Scanning with Parallel Geometry (1st Generation)

Digital Industrial Radiology

for
Computed Tomography (CT)

Two-dimensional
computed tomography
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Digital Radiology
Computed Level II
Tomography Computed Tomography

Scanning with Parallel Geometry (1st Generation) Scanning With Fan Beam Geometry (2nd Generation)
Absorption profile
Schwächungsprofil
()

90°

Detector Scanning
Detektor Abtastweg
lane
135°
45°

y
Projection
Projektions-
angle
 winkel
Object µ(x,y)
Objekt µ(x,y) x

Two-dimensional
computed tomography X-ray
Röntgen-
tube
röhre

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Computed Tomography Computed Tomography

CT-Scanner of 2nd Generation Scanning with Cone Beam Geometry (3rd Generation)

Volume
Volumen

Rotation axis
Drehachse z
Volume
Cone beam
Fächerstrahl
Measurement by Object
Objekt

combination of Source
Quelle
translation and
rotation (slice) x

Three-dimensional
computed tomography Detektor
Detector

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3rd generation

Computed Tomography Computed Tomography

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 Computed Tomography (CT) of 3rd Generation Computed Tomography Spiral-CT

Spiral-CT reduces the

CT is the best method
Feldkamp-Artefacts.
for 3D-testing of
objects. It is well established in
medical applications, but
CT is suitable for gets adapted to NDT.
inspection of objects
in the laboratory.

CT needs 100-1000
projections and
requires high
measurement time.

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Computed Tomography Computed Tomography

Industrial CT of 3rd Generation By GE MCS (Phoenix) Specialized CT Equipment at BAM

LINAC
Synchrotron

10-100 kV
0-80 keV
1.5-200 µm
0.6-11 µm
20 mm
25 mm

450 kV - 12 MV
> 500 µm
Energy 30-225 kV 1000 mm
Spatial resolution 5-200 µm 30-300 kV
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Object diameter 300 mm 10-400 µm
600 mm
Computed Tomography

Computed Tomographie (CT) 3rd Generation Essential conditions for a CT Measurement

CT is the best method

For any CT application the set-ups should avoid the over-
for 3D-testing of exposure of the detector in any part of all projections (and
objects. the free beam). This is achieved by pre-filters (Cu or Sn) at
the tube port.
CT is suitable for
inspection of objects The X–ray energy has to be chosen sufficient high to
in the laboratory. penetrate the specimen in any direction in all projections.
This is adjusted at the object position with the longest
CT needs 100-1000 pathway through the specimen.
projections and
requires high Both conditions ensure that the first CT reconstruction step
measurement time. (log of gray value ratios for conversion into penetrated path
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length) will not introduce any artefacts! 12

Computed Tomography Computed Tomography

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 Accomplishing of a CT Measurement Noise
In terms of the required computing efforts the CT is
tremendously laborious. The data acquisition od followed by Extension of the integration time for each projection or
a reconstruction step (2D projection images into 3D voxel increasing the tube current will reduce the image noise.
set).
The noise within the reconstruction can also be decreased
The computational effort is determined by the number of by increasing the number of angular steps when exposing,
projections (z) * projection size (x*y) for a measurement. i.e. collecting more projections per scan.
The more projections are acquired the more computational
effort will be required rewarded by an improved resolution:
Detector size: Raw data per Measurement!
1k x 1k pixels a 2 byte, 1k projections = 2 Gbyte
2k x 2k pixels a 2 byte, 2k projections = 16 GByte 13 14

Computed Tomography Computed Tomography

Reconstruction Artefacts Reasons of Artefacts

Geometric Errors
The object diameter is larger than the reconstructed one, i.e.
They appear as erroneous the objects protrudes laterally from the fan beam. The
attenuation coefficients resulting artefacts may impede a meaningful reconstruction.
calculated locally where other
coefficients exist in reality. The axis of rotation may be incorrect, the object may be
shifted during the measurement, the adjustment of the axis
Cause: Dynamic range of CT
scanner exceeded.
may be wrong. As a consequence, additional features appear,
the edges become unsharp.

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Computed Tomography Computed Tomography

Reasons of Artefacts Reasons of Artefacts

Overexposure of the detector: Scattered Radiation:

Washy edges, missing object details within thin layer Secondary radiation generated by scattering within the object
structures or also in the manipulator leading to image information in the
detector without any relation to the specimen. The scatter
Incorrect detector compensation:
radiation reduces the image contrast and causes washy
Circular artefact
edges.
Incomplete penetration:
Beam Hardening:
Hazy appearance and erroneous reconstruction of absorption
During penetration the energy spectrum of the X-ray beam is
coefficients, incomplete object features
altered in a non-linear manner. This makes the relationship
between the measured grey value and material layer
thickness not interpretable. This results in overemphasised
edge structures and in wrong reconstructions of absorption
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coefficients. 18

Computed Tomography Computed Tomography

3
 Reconstruction with and without beam hardening Reconstruction with fan beam collimation
correction

without beam hardening with beam hardening

correction correction
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Computed Tomography Computed Tomography

Cut Through the YZ-Plane of the Tomography of an Cut Through the XY-Plane of the Tomography of a Component
Al Casting

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Computed Tomography Computed Tomography

3D-Visualisation of a Tomography with a Virtually Cut Section Application Areas of industrial CT

Flaw analysis
- Characterisation of cavities, pores, inclusions of
impurities, shape of cracks
- Integrity analysis
- Inspection of material transitions and interconnections

Determination of dimensions
- Determination of wall thicknesses
- nominal/actual value comparison with CAD-data.

Reverse Engineering
- Reconstruction of CAD-data from existing
23 components 24

Computed Tomography Computed Tomography

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 Reverse Engineering of Al Cylinder Head Exact Measurement of Inner Dimensions in Industry

isosurface
representation

triangulation

Goebbels, BAM-I.4 25 26

Computed Tomography Computed Tomography

3D-Volume Reconstruction, Visualization and

Smart Manufacturing / Smart NDT Measurement by a Specialized Software

• monitoring the process

• automated defect recognition
• defect characterization and sizing
• increased sustainability
• smart networking of production and NDT
• in-line / at-line
Smart Radiography 4.0
German Company,
• Product obtains an “artificial Intelligence” (digital soul) Example: founded 1997,
high-speed automatic helical inline CT
• Communication required with
GE S&IT, Volkswagen
to develop
▪ Marketing → Costs of NDT vs. cost of product / testing time
special industrial
Oliver BRUNKE, Ferdinand HANSEN, Ingo
STUKE, Franz Friedrich BUTZ
▪ NDT-Manager → Selection of NDT method, testing device, testing
procedure CT software,
▪ Feedback to production, sorting
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today Market leader 28

Computed Tomography Computed Tomography