Revolutionizing Aerospace with CT Scanning: A Leap in Cost Savings and Lead Time Reduction

In the highly competitive aerospace industry, precision, reliability, and efficiency are paramount. As the demand for advanced aerospace components grows, manufacturers are turning to innovative technologies to stay ahead. One such groundbreaking technology is Computed Tomography (CT) scanning, which is transforming the way aerospace components are inspected and manufactured.

What is CT Scanning?

CT scanning, traditionally used in medical imaging, has found a new and vital application in the aerospace industry. This non-destructive testing (NDT) method uses X-rays to create detailed 3D images of an object’s internal structure. Unlike traditional inspection methods, CT scanning can reveal hidden defects, measure internal geometries, and ensure the integrity of complex components without disassembling or damaging them.

Below, we will explore the ways that CT scanning can reduce costs and lead times and enhance safety.

Cost Savings

1. Reduced Scrap and Rework: CT scanning allows for early detection of defects in materials and components, significantly reducing the need for costly rework or scrapping of parts. By identifying issues before they become critical, manufacturers can save substantial amounts on material costs and labor.
   
   IIA’s CT scan and void analysis of two cast ingots of alloyed precious metals before being worked into a final product. This analysis can be performed at any point in the manufacturing process — from raw material to in-process to final product — to help reduce scrap rate and ensure the final part is structurally sound. The CT scans and void analysis was used to verify process changes that eliminated voids in the material before working it.
2. Optimized Design and Manufacturing: With precise internal measurements, engineers can optimize designs for manufacturability and performance. This leads to fewer design iterations and a more streamlined production process, ultimately lowering development costs.
3. Extended Component Life: By ensuring the highest quality standards, CT scanning helps manufacturers produce more reliable components that require less frequent replacements. This longevity translates to cost savings over the lifecycle of the aircraft.

Lead Time Reduction

1. Faster Inspection Processes: Traditional inspection methods can be time-consuming and labor-intensive. CT scanning, on the other hand, provides rapid and comprehensive analysis, significantly speeding up the inspection process. This efficiency allows for quicker turnaround times from production to deployment.
2. Accelerated Prototyping: In the development phase, CT scanning enables faster prototyping by providing immediate feedback on the internal structure of new designs. This rapid iteration capability shortens the overall development cycle, bringing products to market faster.
3. Streamlined Quality Assurance: With the ability to inspect complex geometries and internal features in a single scan, CT scanning simplifies the quality assurance process. This streamlining reduces bottlenecks in production and ensures that only the highest quality components move forward in the manufacturing pipeline.

Case Studies

1. Inspecting 3D-Printed Rocket Components: Industrial CT scanning has been instrumental in enhancing 3D-printed rocket parts. By detecting flaws, such as incomplete fusions and internal cracks, manufacturers can make real-time adjustments to printing parameters, improving part quality and reducing waste. For instance, a flaw detected in a rocket nozzle was addressed early, preventing potential engine failure and optimizing the component’s design for future production runs.
2. Quality Assurance in Aerospace Components: CT scanning is often the only solution for inspecting space systems and their components. As a non-destructive test method, CT scanning opens the door to new possibilities, allowing for 100% inspection of parts for mission-critical components — something that is just not possible with other traditional methods of inspection. This technology helps identify internal defects that could compromise the integrity of essential parts, ensuring that only the highest quality components are used in space missions.
3. Assessing Turbine Blade Integrity: The non-destructive inspection of the integrity of turbine blades could not be performed by any other means than CT scanning. By examining wall thickness, erosion, and wear, CT scanning technology ensures that these critical components meet stringent safety and performance standards. This process not only enhances the reliability of the turbine blades, but also reduces the risk of in-flight failures, leading to significant cost savings and improved safety.

Conclusion

The integration of CT scanning in the aerospace industry is a game-changer, offering unparalleled benefits in cost savings and lead time reduction. By adopting this advanced technology, aerospace manufacturers can enhance their competitive edge, deliver superior products, and meet the ever-growing demands of the market. Embracing CT scanning is not just an investment in technology; it’s an investment in the future of aerospace innovation.