3-Dimensional Shop Floor Measurements To Improve Yield Dr. r. E - - PowerPoint PPT Presentation

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3-Dimensional Shop Floor Measurements To Improve Yield Dr. r. E - - PowerPoint PPT Presentation

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3-Dimensional Shop Floor Measurements To Improve Yield Dr. r. E Eri rik N Novak Good Metrology Saves Significant Money According to Quality Digest, poor quality control costs an average of $2M/year over the 100 companies they surveyed.

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SLIDE 1

3-Dimensional Shop Floor Measurements To Improve Yield

Dr.

  • r. E

Eri rik N Novak

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SLIDE 2

Good Metrology Saves Significant Money

  • According to Quality Digest,

poor quality control costs an average of $2M/year over the 100 companies they surveyed.

  • NIST performed 16 economic

studies since 2000, showing average benefit of metrology investment is 47:1

10/2/2018 2

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SLIDE 3

Consequences of Poor Quality Control Are Severe

Internal Failure Costs

– Waste – Scrap – Rework – Additional failure analysis – Reinspection – Downgrading – Shortages

External Failure Costs

– Repair and service – Warranty claims – Complaints – Returns – Travel and Return time – Throughput – Downtime – Post-warranty costs – Dissatisfaction – Customer perception

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SLIDE 4

The Modern Take on ‘An Ounce of Prevention…’

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SLIDE 5

Effects on Measurement Capability Are Interrelated

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Operator

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SLIDE 6

Micro-Scale Defects Are Critical To Understand

  • Performance

– Pitting/porosity, scratches, affect efficiency – Nicks and dents can cause leaks – Burrs can cause damage to other parts

  • Longevity

– Defects can lead to excessive wear – Imperfections can initiate corrosion – Structural integrity is compromised by voids

  • Perception

– The human eye is excellent at seeing small flaws – The human eye is terrible at estimating their size – Customers will reject parts they suspect

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SLIDE 7

Metrology Tradeoffs Must Be Balanced

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Lateral Resolution Field of View Vertical Resolution Depth Range Standoff Distance

  • Max. Feature Height

Ease

  • f Use

Flexible Software

  • Major Goals:
  • Quantify anything an operator can readily see
  • Quantify anything a scribe gauge or ‘calibrated fingernail’ can feel
  • Meet current and next-gen part spec drawings
  • Instant results
  • Future Proof – Automation Capability, Customizable, Cloud-enabled…
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SLIDE 8

Traditional Shop-Floor Inspection Methods Are Insufficient

Visual / Finger Test

  • Operator dependent
  • Non-gage capable

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Comparison Test Plate

Replication combined with surface profiler

  • High material costs
  • 30+ mins/measurement
  • Operator and material dependent

***When in doubt – reject or rework… Expensive!!!

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SLIDE 9

Test: Which Pit Is Deepest?

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1 2 3 4 5 6

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SLIDE 10

Test: Which Pit Is Deepest?

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25 um .001” 80 um .0032” 20 um .0008” 150 um .006” 150 um .006” 20 um .0008” < 5 um <.0002”

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SLIDE 11

Most Portable Tools Are 2D and Lack Resolution

Laser Scanners and Stereoscopes

  • Limited lateral resolution >2mil (50um)
  • Non-gage capable for micro-defects <10mils
  • Single line doesn’t capture full defect (i.e. deepest point)
  • Sensitive to material finish, reflectivity and slope

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2D Stylus Profilers

  • Limited vertical range
  • Give PV value only
  • Can’t measure edges, corners across steps

***Portable and convenient but not capable of measuring micro-defects

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SLIDE 12

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Pit Measurement Using 2D Trace Varies

.0030” (76 um)

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SLIDE 13

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Pit Measurement Using 2D Trace Varies

.0025” (63 um)

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SLIDE 14

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Pit Measurement Using 2D Trace Varies

.0022” (56 um)

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SLIDE 15

Automated 3D Results Eliminate Uncertainty

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.0028” (71 um)

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SLIDE 16

Large Defects Are Even Harder To Assess

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.0023” (58 um)

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SLIDE 17

Large Defects Are Even Harder To Assess

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.0009” (23 um)

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SLIDE 18

Large Defects Are Even Harder To Assess

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.0017” (43 um)

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SLIDE 19

Large Defects Are Even Harder To Assess

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.0013” (33 um)

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SLIDE 20

Analysis of Entire Defect Eliminates Uncertainty

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.0029” (74 um)

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SLIDE 21

3D Lab-Based Metrology Is Impractical

3D Optical Profilers

  • $75-200K
  • Limited to small parts
  • Requires dedicated, trained operator
  • Slow feedback due to measurement turnaround time

10/2/2018 21

3D Stylus Profilers

  • $25-150K
  • Limited to small parts
  • Limited to single trace – can’t measure full feature
  • Measurements take several minutes
  • Slow feedback due to measurement turnaround time

***Lab-based metrology provides adequate resolution but is not practical for shop-floor inspection

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SLIDE 22

What Are Critical Criteria For Success?

