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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
Some of these impurities are more detrimental than others, but all must be carefully monitored. Too much or too little of these materials can cause the steel to form incorrectly, ending up brittle and unusable. Sulphur, for example, is very harmful, causing the steel’s strength to be reduced. Often times, manganese is added to counter the sulphur, causing it to form manganese sulphide (MnS) instead of iron sulphide, increasing the strength and tenacity of the steel produced. In addition, MnS improve machineability of steel as well. Another side effect of metal impurities is they can affect the grain size of the steel. While phosphorous can increase the strength of steel, it also increases the grain size and decreases the ductility. By refining the grain of the steel, the manufacturer can increase the strength and reduce the ductile-brittle transition temperature of the metal. In order to maintain the standards for the type of steel being created, manufacturers must closely monitor the amounts of metal impurities added into or created by the steelmaking process. Modern equipment plays a large role in the manufacturing of steel, from new steel furnaces to top-of-the-line inclusion analysis software. Having an analytical tool within the steel line can vastly improve the quality of the steel produced.
The Aspex Personal SEM equipped with the Metal Quality Analyzer (MQA) software takes the guesswork out of the steelmaking process. The MQA provides up-to-date inclusion compositional information, allowing adjustments to be made quickly to counter negative impurities. Since the PSEM is a fully-integrated SEM/EDX machine, the system is able to quickly and accurately report count, size, and elemental composition of the sample scanned. Implementing the Aspex MQA provides benefits to the manufacturer that can vastly outweigh the upfront cost. From comparing inclusion counts to standards and analyzing steel cleanliness vs. time, to alloy development and consumable consumption reduction, the Aspex PSEM with MQA software in an all-in-one analytical system designed with the metal industry in mind.
Reference: Aspex http://aspexcorp.com/industries/metals.html Chest of Books, “An Elementary Outline Of Mechanical Processes,” http://chestofbooks.com/crafts/mechanics/Mechanical-Processes/index.html Office of Scientific and Technical Information http://www.osti.gov/bridge/servlets/purl/861397-Tb7pb9/861397.pdf Codecogs Engineering http://www.codecogs.com/reference/engineering/metallurgy/impurities_in_steel.php The United States Pharmacopoeia (USP) defines the allowable limits of particulate matter in injections and parenterals in Test Section 788. This section classifies particulate matter in injections and parenteral infusions as any unintentional presence of mobile undissovled particles, with the exclusion of gas bubbles. The USP sets forth two methods in which to check the amount of particulate matter within an injection: Method 1 is a Light Obscuration Particle Count Test and Method 2 is a Microscopic Particle Count Test. A microscope is needed in order to perform the Microscopic Particle Count Test, and it must meet specific requirements. The microscope must have an ocular micrometer that must be calibrated with and objective micrometer. The microscope must have a mechanical stage capable of holding and traversing the whole of the filtration area of the membrane filter. The microscope must have two suitable illuminators, so that episcopic illumination is provided in addition to oblique illumination. The microscope must be adjustable to 100 ± 10 magnifications. The restrictions for the tests are such that only a relative error within ± 2% is acceptable for the linear scale of the graticule. The results for the Method 1 test comply with the standards if the sample tested does not exceed 6000 particles, on average, per container that are equal to or greater than 10 micrometers, and must not exceed 600 particles equal to or greater than 25 micrometers per container. The results for the Method 2 test comply with the standards if the sample tested does not exceed 3000 per container equal to or greater than 10 micrometers, and does not exceed 300 particles equal to or greater than 25 micrometers per container.
Since such specific limits are set for the allowable undissolved particles, a precise, powerful tool is needed to comply with these standards. The ASPEX Rx is the ideal tool for these tests, being able to quickly and accurately identify foreign particles as small as 0.1 microns. The Rx also is set to perform one click reporting for fast results. Since Rx is designed specifically for the pharmaceutical industry, it is the clear choice for analysis of metallic particles and the identification of particulates within both drug powders and suspensions. The Aspex Personal Scanning Electron Microscope (Personal SEM(R)) with the Rx integrated software is the ultimate automated choice for meeting the USP standards set forth in Test Section 788 with ease and accuracy, built for the pharmaceutical industry with that industry in mind.
Reference: U.S. Pharmacopoeia, http://www.usp.org/pdf/EN/USPNF/revisionGeneralChapter788.pdf Aspex, http://www.aspexcorp.com/products/rx.html Aspex, http://www.aspexcorp.com/industries/health-sciences-reported-info.html
Information about particle type, size distribution, morphology and chemistry is used to identify potential contaminates, as well as minimize the cause of contamination. This information can then be used to develop controls for production in FDA-regulated environments. More manufacturers are now opting for the Quality by Design (QbD) approach to assess the safety of drug products by understanding the entire process and making changes to the process before the final product is completed. When following this approach it becomes necessary to find a monitoring technique that fits the needs of the testing facility and allow changes to the process immediately. There are various techniques available to count and size particles, each with advantages and disadvantages. ASPEX’s Personal SEM® (PSEM) in conjunction with the Automated Feature Analysis (AFA) software is a solution that counts and sizes particles but also gives the chemistry of the particles. This automated particle analysis tool can then be used to locate the source of the contamination during the process. With the easy and quick reporting changes to the process can be made quickly to save downtime and maximize profit. ASPEX’s PSEM complies with 21 CFR part 11 demands and adheres to requirements of cGMP facilities.
