 36 inches wide.
One example of how high energy CT can image complicated structures with very dissimilar material density components is discussed below.
This Hybrid Battery Module is 9.25” x 14.25” and has 35 individual cells to create 120 Volts. The case of the module is made of Stainless Steel and the longest attenuation path is around 9 inches. With 3, 6, and 9 MeV it is possible to not only CT scan individual parts but focus on full assemblies with multiple material densities, and very large attenuative applications.
Utilizing a 9MeV linear accelerator (LINAC) with the increase of penetration capabilities, coupled with advanced technique development procedures, scatter reduction techniques, and backend CT Reconstruction algorithms there is a significant reduction in scatter, streaking, and beam hardening artifacts generally found on multi-material applications. This allows for more accurate and better quality on any assembly with both low and high density materials.
These techniques coupled with this technology for high energy scanning of full assemblies allow for step-by-step slices through this battery module. We see the internal cooling channels that help this battery operate at full capacity without overheating or failure. We can follow the inlet and outlet for the coolant lines from external to internal pathways. As in any pathway the rate of flow is always an important factor. We have captured some basic dimensions of the coolant pathways as well as the openings for the battery housings.
2D slices show the detail of the module. We can see high and low density materials all in one image. It can also be noted that there is little to no artifacts that are generally found in multi-material CT scans.
The pure latitude of materials we can accurately represent with High Energy. You can see here the plastic battery case along with steel and other higher density materials. Notice there are not streaking artifacts from the high density into the low density.
The advantage of efficiency of not having to disassemble modules is apparent in this example. The High-Energy CT Scan, when coupled with advanced software and experienced CT subject matter experts, allows for clarity and accuracy without disassembly. The range of materials in the whole module. We can see here in this one image everything from lead or tin solder, PCB board substrate, copper bus’s, plastic battery case’s, steel screws, steel outer module case, lithium-ion battery cells, copper wires, and among other materials.
The power of being able to inspect a large EV motor without disassembly. As we look at slices through this 11” x 14” assembly containing materials with vastly different densities we are able to identify a missing component without disassembling the complex module. This efficiency and accuracy was not achievable before high-energy CT.
The benefits of high-energy CT extend beyond the manufacturing floor, offering invaluable insights for research and development, first article inspection, failure analysis, and production inspection. By harnessing the power of 3D imaging, manufacturers can uncover hidden flaws, optimize designs, and ensure compliance with stringent quality standards. While companies work to streamline their processes for new materials and component manufacturing, design optimization can be worked upon at high energy CT facilities away from the manufacturing floor with subject matter experts to help develop and refine techniques for specific assemblies, components, and products. This kind of collaborative process helps to further the efficiency of the R&D teams and processes.
Explore More About High Energy CT Systems
As technology continues to evolve, so too will the capabilities of high-energy CT. With ongoing advancements in imaging technology and data analysis techniques, the future of manufacturing inspection looks brighter than ever. By embracing innovation and investing in state-of-the-art solutions like high-energy CT, manufacturers can stay ahead of the curve and unlock new possibilities in quality assurance and product development.
In conclusion, high-energy computed tomography represents a quantum leap forward in the field of manufacturing inspection. With its ability to penetrate dense materials, image materials of various densities without disassembly of modules, detect hidden defects, and provide comprehensive visibility across the entire production chain; high-energy CT is poised to revolutionize the way products are designed, produced, and inspected. As industries continue to evolve and embrace new technologies, the role of high-energy CT will only become more indispensable, driving innovation, efficiency, and quality in manufacturing processes worldwide.
About North Star Imaging
North Star Imaging (NSI) provides configurable 2D X-ray and 3D CT solutions to the manufacturing, non-destructive testing, and defense marketplace. Configuring solutions for industry using their systems, scanning services, training, and repair and maintenance NSI improves the efficiency and quality of companies across the globe. NSI is ISO 9001:2015 certified, ISO 14001:2015 certified, ITAR registered/compliant, ASTM compliant, DOD 4145.26-M Compliant, and has ASNT & NAS 410 certified employees.
NSI's flagship Orlando location boasts this cutting-edge technology, enabling the efficient scanning of large, high-density parts and assemblies crucial to industries like automotive, aerospace, and defense. With a total of 16 state-of-the-art X-ray CT scanners around the U.S. in MN, CA, FL, MA as well as in the UK, NSI is at the forefront of delivering advanced inspection solutions to manufacturers worldwide.
References:
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