Advanced manufacturing technologies, led by additive manufacturing, have undergone significant growth in recent years. These technologies enable engineers to design parts with reduced weight while maintaining structural and functional integrity. In particular, metal additive manufacturing parts are increasingly used in application areas such as aerospace, where a failure of a mission-critical part can have dire safety consequences. Therefore, the quality of these components is extremely important. A critical aspect of quality control is dimensional evaluation, where measurements provide quantitative results that are traceable to the standard unit of length, the metre. Dimensional measurements allow designers, manufacturers and users to check product conformity against engineering drawings and enable the same quality standard to be used across the supply chain nationally and internationally. However, there is a lack of development of measurement techniques that provide non-destructive dimensional measurements beyond common non-destructive evaluation focused on defect detection. X-ray computed tomography (XCT) technology has great potential to be used as a non-destructive dimensional evaluation technology. However, technology development is behind the demand and growth for advanced manufactured parts. Both the size and the value of advanced manufactured parts have grown significantly in recent years, leading to new requirements of dimensional measurement technologies. This paper is a cross-disciplinary review of state-of-the-art non-destructive dimensional measuring techniques relevant to advanced manufacturing of metallic parts at larger length scales, especially the use of high energy XCT with source energy of greater than 400 kV to address the need in measuring large advanced manufactured parts. Technologies considered as potential high energy x-ray generators include both conventional x-ray tubes, linear accelerators, and alternative technologies such as inverse Compton scattering sources, synchrotron sources and laser-driven plasma sources. Their technology advances and challenges are elaborated on. The paper also outlines the development of XCT for dimensional metrology and future needs.

In this paper, a computer-aided training method for hyperparameter selection of limited data X-ray computed tomography (XCT) reconstruction was proposed. The proposed method employed the ant colony optimisation (ACO) approach to assist in hyperparameter selection for the adaptive-weighted projection-controlled steepest descent (AwPCSD) algorithm, which is a total-variation (TV) based regularisation algorithm. During the implementation, there was a colony of artificial ants that swarm through the AwPCSD algorithm. Each ant chose a set of hyperparameters required for its iterative CT reconstruction and the correlation coefficient (CC) score was given for reconstructed images compared to the reference image. A colony of ants in one generation left a pheromone through its chosen path representing a choice of hyperparameters. Higher score means stronger pheromones/probabilities to attract more ants in the next generations. At the end of the implementation, the hyperparameter configuration with the highest score was chosen as an optimal set of hyperparameters. In the experimental results section, the reconstruction using hyperparameters from the proposed method was compared with results from three other cases: the conjugate gradient least square (CGLS), the AwPCSD algorithm using the set of arbitrary hyperparameters and the cross-validation method.The experiments showed that the results from the proposed method were superior to those of the CGLS algorithm and the AwPCSD algorithm using the set of arbitrary hyperparameters. Although the results of the ACO algorithm were slightly inferior to those of the cross-validation method as measured by the quantitative metrics, the ACO algorithm was over 10 times faster than cross—Validation. The optimal set of hyperparameters from the proposed method was also robust against an increase of noise in the data and can be applicable to different imaging samples with similar context. The ACO approach in the proposed method was able to identify optimal values of hyperparameters for a dataset and, as a result, produced a good quality reconstructed image from limited number of projection data. The proposed method in this work successfully solves a problem of hyperparameters selection, which is a major challenge in an implementation of TV based reconstruction algorithms.

The use of x-ray computed tomography for dimensional measurements associated with engineering applications has flourished in recent years. However, error sources associated with the technology are not well understood. In this paper, a novel two-sphere reference sample has been developed and used to investigate the stability of the imaging system that consists of an x-ray tube and a detector. In contrast with other research work reported, this work considered relative positional variation along the x -, y - and z -axes. This sample is a significant improvement over the one sphere sample proposed previously, which can only be used to observe the stability of the imaging system along x - and y -axes. Temperature variations of different parts of the system have been monitored and the relationship between temperature variations and x-ray image stability has been studied. Other effects that may also influence the stability of the imaging system have been discussed. The proposed reference sample and testing method are transferable to other types of x-ray computed tomography systems, for example, systems with transmission targets and systems with sub-micrometre focal spots.

This paper presents a detailed assessment of two rectangular metallic waveguide lines in order that they can be used as primary standards to provide metrological traceability for electrical scattering parameter measurements at submillimetre wavelengths. The assessment comprises a series of dimensional measurements to determine the overall quality of the lines in terms of the waveguide aperture size and alignment. This is followed by electrical measurements to confirm the electrical behaviour of the lines. Finally, the lines are employed as standards to calibrate a vector network analyser which is used to measure devices to verify the performance of the lines as calibration standards, in operando. The waveguide size is WM-380, which operates from 500 GHz to 750 GHz.