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Relever les défis de l'e-mobilité grâce à la tomographie à rayons X

par Adrien le 24 janv. 2022 à 13h56
The aerospace industry encounters several product quality problems because of the complexity of the parts used. From turbine blades, pitot tubes, cast parts to electronic sensors, the challenges are numerous and the industry is very demanding of improving part quality as security is crucial. For any shape or form of aerospace parts, X-ray CT is effective to check-in product quality, develop improved parts by taking into account security, waste reduction, environmentally friendly materials and most importantly inspecting without destroying the part.

X-ray CT offers fast & accurate inspections for aerospace components 

The major advantage of X-ray CT is the non-destructive approach. Indeed, for the aerospace industry, not needing to cut or modify a part in order to scan it, is very important feature to look into damages of the internal vent holes drilled inside a turbine blade for example. This aspect is critical in the aerospace industry since the parts are frequently very expensive thus destructive testing is not an option. It also enables component conformity before launching high-cost manufacturing processes. 
 
In comparison to other industrial sectors, aerospace incorporates most critical components. Be it landing gears, wing parts, cast parts… in order for these parts to perform safely and accurately X-ray CT provides a better understanding of aerospace applications. 
 
When inspecting complex aerospace components, X-ray CT offers shorter inspection time all while delivering accurate results. In addition, key aspects should not be overlooked when scanning a part with X-ray CT such as part size, geometry, part material and thickness. All these factors, have to be identified in order to see better and know more.
 
Scalable enough to operate in all kind of transportation from bikes and cars to trucks, buses and aircrafts, E-mobility components requires high-quality inspections at each step of the production life cycle. Manufacturers and OEMs of New Electric Vehicles and components such as FCEVs (Fuel Cell Electric Vehicles) and BEVs (Battery Electric Vehicles) need to reinvent themselves to adapt the production and assembly of critical electric vehicle components.
 
 
 
Scalable enough to operate in all kind of transportation from bikes and cars to trucks, buses and aircrafts, E-mobility components requires high-quality inspections at each step of the production life cycle. Manufacturers and OEMs of New Electric Vehicles and components such as FCEVs (Fuel Cell Electric Vehicles) and BEVs (Battery Electric Vehicles) need to reinvent themselves to adapt the production and assembly of critical electric vehicle components.
 
 
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EXTENT RANGE

The range refers to the distance an electric transportation system can travel before the battery needs to be recharge. FCEVs travel range is approximately the same than the one of a conventionnal combustion engine.
 
« Range anxiety » is no longer an issue with electric vehicles, as the charging infrastructure is growing fastly and the battery performances seriously grew in the last decade and is still under important R&D investments.
 

EXTENT RANGE

The range refers to the distance an electric transportation system can travel before the battery needs to be recharge. FCEVs travel range is approximately the same than the one of a conventionnal combustion engine.
 
« Range anxiety » is no longer an issue with electric vehicles, as the charging infrastructure is growing fastly and the battery performances seriously grew in the last decade and is still under important R&D investments.
 

Diverse results for diverse components 

 
For aerospace components, X-ray CT is used to find porosities in a 3D model of a part and provide information on the volumes of the various defects. The magnitude of flaws that may be identified is determined by the scan resolution, which is influenced by component size, geometry, and material, as mentioned above. There are also advanced scanning techniques and strategies that can be used to achieve higher resolution and greater image quality.
 
Further analyses can be executed with X-ray CT for aerospace components, such as : nominal to actual comparison (comparison between CAD nominal and CT scanned data to visualize deviations), wall thickness analyses (determination of material thickness to ensure mechanical strength and weight), fiber length and orientation (understand composite parts behavior used in the aerospace industry)…
 
Today, lithium-ion technology is set to be a standard for all-electric cars but while lithium-ion technology continues to improve, another battery technology seems to be the future of long travel range: solid-state batteries. This technology will increase both the storage capacity and the stability of the lithium-ion cells. A hydrogen fuel cell is another technology under high R&D investment.
 
X-ray Computed Tomography, especially X-ray Nano-tomography, also called the nano-CT play an important role in technology improvement. The use of laboratory microtomography has been validated for the analysis of the 3D microstructure in Li-ion cells with silicon electrodes, both for ex-situ analyses on an inert sample and for in situ experiments. This breakthrough enables laboratories and research centres to significantly accelerate their research and development. X-ray, as a non-destructive technology, give a way to inspect the external as well as internal structures of the electrodes, membranes or even a complete battery assembly without any consequence for the part.
 
Non-destructive technology, such as X-ray CT helps to speed up the development and implementation of new battery technologies. Thus, it contributes to reducing the cost of e-transportation technologies.
X-ray inspection can support each manufacturing step, from the development and optimization of new batteries to the final assembly line, to be sure to release a perfect stack.
 

