Introduction

Have you ever wondered about how technology in today’s world protects our lives? Let’s dig deep into the significance of one such technology that could assess the integrity and quality of the given parts quickly and efficiently at an earlier stage. And that’s nothing but an INDUSTRIAL X-RAY MACHINE. 

You may get surprised to hear that. But it’s true. Unlike medical X-rays, parts are assessed and not people. Using an industrial X-ray machine, it is possible to check the internal parts of the given sample without destroying it. Ranging from smaller to larger samples, an X-ray machine can scan at a lower resolution.

How industrial X-ray machine inspects?

For example, let us take a look at the given defective small battery and highlight why we should have a detailed examination! We know batteries are generally used in every sector around us. At times, there will be visible damage like swelling with a dome shape. This is not the only aspect that you should observe. There must be a bigger problem inside the given battery, due to which it got expanded. If we ignore that problem, it may later get manufactured and used by humans. In the hands of the user, there is a possibility of leakage followed by its explosion that proves to be lethal. This is where an X-ray inspection plays a significant role in saving someone’s life.

The smartest task is to discover these issues during the production stage itself. Only then, we can ensure the safety of the sample and prevent manufacturing loss as well. That’s why a batch process is created to reduce the time taken for a multi-part scan. Hence, the ultimate aim is the quick turnaround around to process thousands of samples.

Bring the battery closer to the X-ray source to derive a greater resolution scan having around 4-micron resolution. As the X-ray machine rotates the sample 360 degrees, nearly 1440 images of the sample are taken in multiple orientations, which will together be reconstructed into a 3D model of the sample using Uni X-ray software. Multiple orientations include manipulating the sample in slice, flip, rotate, and spin in a 3D fashion. This kind of detailed scan can elaborate the list of issues within the faulty battery.

Now that you have understood how industrial X-ray inspects. Let us next go through its history, principle, applications, and how Uni X-ray stands out in delivering the best customized industrial X-ray inspection machines.

History of Industrial X-ray machine

Credit goes to Wilhelm Conrad Roentgen (1845-1923), who discovered X-rays on November 8, 1895. He was the professor of physics in Wurzburg, Bavaria. Discovering an X-ray was an accidental one. Roentgen was checking whether cathode rays emitted from a Crookes tube could penetrate glass. Anyway, the cathode tube was covered in dark black colored paper. During this time, a pale luminous green light flew and shown onto a fluorescent screen layered with barium platinocyanide at one meter distance, Roentgen got surprised. 

Roentgen noticed that this mysterious light could pass through many objects leaving shadows of solid objects. Since Roentgen had no idea about the origin and type of these rays, he named them X-rays, otherwise called ‘unknown’ rays.

After working on these X-rays for seven weeks by conducting several experiments, Roentgen submitted the first report “On a New Kind of Rays,” in the Proceedings of the Würzburg Physico-Medical Society on December 28, 1895. 

Finally, in January 1896, his findings were publicly demonstrated before the same society, thereby the rays got another name “Roentgen’s Rays.” These rays are electromagnetic waves with a wavelength 1000 times lesser than the light rays as well as ultraviolet rays, but longer than the gamma rays. The wavelength of X-rays ranges from 10 picometers to 10 nanometers with respect to (30 petahertz to 30 exahertz) frequency range and (124 eV to 124 keV) energies.

Once Roentgen was able to view his wife Bertha’s hand where her wedding ring was clearly visible. That’s when Roentgen observed that these X-rays can pass through human flesh as well while taking the scan of tissues and bones. But these rays cannot penetrate higher-density materials such as lead or bone. This news spread throughout the world and the medical community started using these X-rays for diagnosis purposes. 

Within a year, physicians started using X-rays to determine fractures, gunshots, and swallowed things. Later, they began using X-rays for treating diseases like surface lesions and cancer as well.

Though research scientists including William J. Morton, Thomas Edison, as well as Nikola Tesla highlighted side effects from exposure to X-rays, people across the world started using X-rays in full swing. Hence, Roentgen got the Nobel prize in the year 1901. Although there are many risks due to the use of X-ray instruments, several protocols are developed recently to limit unwanted exposure to this radiation.

