» Industrial Automation

Analyze Oil Contamination – Particulate Analyzers with SEM

Thu, 03 Sep 2009 23:37:17 +0000

Oil contamination in automotive machinery can come either from the mechanical parts themselves or from foreign materials introduced into the system. The majority of mechanical faults and downtime is thought to be from oil contamination, along with the majority of hydraulic and lubrication problems. And, since hydraulic fluid is such a necessary component for any type of manufacturing equipment, the oil must be filtered, analyzed, and replaced. However, even with doing all of these things, there are still downtimes that occur when pumps, valves, cylinders and the like must be replaced do to faulty lubrication.

Oil contamination can happen in several ways. These include fragments left from the manufacturing process, decomposition of components, and manufacturing residue from tools used to create the machinery. General wear and tear on the mechanism also can contribute to oil contamination, friction causing pieces of the machinery to flake off into wear debris that make its way into the oil. Simply replacing the pumps and valves doesn’t cause the contamination to disappear, as even new these pieces can have dirt or other manufacturing debris in them.

In order to combat oil contamination, whether for the reduction of warranty costs, to improve the reliability of the mechanism, or to diagnose an early-warning mechanism for failure, steps must be taken at each level of production and usage. The particle count method has become the most popular analytical tool to assess oil contaminants and find that rare particle that can be the warning signs of a failure of a mechanism. While there are several options for contamination analysis, particle analyzers are as quick and accurate as electron beam analysis.

The Aspex Personal Scanning Electron Microscope (PSEM) has several different software platforms to fit all your analytical needs. The Advanced Quality Control (AQC) software provides manufacturers with the capability of evaluating the size, shape, and composition of all particles present in a sample. Whether in the lab or in the shop, the PSEM with AQC software provides the manufacturer with quick analysis and one click reporting to find the contamination in the oil.

Whether equipped with just the Perception Suite, or with the AQC software, the PSEM from Aspex is a powerful tool for particle contamination analysis in oil.

Reference:

Aspex, http://aspexcorp.com/industries/industrial-automation.html, http://aspexcorp.com/industries/industrial-automation-implementation.html, http://aspexcorp.com/industries/industrial-automation-cleanliness-reporting.html

AllBusiness, http://www.allbusiness.com/chemicals/petrochemicals-industry-petrochemicals-solvents/11447112-1.html

Triple R, http://www.triple-rrr.com/contamination-of-oil.html

EDX – Energy-dispersive X-ray spectroscopy

Tue, 25 Aug 2009 23:35:26 +0000

Energy-dispersive X-ray spectroscopy, commonly EDX, EDS, or EDXA, refers to the analytical technique used in conjunction with a scanning electron microscope (SEM) in order to identify composition and provide chemical characterization of a specimen. An electron beam is focused onto the sample that collides with and possibly ejects some of the sample’s electrons, forcing them to give up some of their energy, causing the x-ray.

The amount of energy released is based upon the starting and ending shell of the electron. The resulting x-ray can be converted into an EDX spectrum plot. This plot shows the different peaks that correspond to the energy levels of the x-rays received. Each part of the sample can be identified by comparing the x-ray against other known atomic structures, since each element has a unique structure. These plots can be shown as a elemental map to evaluate several elements at once or as a line profile to identify a single element.

There are two major types of detectors used for EDX, Lithium drifted Silicon Detector (SiLi) or the Silicon Drift Detector (SDD). While the SiLi must be operated at liquid nitrogen temperatures, the SDD is capable of being used at relatively high temperatures. The SDD has several other advantages over the SiLi, including faster analytical capabilities and better resolution, as well as higher count rate. The larger count rates also have the added benefit of reducing the damage to the sample because smaller specimen currents can be used.

