Powder Proportion Analysis via 3D Computed Tomography
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Solution Overview
Problem
Existing methods for determining the proportion of porosity in metal powders, such as those used in gas turbine engine manufacturing, suffer from low throughput and unreliability due to reliance on two-dimensional imaging and inadequate mixing of powder samples, leading to inconsistent results.
Innovation Solution
A method involving the preparation of a sample powder mixed with a molten material, solidified into a block, and then analyzed using computed tomography to produce a three-dimensional image, allowing for accurate counting and fraction determination of powder particles and pores, including calculation of pore diameters, using X-ray computed tomography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-dimensional imaging methods are used to determine powder porosity, then the device complexity is reduced, but the measurement precision and reliability deteriorate due to inadequate mixing and powder settling
Solution Approach 1:
The patent transitions from two-dimensional imaging to three-dimensional computed tomography imaging to analyze powder particles. This dimensional change enables accurate visualization of powder distribution and porosity without the limitations of planar projection, eliminating the need for complex mixing procedures while maintaining measurement reliability.
Solution Approach 2:
The patent introduces a transparent embedding medium as an intermediary to suspend and hold powder particles in a fixed three-dimensional arrangement. This medium acts as a matrix that prevents particle settling and enables stable imaging, resolving the contradiction between simple device operation and measurement precision.
2Ease of operation
If a simple mixing method is used to prepare powder samples, then the ease of operation is improved, but the reliability deteriorates due to inadequate mixing and particle separation
Solution Approach 1:
The transparent embedding medium serves as an intermediary that simplifies sample preparation by providing a self-supporting matrix. Powder particles are suspended in this medium without requiring complex mixing or handling procedures, yet the medium maintains uniform particle distribution and prevents settling, ensuring reliable and consistent measurements.
Solution Approach 2:
The embedding medium is prepared in advance as a ready-to-use matrix that automatically maintains particle positions. This preliminary preparation eliminates the need for complex mixing operations during sample preparation, while the pre-formed matrix structure ensures uniform particle distribution and measurement reliability.
3Measurement precision
If three-dimensional computed tomography imaging is used to analyze powder particles, then the measurement precision is improved, but the use of energy and device complexity increase
Solution Approach 1:
The transparent embedding medium acts as an intermediary that enhances image contrast and quality, allowing for accurate three-dimensional reconstruction with optimized imaging parameters. This reduces the need for excessive energy input during scanning while maintaining high measurement precision through improved signal-to-noise ratio and particle visibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high-throughput, reliable determination of powder particle proportions and porosity, reducing variability and improving accuracy by utilizing three-dimensional imaging, which is scalable and minimizes the impact of powder settling, thus enhancing the quality control of metal components.
Implementation Method 1
carrying out computed tomography on the block to produce a three-dimensional image of the block
Implementation Method 2
carrying out computed tomography on the block to produce a three-dimensional image of the block
Implementation Method 3
solidifying the mixture of powder and molten material to form a block
Data Source
AI summary
A method of determining the proportions of different powders in a powder comprises obtaining a sample of a powder, adding and mixing the sample into a molten material and freezing the mixture of powder and molten material to form a block. Computed tomography is performed on the block to produce a three-dimensional image of the block, the three-dimensional image of the block comprises a first shade, a second and a third shade corresponding to the material, a first powder particle and a sec and powder particle. The three-dimensional image of the block is analyzed to count the number of regions exhibiting the second shade and the third shade corresponding to the number of first powder particles and second powder particles respectively. The fraction of second particles in the powder is determined by dividing the number of second powder particles by the sum of the number of first powder particles and the number of second powder particles.