In 2018, a certain aerospace engine suffered a direct loss of over 100 million yuan due to the fracture of a. 2mm crack. The significance of industrial X-ray detection is to capture dangers that cannot be detected by the naked eye before disasters occur. Whether it is the burrs on the electrode plates of new energy vehicle batteries or the fiber breakage of aviation composite materials, X-ray technology has always been the “invisible guardian” of industrial safety.
The three major stages of industrial X-ray detection
**Bronze level: 2D DR detection * * 2D DR detection is a fundamental application of industrial X-rays, suitable for rapid screening of obvious defects. For example, the alignment detection of lithium battery electrodes can complete imaging within seconds. For pores or inclusions in steel parts, the detection rate of defects with a diameter of ≥. 5mm exceeds 90%, but crack detection requires adjusting the angle: only when the crack direction is at an angle of 15 °~45 ° with the beam can clear imaging be achieved. In practical operation, technicians often need to adjust the position of the workpiece based on experience, and even need to take multiple photos to locate the problem, which is both a threshold and a compulsory course for beginners.
**Gold and King Rank: CT and Dynamic Imaging * * Computed Tomography (CT) improves detection accuracy to the micrometer level through 3D reconstruction technology. The voxel accuracy of ordinary CT is 50 μ m, which is sufficient to detect shrinkage porosity in castings, while the. 5 μ m accuracy of micro nano CT can capture subtle cracks in semiconductor silicon wafers. Higher order dynamic real-time imaging has achieved “X-ray live streaming” with a frame rate of up to 30fps. For example, in online quality inspection of automotive welding points, the system can judge the quality within 200 milliseconds and directly link with the production line for sorting. This technological breakthrough not only improves efficiency, but also makes real-time monitoring possible
Industry Testing Red Book and Practical Skills
**The lifeline between new energy vehicles and aviation materials * * In the field of new energy vehicles, burr detection of battery electrodes is crucial for safety – an error of 3 millimeters may cause diaphragm puncture and explosion. For this purpose, the equipment must be equipped with a copper filter to eliminate low-energy radiation noise. The testing of aviation composite materials is more complex, and the delamination defects of carbon fibers require specific parameters: 90kV voltage, 150 μ A current, and aluminum copper composite filters. If these parameters are set with deviations, it may lead to missed detection of pores or fiber fractures, with unimaginable consequences.
**Engineer’s “Image Optimization Three Board Axe” * * Faced with blurry X-ray images, engineers need to master three major skills: first, adjust the window width and level, similar to Photoshop’s color grading tool, which can increase the porosity contrast of aluminum alloy castings by more than 50%; The second is pseudo color rendering. The heatmap mode can visually display thickness differences, while the metallic color mode can enhance weld details; The third is AI denoising technology, which uses deep learning models to eliminate scattering patterns and make defect edges clearer. For example, in a certain case, the crack recognition rate after AI processing increased from 75% to 98%.
Security Protection and Future Trends
**The ‘visual bottom line’ of radiation protection: The radiation risk of industrial X-rays cannot be ignored. The radiation level at the detection station is about 2.5 μ Sv/h, which is equivalent to taking an airplane. However, when in direct contact with unprotected areas, the radiation value skyrockets to 800 μ Sv/h, equivalent to continuous shooting of 400 chest X-rays. In emergency situations, the operating procedures must be strict: press the emergency stop button, evacuate all personnel, cover the leak area with a lead blanket, and immediately contact the professional department. These steps may seem simple, but they are the key to avoiding accidents.
**From guessing defects games to intelligent upgrades, in the future, X-ray detection will focus more on interaction and intelligence. For example, the “Guessing Defects” mini game trains engineers’ judgment by gradually blurring images; The addition of AI algorithms enables the system to automatically label defect types and generate reports that comply with ISO standards. At present, some enterprises have achieved full process simulation of bearings from intact to fracture through dynamic CT technology, providing a new approach for fault prediction.
Post time: May-22-2025