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Fully-Automated 3D Metrology and Defect Analysis with High-Resolution 300 kV Microfocus Computed Tomography

With industrial X-ray computed tomography (CT), even low-contrast defects in cast parts, such as cracks, pores and blowholes, can be localized and measured in three dimensions. Analysis of the defects can be performed using either multi-positional 2D cross-section planes or the 3D volume view. Additionally, 3D metrology with CT becomes more and more an effective tool for many tasks in production process monitoring such as the manufacture of plastics, metal castings and precision components like injection nozzles. Particularly complex part geometries with inaccessible or hidden features can be measured with CT in many cases faster than with conventional Coordinate Measuring Machines (CMMs). This paper shows failure analysis and metrology tasks automatically performed on a new GE CT system optimized for stable and reproducible CT scans and equipped with a new unipolar 300 kV microfocus X-ray tube, new CT software for fully automated data acquisition, volume processing and 3D evaluation capability.