Metallurgical Engineering Laboratory
Staffed with seven experienced metallurgists/materials
engineers (M.S./Ph.D.) and three technicians
(Level 2/Level 3 in various NDI techniques), the metallurgical
lab
is a resource for failure and engineering investigations and
metallurgical testing and analysis.
We carry out detailed
conformance-to-blueprint inspections, failure analyses ranging from aircraft structural components to electronics
packaging, fatigue and corrosion testing, corrosion
analysis and control, wear/abrasion evaluations, metallurgical analysis, coating
replacement evaluations, weld evaluations, reverse
engineering programs, and the development of advanced
non-destructive testing techniques.
Services
Comprehensive...Full Range of Metallurgical Services
The metallurgical engineering lab
is fully equipped with various non-destructive flaw detection testing techniques, borescopes,
hardness measurement machines, stereomicroscopes, inverted optical metallograph,
high resolution digital imaging, scanning electron microscope with energy dispersive
spectroscopy, arc emission spectroscope, metallographic sample preparation equipment,
advanced image analysis software, and a comprehensive reference library and specifications
database.
- NDI
- Metallography
- Imaging
- Sem-Eds
- Composition
- Hardness
- Shot Peening Evaluation
- Temper Etching
- Macro- and Micro-Hardness
- Macro- and Micro-Composition
- Microstructural Analysis
- Plating/Coating Analysis
- Grain Size Measurements
- Grain Flow Evaluation
- Case Hardening and Decarburization
- Electrical Conductivity Measurements, Passivation Measurements
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Failure Analysis
Complex Analysis...Pactical Solutions
The metallurgical lab has immediate access to in-house expertise in a wide
range of technical specialties, including EMI/EMC, Shock and Vibration, Environmental Testing, Life Support Systems, Stress Analysis, Engineering Design, and Manufacturing Engineering. This allows us to field a highly skilled interdisciplinary team to
perform detailed root cause analyses (see Flow
Diagram). Also, because of our engineering
experience, our recommendations focus on the practical and can be rapidly tested
using our extensive test capabilities. See Case Histories for our experience in
metallurgical failure analysis.
- Case Histories
- Flow Diagram
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Metallurgical Conformance Inspections
Over 1000 Flight Safety Critical Assemblies Completed...and Counting
Our metallurgical lab performs full conformance-to-blueprint inspections
using our extensive facilities. Our experienced staff of engineers and technicians
generate highly reliable
data on which to base your decisions. Our conformance inspections
include evaluation of Shot Peening, Temper Etching, Hardness Measurements, Compositional
Measurements, Microstructural Analysis, Plating/Coating Analysis, Grain Size Measurements,
Grain Flow Evaluation, Case Hardening and Decarburization Analysis, Electrical Conductivity
Measurements, and Passivation Measurements. See Example for a typical example of
our Metallurgical Conformance Inspections.
- Microstructural Analysis
- Plating/Coating
- Grain Flow
- Decarburization
- Case Harding
- Example
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Reverse Engineering and Materials Selection
Materials, Processes, Joining Methods, Surface Finishes and Treatments
Reverse engineering programs are undertaken as a team effort in which the metallurgical
lab participates as one of the team members. We analyze every metallurgical
characteristic (see Conformance Inspections) to determine alloy selection, manufacturing
processes such as forging, casting and thermo-mechanical sequences, joining methods,
surface finishes such as plating and coating, and surface treatments such as shot
peening. We also specify the governing specifications and participate in developing
technical data packages and vendor qualification.
Click here for Braze Evaluation
Example
Corrosion Testing
High Fidelity Corrosion Testing. High Quality System-Wide Solutions
Using our experience and expertise in corrosion processes, environmental testing,
metallurgical failure analysis, alloy systems, and corrosion protection methods,
we design high fidelity corrosion test programs and provide practical solutions
that apply to the system as a whole. See case histories in Corrosion for our experience
in analyzing corrosion-assisted failures.
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Corrosion Prevention
Control Aapproch
Engineering Development and Investigations
Innovative Engineering...Comprehensive Analysis…Rapid Turnaround
The metallurgical engineering lab undertakes diverse investigative and development programs,
ranging from evaluation of gun barrel damage accumulation to testing cadmium replacement
coatings to measuring powder mixture compositions from X-ray images.
- Gun Barrel Coating Evaluation
- Marking Resistance Testing
- Cadmium Replacement Coatings
Evaluation
- Non-Destructive Testing of
Oxygen Breathing Apparatus
Equipment and Facilitites
Arc Emission Spectroscopy
The arc emission spectroscope is equipped with a comprehensive standards library
for highly accurate quantitative compositional analysis of all types of steels,
cast irons, aluminum alloys, nickel and cobalt base superalloys, titanium base alloys,
and copper base alloys.
Borescopes and Stereomicroscopes
Rigid and flexible borescopes with indexed
movement and imaging in white and dark light illumination are also part of our metallurgical lab. It has several
steromicroscopes with image capture and magnifications ranging from 2.5X to 75X.
All systems are equipped with calibrated digital image acquisition and feature measurements.
Hardness Measurements
All standard and superficial Rockwell scales, and microhardness measurements
with precision stage movements for profiles.
High Resolution Digital Imaging
The high resolution digital imaging setup is equipped with a large defect-mapped
CCD system that is highly suited for macrofractography and grain flow evaluation.
The system is equipped with sophisticated image analysis software for a variety
of feature measurements.
Metallographic Sample Preparation
The metallurgical lab is equipped with all methods of metallographic
sample preparation including electropolishing, low-damage sectioning, and edge retention.
Sample mounting, grinding, and polishing are accomplished by semiautomatic methods
that minimize metallographic artifacts to yield consistently high quality results.
Non-destructive flaw detection
Full range of Non-destructive Testing (NDT) capabilities including Magnetic Particle (MP),
Liquid Penetrant (LP), Dual-Frequency Eddy Current (EC), Ultrasonics (UT), and
Digital Microfocus High Resolution Digital X-Ray (via Teaming with OEM R and D Lab).
Optical Metallograph
An inverted optical metallograph is part of our metallurgical engineering lab, equipped with digital
image acquisition and sophisticated software for stereological and feature measurements.
Illumination options include brightfield and polarized light.
Scanning Electron Microscopy and Energy Dispersive Spectroscopy
The metallurgical laboratory has a fully equipped SEM/EDS system with calibrated
digital image acquisition and feature measurements. Typical applications include
rapid qualitative determination of alloy and coating compositions, and detailed
microfractographic, microstructural, and corrosion analyses.
Advanced Image Analysis Software and Reference Library
All imaging equipment in our metallurgical lab has access to a full suite of image analysis
functions and stereological measurements. We have expertise in automated pattern
recognition, calibrated measurements of a wide range of geometrical relationships
between features, image matching, depth measurements, and extended focal correction
imaging. The laboratory also maintains a comprehensive reference library and specifications
database for rapid access to these valuable resources.
Failure Analysis Case Histories
Click here for Failure Analysis Case History
samples.