MODEL TX-RSA
TX - NDT Systems X-ray Residual Stress analysers
Industrial metallurgists have been
using X-ray residual stress analysis
for many years as the preferred
method for measuring unwanted or
actual residual stresses in crystalline
materials, but the technology
available has always been based on
simple manually operated, often floor
mounted XRD systems employing
relatively insensitive detectors which
always require a high power X-ray
source with a water cooling supply.
Such systems work well enough
although there can sometimes be
safety issues to consider when high
power X-ray tubes are employed.
Water cooling supplies are always
a problem and high X-ray power
means a high power mains voltage
supply There is however an urgent
need in industry for automated
high speed systems with very high
sensitivity allowing a complete
analysis to be made in just a few
seconds plus a need for systems that
can handle larger components that
just will not fit into a safety enclosure
and it is these requirements that our
new universal multi use NDT systems
address.
RSA-10 - Mobile X-Ray Residual Stress Analyser
RSA-20 - Portable X-Ray Residual Stress Analyser
RSA 30 - Industrial X-Ray Residual Stress Analyser
RSA-40 - Robotic X-Ray Residual Stress Analyzer
To improve the analytical method for large
and or massive components we have
developed a very high precision computer
controlled robotic X-ray residual stress
analyser designed to substantially improve
accuracy of stress measurements both in
terms of defining residual stress parameters
within a sample in addition to measuring
Austenite phases and the absolute location
of those parameters about or within the
sample. The new TX Robo-Stress analyser
( RSA-40 ) is based on an extremely
robust computer controlled robot that can
be programmed to accurately position a
compact stress analyser within or about
a defined 3D volume and automatically
measure residual stresses located about
an object by analysing the Xray diffraction
peaks associated with stresses retained in
a material after a manufacturing process.
Powerful software operating in real time
allows the robot to automatically position
the X-ray probe about any 3D object
within or about practically any sample no
matter how large. Such samples can be
aerospace components, turbine blades,
gears, bearings, motor car components
and other large structures. Absolute
positional accuracy is assured by an
integrated laser position finder that can
determine an objects 3D profile and
locate an exact location for analysis and
repeatedly reposition to that location to
within just a few microns without manual
intervention.
RSA-40 robotic residual stress analyser
Robotic Safety
The RSA-10 Robotic Stress Analyser
is the safest instrument in town and
the reason why is that the robot does
all the work and the operator simply
controls the measurement from a
computer console at a distance. All
parameters being under software
control. The X-ray power supply is
just 4 watts making TX NDT systems
the safest in the world to use. Many
commercial stress systems require
high power X-ray sources ranging
from 200W to 2KW. Ours is just 4W
Robotic software is able to control
the position of the stress probe by
accurately and automatically finding
the correct Eulerian coordinates
about any type of sample and
so measuring the correct X-ray
diffraction stress parameters in 2
or 3D space. By employing a free
spatial probe under robotic control
it is no longer necessary to employ
manually operated or fixed position
goniometers allowing massive or
exceptionally large samples to be
analysed with ease
Applications for our robot stress
analysers are industry wide and
include aerospace, motor industry,
bearing manufacturers and most
other manufacturers of large critical
assemblies and components
including structural engineering..
Other but similar applications include
aircraft undercarriage components,
airframe, high pressure or critical pipe
assemblies as well as alloy metal
components, engine and turbine
parts and assemblies and similar
technologies.
MODEL TX-RSA
TX stress systems can employ many
types of X-ray source but for safety
reasons we choose to use low
power AIR COOLED high radiance
X-ray sources designed specifically
for stress analysers. Because of
the exceptional sensitivity provided
by our solid state strip detector
technology, compact air cooled high
radiance sources to be used as
standard and with a power of just
4 Watts we achieve truly excellent
S:N ratios in just a few seconds.
