Enhanced Hybrid Algorithms for Segmentation and Reconstruction of Granular Grains From X‐Ray Micro Computed‐Tomography Images

ABSTRACT Accurate three‐dimensional (3D) reconstruction of granular grains from x‐ray micro‐computed tomography (µCT) images is a long‐standing challenge, particularly for dense soil samples. This study develops a machine learning (ML) enhanced approach to automatically reconstruct granular grains from µCT images. The novel academic contributions of this paper include (a) a hierarchical strategy based on parameter‐independent polygonal approximation, area, and concavity analysis, for the first time, to identify and eliminate both intergranular and intragranular voids; (b) incorporation of a recursive segmentation scheme and ML‐based grain classifier to avoid over‐segmentation; (c) novel modifications on the determination of splitting paths to enhance segmentation accuracy; and (d) an effective approach of assigning initial level set functions for reconstructing granular grains automatically. The hybrid ML algorithm is applied to µCT images of dense Mojave Mars Simulant. The results indicate that the proposed method can accurately segment grain clumps with unclear boundaries. The new automatic reconstruction algorithm eliminates ineffective operations and achieves a three‐fold increase in computational speed than previous methods documented in the literature. Ninety‐one percent of grains with distinct boundaries can be reconstructed and the reconstruction ratio reaches 81% even for grains without distinct boundaries. The overall reconstruction ratio of grains increases by 20% compared with previous methods, achieving a step‐change improvement for one‐to‐one mapping of real soil samples.