Metal particles in raw materials in many cases have costly effects for the automotive and aviation industries. Metal contaminants, flaked off of screws, cylinders, nozzles or other parts that rub together, cause oil and engine failure. Engine oil screens and magnetic sump plugs must be monitored to reduce the risk of failure during operation and of downtime due to contaminants.
Several different types of metal particles can be present in an engine: steel, tin, aluminum, silver and copper (bronze). Depending on the quantity of these contaminants, the engines must be pulled from service until they can be repaired. In the aviation industry, this downtime is costly; not only is the plane not in service, but mechanics must be employed and spare parts must be kept in order to correct the issue and make the plane serviceable again. For the auto industry, metal contaminants in injection moulds can clog the nozzles and cause production decreases until they are unclogged or replaced. The risk of failure during operation vs. downtime for repairs is a reality the quality control personnel and management must consider.
Identification of the metal particles present can help assess the functionability of the engine. Samples of oil from the oil screens can be analyzed, identifying the shape, size, and composition of the contaminants using a scanning electron microscope. For this purpose, Aspex has equipped its Personal Scanning Electron Microscope (PSEM) with the Advanced Quality Control (AQC) software. The AQC is the industry’s only totally integrated solution to detect, identify, and characterize micron-level debris.
The PSEM with AQC platform can be placed directly in the shop, allowing the manufacturers and mechanics with the ability to process samples quickly and efficiently. Once identified, manufacturers can evaluate where in their line the problem is originating from, and mechanics can determine if the contaminants warrant pulling the product from the line. Being able to identify these contaminants has reduced the manufacturing and warranty failures by upwards of 75% in the auto industry.
Reducing the amount of metal particles that make their way into oil and engine parts is a challenge for any manufacturer or shop owner. While there will always be traces of metals in engines, the strict standards for quality in the aviation and auto industries demand reduction of metal particles that would otherwise inhibit the functionality of their product. AQC for the PSEM by Aspex makes identification of foreign particle contaminants quick and easy, giving the auto and aviation industries the tool needed to advance their quality control programs and produce safer, longer lasting products.
Reference:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Integrated Publishing, http://www.tpub.com/content/aviationmaintandmisc/TM-1-1500-204-23-1/css/TM-1-1500-204-23-1_84.htm; http://www.tpub.com/content/aviationmaintandmisc/TM-1-1500-204-23-1/css/TM-1-1500-204-23-1_85.htm
JimTrade, http://articles.jimtrade.com/1/132.htm