An integrated collimator and laser
profiler ensures that the maximum
Xray intensity is available in the exact
position required for the sample
under test. Our ultra high sensitivity
position sensitive detector does the
rest ensuring both high accuracy
and short measure times in the
region of just a few seconds and in
“real time “. The design also ensures
that the requirements of most
world standards for NDT are always
exceeded
Solid state “ultra high
sensitivity” 1280 channel
PSD detector
TX stress analysers employ a
remarkable ultra fast solid state
detector with 1028 separate elements
or channels, each providing a count
rate of 1 X106 cps and therefore an
overall max count rate >1.2 X 109
cps. Efficiency is optimised for Cr
Ka energy. In addition the detector is
single photon counting plus energy
discrimination and a net photon
efficiency that exceeds 90% , making
it the perfect detector for stress
analysis. By employing a wide angle
position sensitive detector with energy
discrimination and single photon
counting sensitivity we are able to
measure stress parameters with
exceptionally low backgrounds. We
have also designed the stress head in
such a way that we are not limited to
measuring just two diffraction profiles
but can analyse up to ten or more
separate diffraction profiles about
the stressed location so allowing
exceptionally good stress data to
be obtained from both low or wide
angles. By employing a “state of the
art” strip detector we are also able to
improve system reliability by providing
a stress analyser that is both rugged
and accurate.
Notes on retained Austenite
When steel is heated as part of a
manufacturing process, phases
present in the structure at ambient
temperatures can change in such a
way that they become transformed
into a face centred cubic structure
generally known as Austenite.
When steel is heat treated as part
of a manufacturing process such
as hardening, the metal is first
heated and then rapidly cooled by
quenching, This causes the Austenite
to transform to Martinsite which is
a very brittle and hard phase. When
this phase is undesirable, metals can
be tempered in such a way so as to
reduce the brittleness but retain most
of its hardness
In fact when steel is tempered or
quenched it is always likely that
Austenitic phases will be retained and
so may seriously effect the design
performance requirements of the
alloy over time, in that stresses can
cause the retained Austenite phase
to slowly change to Martensite, which
may cause dimensional instability or
failure. Clearly control of Martensitic
and Austenitic phases are extremely
important when manufacturing high
performance alloys and it is for this
reason that TX stress analysers
allow the user to simultaneously or
otherwise measure these critical
phases.. See ASTM E975 and SAE
SP-453
How is this achieved
TX Stress systems are sophisticated,
mini X-ray diffractometers designed
to spatially measure diffraction peak
intensities associated with residual
stresses and are retained within a
crystalline matrix, using technology
that allows diffracted X-rays to be
measured in real time and at high
sensitivity. To achieve this we employ
a rugged very high sensitivity X-ray
detector placed at the side of a
low power X-ray source and this
constitutes the Xray diffractometer.
The detector measures the diffraction
pattern associated with that particular
sample over a small or if necessary a
large angular range as determined by
the experiment.
Our Software plus Reitveld
refinement
Residual stress tensors are measured
using X-ray Diffraction technology
and we have manufactured a range
of XRD systems now for several
years. During this time we have
developed sophisticated software
for all XRD applications including
full profile stress analysis using the
Reitveld whole pattern method. This
allows stress and texture analysis
to be made at high speed on a
wide range of materials and alloys
measuring critical microstructures
or multi phase components using
either multi - bi axial or mono axial
geometry plus Sine2 Psi. This means
that residual stress analysis can be
made on any polycrystalline material
using a variety of methods including
plane or triaxial stress using chord,
Marquardt and centroid analysis with
both linear and elliptical interpolation.
The Reitveld whole pattern method
allows stress values to be evaluated
from each phase both with or without
texture and is not limited to analysing
stress tensors from just two or three
diffraction peaks
The unique multi use TX
Goniometer
Our goniometers are exceptionally
compact and are ideally suited for
use as mobile stress analysers or
integrated into a console or robot.
They have a large angular 2 theta
range of 40 degrees and have options
for a motorised phi axis. The multi
RSA-20 portable residual stress analyser
channel detector provides a typical
measure time of just a few seconds
per psi position allowing fast analysis
to be made on any sample.
The overall measurement angle
in “real time “is over 40 degrees (
125 – 165 degrees 2 theta. The Psi
Angular range is 90 degrees ( -45 to
+45 ) degrees and the Phi range is
360 degrees about a radius of 80mm.
