What you want is a successful scan, inspection, and analysis of your part to make a qualified decision within a shorter time frame to maximize profits.
Our process begins by contacting our experienced staff to discuss your project's 3D internal part inspection requirements. A feasibility study is then conducted on each and every project to ensure we are able to meet your inspection requirements while providing the most cost effective solution. Because we run multiple CT systems of varying energies and configurations, we are able to pair each project with the proper CT system for the job. This allows us to offer the best results in the industry at an extremely competitive price. Once parts arrive at our facility, they are logged into our system and scheduled for scanning. After scanning. we then begin analyzing the data for one or more preselected analysis listed below. Upon completion of the analysis, a web conference is hosted by one of our experienced analyst to ensure we are meeting the project requirements and the customer is able to see the results they are looking for. At this time, we also educate our customer on how to use a supplied freeware viewing software. This viewing software allows each client to be in control of the data and review the results even further at the customer’s facility. Results and parts are then delivered back to the client along with a copy of the freeware software.
Types of analysis we provide using Industrial CT Scanning...
An analysis performed by CT scanning one part and evaluating internal porosity or inclusions within a part.
Part to CAD Comparison
An analysis performed by CT scanning one part and comparing it to a supplied CAD model
Part to Part Comparison
An analysis performed by CT scanning two parts and comparing both CT datasets to each other.
An analysis performed by CT scanning one part and taking virtual cross sectional slices through a CT dataset
Development of a CAD file with internal and external geometry from a CT dataset
Wall Thickness Analysis
An analysis performed by CT scanning one part and evaluating inconsistencies of wall thickness within a part
An analysis performed by CT scanning one part and evaluating single or multiple fibers within a part
Development of a measurement plan from a GD&T part print to automatically calculate multiple dimensions simultaneously from a CT dataset
An analysis performed by CT scanning one part, evaluating porosity in a predetermined cross sectional slice within a CT dataset, and comparing it to a specified maximum percentage of porosity for that area
Frequently Asked Questions
- What is an x-ray?
A digital x-ray is performed by energizing photons through a source and capturing the results on a flat panel or line detector array after they pass through an object. Higher density objects are shown lighter and while lower density objects are shown darker.
X-ray sources come in a variety of configurations and power ranges. When an x-ray is taken, insufficient power results in photons bouncing off the parts surface and too much power results in x-rays passing through a part too easy. Both instances can cause faulty errors in the results or inaccurate data.
Digital X-ray resolution is derived by the pixel pitch on the digital detector. Magnification can also be used to increase the recorded resolution of an x-ray. An easy analogy of both pixel pitch and magnification are shown in the picture to the right.
- What is Computed Tomography (CT)?
Tomography is the process of taking several hundred to several thousand 2D x- ray images over 360 degrees and reconstructing them into 3D. The video to the right shows how the most common type of computed tomography, cone beam, works in industry today.
The picture below the video shows how the second most common type of computed tomography, fan/line beam, systems operate.
• Inspection and analysis costs from first article to production are significantly reduced
• Design requirements for both internal and external components are validated quickly and accurately
• Development costs are reduced in creating the first CAD model
• Delicate and fragile parts can be scanned in a Free State environment without fixtures or applying external forces
• Product quality is improved to reduce the risk of recalls
• Internal accuracy can be guaranteed by using proper CT systems and scanning techniques
• Internal complex part features can be precisely measured without destructive testing
- Most Common Uses for Industrial CT
• Preproduction Inspection
• Failure Analysis
• Production Inspection for high valued parts
• Lot inspection for quarantined or suspect parts
What types of Industrial CT machines does JG&A Metrology Center use?
The company utilizes multiple cone beam, line/fan beam, and planar CT systems capable of generating energies from 10Kev to 3.5 Mev.
What are our size limitations?
With our capabilities we can x-ray most parts ranging micro parts as small as .5mm in length to parts as large as 660mm in diameter x 1m in length.
How many parts can we inspect?
We are pleased to work with clients that only have one part all the way up to clients who require several thousand parts needing inspection.
- Frequently Asked Questions
Are Industrial CT systems portable?
No. Industrial CT systems are not portable due to their size and weight.
What is the accuracy of the scan results?
The scan accuracy varies widely from the machine being used, type of detector, resolution of the detector, type of part, and size of part. However, as a guideline, accuracy’s range between 1 micron to 150 micron. For projects requiring accuracy’s tighter than 5 micron, very detailed scan calibration is required. During the quoting phase, scan accuracy can be provided to the customer prior to any scanning.
What is the resolution of the scan?
The scan resolution varies widely from the machine being used, resolution of the detector, spot size of the source, and size of scanning window. However as a guideline, scan resolution ranges between 1 micron to 150 micron. During the quoting phase, scan resolution can be provided to the customer prior to any scanning.
Are our systems calibrated?
Yes. Every system is calibrated on a regular basis for mechanical movement. Due to the number of processing parameters associated with Industrial CT, every scan is also calibrated to ensure the highest accuracy for every project.
How are the parts fixtured during the scan?
Since parts are scanned in a Free State environment and reference planes are not needed for the scan itself, most fixturing is performed with Styrofoam. For multiple parts requiring a highly repeatable setup, robust fixtures are developed on a case by case basis.
Can multiple parts be scanned at the same time?
Yes. Depending on the customers objective and the resolution required to effectively image out the results, JG&A always attempts to scan multiple parts at once to reduce the overall cost of the project.
Does the part heat up?
Does the scan leave residual radiation in the part?
Can a part be CT scanned while it is in motion?
No. Every part within the scan must remain static or non-moving for the entire length of the scan.
Can a part be scanned hot or cold?
Yes. Custom scanning processes and fixtures can be developed between the customer and our analysts to obtain a desired environmental temperature.
How long does a scan take?
The average scan time for our cone beam systems can typically take 45 minutes and the average scan time for line beam system typically ranges from 2 to 20 hours.
In what file format are the initial results captured?
How large are the CT dataset files?
CT datasets typically range from 500MB to 80GB in size
How are the results provided to the customer.
For all analysis except for reverse engineering, results are supplied to the customer using the provided freeware software (show link to page). For reverse engineering, results are provided in the following formats, click here
Every projects objective is highly unique and requires a specific scan resolution matched with the desired type of analysis. Because we attempt to pair the proper CT system with every project to ensure the most cost effective solution and best results possible, each project is quoted separately. To obtain a free quote, please contact us today!
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