How High-Energy Industrial CT Scanning Powers Inspection of Dense Parts

Engineers in the fields of aerospace, defense, automotive, or medical can face challenges with large or dense part inspection. Imagine trying to see through a thick, titanium component with traditional scanning methods. Most systems would fall short of being able to penetrate the denser material. This is where engaging with a leading high-energy CT scanning lab like Nel PreTech Corporation becomes a necessity for interrogating dense materials. Our lab uses computed tomography scanning machines from 130kV (Kilovoltage) to 450kV, and higher-energy X-rays in the MeV (Mega-electron-volt) range, capable of handling challenging materials and geometries.

What is High-Energy CT Scanning?

High-energy X-ray CT is used to create a digital 3D model of the internal structure of dense parts or components. Density is defined as mass per unit volume. Materials are considered dense if they have a high mass relative to their volume. During industrial CT scanning, dense materials will significantly attenuate X-rays. High-energy CT produces photons with a higher maximum energy, resulting in better penetration power than standard industrial CT. High-energy industrial radiology is used to inspect pieces made of nickel-based alloys, tungsten alloys, steel, or other high-density materials. Noise, scattered radiation, and beam-hardening artifacts can cause fidelity issues and should be considered when selecting the proper energy level in computed tomography. MeV systems and other advanced techniques can be used to achieve better signal penetration and improved imaging on thicker, denser parts.

Applications: Industries and Use Cases

• Aerospace: Inspection of turbine blades, engine housings, or combustion components for defects or dimensional inspection.
  
  
• Automotive/EV: High-density battery housings, cast iron parts, and transmission components.
  
  
• Medical devices: Dense implants (orthopedic, dental, cardiovascular devices).
  
  
• Defense/Heavy Machinery: Armor plating, ballistics testing, and industrial equipment parts.

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Technical Capabilities: What Engineers Should Know

Engineers should evaluate key specifications when considering high-energy industrial CT scanning. The list below highlights core technical capabilities and serves as a starting point for discussions with an inspection lab. While not exhaustive, these factors are essential to review with a qualified X-ray inspection provider to ensure accurate, reliable results for dense or complex parts.

• Maximum object size and penetration: Dependent on material density.
• Partial scans: Used to optimize the area of interest (AOI) for desired resolution requirements. This is sometimes used to scan only the critical area in high resolution because the part is too large. 
• CT scan resolution: Some higher-energy CT machines, like a 450kV, can achieve 35-50µm spatial resolution. However, factors like focal spot size can affect the reconstructed image. To learn more about it, watch this video on the CT scanning process and resolution.
• Accuracy: Voxel size, detector type, calibration, scatter reduction software, environment, object size, and density can all affect accuracy. Low tens of microns is a typical range of accuracy on high-energy CT scanners, but it can vary significantly. Click to learn more about accuracy and measurement uncertainty.

Limitations & Considerations of High-Energy CT Scanning

There is often a resolution sacrifice when photons are made energetic enough to penetrate dense or thick-walled materials. Image fidelity can be challenged due to scattering and beam hardening artifacts. Beam hardening can cause a darker center and brighter edges on the resulting imaging. Scattering can leave a hazy appearance surrounding the part. High-energy CT scans are not usually a good candidate for metrology, either. Lower kV machines are better at providing higher resolution, refined imaging. For a more detailed explanation of the resolution capabilities of high-energy CT scanning, read this article on 450kV industrial CT scanning. See the differences between low-res and high-res CT scanning in this informative comparison article. Consider consulting a lab with industrial CT scanning accreditation. Nel PreTech is accredited to ISO/IEC 17025 by A2LA, providing customers with the documentation and confidence to make informed decisions about our industrial CT lab services.

Case Study

This Springfield Armory 1911 Series Handgun was scanned at an 80-micron resolution using a 450kV industrial computed tomography (CT) machine. It allows for visualization of precise detail and material characterization. This is a powerful example of how higher energy can influence the scan results of denser materials like steel:

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How Nel PreTech Helps

High-energy CT scanning opens the door to non-destructive, accurate inspection of dense, large components. If you work with Nel PreTech, you can expect high-level engagement from CT experts who understand how X-rays interact with every material. With advanced CT technology created by leaders in precision inspection equipment, trustworthy accreditation, and experienced staff, you will detect defects or validate material performance with ease. 

Contact us today for a consultation or request a free quote for high-energy CT scanning.