Automated high speed metallographic system
Inventors
Adiga, Umesha P. S. • Hooper, Daylond J. • Joshi, Nina • Banks, Daniel S. • Gorantla, Murali K.
Assignees
Publication Number
US-9528915-B2
Publication Date
2016-12-27
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 is an automated metallographic system comprising a programmable controller, one or more robotic arms, a specimen clamping or holding device, an automated specimen preparation station (including a sectioning saw, mounting station, and polishing station), and an analyzer for examining the specimen. The system is designed to automate the process of preparing, handling, and analyzing specimens, specifically focusing on the analysis of the interface between base materials and applied coatings.
This system addresses the problem of inefficiency, inconsistency, and subjectivity present in traditional manual metallographic specimen preparation and analysis. By integrating robotics, automation, and advanced image analysis, the system ensures precise control over preparation parameters—mounting, sectioning, polishing, cleaning, and imaging—and eliminates the need for human judgment in pass/fail evaluations of coatings.
A processor within the system controls each station and automates specimen transfer and processing, including cutting the specimen to expose the base/coating interface, mounting and polishing the specimen, thorough cleaning, and automated high-resolution imaging. The system algorithmically evaluates image data to provide objective pass/fail determinations, allowing for high-speed, accurate, and repeatable QA/QC analysis in a range of materials science applications.
Claims Coverage
The patent contains two independent claims that define the main inventive features of the automated metallographic system and its method of operation.
Automated metallographic system with programmable control and specimen interface analysis
An automated metallographic system includes: - A programmable controller. - One or more robotic arms for transferring specimens. - A specimen clamping or holding device. - An automated specimen preparation station comprising a sectioning saw to cut the specimen and expose the base/coating interface, a mounting station to mount the specimen in resin, and a polishing station to polish the cut surface. - The controller operates the robotic arms and all preparation stations. - The analyzer obtains an image of the cut and polished specimen surface and interface. - A processor automatically transmits a pass or fail evaluation based at least in part on images obtained by the analyzer.
Method for automated preparation and analysis of coated specimens
A method comprising: 1. Holding a specimen using a specimen holding device. 2. Cutting the specimen to provide a cut surface having the interface between the base and coating. 3. Mounting the cut specimen in a resin. 4. Securing and rotating the specimen using a rotating device. 5. Polishing the cut surface using a polishing head. 6. Transferring the specimen using a robotic arm between stations. 7. Cleaning the specimen. 8. Moving the specimen to an analyzer using the robotic arm. 9. Analyzing the cut and polished surface and the coating/base interface. 10. Evaluating properties of the interface. 11. Displaying an accept/reject determination based on the interface evaluation.
These inventive features define an integrated automated system for specimen preparation, handling, analysis, and objective pass/fail evaluation at the coating-base interface, using programmable control and robotics.
Stated Advantages
Eliminates subjectivity and inconsistency in specimen preparation and image analysis by automating the process.
Provides rapid, high-speed, real time, and repeatable specimen processing and data acquisition.
Enables precise control over metallographic preparation parameters including mounting, sectioning, polishing, cleaning, and imaging.
Improves confidence in depot repairs by eliminating the need for manual preparation and analysis.
Allows pass/fail results for coatings to be obtained without human intervention.
Documented Applications
Automated performance of QA/QC for materials science specimens, including rapid evaluation of coatings applied to various components.
Evaluation of high-velocity oxygen fuel (HVOF) thermal spray tungsten carbide cobalt (W—C—Co) coatings.
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