NANO-CT – VERY HIGH-RESOLUTION FOR R&D APPLICATIONS

The best way to get a 3D rendering of H2 electrodes Nano-CT is very useful to image at very high resolution the 3D microstructure of the anode-electrolyte stack. The stack of proton-exchange membrane fuel cell (PEMFC), also known as polymer electrolyte membrane (PEM) fuels cells are where the electrochemical exchange of the reactant gases hydrogen and oxygen produces electricity. The µCT allows to observe defects inside the volume of these stacks and to show their evolution after the electrochemical reaction. A better understanding leads the way to better anticipation of defects.
 
X-ray nano-CT is a powerful method to get a 3D rendering at a very high resolution of the internal electrode microstructure. X-ray nano-tomography, also called nano-CT is a high-precision 3D rendering technology with sub-micron resolution. This concept is based on further development of existing micro-CT technology. Parts' structures at a cellular level become obvious when the spatial resolution improves. The term nano is used to highlight that the pixel sizes of the cross-sections are in the nanometer range, hence this new method is definitely called Nano-CT.
 
Nano-CT is of interest to scan at very high-resolution the 3D microstructure of anode-electrolyte in an electrochemical cell, as well as the reduction behavior. X-ray CT helps to understand and correct the manufacturing process and get the best returns with such cells.

NANO-CT – VERY HIGH-RESOLUTION FOR R&D APPLICATIONS

The best way to get a 3D rendering of H2 electrodes Nano-CT is very useful to image at very high resolution the 3D microstructure of the anode-electrolyte stack. The stack of proton-exchange membrane fuel cell (PEMFC), also known as polymer electrolyte membrane (PEM) fuels cells are where the electrochemical exchange of the reactant gases hydrogen and oxygen produces electricity. The µCT allows to observe defects inside the volume of these stacks and to show their evolution after the electrochemical reaction. A better understanding leads the way to better anticipation of defects.
 
X-ray nano-CT is a powerful method to get a 3D rendering at a very high resolution of the internal electrode microstructure. X-ray nano-tomography, also called nano-CT is a high-precision 3D rendering technology with sub-micron resolution. This concept is based on further development of existing micro-CT technology. Parts' structures at a cellular level become obvious when the spatial resolution improves. The term nano is used to highlight that the pixel sizes of the cross-sections are in the nanometer range, hence this new method is definitely called Nano-CT.
 
Nano-CT is of interest to scan at very high-resolution the 3D microstructure of anode-electrolyte in an electrochemical cell, as well as the reduction behavior. X-ray CT helps to understand and correct the manufacturing process and get the best returns with such cells.

NANO-CT – VERY HIGH-RESOLUTION FOR R&D APPLICATIONS

The best way to get a 3D rendering of H2 electrodes Nano-CT is very useful to image at very high resolution the 3D microstructure of the anode-electrolyte stack. The stack of proton-exchange membrane fuel cell (PEMFC), also known as polymer electrolyte membrane (PEM) fuels cells are where the electrochemical exchange of the reactant gases hydrogen and oxygen produces electricity. The µCT allows to observe defects inside the volume of these stacks and to show their evolution after the electrochemical reaction. A better understanding leads the way to better anticipation of defects.
 
X-ray nano-CT is a powerful method to get a 3D rendering at a very high resolution of the internal electrode microstructure. X-ray nano-tomography, also called nano-CT is a high-precision 3D rendering technology with sub-micron resolution. This concept is based on further development of existing micro-CT technology. Parts' structures at a cellular level become obvious when the spatial resolution improves. The term nano is used to highlight that the pixel sizes of the cross-sections are in the nanometer range, hence this new method is definitely called Nano-CT.
 
Nano-CT is of interest to scan at very high-resolution the 3D microstructure of anode-electrolyte in an electrochemical cell, as well as the reduction behavior. X-ray CT helps to understand and correct the manufacturing process and get the best returns with such cells.

Electric drivetrains

Electric powertrains are used in vehicles of all scales and exist in various configurations, from two driven wheels to four driven wheels, with motors between one and four as well as inverters and dynamometers. This complex assembly requires high accuracy and reliability to be able to provide all along the vehicle lifetime enough performance and meet the automotive manufacturer quality standards.
 
Components and sub-assemblies can be deeply inspected with X-ray CT to improve their efficiency and reliability.
 

Benefits of inspecting aerospace components with X-ray CT  

-   Non-destructive technique to avoid losing key information by cutting the parts 
 
-   X-ray CT is independent from the sample complexity and offers accurate results for any parts’ shape or form… 
 
-   Simple operations with fast scans save cost and time 
 
-   Early defect detection saves costs, ensures security, reduces waste, and warranty & reclaim issues 
 
-   Inspection for various aerospace components from cast parts to composites 
 
 
With more and more components having complex multi-material structures, finding out whether a part is reliable and achieves conformity restrictions is difficult with traditional testing methods. That is why for aerospace components, X-ray CT offers new inspection alternatives as an all-in-one non-destructive technique representing a 3D model with greater image quality – all while being fast, accurate and automatic.
 
 

Our innovative X-ray CT solutions are suitable for product development, turning ideas into reality from brainstorming to the actual product ready for manufacturing. User-driven improvements are the core of our business, offering you optimal solutions with the right and powerful interface & components.
For a better understanding of X-ray CT, check our blog or contact an expert at www.rx-solutions.com