Cooperating twin robots form a new X-ray diffractometer for stress analysis

Abstract

Abstract X-ray diffraction measurements on large components with complex geometry are needed in industrial applications requiring the non-destructive characterization of the near-surface material condition in terms of residual stresses, work hardening, phase transformation and formation of reaction compounds. Because many regions of interest on these components are not accessible with conventional laboratory or even mobile X-ray diffractometers, a novel center-free diffractometer with two cooperating robots named “Charon XRD” has been developed at MTU Aero Engines. Two six-axis robots are synchronized using a special optical measuring system to achieve the highest positioning accuracies. This paper describes the actual design and operating mode of Charon XRD, its current and potential functionality, and presents calibration and reference measurements, along with results on aero-engine high-technology components like bladed integrated disks.