Industrial CT- and X-Ray Solutions

To examine things, to get to the bottom of them, to get to their core – this desire has always driven science, research, and development. X-ray technology from ZEISS has provided perfect insights for years in these and other areas. When it comes to quality and process control, it reveals what would otherwise remain hidden from even the most watchful of eyes – without  destroying the part.

ZEISS METROTOM

Measure and inspect inner and outer structures non-destructively

ZEISS VoluMax

CT for automated 3D inspection and metrology

SRE MAX from Bosello

Fast destruction-free 2D scans of safety-relevant parts

ZEISS Xradia

3D X-ray microscopy for sub-micron imaging of intact samples

Technology with benefits

It is self-evident that X-ray technology makes hidden things visible. However, the fact that this opens up completely new possibilities in quality assurance and results in significant added value for the customer is less well-known. Let us explain this to you!

  • One scan – full certainty: Measure, analyze, and inspect hidden defects and inner structures that cannot be detected with coordinate measuring machines.
  • Thanks to X-ray, you can cut parts non-destructively and look inside!
  • No more complex fixturing. This saves time and money!
  • By scanning all internal and external structures with computed tomography systems (CT), parts can be reproduced even if no CAD model is available.

An investment that pays off

Amortized after 12 months

A thorough inspection right after the casting process is important when producing aluminum castings. Companies face high costs if defects are not detected until later in production. This is why investing in an automated inline solution for quality assurance pays off in less than 12 months.

Time savings of 30 to 70%

Producing tools and molds is very costly, because it usually requires several iteration loops until tools are optimally adjusted and molds are perfectly formed. This process can be improved and shortened by 30-70% by capturing all structures in a 3D model with CT and the software ZEISS Reverse Engineering (ZRE). In this way, costs of tools can be significantly reduced.

Reduced setup times by up to 80%

Setup time is lost time – which is why it is so important to reduce the time between scans. The setup table ZEISS FixAssist® CT will help you maximize the use of your CT and make your quality assurance processes more efficient. This accessory can reduce setup times by up to 80%. Even better: Your investment will pay for itself in less than four months!

Reveal the hidden secrets of your part

X-ray technology provides completely new insights into the invisible. You can capture, analyze, measure, and inspect internal structures quickly and non-destructively.

Cavities

Vacuum build-up during the cooling process can greatly reduce the quality of the part. If cavities are not detected, this may lead to cracks in the parts under load.

Pores

Pores may form if the temperature is not ideal during casting. Depending on the size, position, and number of air inclusions, this defect weakens the material and may cause functional impairments.

Residuals

Grit in the gears? This will not happen to you, if you examine your parts with X-ray technology. Residuals such as sand from casting molds or metal powder for 3D printing can be detected quickly and easily in just one scan.

Inclusions

Inclusions of slag, oxides, sand, steel or tungsten can be a problem during further processing or cause cracks.

Warpage

All of the parts are finished, but they do not fit together, because they are warped? It is better to measure the internal and  external structures during production and intervene early in the manufacturing process. This cuts costs.

Inclusions

What was initially just a small crack can develop into a major problem under stress. Cracks in the material can have an enormous effect on the stability of the part. This can become a risk, especially with safety-relevant components.

Applications for CT and X-Ray Systems

Take a close look at every detail

Automotive, aerospace, medical technology, electronics, consumer goods – each industry has its own manufacturing processes, along with different potential defects that are normally hidden from the eye. X-raying parts opens up completely new potential applications – from inspecting internal defects and the dimensional measuring of internal structures to structural material analysis.

Metrology

  • Nominal/actual comparison
    Deviations from the CAD model or master part are visualized in a false color comparison.
  • Dimensional control
    Thanks to computed tomography, the dimensional accuracy of complex internal and external features can be checked in just one scan.
  • Wall thickness analysis
    A color-coded representation shows the wall thickness of internal structures.
  • Tool & process optimization
    A comprehensive inspection of the part provides meaningful information on the condition of the tools and the production process.
  • Development & Reverse Engineering
    You can easily create CAD models from 3D volume data – significantly accelerating product development and reverse engineering processes.

Inspection

  • Defect analysis
    You can detect cavities, pores, cracks and other defects quickly and easily.
  • Assembly control
    Assembled parts are checked for function and fit.
  • Joining technology control
    In just one scan you can see whether welded, soldered, glued or riveted joints are really flawless.
  • Electronic testing
    Defects quickly become visible when electronic parts, e.g. circuit boards or batteries, are X-rayed.

Analysis

  • Structural analysis
    A 3D structure characterization provides important insights thanks to high-resolution X-ray microscopy.
  • In-situ & 4D analysis
    With in-situ and 4D analyses, the behavior of materials under external influences and over time can be analyzed.
  • Roughness analysis
    Surface roughness can be analyzed for both external and internal structures.
  • Fiber composite analysis
    Analyzing fiber composites visualizes the 3D distribution and orientation of different elements within a composite material.
  • Analysis of grain size & distribution
    Grain size and distribution are decisive factors in determining the hardness and strength. This is why it is important to analyze them.

More Applications for X-ray Systems

Quality assurance without destructive testing

Example: fit accuracy of a plastic screw-cap

Random sampling in plastic moulding

Example: button for a seat belt buckle

Non-destructive inspection

Example: connector housing