While there are some free-standing EDX machines, SEMs are the typical equipment of choice. Since SEMs have the added bonus of imaging, they can become an integrated SEM-EDX instrument. Aspex’s Personal Scanning Electron Microscope (PSEM(R)) comes standard with an EDX spectrometer and utilizes a SDD X-Ray. Capable of EDX resolution of 135 eV and a particle detection range of 100nm to 5mm, the PSEM is a reliable, easy to use instrument.

Typical uses for EDX include foreign particle analysis, corrosive evaluation, coating composition analysis, and small component material analysis. Industries such as defense, automotive, pharmaceutical and aerospace (Should we link to these industry pages) are common places EDX analysis is used. The PSEM Express is a benchtop SEM that, when combined with Aspex software such as Automated Feature Analysis (AFA) and Complex Feature Analysis (CFA), becomes a fast, fully automated, affordable desktop SEM analysis system.

Reference:

Aspex, http://www.aspexcorp.com/products/psem-express.html

EDX Analysis and WDX Analysis, http://www.siliconfareast.com/edxwdx.htm

Materials Evaluation and Engineering, Inc., http://mee-inc.com/eds.html

Wikipedia, http://en.wikipedia.org/wiki/Energy-dispersive_X-ray_spectroscopy

Particle Size Analyzer – Automated SEM EDS

Mon, 24 Aug 2009 19:42:25 +0000

The automotive industry uses particle size distribution analysis in order to control contamination both before and during the assembly process. Information about particle type, size distribution, and morphology is used to identify potential contaminates, as well as minimize the cause of contamination. In order to combat contamination, identifying and sizing particles is the first step to eliminating foreign debris.

Whether utilized in the pre-building, production, or post-production stages, eliminating contaminates from the final product is a challenge manufacturers face daily.
Since the auto industry uses various different types of materials, the foreign particles entering the product must be monitored in order to maintain the critical cleanliness instituted by the manufacturer.

From paint to oil, engines to steel content, being able to quickly and accurately analyze particle contamination that could affect the quality of the final product is a necessary step. Since contaminates in steel can alter the grain size, and debris in oils and fluids can effect product life, it is advantageous to take precautionary measures to ensure not only that the end product is up to code, but in order to prevent wasted materials that do not meet the company standards. One tool used to help identify and categorize these particles is a scanning electron microscope (SEM) with energy-dispersive X-ray (EDX) capabilities.

The Aspex Personal Scanning Electron Microscope (PSEM) comes standard with an EDX spectrometer and utilizes a silicon drift detector (SDD). EDX technology is used in various industries, such as the automotive and pharmaceutical industries, for foreign particle analysis, corrosive evaluation, and compositional analysis. With EDX resolution of 135 eV and a particle detection range of 100nm to 5mm, small particles are easily identified and sized.

Aspex also has several different software platforms to fit all your analytical needs. The Advanced Quality Control (AQC) software, part of the Perception Suite, provides manufacturers with the capability of evaluating the size, shape, and composition of all particles present in a sample. By inserting the PSEM with AQC into the product line, problem spots can be isolated and controlled, pinpointing where particles are entering the line well before the end product testing is started, thus saving the manufacturer from wasting time creating faulty products.

Whether in the lab or in the shop, the PSEM with EDX capabilities and the AQC software provides the manufacturer with reliable particle analysis techniques to help ensure that the quality of the design is maintained in each step of the manufacturing process.

Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html

Testing Oil Cleanliness Using SEM

tricia — Mon, 27 Jul 2009 22:34:14 +0000

Lubricating oil is used to separate surfaces, in order to reduce the friction between the surfaces and to absorb heat caused by the friction. In order to keep the surfaces well lubricated, the oil needs to be the proper type and uncontaminated, with the machinery in good working order and well maintained. Otherwise, if the oil is contaminated, the metal-to-metal or particle-to-metal contact causes the surface to wear, which generates more friction, more heat, and more wear particles in the oil.

