Void Analysis and Shape Analysis of Automobile Inverter Components with X-Ray CT System

Significance of the Topic

Electric vehicle inverters are critical for power conversion and vehicle performance. Defects such as casting voids can impair heat dissipation, mechanical strength, and reliability. Non-destructive X-ray computed tomography (CT) enables detailed internal inspection of inverter components, supporting quality control and design validation.

Objectives and Study Overview

This study demonstrates the use of the inspeXio SMX-225CT FPD HR Plus microfocus X-ray CT system to analyze automotive inverter components. Key goals include visualization and quantification of internal voids, evaluation of wall thickness distribution, and generation of mesh data for 3D printing and simulation.

Methodology and Used Instrumentation

The analysis employed high-resolution CT imaging combined with specialized software modules. Detailed instrumentation:

• inspeXio SMX-225CT FPD HR Plus Microfocus X-Ray CT System
• VGSTUDIO MAX software
• Porosity / Inclusion Analysis Module
• Wall Thickness Analysis Module
• Mesh Data Conversion Module

Main Results and Discussion

• Fluoroscopic imaging provided rapid overview but suffered from part overlap.
• CT cross-sectional images clearly revealed internal structures and voids within the inverter case, cooling fins, and transistors.
• Porosity analysis colored voids by volume, presented 3D spatial distribution, and produced void size histograms.
• Wall thickness maps highlighted thin and thick regions across large areas, with detailed highlighting of cooling fin geometry.
• CT-derived mesh models enabled downstream applications such as 3D printing and finite element simulations.

These findings confirm the system’s capability to detect critical defects and validate component geometry with high precision.

Benefits and Practical Applications

The combined CT workflow supports multiple applications:

• Non-destructive quality inspection of casting defects
• Verification of wall thickness conformity to design tolerances
• Creation of accurate 3D meshes for prototyping and simulation
• Enhanced development of heat-sensitive automotive parts

Future Trends and Applications

Emerging directions include integrating artificial intelligence for automated defect recognition, real-time in-line CT for production monitoring, higher resolution detectors for finer feature analysis, and advanced materials characterization. Broader adoption in automotive R&D and manufacturing will drive improved safety and performance standards.

Conclusion

The inspeXio SMX-225CT system, combined with VGSTUDIO MAX analysis modules, offers a robust, non-destructive solution for comprehensive inspection of inverter components. It provides detailed void quantification, accurate wall thickness mapping, and mesh generation, enhancing quality control and enabling advanced product development.

References

No specific references were provided in the source document.