ECNDT 2006 - Poster 54

Time Saving in the X-Ray Production

Control by using ASD
Elena TOSTI, AVIO Propulsione AeroSpaziale, Colleferro, Italy

Abstract. Time reduction in production controls are very important to avoid long
waiting time between phases. This either in large number production of middle
dimension units and in small number production of large dimension units. Both
cases exist in the AVIO Space Division in Colleferro. In order to reduce X-Ray time
control, the use of ASD has been implemented with a time saving better of 70% now
guaranteed.

Introduction

In a production cycle the product undergoes Non Destructive Tests. The NDT are
important for monitoring of the quality of the product after a production phase and
eventually to submit the article to repairs or to reject in case of irreparable faults that
compromise the functioning of the object. These reasons justify the costs joined with NDT.
Nevertheless NDT sites are often heap bay for the incoming units since control time
is not lined up with time of the previous phase and it is in general expensive duplicate the
control process. For an organisation of the production line following the concept of “lean
manufacturing” the requirements are to smooth technical times at each bay below the takt
time without losses in effectiveness. In view of cost reduction of the product,
improvements in NDT which imply profits, even with investments, are taken into great
consideration. This paper presents the solution taken in AVIO to reduce costs of NDT
mainly by shortening the control time.

1. NDT in Production Activities

1.1 Organisation of the Production Lines

The production line organisation following the concept of “lean manufacturing” (see
Fig. 1) considers two main requirements, namely: technical times smoothed below the takt
time (in Fig. 1 the arrow indicates a phase out the takt time characteristic of the production
line in consideration) and manpower organised through working team. These two
requirements strongly also affects the logistical aspect of the production line. The first step
minimising the crossing time of the item is to conceive a plant dedicated to the production
of this item where materials come in and the final piece goes out. In the production plant
dedicated to the item all manufacturing phases takes place: realization of the roughing
piece, mechanical finish, resistance tests, NDT controls, dimensional tests, final
assembling. In the dedicated plant the item moves in agreement with the manufacturing
phase flow. In each processing bay the item stands just the time to perform the process. The
technical time of each processing phase does avoid a pile up of pieces in the bay. In the

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case a pile up is generated (see arrow in Fig. 1), means that the technology relevant to the
process is not lined up with the previous one in the production cycle. When wait-time
characterizes a production phase it is necessary to critically analyse the process and to
initiate corrective actions to remove the “bottleneck” effect in the production flux.

METALLIC
THERMAL THERMAL PARTS
PROTECTION PROTECTION PREPARATI
APPLICATION POLIMERISATION ON BAY
BAY IN AUTOCLAVE

MECHANICAL
FINITURE
BAY

METALLIC TAKT TIME

MANDREL

TIME [hours]
ASSEMBLING PARTS
& DI- ASSEMBLING
BAY
SASSEMBLING
BAY FILAMENT
WINDING
BAY
IN
PHASE
X-RAY
HIDRO-PROOF CONTROL DIMENSIONAL OUT
TEST BAY BAY TEST BAY

Figure 1 – Lean manufacturing production line and takt time

1.2 Smoothing of NDT Time

Cut down production costs means to upgrade technologies in view of shortest time
and highest reliability. NDT also are involved in these improvements. To this purpose, after
the selection of NDT methods that meet the reliability requirement, techniques allowing
shortest control time shall be designed. In particular highly manual old techniques shall be
avoided because too slow. In pursuit of optimal NDT for production rate, several methods
have been tested in AVIO among conventional and not conventional NDT: x-ray, US, IR-
lock-in, shearography, acoustic emission.
For the time being, the results of these tests, the discussion of which are beyond the
subject of this paper, show that concerning the product type in AVIO, the radiographic
control has the highest reliability. For this reason activities focused in the reduction of x-ray
control time have been initiated in AVIO by means of the Six Sigma methodology. The
results of these activities are summarised hereinafter.

2. Product Type and Relevant NDT in AVIO

AVIO Space Division in Colleferro is involved in the construction of solid

propellant rockets used on European launchers (Ariane 3, 4, 5 and VEGA). AVIO Space
Division is also involved in the construction of solid propellant rockets of tactical missiles
in defence cooperations among European governments. The last generation of solid
propellant rockets designed in AVIO uses case in carbon fibre instead of metal. In both
applications: space and tactical propulsion, the case construction technology is the same,

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but the dimension of the final product much different (see Fig. 2).

