REDSTONE ARSENAL, Ala. (January 15, 2016) -- Redstone Test Center is best known for its state-of-the-art, military munitions and equipment testing. While there are many facets that feed into that testing process, one piece of the process puzzle is rather unknown -- x-ray capabilities.
The Environmental Component and Test Directorate houses a multitude of capabilities from electromagnetic environmental effects and climatic testing to component and subsystem-level testing. One division within ECTD with unique and critical capabilities is the X-ray Department.
What does a test center x-ray, you might ask? Any and all equipment that will be undergoing tests, from rocket motors and missiles to helicopter parts and other components. The process starts with a visual inspection of the test items, followed by an x-ray and a quality check of the x-ray image. The last step is image interpretation, whether that is film or a more modern digital image.
While RTC is customer-funded and customer-focused, the main reason for x-raying the multitude of explosive devices that come through the facility and Redstone Arsenal in general is for the safety of its employees.
"If we catch it [a fault in the equipment] on x-ray -- for example a loose motor wire -- we not only save our customer money, we prevent the equipment from undergoing testing that is potentially dangerous to our team members," said James Hughes, X-ray Technician and Subject Matter Expert at RTC.
RTC X-ray Technicians go through an extensive training program in accordance with the National Aerospace Standard NAS 410. Their training also includes the American Society of Nondestructive Testing (ASNT) requirements for Nondestructive Test (NDT) technician certification. Currently, RTC has six certified level-two, NDT technicians, two level-three technicians and one level-three engineer.
RTC has been in the X-ray business since the 1960s, and clearly technology has evolved dramatically since then. What started as film technology is now mostly digital and computerized.
"Film has its benefits. There are certain things that film is better for viewing, but speed is a big issue. With digital technology, results are much faster, there are fewer chemicals used, and it's much more cost effective," said Charlie Beyer, recently-retired test engineer and NDT level-three, who worked 33 years in x-ray at RTC.
The actual x-ray technology isn't the only thing that has changed. Capabilities have increased along with demand for services.
One capability that has a major impact on the ability to save the Government and civilian customers' money is portable x-ray equipment. The images take slightly longer to produce with the portable system, but RTC can go on location worldwide to conduct x-ray inspections, which avoids test item shipping costs and reduces its time out of service. Another capability that has seen marked improvements is the ability to accommodate a vast array of sizes of objects which require x-ray.
"We can x-ray items from the size of a microchip to something that is 14 ft. in diameter, and our equipment can penetrate 18 inches of steel. We also have a broad range of Computed Tomography (CT) capabilities, with both high and low energy x-ray," Beyer said. "Offering the high energy capabilities is difficult because of the shielding requirements for safety. These types of facilities are expensive," he said.
The CT system at RTC is capable of generating three-dimensional, x-ray scans of test items providing internal analysis similar to that of CT or CAT scans in the medical field. 3-D CT requires more time to complete than conventional x-rays, but the data provided is significantly more valuable when dealing with complex internal geometry of military hardware. CT provides viewpoints of an item's interior that cannot be seen with other methods of x-ray inspection.
Another interesting capability is the Flash X-ray, which is an image captured during the detonation of an ordnance. "We can x-ray exploding events down to the micro second," Hughes said. Flash x-ray produces a 10 non-second pulse of radiation that provide stop motion imaging of objects moving over 10 times faster than a rifle bullet.
While there are other test centers that have Flash X-ray capabilities, RTC has a transportable Flash X-ray system, which, once again, greatly aids customers in capturing needed data at various locations. This system is not simple to move. It takes days to set up an on-site Flash X-ray, and it requires a power source. Not only is RTC's system transportable, but has multiple x-ray heads with flexible configurations, which allows for capturing numerous angles. "When you x-ray an explosion, you only have one shot," Beyer said.
The data recorded during these events helps determine things like, particle integrity and velocity, target penetration capacity, and detonation effects on other components. The compilation of this data assists in diagnosing problems with ordnance performance, which is integral in the design and analysis process.
"We have the expertise that can help our customers in their design and redesign processes. It's critical that our [U.S.] weapons be the best in the world. Our loved ones are depending on it. If our soldiers don't have confidence in their equipment, they won't have confidence when engaging an enemy," Beyer said.
All of these x-ray specialties require arduous safety measures. "Our safety training is rigorous. X-ray exposure of this magnitude would be like accidentally shooting yourself. X-ray has always been dangerous, and it still is," Beyer said.
RTC is governed by the Nuclear Radiation Commission (NRC) guidelines and is audited every two years to ensure that all safety procedures are up-to-date. "We have a Radiation Safety Officer. We have quarterly checks and annual refresher training. Safety is always under heavy scrutinization, as it should be," Beyer said.
With demand for x-ray services on the rise and the limited availability of facilities capable of working with explosive items, RTC is constructing a new x-ray facility with workflow efficiency in mind. This translates into greater workload accommodation and more jobs available to local community members. The facility is expected to open for business sometime in the spring of this year.
Social Sharing