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THE CASE FOR COMBINING ELECTRON MICROSCOPY AND MICROTOMOGRAPHY
ne example of the complexity of modern materials is functionally gradient materials (FGMs), which feature a continuously variable directional composition and
structure to enhance performance characteristics. FGMs are particularly valuable in industrial applications where materials must withstand extreme thermal, mechanical, or chemical stresses. For instance, aerospace components and high- performance coatings benefit from the ability to tailor material properties across a single part, improving durability and reducing failure risks. However, fully characterising FGMs is challenging, as their continuous compositional changes require a multi-scale analytical approach to ensure no critical variations are overlooked.
Each analytical technique provides unique and complementary insights. EM delivers nanometre- scale resolution, offering detailed information about a material’s surface structure, composition and microstructure. This makes it an invaluable tool for studying fine structural details that influence material performance.
MicroCT, meanwhile, excels at non-destructive 3D imaging of larger samples, revealing internal features such as porosity, cracks and density variations. While its resolution is lower than that of EM, it provides a crucial macroscopic perspective, allowing researchers to understand how internal structures and defects are distributed throughout a material.
COMBINED APPROACH ADVANTAGES By integrating EM and microCT, engineers and researchers can achieve a multiscale understanding of materials that neither technique can deliver in isolation. Bridging the gap between macro- and nanoscale analyses allows for comprehensive visualisation. For example, MicroCT’s 3D imaging maps large-scale defects, while EM adds detailed insights into smaller features such as grain structures and elemental composition.
Combining data from both techniques also enables the identification of defect locations, sizes and types with high accuracy. The insights gained from this hybrid approach can help engineers to refine manufacturing processes, thus improving material properties and performance. Take, for example, cold spray additively manufactured (CSAM) copper nickel (Ni-Cu)
52 May 2025 Instrumentation Monthly
Modern materials — particularly those that have been additively manufactured to meet the rigorous quality demands of industrial applications — are increasingly complex. From lightweight alloys to intricate composite structures, understanding the behaviour and properties of these materials is critical. Yet, it can be difficult to gain a full understanding when relying on a single analytical technique. Here, Franz Kamutzki, senior account manager at Thermo Fisher Scientific, explains how engineers and researchers can combine electron microscopy (EM) and micro-computed tomography (microCT) to obtain a deeper insight into materials at different length scales.
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