Search Results (113)

Background/Objectives: X-ray computed tomography (XCT) is a powerful tool for volumetric imaging, where three-dimensional (3D) images are generated from a large number of individual X-ray projection images. However, collecting the required number of low-noise projection images is time-consuming, limiting its applicability to scenarios requiring high temporal resolution, such as the study of dynamic processes. Inspired by stereo vision, we previously developed stereo X-ray imaging methods that operate with only two X-ray projections, enabling the 3D reconstruction of point and line fiducial markers at significantly faster temporal resolutions. Methods: Building on our prior work, this paper demonstrates the use of stereo X-ray techniques for 3D reconstruction of sharp object corners, eliminating the need for internal fiducial markers. This is particularly relevant for deformation measurement of manufactured components under load. Additionally, we explore model training using synthetic data when annotated real data is unavailable. Results: We show that the proposed method can reliably reconstruct sharp corners in 3D using only two X-ray projections. The results confirm the method’s applicability to real-world stereo X-ray images without relying on annotated real training datasets. Conclusions: Our approach enables stereo X-ray 3D reconstruction using synthetic training data that mimics key characteristics of real data, thereby expanding the method’s applicability in scenarios with limited training resources. Full article

Non-destructive testing (NDT) methods are critical for evaluating the structural integrity of and detecting defects in composite materials across industries such as aerospace and renewable energy. This review examines the recent trends and successful implementations of NDT approaches for composite materials, focusing on articles published between 2015 and 2025. A systematic literature review identified 120 relevant articles, highlighting techniques such as ultrasonic testing (UT), acoustic emission testing (AET), thermography (TR), radiographic testing (RT), eddy current testing (ECT), infrared thermography (IRT), X-ray computed tomography (XCT), and digital radiography testing (DRT). These methods effectively detect defects such as debonding, delamination, and voids in fiber-reinforced polymer (FRP) composites. The selection of NDT approaches depends on the material properties, defect types, and testing conditions. Although each technique has advantages and limitations, combining multiple NDT methods enhances the quality assessment of composite materials. This review provides insights into the capabilities and limitations of various NDT techniques and suggests future research directions for combining NDT methods to improve quality control in composite material manufacturing. Future trends include adopting multimodal NDT systems, integrating digital twin and Industry 4.0 technologies, utilizing embedded and wireless structural health monitoring, and applying artificial intelligence for automated defect interpretation. These advancements are promising for transforming NDT into an intelligent, predictive, and integrated quality assurance system. Full article

Composite insulators are deployed globally for outdoor insulation owing to their light weight, excellent pollution resistance, good mechanical strength, ease of installation, and low maintenance costs. The core rod in composite long-rod insulators plays a critical role in both mechanical load-bearing and internal insulation for overhead transmission lines, and its performance directly affects the overall operational condition of the insulator. However, it remains susceptible to failures induced by complex actions of mechanical, electrical, thermal, and environmental stresses. This paper systematically reviews the major failure modes of core rods, including mechanical failures (normal fracture, brittle fracture, and decay-like fracture) and electrical failures (flashunder and abnormal heating of the core rod). Through analysis of extensive field data and research findings, key failure mechanisms are identified. Preventive strategies encompassing material modification (such as superhydrophobic coatings, self-diagnostic materials, and self-healing epoxy resin), structural optimization (like the optimization of grading rings), and advanced inspection methods (such as IRT detection, Terahertz (THz) detection, X-ray computed tomography (XCT)) are proposed. Furthermore, the limitations of current technologies are discussed, emphasizing the need for in-depth studies on deterioration mechanisms, materials innovation, and defect detection technologies to enhance the long-term reliability of composite insulators in transmission networks. Full article

