Dual-exposure technique for extending the dynamic range of x-ray flat panel detectors

High-dynamic-range micro-CT for nondestructive testing of titanium 3D-printed medical components

Purpose: Industrial microcomputed tomography (micro-CT) scanners are suitable for nondestructive testing (NDT) of metal, 3D-printed medical components. Typically, these scanners are equipped with high-energy sources that require heavy shielding and costly infrastructure to operate safely, making routine NDT of medical components prohibitively expensive. Alternatively, fixed-current, low-cost x-ray units could be implemented to perform CT-based NDT of 3D-printed medical parts in a subset of cases, if there is sufficient x-ray transmission for the CT reconstruction. A lack of signal-caused by areas of high attenuation in two-dimensional-projection images of metal objects-leads to artifacts that can make an image-based NDT unreliable. We present the implementation of a dual-exposure technique devised to extend the dynamic range (DR) of a commercially available CT scanner equipped with a low-cost low-energy (80 kV) x-ray unit, increasing the signal-to-noise ratio of highly attenuated areas for NDT of 3D-printed medical components. Approach: Our high-dynamic-range CT (HDR-CT) technique adequately combines projection images acquired at two exposure levels by modifying the integration times of each protocol. We evaluate the performance and limitations of this HDR-CT technique by imaging a series of titanium-alloy test-samples. One of the test-samples was a resolution and conspicuity phantom designed to assess the improvements in void visualization of the proposed methodology. The other test-samples were four porous cylinders, 17 × 40    mm , with 60%, 70%, 80%, and 90% nominal internal porosities. Results: Our HDR-CT technique adequately combines projection images acquired at two exposure levels by modifying the integration times of each protocol. Our results demonstrate that the 12-bit native DR of the CT scanner was increased to effective values of between 14 and 16 bits. Conclusions: The HDR-CT reconstructions showed improved contrast-to-noise and void conspicuity, when compared with conventional CT scans. This extension of DR has the potential to improve defect visualization during NDT of medium-size, titanium-alloy, 3D-printed medical components.

High-Dynamic-Range CT Reconstruction Based on Varying Tube-Voltage Imaging

For complicated structural components characterized by wide X-ray attenuation ranges, the conventional computed tomography (CT) imaging using a single tube-voltage at each rotation angle cannot obtain all structural information. This limitation results in a shortage of CT information, because the effective thickness of the components along the direction of X-ray penetration exceeds the limitation of the dynamic range of the X-ray imaging system. To address this problem, high-dynamic-range CT (HDR-CT) reconstruction is proposed. For this new method, the tube's voltage is adjusted several times to match the corresponding effective thickness about the local information from an object. Then, HDR fusion and HDR-CT are applied to obtain the full reconstruction information. An accompanying experiment demonstrates that this new technology can extend the dynamic range of X-ray imaging systems and provide the complete internal structures of complicated structural components.