Non-Destructive Testing Guide

Background
X-ray inspection is an invaluable part of Ford’s Materials Technology Centre as it strives to develop new materials and components for tomorrow’s cars. Since the removal of the open X-ray system, large lead-lined room, and wet plate film-processing laboratory from the Materials Science Department in 1999, X-ray inspection has been outsourced on an ad-hoc basis. However, since acquiring one of the latest developments in real-time X-ray inspection technology, the HMX 225 ST from X-Tek Systems last year, the department has not only reduced the cost of having to send components and systems to external test houses, but is expanding the use of X-ray non-destructive testing (NDT) in automotive inspection across a broad range of applications.
How Dependent is Ford on X-Ray Inspection?
The quality and quantity of X-ray inspection work Ford are now completing is a quantum leap ahead of what they were achieving before. The old X-ray room was used about four to six times a year for projects lasting for between one and two weeks, while the real-time X-ray system is used virtually every day. The time spent using the system is highly dependent on the aim of the investigation, material type and number of components, but typically most investigations are completed within one to two days if a few components are being inspected and computed tomography is not required.
Advantages of Computer Controlled X-Ray Inspection Equipment
A key feature of the HMX 225 ST system is image quality The microfocus X-ray system uses a very finely focused X-ray beam, with a focal spot size of less than 5 microns required for the generation of high magnification and high resolution images. Furthermore, unlike wet film technology, no chemical development is needed so images can be acquired in a fraction of the time and artificial features cannot be introduced during the development process.
What Materials Can be Analysed by X-Ray Inspection
The range of materials and components that Dunton deals with every day includes metal castings, metal sheet, powertrain components, polymers (including leather, seating, interior and exterior plastics), rubber, fasteners, chemicals, fluids, paints, and advanced materials, such as carbon fibre, composites and adhesives. Until recently many components were routinely sectioned on arrival in the department to allow detailed visual inspection. Now, in a growing number of cases, Ford engineers are using the X-ray system to carry out faster and more cost-effective test inspections.