High-performance discontinuous carbon-fiber-reinforced thermoplastics (CFRTPs) offer promising manufacturing flexibility and recyclability for advanced composite applications. However, their mechanical performance and reliability strongly depend on the internal fiber architecture, which is largely determined by the molding process. In this study, three distinct compression molding approaches—CFRTP sheet molding compounds (SMCs), bulk molding compounds (BMCs), and free-edge molding compounds (FMCs)—were systematically evaluated to investigate how processing parameters affect fiber orientation, tape deformation, and impregnation quality. X-ray micro-computed tomography (XCT) was employed to visualize and quantify the internal structures of each material, focusing on the visualization and quantification of in-plane and out-of-plane fiber alignment and other internal structure features. The results indicate that CFRTP-SMC retains largely intact tape layers and achieves better impregnation, leading to more uniform and predictable internal geometry. Although CFRTP-BMC exhibits greater tape deformation and splitting due to increased flow, its simpler molding process and better tolerance for tape shape distortion suggest potential advantages for recycled applications. In contrast, CFRTP-FMC shows significant tape fragmentation and poor impregnation, particularly near free edges. These findings underscore the critical role of a controlled molding process in achieving a consistent internal structure for these materials for the first time. This study highlights the utility of advanced XCT methods for optimizing process design and advancing the use of high-performance discontinuous CFRTP in industry. Full article

Powder bed fusion with a selective laser melting (SLM) process is a versatile technology that allows for the manufacturing of complex geometries and lightweight structures. A prototype of a redesigned refrigeration block is made with topology optimization, thereby demonstrating the capabilities and challenges of this approach in terms of design and manufacturing. The geometry obtained was more efficient in terms of thermal performance with respect to the original design, and the simulation of the printing process indicated ways to reduce distortions. Moreover, a demonstrator was printed and measured through X-ray computed tomography (XCT) scanning, showing that the approach used was effective in terms of process parameters, technology used, and materials. In fact, it was found to have a low level of porosity, and although there were some differences in the dimensional comparison, such differences were lower in the areas where greater accuracy was required. The manufacturability was possible because of the appropriate choice of process parameters and the combination of the additive with subtractive manufacturing techniques, such as CNC milling. Overall, the methodology used proved effective for the purpose of the component in terms of thermal efficiency and weight reduction. Full article

Wood drying is the most critical and energy-intensive process in the wood industry. However, the complex pore structure of wood significantly affects its thermal performance. Therefore, it is essential to study the relationship between the pore structure and the thermal properties of wood. In this study, X-ray-computed tomography (XCT) technology, combined with digital image processing (DIP) techniques, was used to visualize and characterize the three-dimensional structure of oak samples. Parameters such as porosity, pore size and distribution, and fractal dimensions were obtained to investigate their relationship with thermal conductivity. Subsequently, the thermal conductivities of the oak samples in the tangential, radial, and axial directions were simulated based on their three-dimensional structure. The simulation results were validated using the transient plane source method (TPS). The results showed that there were significant differences in porosity and pore size between earlywood and latewood, which in turn affect the correlation between fractal dimension and thermal conductivity. The higher the self-similarity of the wood structure is, the stronger the correlation between porosity and fractal dimension will be. Due to the limitations of CT resolution and threshold segmentation methods, there may be some axial deviations in the heat transfer simulation based on XCT. However, overall, this method provides a relatively accurate estimate of the effective thermal conductivity of oak wood. In addition, the pit structure and the research on heat conduction of wood-based multi-scale pore structures are of crucial importance to the study of heat conduction in wood. Full article

Semi-continuous casting is an important method for the large-scale production of high-strength conductive copper-iron (Cu-Fe) alloys in the future. However, serious peeling defects were found on the surface of cold-rolled strips during industrial trials. Due to the multi-step complexity of the manufacturing process (from casting to final product), identifying the root cause of defect formation remains challenging. X-ray computed tomography (X-CT) was used to quantitatively characterize the pores and defects in the horizontal continuous casting Cu-Ni-Sn slab, the semi-continuous casting Cu-Fe alloy slab, and the hot-rolled slab of Cu-Fe, and the relationship between the defect characteristics and processes was analyzed. The results showed that the internal defect sphericity distribution of the Cu-Fe alloy slab after hot rolling was similar to that of the reference Cu-Ni-Sn slab. The main difference lies in the low sphericity range (<0.4). The volume of pore defects inside the Cu-Fe alloy after hot rolling was significantly larger than in the reference sample, with a 52-fold volume difference. This phenomenon may be the source of surface-peeling defects in the subsequent cold-rolling process. The occurrence of internal defects in the Cu-Fe alloy is related to both the composition characteristics and casting processes of the Cu-Fe alloy; on the other hand, it is also related to the hot-rolling process. Full article