Oil contaminates, whether dirt, moisture, metal fragments or other foreign particles, can be identified in order to minimize the impact these particles have on the workings of the machinery. Identifying the source can also help in the oil analysis to see if the oil properties are intact and if the machinery has any wear occurring.

The International Organization for Standardization (ISO) 4406 provides a universal method to report the contamination levels in oils by establishing the relationship between particle count and cleanliness. Using the ISO 4406, limits can be set for acceptable contamination levels based on the particle size in micrometers (µm). In order to size the particles and assess contamination levels, Aspex has created a software platform for its Personal Scanning Electron Microscope (PSEM) called Advanced Quality Control (AQC).

The AQC software, in conjunction with the PSEM, allows manufacturers and machinists to be able to quickly and accurately analyze the particles of oil in order to see what contaminates, if any, are present. This totally integrated solution for the automated detection, identification, and characterization of micron-level debris in automotive manufacturing that can be utilized directly on the manufacturing floor.

By using the AQC to identify and classify the particles found in the oil and using the ISO 4406, manufacturers and machinists have necessary information to examine where the particles are originating. If possible, the oil contaminate source can be eliminated, or at least minimized, once the particles are identified and the elemental composition known.

Oil cleanliness is a high standard to meet, as some particles cannot be prevented from being incorporated into the oil. Taking preventative steps can help save costly downtime in the future due to unusual wear on the machine’s parts, and can aid in extending the life of the machine. The Aspex PSEM with AQC is the ideal tool for identification and sizing of foreign particles in order to meet with the standards of cleanliness required by manufacturers and consumers alike.

Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Noria, http://www.noria.com/learning_center/category_article.asp?articleid=738&relatedbookgroup=OilAnalysis
Bently, http://www.bentlytribology.com/publications/articles/1199white.php
MRT Labs, http://mrtlaboratories.com/iso4406chart.htm

Imminent Bearing Failure Testing Using SEM

tricia — Mon, 27 Jul 2009 22:33:29 +0000

Bearings, or devices that allow constrained relative motion between parts, are an essential part in many machines. Since they can reduce friction between parts by either its shape, by its material, or by containing a fluid between the surfaces, bearings are subjected to high wear-and-tear that must be closely monitored in order to avoid failure.

In the automotive industry, bearings can be found in parts such as the axial, allowing the shaft to rotate, or the wheels, allowing the wheel to rotate. These parts are crucial to the safety of the passengers, and having one fail could be extremely hazardous. Manufacturers strive to meet high standards, yet failures do happen. While some cannot, in many cases these failures can be prevented.

Bearing failures are caused by numerous things. These include:

• Excessive loads
• Overheating
• Brinelling
• Normal fatigue
• Reverse loading
• Contamination
• Lubricant failure
• Corrosion
• Misalignment
• Loose fits
• Tight fits

Bearing life can be estimated statistically by analyzing the load, temperature, vibration, and lubrication that each has, as well as how regular the maintenance is, giving a good idea of how long the bearings can last.

Routine maintenance to identify bearing issues before they fail can save both costly downtime and injury. In order to assess bearing damage from contamination, Aspex has developed a software platform for use on its SEM Electron Microscope (PSEM) called Advanced Quality Control (AQC). The AQC evaluates size, shape, and composition of all the particles present in a sample; thus, it is able to identify foreign particles that could lead to bearing failure due to contamination or find out which bearing is breaking down due to wear-and-tear.

By identifying what type of particle contamination is present, preventative steps can be taken to remove the source of the contamination or reduce its presence. The AQC can identify particles smaller than other optical or gravimetric inspection techniques, allowing for superior cleanliness standards and less chance of failure due to contamination. In places such as an automotive plant, the AQC helps prevent warranty issues in transmission and power steering assemblies.

While bearing failure due to normal life-expectancy cannot be prevented, failure due to contamination and other causes can with routine maintenance. The Aspex AQC for the PSEM gives manufacturers and machinists the cutting-edge technology needed to extend the lifespan of their products, giving them an effective, cost-saving tool to create clean products.

Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Wilcoxon Research, http://www.wilcoxon.com/product_presentations/bearing.pdf
SKF, http://www.alliedbearings.com/downloads/skf_bearing_failureandcauses.pdf
Wikipedia, http://en.wikipedia.org/wiki/Bearing_(mechanical)

Eliminate Clogged Nozzles Using SEM Technology

tricia — Mon, 27 Jul 2009 01:20:30 +0000

Continuous casting nozzle clogs create serious productivity and quality losses in the steel industry. The buildup between the tundish and the mold, due to a variety of inclusions, can decrease productivity by causing either decreasing the casting time or requiring the nozzle be replaced, which also increases cost. These inclusions could also come loose and enter the steel mix, resulting in possible mechanical failures and quality failure due to inclusions. This is particularly true of aluminum-killed low-carbon low-silicon steel in a continuous billet caster that use aluminum as a deoxidation agent.

There are four general types of nozzle clogs: deoxidation products, solidified steel, complex oxides, and reaction products. Buildup of deoxidation products can be the same particle size as is found in the mold, ranging from 1-20 microns, and consists of whichever particles were used as the deoxidizer, such as alumina. Solidified steel occurs when the cast nozzle preheat is inadequate, allowing the steel to freeze within the nozzle. Complex oxides or nonmetallic materials such as calcium aluminates or calcium sulfates, assimilate deoxidation particles and thereby increase the volume of the clog. Reaction products consists of deoxidation particles that react with either air or oxygen and show increased clogging as soluble aluminum concentration is increased.

With the exception of solidifying steel, these causes of clogs can be reduced by monitoring the steel for inclusions as they go from the tundish into the mold flux. By using the ASPEX PSEM eXpress, the desktop scanning electron Microscope with Metal Quality Analyzer (MQA) software platform, manufacturers are able to analyze steel sample for inclusions before they go to the nozzle, allowing for less likelihood of clogging and increasing the cleanliness of the steel product.

The MQA is capable of routine monitoring to improve maintenance issues such as:
• Tundish clogging and erosion minimization
• Nozzle clogging due to calcium aluminates or magnesium spinels
• Varying calcium additions to optimize castability
• Hardware changes, such as tundish linings and their overall effects
By allowing manufacturers to know the size, shape, and elemental composition of the inclusions in the steel line directly on the shop floor, the MQA provides the necessary information to reduce or eliminate the inclusions upstream.

The Aspex PSEM with MQA alerts manufacturers to potential casting nozzle clogs, preventing costly downtime and saving energy consumption, ensuring that they are producing a clean, quality product efficiently.

Reference:
Aspex, http://www.aspexcorp.com/industries/metals.html
SpringerLink, http://www.springerlink.com/content/74063541u0415gt7/
Rackers, K., and B.G. Thomas. 78th Steelmaking Conference Proceedings, Nashville, TN, April 2, 1995, Iron and Steel Society, Warrendale, PA, Vol. 78, 1995, pp. 723-734. http://ccc.illinois.edu/PDF%20Files/Publications/95_ISS%5B1%5D.Conf.paper_post.pdf

Analyze Particle Wear With Automated SEM

tricia — Wed, 22 Jul 2009 00:56:51 +0000

Wear is caused by two solid materials rub against each other, removing pieces from one by some mechanical action. There are several different types of wear that can all lead to failure:
• Adhesive Wear
• Abrasive Wear
• Fretting Wear
• Erosive Wear

While these are not mutually exclusive, identifying the cause of wear particles is essential for preventing mechanical failures.

Often, signs of wear can be seen in the oil that lubricates the wearing parts. Particles flake off of the mechanism and end up in the lubrication between the parts. By examining the oil, manufacturers and mechanists can assess where the problem is originating from and take preventive steps to control potential failure.

