X-Ray Tube Failure Analysis: Autopsy and Root Cause Identification

This report provides a comprehensive analysis of X-ray tube failures, focusing on the autopsy process and identification of root causes. The analysis covers various aspects of X-ray production, including the principles of Bremsstrahlung and K-shell emission. It discusses the functions of different components of the X-ray tube, such as the cathode, anode, and housing. The report details the process of X-ray tube autopsy, examining failures through various samples and providing a process flowchart. Specific failures, like image artifacts, broken glass, casing arcs, and open filaments, are sequentially analyzed. The study emphasizes the importance of selecting appropriate X-ray tubes and the benefits of autopsy processes in managing hospital budgets and improving medical services. The report concludes with findings from the autopsy and recommendations for preventing future failures.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 3

CE 3.1 Project Information
Name of the project: Analyze the X-Ray Failures
Location of the project: [PLEASE FILL]
Project Duration: [PLEASE FILL]
Organization: [PLEASE FILL]
Role and Designation during the time: Team Member
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
X-Ray has been one of the most applicable technology in the medical sector and failures
of X-Ray needs to be analysed in far better and efficient manner. I analysed the process of X-Ray
production and its principle in manner to identify the failures in the functioning of the x-ray. In
manner to analyze the X-ray failures, I discussed the aspects of the x-ray in deep manner as
described in the project. I identified the functioning and application of the different components
of the X-ray tube including cathode, anode, x-ray tube, housing, and tube insert for identifying
the exact working and sections those could lead them to failures. This analysis will be helpful in
the management of the hospital budget and the better medical services to the local community.
CE 3.2.2 Objectives developed for the project
Following were he objectives set for the delivery of the successful and efficient project:
 To analyse the basic principles of the x-ray

 To analyse the functioning of the x-ray tube
 To identify the failures of the x-ray tube
 To deliver the project successfully
 To manage the activities related to analysis within the expected time
CE 3.2.3 My area of work
I had to play the entire project within a team and thus, I had to be a better team player and
should be capable of accommodating within the team and accomplish all the responsibilities
related to my sector of work. I was assigned to analysing and demonstrating the autopsy of the
X-Ray tubes. I collected the data and analyzed the failure of tubes that return from the field and
suggest appropriate corrective actions for the failure modes. I categorized the defected tubes into
groups based on how many scans each tube has undergone before the failure has been reported.
Thereafter, I tested the tubes as per the failures reported by the customers. The reported failures
are of many types such as casing arc, image artifact etc. I loaded the data into the quickplace that
was received on weekly basis from service teams. Data is extracted from e-Life Database (web-
based automatic tube failure data collection system) on a weekly basis and kept in the quickplace
for use.

CE 3.2.4 Project Group
CE 3.2.5 My responsibilities throughout the project
I was responsible for autopsying the X-ray tube and identifying the failed x-ray tubes in
manner to assure that the final project delivery is an efficient and effective result. I had to make
sure that the data being collected and analysed are reliable and accurate and proposing the best
approach for the GE hospital that was the location of the project. I had to execute the following
procedure in an efficient and effective manner:
 Manual observation for ascertaining insert breakage/oil leak/shipping damage
 Bench Test
 Heat run and Functional Test depending upon Bench Test Result

 Noise Test if required
 Tear-down
 Oil Non-destructive Test (Oil kV, Moisture ppm and Particles Count)
 Insert Autopsy/Component Level Autopsy/SEM/EDAX
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the theory of the project
The x-ray tubes are generally the major component while diagnosing the patients and
their medical conditions. I had to analyse the failure cases of the x-ray tubes and assure that
better tubes are being used and the not functioning tubes are separated. I tested the x-ray tubes in
autopsy based on the reported failure, which can be any of the above types. For each of the
errors, I followed the further procedure in autopsy that was not to be the same and I considered
the sector related to the image artifact, and other sectors. For example, if the reported failure is
Image Artifact then the tube should be tested for “Focal Spot,” whereas in case of Casing Arc it
should be tested in BT and FT.
CE 3.3.2 Engineering knowledge and skills applied in the project
I proposed the chart that describes the analysis of various types of errors reported during
the period of Jan 2005-Oct 2005:

Figure 1: Reported Failures
 AI – Image Artifact
 CA – Casing Arc
 CB - Casing Bubble
 CL - Casing Oil Leak
 OE – Tube Loss Due To Failure Elsewhere
 OF – Open Filament
 OG – Arcing
 OH – Other Housing Related
 OL – Generator Overload
 PF – Pump Failure

CE 3.3.3 Accomplishment and task performed
I had to execute the autopsy for analyzing the aspects related to the components and parts
those might result in the failure of the x-ray tubes in manufacturing RG Tubes (Refurbished
Green) after refurbishing. I managed the autopsy of the defected x-ray tubes and the
identification of the root causes those are influencing the x-ray tubes toward failure. I executed
the autopsy and the analysis of the causes leading the tubes towards the failure including seven
major causes those could influence the x-ray tubes. I emphasized on analyzing the following
causes and factors those could influence the x-ray tubes:
1. Image artefact
2. Broken glass
3. Casing arc
4. Casing oil-leak
5. Open filament
6. Arcing
7. Other kind of failures
CE 3.3.4 Identified issues and their solutions
The major issue was to analyse and perform the autopsy of the x-ray tubes in much
efficient and effective manner. I developed the autopsy of the x-ray tubes after collecting and
analysing those data and information in an efficient and effective manner. The other obstacle
identified while delivering the project was the team work. Root cause identification was one of

the identified issue that needed to be identified while executing the project and following
medium were used for identifying them in an efficient and effective manner. Image Artifact,
focal spot measurement, broken glass, classic arc, casing oil leak, open filament, arcing and
many other facts those could lead to the failure of the x-ray tube.
CE 3.3.5 Plan to produce creative and innovative work
There are many causes those could be identified while analyzing the x-ray tubes
however; identifying accurately and precisely need engineering skills for evaluating the proper
functioning of the medic center. I had to execute the inspection and analysis of electronic
assemblies and parts using high-resolution X-ray technology mandate several choices when
selecting a system. I successfully analyzed the x-ray tubes for proposing a system that can be
helpful in the application of the efficient and effective x-ray tubes within the medical centers.
CE 3.3.6 Collaborative work
I was a team player and trued to manage the project constraints in a way that every
individual in the project can contribute their part. I established a better relationship with the
individuals and established the relation that led to the successful and efficient delivery of the
project. We had to execute the project as a team and the entire session of the project was
managed by me and other team members in different sectors. The project was successfully
delivered through the contribution of their respective team members and everyone had
contributed in

CE 3.4 Project Review
CE 3.4.1 Project Overview
I successfully proposed the results after autopsy after analyzing the defective x-ray tubes
that is helpful for the hospital in managing the budget of the project in far better way. I proposed
the versatile X-ray platform that can be helpful in offering a cost-effective approach in manner to
purchase the most suitable system. The type of tube selected represents the most fundamental
decision, as it determines resolution and focal-spot size. Contrast, sharpness, magnification, and
noise, as well as imaging requirements for the application, also represent an important set of
choices. I proposed the approach that can provide the hospitals with an option of selecting the
appropriate approach that can bring likelihood of better bottom line advantages.
My contribution to Work
I successfully analysed the failures of the x-ray tubes and proposed the system that can be
better and cost-effective than other methods or procedures. I contributed in preparing the autopsy
reports of the malfunctioning x-ray tubes and analysed them in an efficient and effective manner
and proposed the results as mentioned in the above paper. I was successful in executing the
autopsy of the damaged x-ray tubes and developing a sophisticated model that can be utilized
within the hospitals for assuring the proper functioning of every x-ray tube in an efficient and
effective manner and within the budget.