Steam curing is a widely used method in the production of industrial precast concrete but it often leads to thermal damage that negatively impacts the material’s long-term durability and mechanical strength. The use of supplementary cementitious materials (SCMs) has shown considerable promise in improving pore structure and alleviating these adverse effects. This study employs high-resolution X-ray computed tomography (X-CT) to thoroughly assess how steam curing temperatures and various subsequent curing regimes influence the pore characteristics of mortars containing high volumes of mineral admixtures. The results shows that steam-cured specimens under water curing (ST8012-WA) achieved a compressive strength of 51.72 MPa and flexural strength of 5.85 MPa, representing improvements of 9% and 19.8%, respectively, compared to natural curing (ST8012-NA: 47.32 MPa and 4.88 MPa). The standard-cured specimen (SD) exhibited the highest compressive strength of 54.18 MPa, highlighting the detrimental effects of elevated steam curing temperatures. The findings reveal that higher steam curing temperatures result in increased porosity and decreased mechanical strength, challenges that can be effectively mitigated through appropriate postcuring techniques. Notably, water curing following steam curing proves especially effective in reducing pore size variability and improving the material’s durability. This research offers new insights into the intricate relationships among curing temperature, pore morphology, and mechanical performance, providing practical recommendations to optimize the quality and longevity of steam-cured precast concrete components. Full article

The thermoplastic composite pipe (TCP) manufacturing process introduces defects that impact performance, such as voids, misalignment, and delamination. Consequently, there is an increasing demand for effective non-destructive testing (NDT) techniques to assess the influence of these manufacturing defects on TCP. The objective is to identify and quantify internal defects at a microscale, thereby improving quality control. A combination of methods, including NDT, has been employed to achieve this goal. The density method is used to determine the void volume fraction. Microscopy and void analysis are performed on pristine samples using optical micrography and scanning electron microscopy (SEM), while advanced techniques like X-ray computer tomography (XCT) and ultrasonic inspections are also applied. The interlayer between the reinforced and inner layers showed good consolidation, though a discontinuity was noted. Microscopy results confirmed solid wall construction, with SEM aligning with the XY axis slice, showing predominant fibre orientation around ±45° and ±90°, and deducing the placement orientation to be ±60°. Comparing immersion, 2D microscopy, and XCT methods provided a comparative approach, even though they could not yield precise void content values. The analysis revealed a void content range of 0–2.2%, with good agreement between microscopy and Archimedes’ methods. Based on XCT and microscopy results, an increase in void diameter at constant volume increases elongation and reduces sphericity. Both methods also indicated that most voids constitute a minority of the total void fraction. To mitigate manufacturing defects, understanding the material’s processing window is essential, which can be achieved through comprehensive material characterization of TCP materials. Full article

