Automated high speed metallographic system
Inventors
Adiga, Umesha P. S. • Hooper, Daylond J. • Joshi, Nina • Banks, Daniel S. • Gorantla, Murali K. • Hogendoorn, Roland Adrian • Jenkins, Elizabeth J. • Ondera, Robert F.
Assignees
Publication Number
US-10473558-B2
Publication Date
2019-11-12
Expiration Date
2033-11-11
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Abstract
An metallographic system comprising a programmable controller, a robotic arm, a specimen clamping or holding device, a sectioning saw, a mounting station, a polishing station, a specimen preparation station, and an analyzer for examining the specimen.
Core Innovation
The invention described is an automated metallographic system that integrates a programmable controller, robotic arms, a specimen holding and clamping device, a precision sectioning saw, a mounting station with resin dispensing and vacuum capability, a polishing and grinding unit, and an analyzer for specimen examination. The system automates the sequence of specimen loading, precise sectioning, resin-based mounting, polishing, cleaning, and high-resolution imaging by coordinating each component under centralized control. A user input interface allows entry of specimen identification, while transport between stations is achieved via robotic arms that handle both mounted and un-mounted specimens.
The problem addressed by the invention is the inefficiency, inconsistency, and subjectivity of manual specimen preparation and analysis in metallography, which affects the reliability of quality assurance and quality control (QA/QC) decisions in materials science. Conventional methods require significant operator skill, time, and can result in inconsistencies due to human intervention, especially in the assignment of pass/fail grades for coatings. The automation provided by the system eliminates manual steps, increases throughput, and provides precise control over critical preparation parameters.
This system enables fully automated handling and analysis for metallographic specimens from start to finish, including precise specimen orientation, flexible loading options (including bypass for pre-mounted samples), automated resin mixing and mounting, programmable polishing routines, and integrated imaging stations using optical or electron microscopy. Coupled with advanced image processing and machine learning algorithms, the analyzer provides objective, repeatable evaluation of specimen attributes such as coating characteristics, thickness, and surface features, collecting and processing data to facilitate pass/fail determinations without manual review.
Claims Coverage
The patent claims coverage is based on a single independent claim, which outlines seven main inventive features of the automated metallographic system.
Automated metallographic system architecture
An automated metallographic system comprising: - An outer housing. - A loading station, preparation station, mounting station, material removal station, analyzer, user input interface, and controller. The preparation and mounting stations are located within the outer housing.
Loading station configured for un-mounted specimens
The loading station includes an input opening through the outer housing specifically configured to receive un-mounted specimens for processing.
Preparation station with cutting device
The preparation station contains a cutting device designed to cut the un-mounted specimen, providing a cut surface for subsequent analysis.
Automated transport assembly for specimen movement
The automated transport assembly is engineered to transport the un-mounted specimen from the preparation station to the mounting station, ensuring sequential handling without manual intervention.
Resin-based mounting with programmable orientation
The mounting station incorporates a resin reservoir and a resin dispenser, and is configured to mount the specimen in resin with its cut surface orientated in a predetermined manner.
Material removal station for cut surface finishing
The material removal station is designed to remove material from the cut surface of the mounted specimen, such as by grinding and polishing, to prepare it for analysis.
Integrated analyzer and programmable control
The analyzer is configured to obtain images of a surface of the mounted specimen, while the controller is programmed to operate the cutting device, automated transport assembly, and resin dispenser. The user input interface is used to receive identification information associated with each un-mounted specimen.
In summary, the claims cover an integrated, automated system for specimen loading, sectioning, mounting, finishing, and imaging within a centralized and programmable architecture, emphasizing hands-free operation, precise orientation, and full process control from un-mounted input through analysis.
Stated Advantages
Significantly improves the efficiency and consistency of specimen processing by automating metallography tasks.
Eliminates the subjective nature of specimen preparation and image analysis, providing objective, repeatable results.
Enables rapid quality assurance and quality control (QA/QC) for materials science without human intervention.
Provides precise control over all metallographic preparation parameters including mounting, sectioning, polishing, cleaning, and imaging.
Delivers high-speed, real-time, and accurate data to improve confidence in depot repairs and quality decisions.
Reduces or eliminates the manual labor required for specimen preparation and analysis.
Allows pass/fail results for coatings to be obtained automatically, improving throughput and reliability.
Documented Applications
Automated evaluation of coatings applied to various components, including pass/fail grading for quality control purposes.
Analysis of high-velocity oxygen fuel (HVOF) thermal spray Tungsten Carbide Cobalt (W—C—Co) coatings.
General specimen preparation and analysis in materials science for QA/QC applications.
Evaluation of thermal spray coatings, paint, epoxy, glass, or other coatings applied to surfaces of specimens composed of materials such as wood, ceramic, composite, metal, plastic, organic or biological materials.
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