Data acquisition
alloys used in rocket combustion chambers. Additively manufacturing these components provides a way of producing complex, lightweight structures at lower costs and with faster iterative development times. However, in the case of combustion chambers, the components must also be able to withstand extreme thermal and mechanical stresses. For FGMs such as CSAM Ni-Cu alloys, relying on one analysis technique risks missing critical details about material properties. Given the potential safety issues that low-quality rocket components could cause, it is a risk that no engineer can afford. In Multi-scale Characterization of Functionally Gradient Bimetallic Ni-Cu CSAM Alloys, Yorston et al. demonstrate how employing a hybrid approach can help to tackle this issue. MicroCT was employed to visualise porosity distribution in 3D, revealing trends such as increased pore density in nickel-rich regions. Meanwhile, EM provided nanoscale data on defect morphology and elemental distribution, uncovering smaller defect classes that microCT could not detect. These insights informed adjustments to the alloy composition and processing parameters, ultimately enhancing material reliability. The benefits of combining EM and microCT extend far beyond this example. In other industries that make use of additively manufactured alloys such as aerospace, automotive and energy, a combined microscale analysis approach ensures a thorough understanding of material properties. In these cases, the hybrid approach can help to accelerate iterative development, reduce failure rates and open the door to innovations that might otherwise remain out of reach.
BREAKING DOWN ADOPTION BARRIERS Despite its potential, the widespread adoption of combined EM and microCT analysis faces challenges. For instance, in industrial applications where operators are not necessarily experts in specific microscopy techniques, this approach may be perceived as overly complex. Others may question its scalability for routine industrial use that requires the analysis of thousands of samples. However, advancements in supporting software are helping to address these concerns. One such solution is Thermo Scientific Avizo Software plays a pivotal role in overcoming the barriers to adopting a combined approach by streamlining data correlation and visualisation. Regardless of the scale and data modality used, Avizo provides digital imaging-based workflows to facilitate materials characterisation and quality control from a single environment. The software offers advanced automation capabilities, making it easy to create repeatable, reliable workflows to conduct analysis at scale. For engineers that are less confident with image processing, the inclusion of artificial intelligence enables them to save time on complex analysis while ensuring results consistency. In addition, Thermo Fisher’s dedicated support team, training sessions and how-to guides help to reduce the learning curve for non-expert operators. By bridging the gap between these two methods, Avizo ensures that the combined power of microCT and EM is both practical and scalable, ultimately driving faster, more informed decision-making in materials analysis.
As materials continue to grow in complexity, embracing a hybrid analysis approach can help engineers and researchers to unlock deeper insights into material properties. Combining EM and microCT with the support of a visualisation software delivers a complete picture of materials from the atomic scale to the macrostructure. This hybrid approach enables better defect detection, process optimisation and product performance, ensuring that materials can meet the demands of modern engineering.
Thermo Fisher Scientific
www.thermofisher.com
Instrumentation Monthly May 2025 53
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