Anatomy of an Injector
Much like a physician using a computer tomography system (CT) to look into a patient’s body, Bosch researchers are peering deep into the hearts of automotive components. Their objective is to discover even the tiniest material defects, determine their causes and achieve zero-defect production.
Bosch researchers benefit from the fact that computer tomography is noninvasive and nondestructive. High-energy X-rays penetrate common industrial materials like steel or aluminum before impinging on a detector. A three-dimensional image is created in the system’s computer by revolving the component through 360 degrees within the tomograph. Advanced analytical algorithms are applied to search for critical material defects: Where do pores tend to form most frequently? Have any cracks formed, for instance in the welds?
The measured results are then categorized, because not all defects are equally critical. A pore on the sealing surface of the injector renders it unusable. Deeper down within the material, a pore is no problem; on the other hand, a more deep-seated crack could work its way to the surface during use. This is where the full range of the materials scientists’ expertise is needed.
At present the resolution of this technique is in the range of ten micrometers (millionths of a meter). But for tomorrow’s high-tech components, scientists must be able to measure with greater accuracy – the goal is one micrometer. What’s more, the tomograph must be able to keep step with the production cycle. While today’s CT measurements take ten minutes, the goal is to shorten this time to mere seconds. The researchers are developing sophisticated systems to make this possible. Both automakers and car buyers will benefit, because this technology ensures that every single component will be thoroughly inspected, and material defects will become a thing of the past.
The measured results are then categorized, because not all defects are equally critical. A pore on the sealing surface of the injector renders it unusable. Deeper down within the material, a pore is no problem; on the other hand, a more deep-seated crack could work its way to the surface during use. This is where the full range of the materials scientists’ expertise is needed.
At present the resolution of this technique is in the range of ten micrometers (millionths of a meter). But for tomorrow’s high-tech components, scientists must be able to measure with greater accuracy – the goal is one micrometer. What’s more, the tomograph must be able to keep step with the production cycle. While today’s CT measurements take ten minutes, the goal is to shorten this time to mere seconds. The researchers are developing sophisticated systems to make this possible. Both automakers and car buyers will benefit, because this technology ensures that every single component will be thoroughly inspected, and material defects will become a thing of the past.
Direct view through the tip of an injector nozzle: The X-ray CT system includes computer processing that makes it possible to directly view and measure the component’s geometry and any material defects in three dimensions. As a result, the component’s quality can be checked noninvasively and nondestructively.
