Automated Porosity Characterization for Aluminum Die Casting Materials Using X-ray Radiography, Synthetic X-ray Data Augmentation by Simulation, and Machine Learning.

Detection and characterization of hidden defects, impurities, and damages in homogeneous materials like aluminum die casting materials, as well as composite materials like Fiber-Metal Laminates (FML), is still a challenge. This work discusses methods and challenges in data-driven modeling of automated damage and defect detectors using measured X-ray single- and multi-projection images. Three main issues are identified: Data and feature variance, data feature labeling (for supervised machine learning), and the missing ground truth. It will be shown that simulation of synthetic measuring data can deliver a ground truth dataset and accurate labeling for data-driven modeling, but it cannot be used directly to predict defects in manufacturing processes. Noise has a significant impact on the feature detection and will be discussed. Data-driven feature detectors are implemented with semantic pixel Convolutional Neural Networks. Experimental data are measured with different devices: A low-quality and low-cost (Low-Q) X-ray radiography, a typical industrial mid-quality X-ray radiography and Computed Tomography (CT) system, and a state-of-the-art high-quality µ-CT device. The goals of this work are the training of robust and generalized data-driven ML feature detectors with synthetic data only and the transition from CT to single-projection radiography imaging and analysis. Although, as the title implies, the primary task is pore characterization in aluminum high-pressure die-cast materials, but the methods and results are not limited to this use case.

Microstructural analysis of slag properties associated with calcite precipitation due to passive CO2 mineralization.

CO2 mineralization in slag has gained significant attention since it occurs with minimal human intervention and energy input. While the amount of theoretical CO2 that can be captured within slag has been quantified based on slag composition in several studies, the microstructural and mineralogical effects of slag on its ability to capture CO2 have not been fully addressed. In this work, the CO2 uptake within legacy slag samples is analyzed through microstructural characterization. Slag samples were collected from the former Ravenscraig steelmaking site in Lanarkshire, Scotland. The collected samples were studied using X-ray Computed Tomography (XCT) to understand the distribution and geometry of pore space, as well as with scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS) to visualize the distribution of elements within the studied samples. Electron backscatter diffraction (EBSD) was used to study the minerals distribution. The samples were also characterized through X-ray diffraction (XRD) and X-ray fluorescence (XRF), and the amount of captured CO2 was quantified using thermogravimetric analysis (TGA). Our results demonstrate that CO2 uptake occurs to the extent of ∼9-30 g CO2/ kg slag. The studied samples are porous in nature, with pore space occupying up to ∼30% of their volumes, and they are dominated by åkermanite-gehlenite minerals which interact with the atmospheric CO2 slowly at ambient conditions. EDS and EBSD results illustrate that the precipitated carbonate in slag is calcite, and that the precipitation of calcite is accompanied by the formation of a Si-O-rich layer. The provided analysis concludes that the porous microstructure as well as the minerals distribution in slag should be considered in forecasting and designing large-scale solutions for passive CO2 mineralization in slag.

Otosclerosis under microCT: New insights into the disease and its anatomy.

Purpose: Otospongiotic plaques can be seen on conventional computed tomography (CT) as focal lesions around the cochlea. However, the resolution remains insufficient to enable evaluation of intracochlear damage. MicroCT technology provides resolution at the single micron level, offering an exceptional amplified view of the otosclerotic cochlea. In this study, a non-decalcified otosclerotic cochlea was analyzed and reconstructed in three dimensions for the first time, using microCT technology. The pre-clinical relevance of this study is the demonstration of extensive pro-inflammatory buildup inside the cochlea which cannot be seen with conventional cone-beam CT (CBCT) investigation. Materials and Methods: A radiological and a three-dimensional (3D) anatomical study of an otosclerotic cochlea using microCT technology is presented here for the first time. 3D-segmentation of the human cochlea was performed, providing an unprecedented view of the diseased area without the need for decalcification, sectioning, or staining. Results: Using microCT at single micron resolution and geometric reconstructions, it was possible to visualize the disease's effects. These included intensive tissue remodeling and highly vascularized areas with dilated capillaries around the spongiotic foci seen on the pericochlear bone. The cochlea's architecture as a morphological correlate of the otosclerosis was also seen. With a sagittal cut of the 3D mesh, it was possible to visualize intense ossification of the cochlear apex, as well as the internal auditory canal, the modiolus, the spiral ligament, and a large cochleolith over the osseous spiral lamina. In addition, the oval and round windows showed intense fibrotic tissue formation and spongiotic bone with increased vascularization. Given the recently described importance of the osseous spiral lamina in hearing mechanics and that, clinically, one of the signs of otosclerosis is the Carhart notch observed on the audiogram, a tonotopic map using the osseous spiral lamina as region of interest is presented. An additional quantitative study of the porosity and width of the osseous spiral lamina is reported. Conclusion: In this study, structural anatomical alterations of the otosclerotic cochlea were visualized in 3D for the first time. MicroCT suggested that even though the disease may not appear to be advanced in standard clinical CT scans, intense tissue remodeling is already ongoing inside the cochlea. That knowledge will have a great impact on further treatment of patients presenting with sensorineural hearing loss.

