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Applicationofneutronradiography
toindustriesandlargestructure
inspection
YutakaYAMAGATA
RIKEN,InnovationCenter,
VCADAppliedFabricationTeam
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Demandsfornondestructivetestinginindustries
RecentproblemsinproductiontechnologyinJapan
Lowercost,energyefficient,recycledmaterial,highquality,productliability
Slim,leanbutsufficientdesignforoptimumcost/performance
Utilizationofcomputersimulationinthedesignprocessiskeen
Optimizehydrodynamicform Minimizecarbodyweight
Simpleandsufficientdesignofengines,motorsandbatteries
Computersimulation(Structural,CFD/thermal,molding...)arenotalways
accuratewithoutmetrologicaldata
Methodologyto"measure"realphysicalphenomenabecomeimportant
Fluidvisualization,stressmeasurement,temperature,magnetic/electricfield,
chemicalreactionandsoon
SignificanceofNondestructivetestinggoesup
Productliability,qualitycontrol
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VCADSystemResearchProgram
VCADSystem(VolumeCAD)canrealizecomptermodelbasedon"real"
object
VCADmodel
BasedonVCADmodel,variouscomputationalsimulationscanbecarried
out(CFD,Structural,molding,optical...)
ThesesimulationsarefarrealisticthanthosebasedonCADmodels
Externalsimulationsoftwares
IGES
STL
VCAD Modelling Generalized VCAD model
S-CAD
X-Ray CT, MRI, Slicer, Neutron Radiography
Discrete "Geometory" model
Subdivision surfaces
The Nagata patch
Implicit Surfaces
V-Slim
Triangles with normalsV-ObjCreator
Noise RemovalV-Smoother V-Cat
Structural AnalysisX-FEM)
Structural AnalysisFEM
OpticsRaytracing
FluidThermalSimulation
V-X3D
V-Struct
V-Shrink
V-MultiMat
V-Sphere
V-Opt
V-Flow2DD
CAM
Design
3D Metrology + internal strucutre
Analytical form
Point Cluds
BMPTIFF
VOXELExternalMeshGenerator
V-Biomech
V-Cam2
V-Polish
BoneRemodelling
V-BoneRemodeling
Octree Voxel
V-Xgen
Tetrahedral Elements
Vxxx2tets
VCAD Framework
Degenerated Hexahedral ElementsVxxx2hex
V-Subdivision3D
VCAD Modeller
Discretemodelof"Object"and
"Fluidics"controlledbycell
VSphere Softwareinpublicrelease
Metrology
HandlingofVolumeData
type"VCAD"atGoogletoseeVCADWebsitehttp://vcadhpsv.riken.jp/en/
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XrayCTfoindustrialandmedical
3DVolumedatainputmethodtoVCADSystem
3Dinternalstructure
microscopy(Slicer)
Confocallasermicroscopy
NeutronRadiography(JRR3)
Metrologyofvolume3Ddataofreal"objects"
INPUTtoVCAD
Surface
metrology
CADDesigndata
volume 3D data
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Exampleofsimulationbasedon "real"object
BasedonXrayCTimage,a"real"simulation
ofaluminumcastedbrakecaliperisconducted
usingVCADsystemsoftwares
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Measurment of actual product
XX--ray CT ray CT instrumentationinstrumentationAn X-ray CT
scanning device is used to measure 3D shape of industrial
parts. VCAD software V-Cat
can extract the information from the X-
ray CT scan or MRI tomograms and transfer a variety of
information on the material into the VCAD framework, which already
contains information on the complex internal structure and material
distribution.
motorcycle brake caliper : cast aluminummotorcycle brake caliper
: cast aluminum
CTCT
scanscan
Height 155mm, 306 images , 0.5mm
pitch
155m
m
X-ray CT imaging
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Representation of actual product dataVCAD data can grasp
quantitatively the size of each pore and theist relative position.
VCAD data makes it possible to detect the hidden defects of a
product while it is still in the casting stage.
magnificationmagnification
Detecting casting defects
Castingpore
Meshing and application of boundary conditions for structure
analysis
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Structure analysis using measurement data
VCAD software V-Struct
can dealing with VCAD data of actual
product measurement and analyze numerically static fracture
strength. The VCAD system can be operated easily, from the
extraction of measurement data to structure analysis.
Maximum principal stress distribution (MPa)Maximum principal
stress distribution (MPa)
Structureanalysisresultwithmeasurementdata
Displacement distribution for the deformed shape (mm,
Displacement distribution for the deformed shape (mm,
magnificationmagnification30 times)30 times)
25MPa
0MPa
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LimitationofXrayCTandpossibility ofneutronradiography
LimitationofXrayCT
Penetrationdepth,especiallyforheavymetalsincluding
steel Notabletoobservelightelements;plastic,waterandoil
ThesearewellknownproblemsinXrayimaging,
butduetotheincreasingdemandfor"real"object
modellingandsimulation,theyareveryimportant.
