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image analysis Applications in Materials Engineering Leszek Wojnar CRC Press Boca Raton London New York Washington, D.C. © 1999 by CRC Press LLC CRC Series in Materials Science and Technology Series Editor Brian Ralph Control of Microstructures and Properties in Steel Arc Welds Lars-Erik Svensson The Extraction and Refining of Metals Colin Bodsworth The Quantitative Description of the Microstructure of Materials K.J. Kurzydlowski and Brian Ralph Grain Growth and Control of Microstructure and Texture in Polycrystalline Materials Vladimir Novikov Corrosion Science and Technology D. E. J. Talbot and J. D. R. Talbot Image Analysis: Applications in Materials Engineering Leszek Wojnar © 1999 by CRC Press LLC Library of Congress Cataloging-in-Publication Data Wojnar, Leszek. Image analysis applications in materials engineering / Leszek Wojnar. p. cm. -- (Materials science and technology series) Includes bibliographical references and index. ISBN 0-8493-8226-2 (alk. paper) 1. Materials--Testing. 2. Image analysis. 3. Image processing- -Digital techniques. I. Title. II. Series: Materials science and technology (Boca Raton, Fla.) TA410.W65 1998 621.1'1---- dc2l 98-34435 CIP This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. The consent of CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from CRC Press LLC for such copying. Direct all inquiries to CRC Press LLC, 2000 Corporate Blvd., N.W., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are only used for identification and explanation, without intent to infringe. © 1999 by CRC Press LLC No claim to original U.S. Government works International Standard Book Number 0-8493-8226-2 Library of Congress Card Number 98-34435 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper (cid:9)(cid:9)(cid:9) Preface Many of my friends complained that all the books on image analysis were prepared for mathematicians rather than for laboratory workers. It was an impulse to issue in 1994, in collaboration with Miroslaw Majorek, a simple textbook on computer-aided image analysis, obviously written in Polish. Some of my foreign colleagues looked at this book, appreciated its graphic form and... suggested, that it should be published in English. My first reaction was that it was not worthy enough. Surprisingly, they answered with a very tempting argument: you started to write this book because you did not find appropriate ones on the market. Maybe yes... So, now you have my English version in your hands and I would like to point out its three main properties, that can be important for you, as a reader: • it is devoted really to applications. So, you will not find a system- atic description of image processing operations. Instead, you can look for a certain problem - for example, grain boundary detection - and get immediately, possibly a full solution to this problem • it is written in a very simple manner and illustrated with numerous pictures that will help you to understand it. Probably, many items can be understood after studying only the illustrations. But do not worry about the text - I avoid equations whether possible • all the examples were processed by myself and thoroughly ex- plained. You will not find incomplete explanations, cited from other works. It may happen that my solution is not the optimum one, but it always works. You will know how to repeat it on your own equipment and I hope, my book will inspire you to experiment with your apparatus. Probably nobody is able to face a challenge such as writing a technical book without significant help from others. I am not an exception, either. So, I would like to express my sincere thanks to all those, who helped me, even if I am unable to cite their names - simply, the list would be too long. But among these generous persons there are a few I must list here. First, I am really indebted to Brian Ralph, who generously agreed to undertake the burden of improving my English. Second, I would © 1999 by CRC Press LLC (cid:9) like to thank Christopher Kurzydlowski, who encouraged me to start the whole project, for his support. I have to point out that my under- standing of image analysis would be much, much less without the support from my French colleagues, Jean Serra and, especially, Jean- Louis Chermant. I would like to acknowledge also all my friends who gave me their images which were used to illustrate the algorithms. And last but not least - many thanks to Bruno Lay and Gervais Gauthier from ADCIS/AAI, who delivered free of charge, the newest version of their image analysis software to use for processing all the examples. - Cracow, August 1998 © 1999 by CRC Press LLC The Author Leszek Wojnar, D.Sc., is an Associate Professor at Cracow University of Technology, Poland. His research inter- ests are in image analysis, stereology and materials engineering. He is affili- ated with the Polish Society for Materi- als Engineering, the International Soci- ety for Stereology and the Polish Soci- ety for Stereology. His Ph.D. thesis obtained at the In- stitute of Materials Science, Cracow University of Technology (1985) was dedicated to the role of nodular graphite in the fracture process of cast iron. Dr. Wojnar is known for his innovative methods in teaching oriented towards problem solving. In recent years (1990-1997) he has worked on various aspects of the application of computer technology in materials science, including image analysis and development of the software for weldability assessment. Dr. Wojnar has participated as a member to various advisory boards of the congresses in stereology (Freiburg, 1989, Irvine, California, 1991, Prague, 1993 and Warsaw, 1997). He was an invited lecturer in Freiburg and Warsaw and worked as editor for many conference