Development of Real-time X-ray Inspection Equipment

At present, the X-ray machine is also used in the industrial field. Hence, we call it an ‘industrial X-ray’ machine. As mentioned already, an industrial X-ray machine is used to determine any minute defect in a given sample within the shortest duration. 

Industrial manufacturers use X-ray machines as the non-destructive method to detect internal flaws without causing any harm to the given component. Furthermore, an X-ray machine can measure the dimensions of the given sample and keep a record of them. 

An X-ray machine is available as a fixed one or a portable one. So, you can move it anywhere or place it in an elevated position to perform this test. Just surface preparation is enough.

The invention of digital X-ray machines

As days go on, a film-based conventional X-ray machine was replaced by a digital X-ray machine. Since film-type consumes more time, the digital version is used where digital X-ray detectors are reusable and can deliver the final image on the computer screen instead of a film. Unlike film types, results derived in digital X-ray testing are stored in the cloud and can be shared easily by generating multiple copies. There is no need for darkroom conditions and chemicals. It is safe to work for digital X-ray operators, unlike the traditional ones.

There are four types of digital X-ray testing:

• Computed Radiography (CR)
• Digital Radiography (DR)
• Real Time Radiography (RTR)
• Computed Tomography (CT)

Although digital radiography is the advanced form of computer radiography, there are few differences between them.

Principle of Industrial X-ray inspection machine

X-rays are electromagnetic waves emitted due to the transition of electrons between lower and higher energy levels with energies between 0.1 and 1,000 kV. With a shorter wavelength, X-rays lie between ultraviolet and gamma rays.

Industrial X-ray machine involves three elements listed below:

• X-ray tube to produce X-rays
• A sample operation platform – This is where the given sample is placed so that it can be examined from different angles
• Digital X-ray detector – It helps to capture the emitting X-rays from the given test sample, which gets converted into an image.

The smaller the wavelength, the more the dispersion will be. That’s the principle of industrial X-ray, similar to medical X-ray. Since X-rays have a lesser wavelength (<100nm), they are used to pass through the denser objects used in the industries. In case if the test sample is thicker, only a lesser X-ray can only pass through.

Highly penetrating X-rays pass through the sample onto a photographic film. The resultant rays deliver an image of the sample’s interior structure on the film. The quantity of energy absorbed by the sample depends on the thickness and density of the sample. The energy not absorbed will look darker once you develop the film. Therefore, the portions of the sample exposed to minimal energy will look lighter. And of course, the flaws with respect to the changes in thickness will appear as dark outlines on the film. The final image can be delivered in variable degrees as per the density of rays. The variation in the density of the final film is due to the discontinuities in the target material.

The list of steps involved in the industrial X-ray testing are given below: 

• Keep the radiographic film on the distant side of the sample.
• Pass the X- rays emitted from an X-ray tube from one side to the opposite side where the film is kept.
• The radiographic film determines these rays and measures them in various quantities over the entire surface. 
• Process this radiographic film at once in darkroom conditions 
• Check the resultant image using a special light-emitting device. 
• The resultant image will appear in various degrees of black and white according to the density of X-rays.
• The alteration in the density of the processed film is due to the presence of flaws in the sample.

A false understanding of the inspection results becomes costlier and affects productivity seriously. Therefore, keep in mind that only a competent and well-experienced X-ray inspector should perform the X-ray test and interpret the ultimate images to determine the position and type of defect in the sample. It involves the skill of experienced personnel as the incorrect readings may considerably harm the efficiency as well as proves to be costly.

Industrial X-ray machine works by electricity. Hence, when you switch it off, the X-ray is not emitted.

What are the considerations you should pay attention to before using an industrial X-ray inspection machine?

Every part like battery, welds, etc. is critical in the manufacturing field. Therefore, these parts should be examined properly to make sure that they strictly adhere to the international guidelines before they are put into service. But before proceeding with radiographic inspection using an X-ray system, we recommend you pay attention to the following three phases:

1. Adjust the X-ray instruments used for the quality check to a known standard. This calibration helps in delivering precise test results.
2. Examine if you need to use a combination of NDT techniques. Usually, companies use a combination of methods to evaluate metal components such as pipes, joints, as well as bends. Manufacturing industries including petroleum, automotive, as well as aerospace industries, not only go for X-ray examination. They also use other inspection methods such as magnetic particle inspection, ultrasonic inspection, as well as dye penetrant testing. This can ensure the completeness of the reliability and inspection of the results.
3. Before selecting the combinational NDT techniques, verify the advantages and disadvantages of all the techniques. Different defects may need diverse inspection techniques. For instance, planar cracks, as well as de-laminations, can be examined by ultrasonic and acoustic-based inspection tests. Just radiography technique is not enough. Correspondingly, the size of the surface area may also decide the testing type. For instance, a large surface area at a reduced cost requires dye penetrant testing. However, there is one drawback. This method needs appropriate surface preparation as well as chemical handling precautions.