A Micro-Computed Tomography Comparison of the Porosity in Additively Fabricated CuCr1 Alloy Parts Using Virgin and Surface-Modified Powders.

Recently, the use of novel CuCr1 surface-modified powder for reliable laser powder-bed fusion (LPBF) manufacturing has been proposed, enabling a broader LPBF processing window and longer powder storage life. Nevertheless, virgin CuCr1 powder is also LPBF processable, on the condition that a high-energy density is employed. In this work, we compare two dense specimens produced from virgin and surface-modified CuCr1 powder. Furthermore, a third sample fabricated from surface-modified powder is characterized to understand an abnormal porosity content initially detected through Archimedes testing. Utilizing high-resolution micro-CT scans, the nature of the defects present in the different samples is revealed. Pores are analyzed in terms of size, morphology and spatial distribution. The micro-CT data reveal that the virgin CuCr1 dense specimen displays keyhole pores plus pit cavities spanning multiple layer thicknesses. On the other hand, the sample fabricated with the surface-modified CuCr1 powder mainly contains small and spherical equi-distributed metallurgical defects. Finally, the CT analysis of the third specimen reveals the presence of a W contamination, favoring lack-of-fusion pores between subsequent LPBF layers. The LPBF melting mode (keyhole or conductive), the properties of the material, and the potential presence of contaminants are connected to the different porosity types and discussed.

Analysis of Advanced Pore Morphology (APM) Foam Elements Using Compressive Testing and Time-Lapse Computed Microtomography.

Advanced pore morphology (APM) foam elements are almost spherical foam elements with a solid outer shell and a porous internal structure mainly used in applications with compressive loading. To determine how the deformation of the internal structure and its changes during compression are related to its mechanical response, in-situ time-resolved X-ray computed microtomography experiments were performed, where the APM foam elements were 3D scanned during a loading procedure. Simultaneously applying mechanical loading and radiographical imaging enabled new insights into the deformation behaviour of the APM foam samples when the mechanical response was correlated with the internal deformation of the samples. It was found that the highest stiffness of the APM elements is reached before the appearance of the first shear band. After this point, the stiffness of the APM element reduces up to the point of the first self-contact between the internal pore walls, increasing the sample stiffness towards the densification region.

Characterization of Geometrical Changes of Spherical Advanced Pore Morphology (APM) Foam Elements during Compressive Deformation.

The mechanical properties of Advanced Pore Morphology (APM) foam elements depend strongly upon their internal porous and external structural geometry. This paper reports on a detailed investigation of external (e.g. shape and size) and internal (e.g. distribution, size, number of pores) geometry and porosity changes of APM foam elements, during compressive loading by means of the ex-situ micro-Computed Tomography, and advanced digital image analysis and recognition. The results show that the porosity of APM foam elements decreases by only 25% at the engineering strain of 70% due to an increase of the number of pores at high stages of compressive deformation. The APM foam elements also exhibit a positive macroscopic Poisson's ratio of υ = 0.2, which is uncharacteristic for cellular structures.

Designing a Tool System for Lowering Friction during the Ejection of In-Die Sintered Micro Gears.

The continuous improvements in micro-forging technologies generally involve process, material, and tool design. The field assisted sintering technique (FAST) is a process that makes possible the manufacture of near-net-shape components in a closed-die setup. However, the final part quality is affected by the influence of friction during the ejection phase, caused by radial expansion of the compacted and sintered powder. This paper presents the development of a pre-stressed tool system for the manufacture of micro gears made of aluminum. By using the hot isostatic pressing (HIP) sintering process and different combinations of process parameters, the designed tool system was compared to a similar tool system designed without a pre-stressing strategy. The comparison between the two tool systems was based on the ejection force and part fidelity. The ejection force was measured during the tests, while the part fidelity was documented using an optical microscope and computed tomography in order to obtain a multi-scale characterization. The results showed that the use of pre-stress reduced the porosity in the gear by 40% and improved the dimensional fidelity by more than 75% compared to gears produced without pre-stress.