Secondary electron imaging is used to obtain surface information to qualitatively describe the sample using surface defects, porosity and tri-dimensional structure evaluation. Backscatter electron imaging displays compositional contrasts used to find features during the automated analysis, and can be digitally stored or captured on film. The energy dispersive spectrometer (EDS) uses silicon drift detectors (SDD) to provide high throughput particle analysis but providing the chemical composition and relative proportions of the sample. Particle Size Distribution is a valuable tool for pharmaceutical production, leading to identification and possible elimination of harmful foreign particulates. By utilizing the Personal Scanning Electron Microscope (PSEM) with Automated Feature Analysis (AFA) software, pharmaceutical companies have the most powerful tool on the market to quickly and accurately analyze particles.
Reference: http://www.pharmpro.com/ShowPR.aspx?PUBCODE=021&ACCT=0015199&ISSUE=0811&RELTYPE=ATO&PRODCODE=6040&PRODLETT=A&CommonCount=0
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, both of the raw materials and the intermediates as well as the interactions between the two. In other words, they must understand how the Critical Process Parameters (CPP) affects the variability in the Critical Quality Attributes (CQA) so that these can be measured and controlled in the manufacturing process. The solution needed to identify and analyze products in real-time is the ASPEX® Rx for the Personal Scanning Electron Microscope (PSEM). ASPEX® Rx allows manufacturers a way to identify and analyze foreign particles in the production process by using the automated analysis to acquire images, morphology and elemental composition information with a dedicated interface. By allowing for quality control through the product stream, manufacturers can quickly identify foreign particles that would otherwise compromise their product’s quality. And since ASPEX® Rx can identify particles as small as 0.1 microns, it is an ideal tool for microcontamination quality control. The benefits of the FDA’s QbD to the business are plentiful. Since these products by their very design are superior quality, there is a reduced failure rate in the product batches. Also, since there is less need for final product testing, which can end up costing the manufacturer and the consumer money, the cost of operations and the cost of the product could be lowered. Since there is also increased predictability of product quality in the manufacturing process, there can also be faster approval for new products.
The advantages to QbD in the pharmaceutical field, while changing the way manufacturers think about product production, can greatly outweigh any upfront costs that are needed to see the system put in place. ASPEX® Rx for the PSEM is an affordable micro contamination analysis solution for manufacturers to comply with the FDA’s QbD standards.
References: Aspex Rx, http://www.aspexcorp.com/products/rx.html NGP(http://www.ngpharma.com) Pharmaceutical Processing (http://www.pharmpro.com)
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 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. 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: Jet engine failure can be a very hazardous event, regardless if it is on a commercial or military plane. Preventative steps must be taken to ensure the safest, functional products are produced, and regular maintenance intervals must be implemented to ensure functionality. One of the necessary steps to preventive maintenance includes the removal of all particle contamination from the engine. Quality control starting at the factory is crucial for the cleanliness of the materials constructing of the engines. Manufacturers are striving to provide clean steel, minimizing the foreign particles and balancing the composition to achieve the highest quality materials. Using technology like the Aspex Personal Scanning Electron Microscope (PSEM) with Advanced Quality Control (AQC) software, manufacturers are eliminating much of the unwanted particles that could result in mechanical failure. Just as the original manufacturers strive to produce quality parts, the operators strive to maintain these parts in top running order. Routine inspection of each engine is essential to employed to ensure the highest standards are adhered to and quality is maintained. In order to achieve these goals, ASPEX has developed the industry’s only totally integrated solution for the automated detection, identification, and characterization of micron-level debris in automotive manufacturing and cleansing operations. The Jet Engine Mobile Monitor (JEMM), validated and tested by the United States Air Force, was designed with the military standards in mind yet can be adapted to other engines with ease. The automated analyzer can be set to check jet propulsion operations and engine wear, in order to provide a first-warning system of proactive maintenance. Compact and forklift ready, the PSEM Xtreme works where the problem is – on land or on sea. With a built-in anti-shock base and the multi-stage vibration isolation, the PSEM minimizes the outside interference of extreme environments to assess the problem at hand. The Aspex PSEM with the JEMM software make jet engine monitoring and cleanliness, in the hanger or in the field, less daunting and more obtainable. Reference: |
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