X-ray simulation for structural integrity for aerospace components – A case study

Abstract

Abstract. The use of Integrated Computational Materials Engineering (ICME) has rapidly evolved from an emerging technology to the industry standards in Materials, Manufacturing, Chemical, Civil, and Aerospace engineering. Despite this the recognition of the ICME merits has been somewhat lacking within NDE community. This is due in part to the makeup of NDE practitioners. They are a very diverse but regimented group. More than 80% of NDE experts are trained and certified as NDT Level 3's and auditors in order to perform their daily inspection jobs. These jobs involve detection of attribute of interest, which may be a defect or condition or both, in a material. These jobs are performed in strict compliance with procedures that have been developed over many years by trial-and-error with minimal understanding of the underlying physics and interplay between the NDE methods setup parameters. It is not in the nature of these trained Level 3's experts to look for alternate or out-of-the box, solutions. Instead, they follow the procedures for compliance as required by regulatory agencies. This approach is time-consuming, subjective, and is treated as a bottleneck in today's manufacturing environments. As such, there is a need for new NDE tools that provide rapid, high quality solutions for studying structural and dimensional integrity in parts at a reduced cost. NDE simulations offer such options by a shortening NDE technique development-time, attaining a new level in the scientific understanding of physics of interactions between interrogating energy and materials, and reducing costs. In this paper, we apply NDE simulation (XRSIM as an example) for simulating X-Ray techniques for studying aerospace components. These results show that NDE simulations help: 1) significantly shorten NDE technique development-time, 2) assist in training NDE experts, by facilitating the understanding of the underlying physics, and 3) improve both capability and reliability of NDE methods in terms of coverage maps.