Application of X-Ray Computed Tomography in Frontier Research of Advanced Materials

doi:10.12141/j.issn.1000-565X.250168

Abstract

Abstract:

As an advanced non-destructive three-dimensional (3D) imaging and detection technology, X-ray computed tomography (CT) enables the visualization and characterization of the internal structure of samples. This technique operates based on the interaction mechanism between X-rays and matter, collecting signals after X-rays penetrate the sample to form images. Then computer algorithms process the acquired tomographic images to reconstruct a 3D representation of the sample. With advantages such as high-density resolution and convenient digital processing, this technology has achieved significant breakthroughs in fields including medical diagnostics and industrial inspection. This paper focuses on the application of X-ray CT technology in the cutting-edge research field of advanced materials, particularly structural materials and new energy materials. It systematically sorts out the core principles of X-ray CT, including X-ray attenuation, signal conversion and 3D reconstruction. With an emphasis on materials science applications, this paper clarifies the role of CT in defect localization, damage tracking and microstructure quantification through case studies, such as weld defect detection in aerospace components, hidden defect identification in in electronic packaging solder joints, and porosity quantification in additive manufacturing materials. By examing its applications in studies on lithium-ion battery electrode evolution, fuel cell water management and metal anode dendrite tracking, this paper highlights the function of CT technology in revealing the relationship between material structure and electrochemical performance, optimizing device design and improving safety. Furthermore, this paper summarizes the advantages of CT Technology, including its non-destructiveness nature, 3D quantitative capability and dynamic tracking capacity. It also analyzes the bottlenecks such as low efficiency in nanoscale imaging and difficulties in data fusion. Finally, potential pathways for future advancements are proposed, including the development of novel detectors, artificial intelligence (AI)-assisted reconstruction and the integration of multiple complementary techniques. These insights aim to guide the deeper application of CT in enhancing the performance of structural materials and advancing the development of new energy materials. These discussions can provide directions for technological innovation for researchers and contribute to improving China’s independent R & D capabilities of high-end detection equipment.

Key words: X-ray computed tomography, 3D imaging, detection technology, structural materials, new energy materials

CLC Number:

TB302.5

CUI Jie, GUI Yan, ZHANG Chengyi, YANG Xianfeng. Application of X-Ray Computed Tomography in Frontier Research of Advanced Materials[J]. Journal of South China University of Technology(Natural Science Edition), 2026, 54(3): 135-147.

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Table 1

Analysis of problems in the application of x-ray CT technology in the field of materials research"

技术瓶颈		具体表现	典型案例
结构材料表征领域	宏观覆盖与微观精度的矛盾	大型构件需厘米级视场保证完整性，但Micro-CT在此尺度下分辨率降低，难以识别微小缺陷	航天器燃料箱焊缝等大型构件需厘米级视场，Micro-CT在此尺度下分辨率降至5 μm以上，无法识别小于1 μm的焊缝间隙^［24-25］
	动态损伤演化捕捉能力不足	同步辐射CT虽能追踪疲劳裂纹扩展，但时间分辨率不够，无法捕捉瞬时断裂过程	现有1 Hz的时间分辨率无法捕捉冲击载荷下的毫秒级瞬时断裂过程，导致裂纹尖端应力场分析存在时间盲区^［29］
	高原子序数材料穿透有困难	金属材料高原子序数特性导致X射线穿透深度不足，需增加曝光时间，还可能引入伪影	对厚度> 5 mm的Ti64合金构件，需增加曝光时间3倍，且会因样品台漂移引入伪影^［26］
新能源材料表征领域	轻元素成像精度低	轻元素体系依赖相位衬度成像，但受同步辐射装置机时限制，实验室级相位衬度CT识别率低	实验室级相位衬度CT的硫相识别率仅65%，而同步辐射的识别率可以达92%^［12］
	原位测试稳定性差	电解液挥发导致样品漂移，电极膨胀，使枝晶生长轨迹三维重建误差大	样品漂移> 2 μm，电极循环过程中厚度变化达10%时枝晶生长轨迹的重建误差超15%^［63］
	高温环境干扰较大	高温下样品台热漂移易导致孔隙率计算偏差，难以建立精准关联	800 ℃高温下样品台热漂移会导致孔隙率计算偏差达8%^［37］
跨领域的共性问题	数据处理效率不足	大型数据集重建耗时过长，超出传统设备处理能力	增材制造构件全尺寸扫描数据（10 TB）需72 h重建；电池动态数据集（1 TB/h）难以实时处理^［10］
	辐射损伤的材料存在差异性	不同材料对辐射剂量的耐受度矛盾	聚合物粘结剂在10⁴Gy剂量下分子链断裂率> 30%，但金属材料需更高剂量才能保证衬度^［18-21］
	多模态数据融合技术有断层	结构材料与新能源材料的“结构-性能”模型独立，缺乏统一分析框架	结构材料“CT-力学性能”模型与新能源材料“CT-电化学性能”模型无法复用，制约技术普适性^［29-30］

Table 1

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