Industrial metrological computed tomography system

• Subject Area: Production Technology
• Term: Funded in 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 519769523

Non-destructive testing and measuring of components and materials using X-ray computed tomography (CT) is increasingly prevalent in industry. This is due to the CT method's numerous advantages as well as its versatility. In comparison to traditional tactile or optical assessment methods, a single CT scan can be utilized to analyze not just the outside shape, but also the interior of a component or difficult-to-access structures in three dimensions. Furthermore, not only metrological measurements but also material analyses are possible. However, CT technology's performance is offset by its complexity, which must be understood and regulated. If its potential is better realized, new areas of use in new industries or for other applications will emerge. For almost ten years, the wbk has been involved in CT research and implementation. In addition to the development of user support systems, the technology is used in the institute's key research areas - lightweight construction, electromobility, additive manufacturing, Industry 4.0, and sustainable production - for testing non-destructive component analysis, component measurement, and as a high-precision reference measurement technique. To date, the work has been done using a Metrotom 800 CT system, which is now 9 years old and is specifically intended for the inspection of lightweight plastic components with diameters up to 150 mm. With this approach, research activities involving components and materials of higher density and size are either impossible or only possible to a limited extent. The deficiencies impede projects requiring the detection of pores, such as those in the field of additive manufacturing of metallic components. Furthermore, this has an impact on common challenges in the field of electromobility, such as battery and fuel cell manufacture, as well as the development of electric motors. Activities in these areas range from defect detection to determining anode overhang in battery cells to investigating windings in electric motors. Further, this limits research in the field of user support. For example, the results achieved can only be used for components that meet the strict size and material restrictions. Sustainable production, particularly remanufacturing, is an important research field for the institute, in which deteriorating old products with significant variance in terms of flaws are automatically inspected, deconstructed, refurbished, and reused. The required circular factory will be developed and built as part of a collaborative research center. However, the current CT system cannot match the resulting needs for such a production, especially given the variety of variants and the required store floor integration. Based on these circumstances, a new industrial metrological CT system will be purchased that will match the institute's standards for accuracy, resolving power, and radiographic performance, as well as the institute's different research questions.

• DFG Programme: Major Research Instrumentation
• Major Instrumentation: Industrielles metrologisches Computertomographie-System
• Instrumentation Group: 4070 Spezielle Röntgengeräte für Materialanalyse, Strukturforschung und Werkstoff-Bestrahlung
• Applicant Institution: Karlsruher Institut für Technologie
• Leader: Professorin Dr.-Ing. Gisela Lanza