Other times, wear can be seen as cracks in the surface of the metal pieces. This can cause immense failure potential in the mechanism, such as bearings, if it is not caught early and preventive steps taken. By analyzing the bearings, mechanics can either file down or replace bearings that could be a potential failure issue.

Since wear can manifest itself in several different ways, it is helpful to be able to identify several different types of wear directly on the shop floor. The Aspex Personal Scanning Electron Microscope (PSEM) with edx analysis can do just that, sizing and analyzing the particles quickly by using the Advanced Quality Control (AQC) software. The AQC not only provides manufacturers with a visual of the particles, but also with the elemental composition, allowing them to identify the source of the problem and take corrective action upstream.

Using the AQC software, automotive manufacturers have cut down on manufacturing and warranty failures, savings far out weighting the upfront cost of implementing the PSEM system. And, with the push towards critical cleanliness and higher-quality products, manufacturers have saved both time and money, reducing the failures and cutting down on product loses due to failures.

Understanding particle wear can be easier than fixing the issue, but it is definitely more advantageous than imminent failure caused by wear failure. Being able to predict wear failure, and then take preventive steps, is a crucial step in quality control programs. The Aspex PSEM with AQC software can identify microscopic wear particles quickly and accurately, directly on the manufacturing floor.

References:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Wikipedia, http://en.wikipedia.org/wiki/Wear

Oxide Inclusion Analysis Using SEM

tricia — Sun, 12 Jul 2009 20:49:55 +0000

Inclusions in steel can alter the quality of the metal being produced, making it too brittle, non-ductile, or both. Since inclusions cannot be avoided, for the most part, the quantity and composition of the inclusion must be monitored to produce a top-of-the-line product.

Foreign particles make it into the steel mix either from outside sources, such as a lime additive, or internal sources, such as chemical reactions between the metal and the air. Oxides are some of the more common inclusions in steel, because of oxygen’s high reactivity. Calcium oxide, made from adding calcium carbonate – quick lime – to the steel mix, reacts quickly with other elements in the steel. Carbon monoxide shows up in abundance, and can be regulated with aluminum, creating alumina (Al2O3) instead. If both calcium oxide and aluminum oxide are both present, they react to form calcium aluminates, which reduce the amount of sulfur in steel.

With all these additives and reactions to keep track of, it is difficult to produce quality steel without insight into the inner workings of the compounds. Steelmakers must closely monitor all foreign particles that make it into the steel mix, and, to do this quickly and efficiently, have demanded an analyzer that can work on the shop floor. Aspex has responded to that demand with its Personal Scanning Electron Microscope (PSEM) with edx analysis combined with the Metal Quality Analyzer (MQA) software.

The MQA provides up-to-date inclusion composition directly on the shop floor. It quickly and accurately scans the sample with the electron beam, and, if the backscatter is dark enough to signify an inclusion, it automatically starts the inclusion identification process through use of the ‘rotating chord algorithm’ (RCA). After the inclusion is sized, the MQA uses the energy dispersive X-ray (EDX) to determine the elemental composition of the inclusion. This fully-automated analysis process is the fastest on the market, reaching scan speeds of up to 10,000 inclusions per hour.

Once the inclusions are identified, manufacturers can backtrack through the steel line to figure out where the foreign particles are coming from, and possibly take corrective action to eliminate the issue. By using the PSEM with MQA, steelmakers can reduce consumable consumption and increase energy savings far beyond the cost of implementation. The PSEM with MQA by Aspex is an all-in-one inclusion analyzing system, allowing manufacturers to have inclusions identified and elemental composition determined anywhere on the steel line.

Reference:
Aspex, http://www.aspexcorp.com/industries/metals.html

Bearing Failure Analysis Using SEM

tricia — Fri, 10 Jul 2009 22:01:28 +0000

Bearings, or devices that allow constrained relative motion between parts, have a tendency to wear out prematurely. Since they are a crucial part of many mechanical operations, it is important to monitor the bearing for signs of wear and replace when needed, or remove the cause of the wear. Understanding the causes of failure can help prevent costly downtime due to mechanical failure.