388 mm

3000
1929 mm

9320

Figure 2 – Typical dimensions for solid propellant thrusters used

in space application (on the left) and in tactical application (on the right)

In this type of rockets: the possible defects, the roughness of the surface, the shape,
the existence of not accessible areas, the internal feature of the case obtained by means of
complex layering operations in filament winding technology, make NDT control not easily
feasible. The only NDT method allowing for unambiguous results is the radiographic
control.
Unfortunately the severe requirement in the defect detectability (thin delaminations
how 0.3 mm inside 500 mm of material thickness) needs to use conventional film and
exclude videoscopy systems already available in AVIO since 1985 for Ariane rockets x-ray
control. Radiographic controls using conventional film fulfil the sensitivity requirement,
but not the shortest control time requirement that causes the “bottleneck” effect in the
production flux either in large number production of middle dimension units and in small
number production of large dimension units. The RT using conventional film implies
several causes of lengthening of control time: exposure preparation in the dark room and in
the exposure area, exposure time, film processing. The Fig. 3 shows the typical (theoretical)
time for each operation. In case of units of large dimensions, being implied high energy
accelerator (9-15 MeV), the phase of film positioning/removing can require time longer
than in film processing. The long time is due to safety operations implied when high energy
accelerator is used. The processing time indicated in Fig. 3 is at least 1 minute (time
necessary to the film insertion in the processing machine), but 8 minutes have to be
considered if is necessary the control of the result before the next radiography.
All causes of lengthening of the control time give a serious percentage increase of
the overall time that only the “imaging” technique in x-ray can overcome.

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 FILM CONTROL CYCLE

DARK ROOM BUNKER CONTROL ROOM

CHASSY FILM FILM DENSITY

LOADING POSITIONING EXPOSURE
CHECK
Te Te
1.5 1.5 5 1
0.1 0.1
FILM
SHELVING

BUNKER FILM READING:

FILM FILM ACCESS
PROCESSING REMOVING ABILITATION • DEFECT
DIMENSIONING
1-8 1-8 5 1 • APCEPTANCE
1-3 0

LEGENDA

PHASE NOT INCLUDED IN TIME REDUCTION DESIGN

MANUAL AND AUTOMATIC OPERATIONS

REQUIRED TIME [min] FOR RX TUBES AND ACCELERATORS

Figure 3 – Time required for each operation of an x-ray control through conventional film

4. Shortening of Control Time by Using Digital Flat Panel Radiographic Systems

Among the imaging systems, the x-ray Amorphous Silicon Detector (ASD) has
been selected as its performance reach the radiographic class C3 (EN 584.1) which is the
class used for control in AVIO and it allows for control without access to the inspection
area. Performance was tested both on middle dimension units and large dimension units.
The results [1] obtained through x-ray ASD, showed the same or better image quality with
respect conventional film. The first digital radiographic system implemented in AVIO
Colleferro was for control of middle dimension units and it is composed by (see Fig. 4):

• X-ray tube 225 kV, 640 W (1 mm focal spot) and control unit
• X-ray tube diaphragm and control unit
• DR flat panel 127 μm pixel pitch, Gd2O2S conversion screen, 29.3x40.6 cm pixel area
• Image processing and remotely control unit
• Motorised movements test bench and remotely control unit
• Surveillance camera

Control by means x-ray ASD is performed in agreement to the flow in Fig. 5. In the
figure are also specified typical time (theoretical) for each operation. The comparison with
Fig. 3 lets to determine the advantages in time saving when x-ray ASD is used.
Time saving is consequent to remotely performed operations avoiding continuous

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access to the inspection area, as well as to shorter exposure times (see Table 1). Exposure
parameters by using ASD detector are smoother with respect conventional film not only
concerning exposure time but also energy. This since ASD detector efficiency is higher
than the film efficiency.

CONTROL BUNKER
ROOM

SURVEILLANCE
CAMERA
X-RAY
ASD

INTERNAL
VIEWS

X-RAY TUBE
DIAPHRAGM
CONTROL
UNIT X-RAY
TEST BENCH TUBE
CONTROL
X-RAY TUBE
UNIT
CONTROL UNIT

Figure 4 – X-ray control system using ASD detector

ASD CONTROL CYCLE

CONTROL ROOM

FLAT PANEL
POSITIONING IMAGE
PROCESSING
0.4

IMAGE
STORAGE
RX TUBE EXPOSURE
SETTING IN “LIVE” ACQ

0.3 0.3
IMAGE
ANALISYS:
• defect
COLLIMATOR dimensioning
SETTING 10 FRAMES
INTEGRATION • acceptance
0.4
0.6