proceedings. Dr. Wojnar has published more than 50 articles in periodicals and conference proceedings and has published two books (in Polish): Computerized Image Analysis with M. Majorek (1994) and Applica - tion of Computational Methods in Weldability Assesment with J. Mikula (1995). His work Principles of Quantitative Fractography (1990) issued at the Cracow University of Technology was the first such complete monograph in Poland and gave him the D.Sc. position. An unusual accomplishment and one which stems from the exist- ing financial climate surrounding Cracow University is that he devel- oped his own private laboratory on image analysis which now works in conjunction with universities throughout Poland. Recent works of this small laboratory are devoted mainly to applications in medicine. © 1999 by CRC Press LLC (cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9)(cid:9) Acknowledgments I would like to express my sincere thanks to all my friends and colleagues who nicely allowed me to use their images as illustration material in this book. These generous helpers were (in alphabetical order): Jacek Chrapon'ski (Figures 4.11, 4.12a and 4.13a) • Aleksandra Czyrska-Filemonowicz (Figures 4.29, 4.31a, 5.6 and • 5.7) • Wieslaw Dziadur (Figures 2.3 and 4.23a, b) • Marek Faryna (Figures 4.4a and 4.23d) Gervais Gauthier (Figure 4.16a) • • Jan Glownia (Figure 4.27) Gabriela Górny (Figures 2.18a, 2.28a and 4.28a) • • Krzysztof Huebner (Figures 2.32, 3.1, 3.2, 3.3, 3.4, 3.5 and 3.6) • Anna Kadluczka (Figure 4.3a) • Jan Kazior (Figures 2.10, 2.11 a and 7.2) • Krzysztof Kurzydlowski (Figure 4.24) • Anita Myalska-Olszówka (Figure 5.9 ) • Carl Redon (Figure 4.40a) • Kazimierz Satora (Figures 4.23e, 5.14a and 5.15a) • Janusz Szala (Figures 3.7, 3.8, 3.9, 4.17a and 4.18b) • Adam Tabor (Figures 2.9, 3.10 and 4.26) • Roman Wielgosz (Figures 2.13a, 2.15a and 4.30a). Thank you. © 1999 by CRC Press LLC Contents Chapter one - Introduction 1.1 Digital images and their analysis versus the human vision system 1.2 General concept of the book Chapter two - Main tools for image treatment 2.1 About this chapter 2.2 Basic image enhancement 2.3 Filters 2.4 Binarization 2.5 Mathematical morphology 2.6 Fourier transformation 2.7 Edge detection 2.8 Combining two images 2.9 Mouse etching Chapter three - Image acquisition and its quality 3.1 Specimen preparation 3.2 Image acquisition 3.3 Shade correction 3.4 Removing artifacts 3.5 Basic tips Chapter four - Detection of basic features 4.1 Grain boundaries Example 1: Grains in a model alloy used for machine- ability tests Example 2: Restoration of grain boundaries in the QE 22 alloy after high-temperature homogenization Example 3: Grains in a polystyrene foam Example 4: Grains of a clean, single-phase material Example 5: Grains in a CeO ceramic 2 Example 6: WC-Co cermet Example 7: Grains in a high-speed steel Example 8: A tricky solution to a nearly hopeless case © 1999 by CRC Press LLC 4.2 Other features detected like grains 4.3 Pores and isolated particles 4.4 Chains and colonies 4.5 Fibers Chapter five - Treatment of complex structures 5.1 Textured and oriented structures 5.2 Very fine structures 5.3 Fracture surfaces Chapter six - Analysis and interpretation 6.1 Image processing and image analysis 6.2 Measurements of single particles 6.3 First measurements - numbers 6.4 Shape 6.5 Grain size 6.6 Gray-scale measurements 6.7 Other measurements Chapter seven - Applications and case histories 7.1 Quality and routine control 7.2 Simulation 7.3 Research and case histories 7.4 Concluding remarks References © 1999 by CRC Press LLC Chapter one Introduction 1.1 Digital images and their analysis versus the human vision system During the last ten years we observed a tremendous expansion of more and more powerful personal computers and development of user-friendly, graphically oriented operating systems. The computing power of commercial machines doubles in approximately one to two years, and even more powerful computers are used on a laboratory scale. Obviously, the most advanced computer is worth nothing without appropriate software. The unprecedented market success of general purpose software developers forced numerous smaller companies to look for niche applications, very often connected with computer graphics. The availability of frame grabbers, together with the wide range of video cameras, allows the computer to see images and in- duces the temptation to try simulation of the human vision system. As a consequence, a good deal of image analysis software is currently at hand. It allows many research workers to practice with tools previ- ously available only for a limited group of specialists. However, new tools also provide new problems, often caused by some misunderstanding. High resolution graphics allows one to pro- duce photo-realistic effects, leading to impressive virtual reality prod- ucts. One can walk through non-existent buildings, observe crash tests of newly designed but still non-existent cars, train surgeons on virtual patients, etc. Similar effects can be obtained on small scale in almost all personal computers and the appropriate software is commercially marketed. Computerized graphical presentations, often demonstrated in real- time mode, are extremely impressive, especially for novices. They are used very frequently, particularly for advertising purposes. Unfortu- nately, such breathtaking spectacles in virtual reality may lead to a false impression that computers can do almost everything. Moreo- ver, many people are disappointed and frustrated when trying to do anything on their own. Such a case is very common in image analysis applications, which work perfectly, but only on the test images. Let us try to find the reason for this situation. © 1999 by CRC Press LLC