Bearing failure occurs for several different reasons, including:
• Dirt (Foreign Particles)
• Misassemble
• Misalignment
• Insufficient (or Contaminated) Lubricant
• Corrosion
Since some of these will happen under normal operating conditions, the machinist must be able to monitor the bearings on the work floor.

Simply replacing the bearings, however, doesn’t always make the problem go away. In the case of dirt or contaminated oil, the new bearing would be exposed to the same circumstances that caused the old bearing to fail. Eliminating the source of the problem can extend the life of the bearings, and the machinery.

If, when inspecting the bearings for signs of wear, the mechanic finds evidence of foreign particles, the next step is often finding out where the particles are originating. The desktop SEM, Personal Scanning Electron Microscope (PSEM eXpress) by Aspex with Advanced Quality Control (AQC) software is capable of running particle analysis directly in the mechanic’s shop.

The AQC evaluates size, shape, and composition of all the particles present in a sample, allowing the mechanist to determine what particles are making it to the bearings and causing unnecessary wear. Since these particles are often on the micron-level, having a PSEM on the shop floor that can identify size and composition of these particles can save time and money: the particles are quickly identified and the source of the wear can be reduced or eliminated.

In the automotive industry, bearing failure of any kind can be catastrophic. Having the ability to analyze the cause of bearing failure is one of the first steps in implementing a solid quality control strategy. The AQC also helps prevent warranty issues in transmission and power steering assemblies, saving companies much more than the upfront cost of implementation.

While the AQC can’t prevent bearing failure, it can analyze the causes of bearing failure so that preventative steps can be taken in order to reduces the instances of failure due to contaminates. The PSEM with AQC by Aspex is a fully-automated, industrial particle analysis machine.

Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Engine Parts, http://www.engineparts.com/publications/CL77-3-402.pdf

Manufacturing Contamination Control Using SEM

tricia — Mon, 01 Jun 2009 00:18:31 +0000

The recent turn of the pharmaceutical industry towards Quality by Design (QbD) instead of Quality by Inspection (QbI) has sparked the interest of other industries as well. The QbD philosophy proclaims that manufacturers must know how the product will turn out before it is finished, not afterwards by inspection.

In order for the developers to produce this desired state of product, they need to have a complete understanding of all the pieces involved in the process. This means understanding the raw materials and the intermediates as well as the interactions between the two. With such an intimate understanding required to produce such quality products that are in demand, manufacturers are looking for ways to control the contamination before it reaches the final product.

The automotive industry has taken steps to move towards manufacturing contamination control by implementing steps to monitor the quality of their products. Some ways to control the foreign particles include: inspect the components going into the products, ensure that only critically clean parts are used, and maintain parts in top working order. While maintaining contamination control in the manufacturing industry is a lot harder to preach than to practice, advancements in scanning electron microscopes have heightened the awareness available on the manufacturing line.

Aspex has created its Advanced Quality Control (AQC) software for the Personal SEM Electron Microscope to count, size, and identify foreign particles in oil, bearings, steel, and other samples. Manufacturers can now see what is going into their products before it makes it to the final stages. The AQC is totally integrated, capable of automatic detection and identification of microns on the assembly line.

With the AQC software, manufacturers can
• Examine steel samples to see if the ratios of inclusions are at acceptable levels
• Assess bearing wear to identify potential causes of failure
• Assure the quality of pharmaceutical products by knowing components

The AQC from Aspex gives manufacturers the control needed to produce quality, clean products in a controlled environment. With reliable, automated scanning that allows the for backtracking to find the origin of the contaminates, the AQC provides insight into the smallest particle interactions. By setting cleanliness goals, monitoring product lines, and using the PSEM with AQC from Aspex, companies can control contamination to provide high-quality end results to their consumers.

Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html