Materials Engineering

2013 Summer Internship

Robert Schuld

R&D Engineering/ Philips-Dunlee

09/20/13

Objective 1: Develop new inspection techniques to characterize the surface of ball

bearings to improve the lifetime, reliability and noise of the X-ray tube

Objective 2: Characterize structure of brazed TZM/Graphite sample to find

relations to processing, properties and performance of the material

Objective 3: Perform SolidWorks simulations to analyze the materials and design

of X-ray tube components

Objective 4: Perform a baseline characterization of (MIL-PRF 22191F) plastic

packaging for precision components

Projects

Image Processing Results

Raw Image

Image processing tool used: ImageJ

Measured Characteristics M62 ball bearing

“Use image processing software to quantitatively

measure ball characteristics”

Image Processing Results

Number of Particles

Counted Total particle area (µm2) Average Area (µm2)

% of Total

Area

M62 2640 10959.7 4.15 18.9

0

0.2

0.4

0.6

0.8

1

0 5 10 15 20 25 30

Cu

mu

lati

ve P

rob

abili

ty

Particle Area (µm2)

Cumulative Probability

0

0.05

0.1

0.15

0.2

0.25

0.3

0 5 10 15 20 25 30

Pro

bab

ility

Den

sity

Particle Area (µm2)

Probability Density

“Use image processing software to quantitatively

measure ball characteristics” Measured Particles

EDS Simulation Results

0 1 2 3 4 5 6 7 8 9 10

keV

Experimental Vs Simulation M62 Steel

Ball 1

Simulation

Experiment

C

Fe

Result: EDS simulation can closely predict experimental results

“Use energy-dispersive X-ray spectroscopy (EDS) simulation

software to better understand ball coating”

Mo

W

Cr Cr

V

Fe

Fe

• Used DTSA-II and calibrated simulation detector with Dunlee’s Si(Li) detector

EDS Simulation Results

1000 A Coating 1

100 A Carbon

Steel Ball

5000 A Coating 1

Steel Ball

0

2000

4000

6000

8000

10000

12000

14000

16000

0 2 4 6 8 10

Inte

nsi

ty

Energy (keV)

EDS Spectrum

Coating 1

M62 steel with Coating 1

C

Example 1

Example 2

C/Coating 1 Ratio: 0.0206

Monte Carlo Trajectory Simulation

Program: NIST DTSA-II

1000 A Carbon

0

2000

4000

6000

8000

10000

12000

14000

16000

0 2 4 6 8 10

Inte

nsi

ty

Energy (keV)

EDS Spectrum

C

Coating 1

C/Coating 1 Ratio: 0.0812

“Use energy-dispersive X-ray spectroscopy

(EDS) simulation software to better

understand ball coating”

EDS Simulation Results

1

10

100

1000

0 10 20 30

Log

(Co

atin

g 2

Th

ickn

ess

)

C/Coating 2 Ratio

C/Coating 2 Ratio vs Coating Thickness

0 Angstroms C

100 Angstroms C

1000 Angstroms C

2000 Angstroms C

5000 Angstroms C

0

50

100

150

200

250

0 0.2 0.4 0.6

Co

ati

ng

2

Th

ick

nes

s (A

ng

stro

ms)

C/Fe Ratio

M62 Coating 2 1000A C

“Use energy-dispersive X-ray spectroscopy (EDS)

simulation software to better understand ball coating”

Knowing the C/Fe ratio can help

determine Ag thickness

Characterization of multilayer TZM sample

Characterize the multilayer TZM sample in order to better understand its structure. A larger understanding of the structure will allow a greater understanding of its processing, properties, and performance.

Components to Analyze:

• Composition

• Void and Grain size

• Layer thickness

• Shape and size of microstructure

• Grain orientation

• Eutectic region percent area

Purpose:

Characterization of multilayer TZM sample

EDS Compositional Line Scan Results

Characterization of multilayer TZM sample

Element Wt%

C 3.9

Ti 61.6

Mo 34.5

Element Wt%

C 10.4

Ti 89.6

EDS results

Phase Equilibria of the Ti-Mo-C System

Characterization of multilayer TZM sample

EBSD Results

Different Grains Crystal Orientation

SolidWorks Simulation

Anode Tube Glass Insulator

Borosilicate

glass

Kovar

X-ray Tube

Kovar

SolidWorks FEA Results Stress and Displacement (exaggeration)

Force applied

Fixed location

time

str

ess

Stress vs Time 1 cycle of use

FTIR Polymer Bag Results

4 5

6

7 8 9

10 11 12

FTIR Polymer Bag Results

Conclusion

• Combined several materials characterization tools and techniques

(SEM, FTIR, EDS, EBSD) for analysis of component properties and

microstructure development

• Developed procedures to improve product inspection techniques of

X-ray tube components by using image processing and EDS

simulation software

• Created 3D SolidWorks models for thermo-mechanical stress

analyses of components

Acknowledgments

• Michael Drory

• Rachel Wang