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The goal of “as-built” computational modeling is to incorporate the most representative geometry and material information for an (fabricated or legacy) object into simulations. While most engineering finite element simulations are based on an object’s idealized “as-designed” configuration with information obtained from technical drawings or computer-aided design models, as-built modeling uses nondestructive characterization and metrology techniques to provide the feature information. By incorporating more representative geometry and material features as initial conditions, the uncertainty in the simulation results can be reduced, providing a more realistic understanding of the event and object being modeled. In this paper, key steps and technology areas in the as-built modeling framework are: (1) inspection using nondestructive characterization and metrology techniques; (2) data reduction (signal and image processing including artifact removal, data sensor fusion, and geometric feature extraction); and (3) engineering and physics analysis using finite element codes. We illustrate the process with a cylindrical phantom and include a discussion of the key concepts and areas that need improvement. Our results show that reasonable as-built initial conditions based on a volume overlap criteria can be achieved and that notable differences between simulations of the as-built and as-designed configurations can be observed for a given load case. Specifically, a volume averaged difference of accumulated plastic strain of 3% and local spatially varying differences up to 10%. The example presented provides motivation and justification to engineering teams for the additional effort required in the as-built modeling of high value parts. Further validation of the approach has been proposed as future work.

Gamma-ray computed tomography (CT) is potentially powerful nondestructive method for assessing the degree of distress that exists in reinforced-concrete structures. In a study to determine the feasibility of using CT to inspect reinforced-concrete specimens, we verified that CT can quantitatively image the internal details of reinforced concrete. To assess the accuracy of CT in determining voids and cracks, we inspected two fiber-reinforced concrete cylinders (one loaded and one unloaded) and a third cylinder containing a single reinforcing bar (rebar). To evaluate the accuracy of CT in establishing the location of reinforcing bars, we also inspected a concrete block containing rebars with different diameters. The results indicate that CT was able to revolve the many different phases in reinforced concrete (voids, cracks, rebars, and concrete) with great accuracy. 15 refs., 10 figs.

X-ray computerized tomography (CAT or CT) is a sophisticated imaging technique that provides cross-sectional views of materials, components and assemblies for industrial nondestructive evaluation (NDE). We have studied the feasibility of using CT as an inspection tool for reinforced concrete and the use of multi-energy, linear, attenuation techniques to deduce variations in density (ρ) and/or atomic number (Z) that could be caused by varying the types of concrete mixes and/or compaction in the concrete itself. To perform this study, we designed and built a prototype medium-/high-energy (200- to 2000 keV) CT scanner — ZCAT — to image small concrete samples (± 30 cm in diameter and ± 75 cm in height) with a spatial resolution of about 2 mm. We used ZCAT to quantitatively inspect a 20 cm concrete cube with 1.27 cm diameter reinforcing bars (rebars) and to measure p and/or Z variations in a 20 cm diameter concrete cylinder. We describe the ZCAT scanner design, some of its physical limitations and the data-acquisition parameters used in our study. Our results and those of others [1,2] show that CT can be used to inspect reinforced concrete and to distinguish material p and/or Z variations within concrete.

Computed Tomography (CT) using penetrating radiation (x- or gamma-rays) can be used in a number of aircraft applications. This technique results in 3D volumetric attenuation data that is related to density and effective atomic number. CT is a transmission scanning method that must allow complete access to both sides of the object under inspection; the radiation source and detection systems must surround the object. This normally precludes the inspection of some large or planar (large aspect ratio) parts of the aircraft. However, we are pursuing recent limited-data techniques using object model information to obtain useful data from the partial information acquired. As illustrative examples, we describe how CT was instrumental in the analysis of particular aircraft components. These include fuselage panels, single crystal turbine blades, and aluminum-lithium composites.© (1993) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

Members of the Nondestructive Evaluation Section at the Lawrence Livermore National Laboratory (LLNL) are implementing the advanced three-dimensional imaging technique of x- and gamma-ray computed tomography (CAT or CT) for industrial and scientific obscured object evaluation. This technique provides internal and external views of materials, components, and assemblies nonintrusively. Our work includes building of CT scanners as well as data preprocessing, image reconstruction, display and analysis algorithms. These capabilities have been applied to a variety of industrial and scientific NDE applications. We have used CT to study various objects with obscured features at our laboratory ranging in size from 1 mm3 to 1 m3. In these studies, CT has revealed flaws (e.g. cracks, voids, and inclusions), internal and external dimensional information, differences in elemental composition or material density, and other important material characteristics. CT has also been used to localize, identify, and quantify radioisotopes within canisters. As illustrative examples, we describe how CT was instrumental in the analysis of concrete specimens, diesel engine thermocouple plugs, jet engine turbine blades, ballistic target materials, and radioactive waste canisters.© (1993) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.