  • Easy To Use
  • Non-Destructive
  • Sufficient Resolution
  • Sufficient Range
  • Field of View
  • Correlation

– Between Units – With other techniques

  • Robustness
  • Extensible

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SLIDE 23

3D Shop Floor Measurements Provide Instant Feature Analysis

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SLIDE 24

Interferometry/Structured Light/Fringe Projection: Scalable Surface Metrology

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Laser Interferometry: Optic Shape White Light Interferometry: Micro-Roughness Fringe Projection: Large Irregular Shape Optical Coherence Tomography: Retina Phase Contrast Microscopy (DIC): Spyrogira Cell

24

4D Technology Corporation

10/2/2018

Resolution depends primarily on the wavelength of fringes

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SLIDE 25

Polarization Combined With Structured Light Allows Fast 3D Measurements

Array of micro-polarizers matched to detector

US Patent 7,230,719

α=45, φ=90 α=0, φ=0 α=135, φ=270 α=90, φ=180

Unit Cel

  • Uses 4 pixels to reconstruct phase
  • 3D image in one frame
  • Slight loss in lateral resolution

25 25

4D Technology Corporation

10/2/2018

Array of color filters matched to detector

  • Uses 4 pixels to reconstruct color
  • Color image in one frame
  • Slight loss in lateral resolution

10/2/2018

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SLIDE 26

Polarized Structured Light (PSL) Enables Precision Hand-Held Metrology

  • Structured light uses the

bending of projected lines to compute 3D shape

  • Generally requires multiple

patterns, colors, or angles so is not vibration-immune

  • High-resolution difficult to

achieve, especially on metal surfaces

  • Polarization enables both

single-frame and high- resolution measurements

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SLIDE 27

4D InSpec Designed Specifically for Shop Floor Metrology

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Specification 4D InSpec 4D InSpec XL

Vertical Resolution 2.5 um (0.0001”) 2.5 um (0.0001”) Depth Range 2.5mm (0.1000”) 9mm (0.35”) Standoff distance 35mm (1.3”) 60mm (2.3”) Field of View 8 x 8mm (0.3”x0.3”) 15x15mm (0.6”x0.6”) Lateral Sampling 3.5 um (0.00015”) 7.0 um (0.0003”) Meas+Analysis time <1sec <1sec

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SLIDE 28

PSL Measures Many Materials and Finishes

  • Carbon Fiber
  • Composites
  • Glass
  • Plastics
  • Cast Iron
  • Metals
  • Silicon
  • Rubber
  • Paper
  • Textiles
  • Semi-transparent/cloudy Surfaces
  • Ultra-finish
  • Matte
  • Rough
  • Flat
  • Curved
  • Corners

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Paint Layer Thickness Ultra-finished Blades Spline Gear

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SLIDE 29

PSL Provides High Repeatability

  • Measured 0.00075” (19um) defect 30 times
  • Results Shown Below
  • Standard deviation = .00002” (0.5um)

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0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 5 10 15 20 25 30 35 Pit Depth (inches) Measurement #

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SLIDE 30

Cross Platform Correlation Is Important

  • Range of pit depths observed on field hardware (25-75 um, 0.001 to 0.003”)
  • Results are within ±2.5um (0.0001”) on average
  • FRT white light profilometer and 4D InSpec are statistically indistinguishable

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SLIDE 31

3 System Correlation Data Shows Excellent Agreement

  • Feature range from .0008

to .014” (20 um to 355 um)

  • Offset <.00009” (2 um)
  • Slope <1.2% different
  • R^2 >.996

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y = 1.0125x + 9E-05 R² = 0.9961

  • 0.016
  • 0.014
  • 0.012
  • 0.01
  • 0.008
  • 0.006
  • 0.004
  • 0.002
  • 0.01600 -0.01400 -0.01200 -0.01000 -0.00800 -0.00600 -0.00400 -0.00200 0.00000

IS171104 vs. IS161201

y = 0.9986x - 6E-05 R² = 0.9975

  • 0.01600
  • 0.01400
  • 0.01200
  • 0.01000
  • 0.00800
  • 0.00600
  • 0.00400
  • 0.00200

0.00000

  • 0.016
  • 0.014
  • 0.012
  • 0.01
  • 0.008
  • 0.006
  • 0.004
  • 0.002

IS171104 vs. Demo

y = 0.9989x - 6E-05 R² = 0.9973

  • 0.01600
  • 0.01400
  • 0.01200
  • 0.01000
  • 0.00800
  • 0.00600
  • 0.00400
  • 0.00200