This exceptional goniometer allows
the measurement of stress tensors
in many different alloys without
the need to adjust the goniometer
allowing retained Austenite also to be
measured in a single measurement
with stress and in “real time “ . This
compares favourably with any other
commercial instrument which may
offer typically only 20 degrees in a
single measurement and must be
readjusted every time the sample alloy
type is changed.
RSA-20 portable residual stress analyser
RSA-20
This remarkable portable “go
anywhere” stress analyser weighs just
3 Kgs including a high speed solid
state multi channel detector and X-ray
source and is one of the most compact
stress analysers available today. It
features a solid state single photon
counting high speed detector that
allows accurate stress measurements
to be made in just a few seconds
including retained Austenite. The stress
probe can be fixed to any object by
way of a simple adjustable arm or
clamp including a simple magnetic
clamp which is very useful for out of
doors applications such as bridge
structures or pipelines. The measuring
head is very small allowing stress
measurements to be made inside
bearings or gears or other objects with
complex shapes.
RSA-30 Is a console based stress
analyser designed for laboratory
environments where both large and
small structures require analysis and
certification. Large or heavy samples
can be positioned about the stress
measurement head with ease and
provides an extremely accurate and
fast stress measurement system that
is easy to use and very robust
3D measurements using our
electrolytic depth profiler
Sometimes it is interesting to
measure stress as a function of depth
within a sample which means that
material must be removed to expose
stressed crystalline layers under the
surface. Normal machining is not
possible as this would introduce
further stresses within the material.
To overcome this difficulty we have
developed a small easy to use electro
etching process that allows material
to be removed without inducing
further stress
An analytical service to
our customers with 2Effe
engineering
We provide both an on site and
an in house analysis service for all
stress / NDT requirements as well
as offering a certification programme
for finished parts. We have several
types of residual stress and X-ray
diffraction instruments available and
this service is available in any country
on demand. In Europe we are able
to provide a stress relieving service
for finished products including shot
peening and product certification for
residual stress and Austenite phases
System Specifications
Goniometer
Psi Angular range
Phi angular range Radius
Solid State strip detector range
Sample alignment Sample 3D profiling
Motorised phi axis option
Double 2D inclinometer option
Can be used in any orientation
Type 2 Goniometer
Super lightweight sress probe designed for use as a mobile analyser or
robotic probe.
A rugged multi access goniometer designed for laboratory applications
and interfaced to an adjustable tripod mount.
Communication
System Control
Retained Austenite
Method
Detector Option 1
Alloys Xray Power supply
Xray Source
Ethernet or wireless communication
Automatic under software control
Simultaneous analysis + stress
Single direction - bi-axial – tri-axial analysis
Sine2 Psi using the Rietveld method Mythen ultra fast detector with single photon counting
Type strip detector, 320 microns thick with low background
Overall max count rate 1.2 X 109 cps
Strip width each 50 microns. Total number of strips 1280.
Efficiency 90% @5KeV.
Allows analysis over 40 degrees (125 – 165) degrees 2 theta
Analysed with standard detector include St - Steel, Al. , Austenitic steels etc
0-35KV 0-100uA air cooled 4Watt
Cr Air cooled long life
Light weight stand
Console System
Multi Axis Robot
Stress Software A compact portable stress stand that can be used in the lab or out side.
For use with both small and very large structures
A standard safety enclosure console for stress measurements in the lab.
Suitable for small and large structures
Multi axis Robot providing centre less sampling
All positions under software control
Full profile analysis using Rietveld method
Multi material program
Weight stress head
Water
Power
Net 3Kgs according to detector and model
Not Required
Mains operation 110 – 240V AC standard
Or Battery Operated for mobile use
Type 10 Goniometer
System
RSA-30 industrial residual stress analyser
90˚ ( - 45 to + 45 ) degrees
360˚ degrees
80mm
40˚ degrees ( 125˚ – 165˚ degrees 2 theta
Laser controlled height adjustment
Laser 3D analyser
Portable Tri Axis Services
CAT412050
Representative
In association with TNX srl and 2EFFE srl
International X-Ray Associates, Suite 5 Enterprise Centre, Shrivenham Business Park, Swindon Wiltshire UK
Tel 44(0) 1793 783666 E [email protected] www.spectrolab.co.uk www.xrayassociates.co.uk