High-energy X-ray computed tomography of the progression of the solidification front in pure aluminum

An X-ray computed tomography (CT) system was developed for monitoring the solidification front in metal casting. The X-ray source was a 6 MeV linear accelerator (linac) emitting photons in 5 µs pulses at a rate of 180 Hz. The source intensity was 300 R/min at 1 m. The X-ray beam was collimated in a 30 deg fan shape with a 10-mm height. A detector array comprising 128 elements was located 845 mm from the source. Pure aluminum in a clay-graphite crucible (178-mm o.d., 146-mm i.d.) was melted in a resistance heater furnace, and a cooling tube at the center of the crucible solidified the molten aluminum to simulate the casting process. A solidification front formed around the tube and progressed outward over an hour until the aluminum was completely solidified. X-ray attenuation measurements were taken every minute during this time. Density images were later reconstructed from these measurements using CT. From these images, the progression of the solidification front was determined with a planar resolution of 1.3 mm and a sensitivity of 3.7 pct. The density maps agree with expected values and correlate well with temperature measurements obtained independently by thermocouples.