In Line Phased Array Inspection of Encapsulated Battery Structural Adhesives
Inline phased array testing maps structural adhesive wet-out and void formation through metal pack enclosures in real time at production line speeds.
Void Fraction Mapping
Meaning
Quantitative assessment identifies the percentage and spatial distribution of gas pockets within a solid matrix. Utilizing void fraction mapping allows engineers to pinpoint regions of weakness in cast or composite battery components. It relies on non-destructive data from industrial scans.
Digital Visualization
Generation of a three-dimensional model represents the internal architecture of the material. Inside the void fraction mapping software, colored gradients indicate the concentration of porosity. This view helps identify if pockets are isolated or connected in a way that could cause a leak.
Structural Risk
Presence of excessive empty space reduces the load-bearing capacity and thermal conductivity of the part. High levels found through void fraction mapping suggest that the manufacturing process, such as vacuum infusion or high-pressure die casting, needs adjustment. If these defects congregate near a mounting point, the risk of fatigue failure increases greatly.
Engineers use this data to decide if a batch must be scrapped or if the part is acceptable for service.
Analysis Precision
Accuracy of the results depends on the resolution of the sensor and the algorithms used for segmentation. Improving void fraction mapping requires high-energy sources for thick or dense metals. The final output provides a standard metric for quality control departments.