Hence, the digital X-ray system is considered as the quick, precise, and reliable tool to examine the internal defects present in the given test sample.

Applications of Industrial X-ray Machine

Industrial X-ray machine is used in the following multiple sectors such as 

• Transportation
• Aerospace
• Offshore
• Packaging
• Marine
• Waste management
• Medical devices
• Petrochemical
• Military
• Manufacturing
• Automotive
• Power generation

Major applications:

X-ray in Fuse Inspection

• X-ray instrument is used to measure the interior structure and linear distances accurately
• Verify the probability of open circuits, short circuits, defects, or inappropriate connections in linking circuits of multiple types.
• Determine fuses, insulation layer, faulty assemblies, broken cables, etc.
• Examine the flaws such as bursts, holes, voids, layer peel, misalignment (twist and fitting) in the stacked wire, and integrity testing of wire.
• Analysis of the failed fuses
• X-ray examination at every phase can predict the probability of any short circuit 

X-ray in Car Tires Inspection

The wheel should be of good quality since it is a significant part of a car. Hence, a strict quality inspection should be followed during its production series. In case the wheel fails in terms of quality, there may be a chance of accidents.

Hence, an X-ray inspection test should be integrated directly into the manufacturing step to inspect the internal portion of every car tire. This X-ray inspection helps in detecting foreign objects, pores, slags, missing wires in the belt plies, cracks, air inclusions, looseness, and shifts in the reinforcement plies within these automobiles in an accurate manner. Even the anomalies including position, spacing, and damage in steel wires can also be determined. 

X-ray in Lithium Battery Inspection

Lithium battery is widely used in household appliances, consumer electronics, electric vehicles, aviation, military, as well as other sectors. Since lithium battery emits more heat, it is wrapped by a stainless-steel sheet with the right thickness to avoid any leakage or prevent any harm. The more the battery use, the more will be its probability of failure. A small imperfection can also turn out to be life-threatening. Therefore, you follow strict quality control standards to make sure of its safety. 

A high-resolution inspection of X-ray equipment can assess the quality of any complete battery cells and verify if the welding inside the battery is proper or not. If the rolls are aligned well, the winding will not have a short-circuit and explosion. 

Furthermore, the X-ray system can inspect the following aspects such as:

• Examine if the lithium battery is completely functional
• Assess the quality of the stainless-steel weld used to wrap the battery.
• Identify the sign of holes, voids, or misalignment in the stacked parts
• Detects insulation layer, fuses, welds, faulty assemblies, broken cables, etc.
• Measures the missing material, overhangs, and foreign material inclusions

• Determine the presence of nick as well as its length, fitting, and twist.
• Measures the internal structure, linear distances, as well as alignments precisely

X-ray in Ceramic Knives Inspection

Ceramic knives are precious, elegant, and made up of hi-tech nano zirconium oxide. The combination of zirconia with alumina powder can be pressed with high pressure of 300 tons into a blank, sintered at 2000 degrees Celsius, followed by polishing with a diamond to prepare a ceramic knife with fine finishing. It is ten times sharper when compared with the steel blade. Ceramic knife has the features of anti-oxidation, anti-magnetization, increased density, hardness, as well as temperature resistance, etc. 

In case the combination of the zirconia is inappropriate with alumina powder, the texture may become very fragile with the probability of defects like voids and inclusions. These defects can reduce the stiffness of the overall zirconia- alumina composition followed by the reduction in thermal conductivity followed by the formation of cracks. This is where an X-ray device can determine volumetric information, including dimensions, density variations, voids, and inclusions, within the ceramic knife by scanning its internal and external structures from multiple angles.