The inherent porous structure of concrete enables the penetration of water and Cl⁻ ions through its pores, which eventually leads to rebar corrosion within the concrete. Consequently, the densification and impermeability of concrete protective layers play a critical role in the durability of reinforced concrete structures. This study proposes a composite anti-corrosion treatment for mortar protective layers by integrating nano-ion capillary crystalline with silane hydrophobic processing. Targeting existing mortar samples, a series of experiments were conducted, utilizing scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), differential scanning calorimetry-thermogravimetry (DSC-TG), X-ray computed tomography (X-CT), contact angle measurements, permeability tests, and electrochemical tests. These experiments systematically evaluated the effects of composite anti-corrosion treatment on the microstructure of hydration products, pore characteristics, surface hydrophobicity, impermeability, and the overall corrosion resistance of mortar-rebar samples in a Cl⁻-contained environment. The results reveal that nano-ion capillary crystalline materials react with free calcium ions in the mortar to produce secondary hydration products, effectively filling micro-pores, densifying the pore structure and inhibiting the invasion of Cl⁻ ions. The combination of capillary crystalline and silane hydrophobic processing synergistically enhances surface hydrophobicity and impermeability, preventing the ingress of corrosive agents, such as Cl⁻ ions, and significantly improving the anti-corrosion performance of mortar in a Cl⁻-contained environment. Full article

Slags containing critical minerals concentrated in artificial phases, so-called engineered artificial minerals (EnAMs), are a novel source of critical raw materials. To liberate the EnAMs, the slags need to be comminuted, reducing the size of the particles. This work investigated the dependence of the breakage behavior on particle size and mineral structure during the comminution of an EnAM-containing slag. Piston-die experiments were performed for particles in the 3 mm to 5 mm size range. Nanoindentation and two-roller breakage tester experiments were performed for those in the 50 µm to 200 µm size range. The investigations were accompanied by X-ray computed tomography (XCT) and scanning electron microscope/energy dispersive X-ray spectroscopy (SEM/EDX) measurements as well as a micro X-ray fluorescence analysis to examine the mineral microstructure. It was found that the commonly assumed exponential connection between particle size and strength differed in the two size ranges. This behavior can be linked to different grain and cluster sizes, which were found in the investigation of the mineral microstructure. In addition to particle size, it was found that mineral structure plays an important role when characterizing the breakage behavior. Full article

X-ray Computed Tomography (X-CT) is now an established technique for the investigation and diagnostics of Cultural Heritage. Its advantages include non-invasiveness, non-destructiveness, and the possibility of exploring the inner parts of an object without any modification. X-CT is often employed to investigate the construction methods of complex artifacts made with different parts or materials, but it is also able to support the analysis, intervention, monitoring and enhancement processes of artworks, creating digital models that can aid in the conservation and restoration procedures. In this work, several case studies are presented in which the CT technique has been decisive in identifying the effects of time and the events that occurred during the object’s life influencing its state of conservation. These range from large objects, such as an 18th century CE writing cabinet or an ancient Egyptian wooden coffin, to very small artifacts, like Mesopotamian lapis lazuli beads or fragments of Roman colored glass. Additionally, the results obtained by µ-CT investigations on the conservation state of a bronze arrowhead uncovered from the Urama-chausuyama mounded tomb (Japan, Kofun period, end of the 3rd century CE) are presented here for the first time. Lastly, the versatility of the technique when applied with different setups is highlighted. Full article

The present study focuses on advancing one of the most popular AM techniques, namely, laser powder bed fusion (LPBF) technology, which has the ability to produce complex geometry parts with minimum material waste but continues to face challenges in minimizing the surface roughness. For this purpose, a novel hybrid manufacturing technology, which applies in a single setup (in-envelope) both LPBF technology and high-speed machining, was examined in this research for the fabrication of tensile specimens with three different surface finish conditions: as-built, hybrid (in-envelope machining) and post-machining (out-of-envelope) on Inconel^® alloy 718, hereafter referred to as IN718. As the application of the IN718 alloy in service is typically specified in the precipitation-hardened condition, three different heat treatments were applied to the tensile specimens based on the most promising thermal cycles identified previously for room-temperature tensile properties by the authors. The as-built (AB) specimens had the highest average surface roughness (R_a) of 5.1 μm ± 1.6 μm, which was a significant improvement (five-fold) on the hybrid (1.0 μm ± 0.2 μm) and post-machined (0.8 μm ± 0.5 μm) surfaces. The influence of this surface roughness on the mechanical properties was studied both at ambient temperature and at 650 °C, which is close to the maximum service temperature of this alloy. Regardless of the surface conditions, the room-temperature mechanical properties of the as-fabricated IN718 specimens were within the range of properties reported for standard wrought IN718 in the annealed condition. Nonetheless, detailed examination of the strain localization behavior during tensile testing using digital image correlation showed that the IN718 specimens with AB surfaces exhibited lower ductility (global and local) relative to the hybrid and post-machined ones, most likely due to the higher surface roughness and near-surface porosity in the former. At 650 °C, even though the mechanical properties of all the heat-treated IN718 specimens surpassed the minimum specifications for the wrought precipitation-hardened IN718, the AB surface condition showed up to 4% lower strength and 33–50% lower ductility compared with the hybrid and PM surface conditions. Microfocus X-ray computed tomography (µXCT) of the fractured specimens revealed the presence of numerous open cracks on the AB surface and a predisposition for the near-surface pores to accelerate rupture, leading to premature failure at lower strains. Full article