Neutronradiographycansolvetheseproblems
Castironvalves
Castirongearbox
truckfortrainPlasticinjectionmoldedpartswith
metalinserts
Largesteelweldedcomponents
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HowneutronradiographyisusedinindustrialR&D
Dependingonthephaseofproductionprocess,
characteristicsofmeasuringinstrumentmaydiffer
R&Dphase:precisionanalysiswithlargescaleequipment
Productiondesignphase:Lesspreciseanalysiswithcompactand
convenientequipment
Massproduction,maintenance,recyclephase:Onsiteanalysisusing
portableequipment
ResearchandDevelopmentResearchandDevelopment
ProductDesignProductDesign
ManufacturingDesignManufacturingDesign
ProductionProcessProductionProcess
UsageMaintenanceUsageMaintenance
RecycleRecoveryRecycleRecovery
LargeScaleEquipment
CompactEquipment
PortableEquipment
JPARC,JRR3 CompactNeutronSources
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Neutronradiographyexamples
Neutronradiographyexperimentsare
conductedatJRR3guidehallMUSASIH/L
ports,whichhavesimilarbeamfluxexpected
forcompactneutronsource.
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Steelpyramid,Cylinderwithslits
Radiographyexperimentsareconducedat
MUSASILports. Beamfluxisclosetocompactneutron
source. ImagingplatesandhighsensitivityCCD
camerawithscintillaterplatewereused.
Thermalneutronradiographyimage Steelpyramid
XrayimageV
JRR3(JAEA,Tokai)
MUSASIL2.4,semimonochromaticflux~8x105
n/cm2/secBeamdiameter~5cmx4cm
M12Screw
ThermalNeutron
Xray(450kV)
MagnifiedImage
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Compositematerial Carbonfibercompositematerialafter
fracturetest. Fiberstructureinsidesamplesuchas
delamination,fiberdirectioncanbe observed.
Effectofscatteredneutronbeamcanbe
loweredbytakingcertaindistancefromIP.
Delamination
Delaminationinside
Fiberdirection
Fractureline
SampleontheIP(Strongscatteredbeam)
10mmdistancefromIP(Scatteredbeamlowered)
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CrackcausedbyfatiguefailuretestXray(450kV)Xray(450kV)
Neutron
Radiography
Neutron
Radiography
Cracksobserved,
butnotveryclear
Cracksobserved,
butnotveryclear
ClearerimageofcrackClearerimageofcrack
Material:toolsteelTensileforce:70KN7KNRep.freq.:
10KHzRep.Cycles:24,000
Itwaspossibletoobserveunopened
fatiguecrackbothbyXrayandNR,but
NRimageseemstobeclearer.
(Possibly
resolutiondifferenceinimagingsystem.)
Itmaybepossibletodetectcracksinside
thicksteelobjectusingNR.
Crackisvisible
atsurface,
althoughnot
open.
Crackisvisible
atsurface,
althoughnot
open.
Test piec
e
Test piec
e
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Plasticinjectionmoldingdie
Plasticmaterialinsiderunner
Cavityfortheproduct
Thickness:Exp.time:60minbyIP
Itwaspossibletodistinguishemptycavityandfilled
runnerinsidemoldingdie.MoldingdiecoutesybyNagatsuPrecisionMold
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Material:Cementandaggregates
NRimagetakenbyLiF/ZnS:Agscintillator+CCDat
MUSASIL(JRR3) AfterCTreconstruction,cementandaggregatesare
separatedbyVCatsoftwareandmeshwas
generated.
Concretesample CTreconstructionandsimulation
70mm
35mm
Concrete sample
CT Reconstruction
Segmentation by V-Cat
Mesh generation
Cooled CCD camera
NR image x180
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StructuralsimulationbyVStruct
Stress concentration to boundary of differet materials
observed.
Equivalent stress (MPa)Defect
AggregatesZ directiondisplacement
fixed
BoundaryCondition
Strain Displacement
Analysis conducted by V-Struct .Evaluation of multi-material
sample is possible by NR and VCAD softwares.
Analysis
conditionFordetail,pleasecometoPoster!Fordetail,pleasecometoPoster!
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Movementstowardcompactneutronimaging
systemanditsapplicationsatRIKEN
Acommitteeforthediscussionofcompactneutronimagingsystemsand
itsapplicationtomanufacturingtechnologiesandlargestructure
inspectionwascalledforatRIKEN.