X-ray machine for Electronics 

PCBA (Printed Circuit Board Assembly) is the major component used during the manufacture of electronic products. Surface mount technology (SMT) helps in making the packages smaller. The attributes like high density, less size, with intense PCB complexity have made it impossible to detect defects visually. So, it is mandatory to use an industrial X-ray machine to ensure the quality of PCB.

Here is the list of features assessed by the X-ray instrument:

• X-ray equipment can inspect the IC package faults including bursts, cracks, layer peel, voids, and integrity testing.
• Faults in the printed circuit board process, including open circuits, poor alignment, short circuits, bridging, or improper connections in various circuits.
• Integrity testing of solder balls in cladding chip and solder array packages.
• Figure out and measure chip size, voids, marking and wire arc, and tin component area ratio.             

• Electrical and electronic components for broken wedge bonds die-attach, lifted ball bonds, and wire sweep

• Check populated and unpopulated PCBs, CSPs, and BGAs (ball grid arrays)
• A detailed study of vias through multi-layer alignment and hole plating

X-ray equipment for Automobile

All the materials used in automobiles are made up of metals like cast aluminum, cast steel, etc. The quality of these castings has a direct effect on the safety and service life of the cars. Every workpiece used in the car including the car’s engine, connecting rods, brake braking system, pistons, piston rings, steering wheel, shock absorber rods, car wheels, and other parts should have no defects like a bubble or crack formation. Hence, it is compulsory to inspect all these workpieces using an industrial X-ray machine.

X-ray equipment for security

Hijacks are quite common and hence, airport security plays a vital role. That’s where security doors and security machines are used predominantly to protect people’s lives. 

X-rays are integrated into security doors and handheld machines where they can pass through wood, fabric, ceramic, metal, glass, liquid, and many others. After passing through them, these rays hit the circuit board below the conveyor belt in order to develop a radiation signal, when then converts into a computer image. Various materials have varied X-ray penetration degrees followed by the difference in the image color. Dangerous objects like knives, dagger, and guns are displayed as dark blue or black. Lighters or other explosive items appear blue in color with the middle part in green color.

In the case of walk-through security doors, there will be an alarm sound in case you carry a knife, explosive, or any other prohibited items. Therefore, hi-tech X-ray security screening saves time and manpower by identifying the threats quickly and effectively.

X-ray equipment for welding

Welds should also be smooth, tidy, and rust-free. However, fatigue, stress, or excess pressure can weaken any weld over time. Hence, there will be varied flaws in the structure of the weld such as cracks, porosity, slag inclusion, cold lap, incomplete fusion, incomplete penetration, mismatch, cracks, or external/internal undercut. This is where X-ray equipment can determine these flaws quickly and effectively. As a result, the outcomes are stored as a permanent record.

Factors you should consider while purchasing the industrial X-ray machine

Remember that the cost of the industrial X-ray machine differs corresponding to the needs and features. Several factors including the power, spot size, voltage, resolution of the detector, as well as the closeness of the X-ray source to the sample that can determine the quality of the image.

• The grade of automation quickens the procedure with the recurrent examination. As the X-ray equipment is more automatic, it is quick to launch and can provide the outcome of the inspection results with only ‘pass/fail’ standards. This procedure does not need much expertise. However, the price can remain on the upper end.
• The greater the resolution, the more elaborate details users can view. Nevertheless, a resolution of 2μm or lesser is obligatory to examine samples like CSPs and BGAs.
• When the voltage goes higher, it will be easier to examine samples with more density as well as thickness. For instance, the PCB with 5 microns thickness may need an X-ray tube of 90KV. However, the military-based PCB that has greater than 3 mm thickness needs more than 130KV. 
• If the objective sample is only one-sided, you select the X-ray instrument that has a low voltage. Nevertheless, you need high voltage when it comes to multiple layered boards.
• Choose if you need a flat panel detector or an image intensifier. Unlike flat panel detector, the image intensifier can provide an image with lesser brightness. Still, it is less expensive when compared to the flat panel detector. However, a flat panel detector depicts a bright high definition (HD) image.
• The greater the conditions of the generators, the clearer will be the value of performance and inspection of the industrial X-ray machine.
• Choosing either 2-dimensional (2-D) or 3-dimensional (3-D) inspection systems with online or offline preferences is dependent upon the number of the sample, the anticipated quality of examination, as well as the time taken to finish the inspection procedure.
• 2D X-ray system is often used for single-sided PCB board components while 3D X-ray system is meant for high-density double-sided boards. Hence, manufacturers use 2D X-ray systems in automotive applications and 3D industrial X-ray systems in electrical applications respectively.
• The offline system is comparatively quick to run when compared to the online system. When it comes to a large quantity of complex printed circuit boards, online mode is used where the level of inspection is comparatively complex.
• Open or closed tube? Do you wonder which one is the best option? The closed tube is comparatively stable and inexpensive. It can last for years, but the filament lifespan will be 10000 hours. The resolution of the closed tube is a minimum of ≥1μm at lesser tube voltage and power. Since it involves lesser magnification, no system maintenance cost is involved. But closed tubes involve a high replacement cost compared to open tubes.