LEGENDA
PHASE NOT INCLUDED IN TIME REDUCTION DESIGN
REQUIRED TIME [min] FOR RX TUBES
OPERATIONS FROM REMOTE

Figure 5 – Time required for each operation of an x-ray control through ASD

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 TABLE I – Exposure parameters used for X-ray control of middle
dimension solid propellant thrusters by means conventional film and x-ray ASD

No. of
ENERGY INTENSITY EXPOSURE EXPOSURES OTHER PARAMETERS
[kV] [mA] TIME (0°-90°-
ZONE of [s] 180°-270°)
THE MOTOR [#]
FILM ASD FILM ASD FILM ASD FILM ASD FILM ASD
DOME 180 100 6 6.4 240 30 4 4 ASD:Fine
Film: FO =
Class C3 1050 mm
CYLINDER 180 140 6 4.55 90 30 4x4 4x4 OF =
FO = 300 mm
1200 mm
OF = ASD:Fine
190 mm
FLANGE AT 220 100 6 6.4 420 30 4 4 Radio- FO =
CYLINDER graphic 1050 mm
END density: OF =
1.5÷3.0 300 mm
(double
exposure) 180 225 6 2.8 110 75 4 4 FO =
440 mm
OF =
300 mm

METALLIC
CONNECT- 180 (*) 6 (*) 300 (*) 3x4 0
/
ION THE
CYLINDER

(*) exposures of sectors on the cylinder let the simultaneous control on both: fibre case and metallic
connections, due to ASD higher dynamic than film [2].

In order to evaluate the true time reduction in replacing the x-ray control by
conventional film with x-ray control using ASD, two lots of 25 thrusters each have been
considered and the relevant distributions of the control times for unit have been traced out
(see Figs. 6 A and B).
In Fig. 6A the control times necessary when traditional films are used, are in any
case longer than the takt time. On the contrary, the control times are greatly reduced below
the takt time when the control is performed through x-ray ASD.
The times needed for control by means ASD have been lowered below the required
specifications, but the technique allows control time below the monitored mean value of
1.68 hours. In effect the technical time for frame is 2 minutes (see Fig. 7) which is the
minimum got time. In this time is excluded the analysis of the frame necessary for
dimensioning of eventual defects and for acceptance because this operation can be
performed by a second operator on a parallel PC. The same procedure apply to
conventional film, where other operators evaluate defects during x-ray control.
In Fig. 7, where the distribution of the time for single frame is shown, the empty
rectangles are relevant the time typical for a skilled operator, while the full rectangles are
relevant the time typical for not skilled operator or obtained when the analysis is performed
during the control. In considering the 2 minutes or “technical time” for frame, the evaluated
“technical time” for control of the thruster is 1 hour with x-ray ASD versus 4.3 hours when
conventional films are used for control. This improvement, not actually necessary, can be
considered for future demands.

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 Process Capability Analysis for TEMPI RX (DR

TAKT TIME
8 A 0 B
TAKT TIME

5
0
FREQUENCY

FREQUENCY
6

6
2

0
8
3
0 8 0
4 5 6 7 8 9 1.0 1.2 1.4 1.6 1.8 2.0 6.0
CONTROL
Observed Performance
TIME [hours]
Exp. "Within" Performance Exp. "Overall" Perfor
CONTROLExp.TIME
Observed Performance
[hours]
"Within" Performance Exp. "Overall" Performa
PPM < LSL 0 00 PPM < LSL 0 09 PPM < LSL PPM < LSL 0 00 PPM < LSL 0 00 PPM < LSL

Figure 6 – Distributions of x-ray control time per unit by means film (A) and ASD (B)

180
150
120
FREQUENCY

90
60
30
0
0 1 2 3 4 5 6 7 8 9 10 11
TIME FOR SINGLE IMAGE [hours]

Figure 7 – Distributions of times for single image by x-ray ASD

5. Conclusions

The use of x-ray control by means ASD in place of conventional film, has allowed
the reduction of the control time in the production line for middle dimensions thrusters. The
reduction has been 76% and a potential reduction up to 86% has been evaluated how the
maximum allowed.

Acknowledgements

The author wishes to acknowledge Dr. U. Heike, Mr. D. De Toni and Mr.
M. Calvi for their help during the set-up of the system.

References

[1] Tosti E., Gatta A., “Controlli non Distruttivi effettuati su Componenti Aerospaziali mediante un Sistema
di Radiografia Digitale”, 10° Congresso Nazionale AIPND, Ravenna 2003, ITALY.
[2] Ewert U., Zscherpel U., and K. Bavendiek “Film Replacement by Digital X-Ray Detectors - The Correct
Procedure and Equipment”, 16th WCNDT, Montreal 2004, CANADA.