0.00000

  • 0.016
  • 0.014
  • 0.012
  • 0.01
  • 0.008
  • 0.006
  • 0.004
  • 0.002

IS161201 vs. Demo

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SLIDE 32

InSpec Vs. 3D Microscope Shows Excellent Correlation on Shot Peened Roughness

10/2/2018

4D Technology Corporation Confidential Info

32

y = 1.0048x + 0.5809 R² = 0.9978 5 10 15 20 25 5 10 15 20 25

Ra (micrometer)

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SLIDE 33

Reliability Can Matter as Much as Capability

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SLIDE 34

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Optics Allow Fold Mirror To Access Tight Spaces

10/2/2018

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SLIDE 35

Custom Fixturing Makes Specific Part Measurements Simple

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45º Blade Edge Corner Flat

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SLIDE 36

Key Shop Floor Measurement Applications

  • Part Types

– Turbine blades – Pipes – Shafts – Gears and transmissions – Solder joints and connectors – Rivets and fasteners – Solar panels – 3D printed metals and plastics

  • Types of Measurements:

– Porosity – Corrosion depth, volume, areal coverage – Rivet depth and planarity – Radius of curvature – Pit and scratch depth, area, aspect ratios, volume – Die peen, laser mark depth, uniformity, and planarity – Cooling hole geometry

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SLIDE 37

Intuitive, Touchscreen Interface Provides Instant Results

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Live Video Results History Analyses

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SLIDE 38

Rapid Return on Investment Possible With Appropriate Metrology

  • Reduced rework rate by 30% on a critical engine

component with ability to measure corrosion and wear

  • Reduced measurement time of pitting on a large

aerospace component from 3 days to 2 hours

  • Increased yield by 20% at a new-make machine

shop after quantifying visually ID’d defects as merely cosmetic

  • Reduced labor by 1 week in service through

elimination of disassembly/assembly prior to inspection of a critical component

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SLIDE 39

Good Metrology Enables Integration and Customization

  • Remote Interface option allows control of

InSpec from 3rd party applications for easy of use with robotics and automated staging

  • Full surface can be exported into XYZ point

cloud for outside analysis, storage, or CAD integration

  • Defect results stored in simple CSV format for

interface with factory QC systems

  • IronPython Scripting allows user-customized

analyses

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SLIDE 40

Applications: 3D Sintered Printing

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SLIDE 41

Applications: 3D Polymer Printing: Layer Height, Periodic Errors

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SLIDE 42

Applications: 3D Polymer Printing – Process Variations

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SLIDE 43

Rivet Depth And Planarity

  • Large depth of focus and

field of view allows snapshot measurement of fasteners

  • Quantify

– Recession – Tilt – Uniformity

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SLIDE 44

Applications: Cooling Hole Geometries benefit of large depth of focus

  • Angle of hole is about 20

degrees with respect to surface

  • Depth of hole is about 20

mils

  • Geometry can be checked

without bright-field uncertainties

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SLIDE 45

Dot Peen, Laser Marking Depths Are Easily Quantified

  • Structures too deep can

lead to corrosion

  • Markings too shallow can

wear prematurely and cause loss of serialization

  • InSpec quantifies each

individual feature automatically

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SLIDE 46

Applications: Defects on Radiused Surfaces

  • User defined size thresholds

for identifying features of interest

  • Finds all defects that meet

criteria

  • Reports depth, volume, area,

slope, location and more

10/2/2018

4D Technology Corporation Confidential Info

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*** Auto Feature Analysis removes all uncertainty

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SLIDE 47

Applications: Scratch Severity

  • No need to guess at

maximum depth

  • InSpec calculates 2 point

maximum depth and weighted depth (average

  • f user set % of deepest

points)

10/2/2018

4D Technology Corporation Confidential Info

47

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SLIDE 48

Applications: Corrosion Tracking

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SLIDE 49

Applications: Robotic Inspection

  • Vibration immunity allows

measurement without isolation

  • Defects automatically

reported as they are found

  • 100% Inspection possible

10/2/2018

4D Technology Corporation Confidential Info

49

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SLIDE 50

Shop Floor 3D Measurements Saves Money

  • Measure components prior to

disassembly

  • Avoid delays from using metrology lab
  • Halt reliance on human’s ‘calibrated

fingernail’ or ‘calibrated eye’

  • Eliminate errors from replicast/cross

sectioning

  • Measure at any angle
  • Measure without line of sight
  • Accurate, repeatable results
  • Improve Yields Dramatically!

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SLIDE 51

NSF Acknowledgement

  • This material is based upon work supported by the

National Science Foundation under Grant No.

  • 455066. Any opinions, findings, and conclusions or

recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the National Science Foundation.

10/2/2018 51

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SLIDE 52

Questions? For more info please: Visit IMTS booth 122027 visit www.4dInSpec.com email us at info@4dtechnology.com call at (520) 294-5600

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