Advanced characterization of metal components

See the hidden details in metal components by having non-destructive analyses performed at large-scale facilities

At the Danish Technological Institute, we can help you gain new insights into common challenges in the metal industry - including fatigue strength and manufacturing- and corrosion-related issues. We do this by applying advanced characterization using neutrons and X-rays, which make it possible to look deep into the metal.

The challenge of residual stress

In the metal processing industry, we see many challenges related to invisible, unresolved stress in metal components, also known as residual stress. This residual stress is the reason why components, for example:

• warp
• are affected by stress corrosion cracking
• experience premature cracking
• are designed with excessive safety factors
• must be inspected frequently

Precise in-depth measurements

Several of the properties that are important for the performance of metallic materials and components can be measured precisely and in-depth using neutrons and X-rays, and these measurements can be used to:

• Extend lifetime estimates
• Drastically reduce service intervals
• Perform failure analysis, especially regarding cracks
• Increase safety and prevent component failure
• Reduce wall thickness and thereby save material

By performing measurements with neutron and X-ray radiation at large-scale facilities around Europe, we are able to carry out very fast, high-resolution measurements at great depths. In this way, we can often perform measurements similar to those you know from conventional laboratories, but on specimens or at depths that cannot be measured using standard lab equipment.

The relevance of non-destructive methods

We specialize in non-destructive methods and use advanced technology that allows for 100 percent quality control. The techniques we use are crucial for evaluating key factors for the long lifetime of critical components, e.g., within aerospace as well as for the reuse of critical components.

Let us take an example: Residual stress in metal parts can drastically affect fatigue strength and perhaps cause deformation after machining, leading to problems with remaining within dimensional tolerances.

Stress corrosion cracking is a critical phenomenon that is often caused by unresolved residual stress, and it is difficult to detect these cracks before the component fails catastrophically. Based on a measurement of the residual stress in the component, it will be possible to assess the risk of the aforementioned challenges -- before the component is put into service.

Opportunity to measure unseen details

These analytical methods provide great flexibility and the potential to measure unseen details in any type of material - from stainless steel to aluminium and titanium alloys.

Experience shows that many components are designed without taking residual stress into account, or by assuming a 'worst-case scenario'. By measuring the residual stress, it is usually, possible to reduce material usage or extend the lifetime. Alternatively, it can be demonstrated that it would be beneficial to implement processes that control residual stress.

Each solution is customer-specific, so do not hesitate to contact Nikolaj Henriksen, PhD and specialist in residual stresses, for more information.