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X-Ray Computed Tomography of Full-Scale Castings
Interim rept. Mar-Dec 1990
BOEING DEFENSE AND SPACE GROUP SEATTLE WA
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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 aircraftaerospace 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.
APPROVED FOR PUBLIC RELEASE