Improve first-pass yield by 1 second CT scans
High-speed inline CT with MetalJet E1+
Reliable energy storage and efficient renewable energy production are key to a sustainable future. Fast-changing global vehicle fleets will require exponential growth in the number of battery cells produced. Excillum’s MetalJet X-ray sources enable full inline CT scanning capabilities with micrometer resolution, giving manufacturers the high-speed, high-resolution 3D imaging they need to increase the yield as well as ensure product safety and quality at the highest throughputs.
Inline X-ray computed tomography (CT) is a powerful inspection technique that can further reduce the risk of defects and recalls, compared with today’s 2D X-ray inspection techniques. Furthermore, when X-ray CT is integrated in cell assembly, defects can be automatically detected in real-time to enable immediate corrective actions, thereby eliminating yield losses and quickening change control-type processes. However, to achieve the levels of inspection coverage, throughput, and resolution necessary for high-volume battery production, a high-power X-ray source with a micrometer-sized X-ray spot is necessary. The Excillum MetalJet E1+ source makes this possible, achieving a full scan with micrometer resolution in just one second, or less.
Anode-cathode overhang
An internal feature to be inspected during manufacturing of a battery is the anode overhang. The anode should be dimensioned to overlap the cathode. To produce this with repeatability puts high demands on the manufacturing and process precisions. To inspect this with precision in prismatic battery cells, X-ray CT is a pre-requisite. Furthermore, to have a 3D model of each produced battery cell can be very helpful for forensics in case a battery cell fails in the field – in order to minimize a recall to an as small volume as possible.
These images, of pouch, prismatic and cylindrical cells, were captured in just one second, or less, by an Excillum MetalJet E1+ X-ray source, making CT highly suitable for inline and end-of-line inspection during high-volume manufacturing.
About the Excillum MetalJet E1+
High speed full inline CT scanning by MetalJet technology
The MetalJet E1+ delivers 17 times higher X-ray brightness compared to conventional microfocus X-ray sources, which enables fast inline CT inspection in battery cell manufacturing.
Excillum’s MetalJet X-ray tubes feature a liquid-metal jet anode, eliminating traditional X-ray source power limitations caused by anode damage. This innovation supports higher electron-beam power, resulting in significantly increased X-ray brightness.
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Built for 24/7 continuous performance The MetalJet E1+ is designed for high-throughput, 100% duty-cycle operation with up to once-per-year preventive maintenance cycles. This eliminates the need for frequent filament changes as required by traditional tubes. |
Sub-µm positional stability Although running at a high thermal load of 1000 W, the MetalJet E1+ maintains a positional stability of below 1 µm during continuous long-term operation. |
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Features and benefits |
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Technical specifications |
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Target material1 Target type Voltage Power2 Max current |
Liquid metal alloy Liquid jet 30-160 kV 0-1000 W 6.25 mA |
Min. focal spot size Emission stability3 Position stability3 Min. focus-object distance Beam angle |
< 10 μm < 1% < 1 μm 22.5mm 20° |
1) The room temperature liquid metal alloys supplied for the MetalJet source consist mainly of gallium, indium and tin. They have low reactivity and low toxicity but should be handled according to their safety data sheets and local regulations.
2) The actual power used is dependent on spot-size and voltage. However, maximum output power of the 160 kV high-voltage generators is 3000 W software limited to 1000 W.
3) Standard deviation.
1 second X-ray CT of an EV battery cell