How long does it take to inspect a typical part (e.g., 100 mm x 100 mm x 100 mm)?
The time required to conduct a comprehensive X-ray CT inspection on a typical 100 mm cube part is highly variable, ranging from approximately 2 to 8 hours. This duration is not based on a simple volumetric calculation but is influenced by a critical trade-off between inspection speed, resolution, and the material's density. The process can be broken down into three main phases: setup, scanning, and data analysis.
Key Factors Determining Inspection Duration
1. Required Resolution and Scan Parameters
This is the most significant variable. The need for finer detail drastically increases the scan time.
Standard Resolution (e.g., 50-100 µm voxel size): Suitable for detecting larger porosity and general internal defects. A scan at this resolution for a 100 mm part might take 2-4 hours.
High Resolution (e.g., 15-30 µm voxel size): Necessary for finding micro-porosity, fine cracks, or validating thin walls. To achieve this, the system must take many more individual projections (X-ray images), potentially increasing the scan time to 4-8 hours or more.
2. Material Density and X-ray Energy
The part's material directly dictates the technical setup.
Low-Density Materials (e.g., Aluminum Alloys, Plastics): These allow for lower energy X-rays and faster exposure times, leading to shorter scan durations, often in the 2-4 hour range.
High-density materials (e.g., Titanium Alloys, Stainless Steel) require high-energy X-rays and longer exposure times per projection to achieve sufficient penetration, which pushes scan times toward 4-6 hours.
Very High-Density Materials (e.g., Superalloys like Inconel 718): Present the greatest challenge, often requiring the longest exposure times and thus the longest scan durations.
The Three Phases of the Inspection Workflow
The total lead time you experience encompasses more than just the scanner's runtime.
Setup and Mounting (~30-60 minutes): This involves carefully positioning the part on the rotary stage to optimize the scan path and ensure stability, which is critical for image clarity.
Data Acquisition (Scanning) (~2-8 hours): This is the actual CT scanning process, where the system collects hundreds to thousands of 2D X-ray projections as the part rotates.
Data Reconstruction and Analysis (~1-4 hours): After scanning, the 2D projections are computationally reconstructed into a 3D volume. This is followed by the crucial step of an analyst evaluating the data, segmenting defects, and generating a report. This analysis time can be as important as the scan time itself.
Strategic Application and Timing
Understanding this timeline is crucial for effective project planning, particularly for components intended for critical applications.
Rapid Feedback: For process development or non-critical checks, a faster, standard-resolution scan may be sufficient.
Final Quality Certification: For a safety-critical component in Aerospace and Aviation or a Medical and Healthcare implant, a high-resolution scan is a non-negotiable investment of time to ensure the part is free from detrimental defects that could lead to failure. This detailed inspection provides the final validation that complements other quality data, such as mechanical testing of [witness coupons](### The Purpose and Importance of Testing Final Parts).
In summary, while a 100 mm cube part can be scanned in a few hours, it is recommended to plan for a full business day to account for the entire workflow, with the understanding that higher scrutiny for critical components will require more time.
