X-Ray Computed Tomography of Full-Scale Castings
Abstract
Computed Tomography (CT) has been investigated for its potential to evaluate full-scale castings. Currently, casting manufacturers suffer from a number of shortfalls in inspection which affect the use of castings in the aircraft/aerospace industry. An earlier task assignment indicated that CT has superior sensitivity to casting defects in small test coupons than conventional film radiography. But, as casting size and geometric complexity is increased, the CT sensitivity and measurement accuracy are reduced. In this task, CT testing was conducted to quantify the detection sensitivity and measurement accuracies possible on full-scale castings and to establish the CT system performance factors necessary for defect detection. The identification of cost- effective applications for CT in the casting industry was also sought. This effort has identified four areas in which CT can be cost-effectively utilized in casting manufacturing. These areas are new product development, early screening, manufacturing of complex geometries and critical region inspection. A CT system may be cost effective if the foundry has: (1) a large production rate (> $100M/ year), (2) a high percentage of parts requiring internal dimensional measurements, (3) a large percentage of complex aerospace castings, or (4) material review board (MRD) authority for engineering buy-off of rejected castings. X-Ray, Computed Tomography (CT), Casting, Manufacturing, Defects, Voids, Design, Sensitivity, Product Development, Finite Element Analysis.
Document Details
- Document Type
- Technical Report
- Publication Date
- Oct 31, 1991
- Accession Number
- ADA247101
Entities
People
- Gary E. Georgeson
- Richard H. Bossi
Organizations
- Boeing Defense, Space & Security