Approach to Determine the Characteristic Dimensions of Clinched Joints by Industrial X-ray Computed Tomography

Destructive micrograph analysis (MA) is the standard method for the assessment of clinched joints. However, during the joint preparation for the MA, geometric features of the joint can change due to elastic effects and closing cracks. X-ray computed tomography (CT) is a promising alternative to investigate the joint non-destructively. However, if the material properties of similar joining partners are the same, the CT is not able to correctly resolve surfaces in the joint that are close to or pressing onto each other. These surfaces are relevant for the determination of characteristic dimensions such as neck thickness and undercut. By placing a thin, highly radiopaque tin layer between the joining partners, the interfacial area in the reconstructed volume can be highlighted. In this work, a method for the localisation of the tin layer inside the joint as well as threshold value procedures for the outer joint contour in cross section images are investigated. The measured characteristic dimensions are compared with measured values from MA of the same samples and of samples without tin layer. In addition, possible effects of the tin layer on the joining point characteristics as well as problems of the MA are discussed.