Debonding of the primary anode caused by anodic acidification is one of the major failure modes of the impressed current cathodic protection (ICCP) system in reinforced concrete structures. This study used 3D micro X-ray computed tomography (μ-XCT) to monitor the in situ evolution of the anodic acidification-affected zone. Samples were scanned after 0 to 40 days of the accelerated anodic acidification test. The anodic acidification-affected zone was identified in μ-XCT images using the gray level segmentation method. The total volume of this zone was measured using the 3D reconstruction method. It was found that detailed 3D information can be extracted using the 3D reconstruction method. The spatial heterogeneity was analyzed using this reconstructed volume information. The Faraday efficiency was calculated and found to increase after 20 days of operation. It was also found that the affected zone was proportional to the input electrical energy. The proposed model is useful for estimating the durability of an ICCP system. Full article

Permeability is a crucial parameter in the exploration and development of oil and gas reservoirs, particularly in unconventional ones, where fractures significantly influence storage capacity and fluid flow. This study investigates the fracture permeability of granite reservoirs in the South China Sea, introducing an enhanced evaluation model for planar fracture permeability based on Darcy’s law and Poiseuille’s law. The model incorporates factors such as fracture heterogeneity, tortuosity, angle, and aperture to improve permeability assessments. Building on a single-fracture model, this research integrates mass transfer equations and trigonometric functions to assess intersecting fractures’ permeability. Numerical simulations explore how tortuosity, angle, and aperture affect individual fracture permeability and the influence of relative positioning in intersecting fractures. The model makes key assumptions, including minimal consideration of horizontal stress and the assumption of unidirectional laminar flow in cross-fractures. Granite outcrop samples were systematically collected, followed by full-diameter core drilling. A range of planar models with varying fracture apertures were designed, and permeability measurements were conducted using the AU-TOSCAN-II multifunctional core scanner with a steady-state gas injection method. The results showed consistency between the improved model and experimental findings regarding the effects of fracture aperture and angle on permeability, confirming the model’s accuracy in reflecting the fractures’ influence on reservoir flow capacity. For intersecting fractures, a comparative analysis of core X-ray computed tomography (X-CT) scanning results and experimental outcomes highlighted discrepancies between actual permeability measurements and theoretical simulations based on tortuosity and aperture variations. Limitations exist, particularly for cross-fractures, where quantifying complexity is challenging, leading to potential discrepancies between simulation and experimental results. Further comparisons between core experiments and logging responses are necessary for model refinement. In response to the challenges associated with evaluating absolute permeability in fractured reservoirs, this study presents a novel theoretical assessment model that considers both single and intersecting fractures. The model’s validity is demonstrated through actual core experiments, confirming the effectiveness of the single-fracture model while highlighting the need for further refinement of the dual-fracture model. The findings provide scientific support for the exploration and development of granite reservoirs in the South China Sea and establish a foundation for permeability predictions in other complex fractured reservoir systems, thereby advancing the field of fracture permeability assessment. Full article