Anyhow, other factors including certification for import and installation, application support, facility of constant service maintenance, as well as online/offline training support should be taken care of before choosing the X-ray instrument finally.

How Uni X-ray stands out?

Established in the year 2002, Uni X-ray manufactures high-resolution industrial X-ray inspection machines that could be easy to handle with precise assessment. Our company has nearly two decades of experience in doing research and business in X-ray technology. 

Our company headquarters is located in Shenzhen, China. Since the company has a history of developing and manufacturing the customized intelligent X-ray inspection machine, Uni X-ray is a nationally reputed high-tech X-ray instrument manufacturer. Not only at the national level, but we also have an international connection with many clients who still use our instruments for performing their photovoltaic components’ testing and BGA testing. Our super tech-hive includes three modern factories covering nearly 30,000 square meters as well as R&D centers with 630+ staff members that work constantly on upgrading the industrial X-ray machine.

Our Uni X-ray equipment can also evaluate SMT, batteries, ceramic products, electronic devices, connectors, CSP, wires, and many semiconductor components. 

Furthermore, our company developed X-ray equipment for food as well as footwear industries in the year 2014.

Our products are renowned for cost-effectiveness, reliability, high quality, ergonomics, ease of use, and durability that could sustain the testing time.

Our X-ray Inspection products include the following features:

• Timesaving
• Sub-millimeter inspection of the given samples in multiple orientations
• Precise high-quality analysis in detail 
• 100 percent in-line inspection
• Real-time automatic pass/fail display
• Quick and easy integration with factory systems
• Can proficiently work across the full week covering 24 hours a day 
• Instinctive remote support to alter system parameters during the manufacturing step
• Real-time images with high clarity
• Inherent flexibility

The reasons behind our long-term success are listed below:

• 100% assurance in manufacturing integrity of all products
• Assured safety as well as reliability 
• Strict avoidance of product recalls
• Constant improvement in examination efficiency
• Constant improvement in client satisfaction score

Our Products:

As already mentioned, Uni X-ray is a company renowned for developing and manufacturing industrial X-ray instruments according to your requirements. Would you like to buy an X-ray machine for security, welding, auto parts, tires, lithium battery, or electronics?  Our Uni X-ray company is there to help you to find the best equipment to address your challenges. You can find the purpose-specific list below as per your requirements.

Electronics

• X-ray machine for Electronics AX9400
• X-ray machine for Electronics AX8600 
• X-ray machine for Electronics AX8400
• X-ray machine for Electronics AX8000
• Online X-ray Machine LX3000
• Desktop X-ray Machine AX3100

Automobiles

• X-ray machine for Auto parts UNC180S
• X-ray machine for Auto parts 170S
• 320KV X-ray machine for Auto parts UNC330

Lithium battery

• X-ray machine for stacked lithium battery AX9000
• X-ray machine for stacked lithium battery LX-1Y60-140

Welding

• X-ray machine for Welding UNC180

Security

• X-ray Baggage Scanner UNX6560
• X-ray Baggage Scanner UNX6040E
• X-ray Baggage Scanner UNX5040E

If you would like to know which one among the list suits you, contact Uni X-ray right away!

The Upshot?

Though it is challenging to sustain the manufacturing integrity of our customers’ products, we can still offer the best reliable product with top-class high-quality standards. Do you wonder how? The acclaim goes to our Uni X-ray’s highly qualitative real time X-ray inspection equipment that can be widely customized according to the customers’ demands.