38membersfromuniversities,researchinstitutesandcompanies
participatedinthediscussion.
Threeworkinggroupwasorganized:compactneutronimagingsystem
WG,manufacturingtechnologyapplicationWG,andlargestructure
inspectionapplicationWG.
EachWGproposedpossibleapplicationsofneutronimagingand
feasibilitywasdiscussed.
Besides,twosymposiumsareorganizedbyRIKENincollaborationwith
PWRI,KEKandJAEA.
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Manufacturingprocessapplications
applicationsproposedbycommitteedisucssion
Electriccomponentsforhybrid/electriccarOptimizationofmotorPerformanceoptimization/safetyinspectionofbatteries
Magnetic field Nature Physics)
Temperaturemeasurement(Kiyanagi
etal.)Fuelcell/batteryobservation
Engine
components DriveShaft
Strainmeasurementbypulsedneutronimaging
(byKiyanagi
etal.)
LeandesignStress/strainmeasurement
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Inspectionoflargestructures
Bridges,buildings,civilengineering
Bridgestructures Prestressedconcrete,reinforced
concrete,steel Inspectionpossibilities
Prestressedconcretebeam Steelreinforcement,steeltruss
strucuture,compositestrucutre Saltcorrosion
4%
18%
39%
39%
P C
InspectionofPCbeams Inspectionofsteelstrucutures
Saltcorrosiondamage
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Summary Ithasprovedthatneutronradiographyatbeamfluxaround105
to106
(n/cm2/sec)isquiteusefulinindustrialapplications,thankstothe
advancesinimagingdetectors.
Itisnotpossibletoobtainhighspeedimageormovieswiththisflux,
althoughstillimagesorCTreconstructionispossiblewithacceptable
timeandquality.
Radiographyimagetocomputationalsimulationwasdemonstrated
usingVCADsystemsoftwares,whichwillbeausefultooltoindustrial
applications.
Ifitispossibletoobtainmorematerialinformationlikeresidual
stress/strain,elementrecognition,temperature,magneticfiled..,
theseinformationwillbeextremelyusefulinindustrialapplications
combinedwithradiographyimagedata.
Compactneutronsourcewillbeveryusefulforindustrialapplicationsin
thephaseofproductdesign,productionandmaintenance.
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FutureplanatRIKEN
ConstructsmallacceleratorbasedneutronsourceatRIKEN
andstartradiographyexperiments/serviceswithcomputer
modeling/simulation.(CTreconstruction,regionseparation,
meshing,andsimulation)
Organizeaindustrialconsortiumforneutronimaging applications.
Continuefacilitydevelopmenttowardadvancedneutron
imaging.(stress/strain,temperature,elements,magnetic..)
Searchforthepossibilityofportableneutronsourcefor
safetyinspectionoflargestructures.
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Collaboratorsandacknowledgements
RIKEN,VCADSystemResearchProgram
Dr.Akitake
Makinouchi,Prof.Fumihiko
Kimura(Hosei
University),Dr.Hideyuki
Sunaga,
Dr.Hideo
Yokota,Mr.Shinya
Morita,Dr.Toshihiro
Sera,Dr.Jungmyoung
Ju,
Mr.Shunsuke
Mihara,Mr.Dinh
Tien
Dung
RIKEN,RadiationLaboratory Dr.Katsuya
Hirota,Dr.Yoshie
Otake
KEK Prof.Hirohiko
M.Shimizu,Dr.Kenji
Mishima
HokkaidoUniversity Prof.YoshiyukiKiyanagi
KyotoUniversity Dr.YasuhisaIwashita
JAEA Dr.Naoto
Metoki,Dr.Takenao
Shinohara
RIKENInnovationcenteradministrativeoffice
Committeemembersofcompactneutronimagingsystemandapplications
PWRI
Dr.YoshitomiKimura
Application of neutron radiography to industries and large
structure inspection Demands for non-destructive testing in
industriesVCAD System Research Program 4Example of simulation based
on "real" objectMeasurment of actual productRepresentation of
actual product data Structure analysis using measurement
dataLimitation of X-ray CT and possibility of neutron
radiographyHow neutron radiography is used in industrial
R&DNeutron radiography examplesSteel pyramid, Cylinder with
slitsComposite material Crack caused by fatigue failure testPlastic
injection molding dieConcrete sample -CT reconstruction and
simulation- Structural simulation by V-Struct Movements toward
compact neutron imaging system and its applications at
RIKENManufacturing process applications-applications proposed by
committee disucssion-Inspection of large structures-Bridges,
buildings, civil engineering-SummaryFuture plan at
RIKENCollaborators and acknowledgements
