A summary of my internship at Philips Dunlee

1. Materials Engineering
2013 Summer Internship
Robert Schuld
R&D Engineering/ Philips-Dunlee
09/20/13

2. Projects
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

3. Image Processing Results
“Use image processing software to quantitatively
measure ball characteristics”
Raw Image
M62 ball bearing
Measured Characteristics
Image processing tool used: ImageJ

4. Image Processing Results
“Use image processing software to quantitatively
measure ball characteristics”
Number of Particles
Counted
2640
M62
Total particle area (µm2)
4.15
Cumulative Probability
Probability Density
0.3
0.8
0.25
Probability Density
1
Cumulative Probability
% of Total
Area
18.9
Average Area (µm2)
10959.7
Measured Particles
0.6
0.4
0.2
0
0.2
0.15
0.1
0.05
0
0
5
10
15
20
Particle Area (µm2)
25
30
0
5
10
15
20
Particle Area (µm2)
25
30

5. EDS Simulation Results
“Use energy-dispersive X-ray spectroscopy (EDS) simulation
software to better understand ball coating”
• Used DTSA-II and calibrated simulation detector with Dunlee’s Si(Li) detector
Result: EDS simulation can closely predict experimental results
Experimental Vs Simulation M62 Steel
Fe
Ball 1
Experiment
Mo
Simulation
W
Fe
C
0
V Cr
1
2
3
4
5
keV
Cr
6
Fe
7
8
9
10

6. EDS Simulation Results
M62 steel with Coating 1
Example 1
“Use energy-dispersive X-ray spectroscopy
(EDS) simulation software to better
understand ball coating”
EDS Spectrum
16000
100 A Carbon
14000
Coating 1
1000 A Coating 1
Steel Ball
Intensity
12000
10000
C/Coating 1 Ratio: 0.0206
8000
6000
4000
2000
C
0
0
2
4
6
Energy (keV)
8
10
Example 2
1000 A Carbon
Steel Ball
Intensity
5000 A Coating 1
EDS Spectrum
16000
14000
12000
10000
8000
6000
4000
2000
0
Coating 1
C/Coating 1 Ratio: 0.0812
C
0
Monte Carlo Trajectory Simulation
Program: NIST DTSA-II
2
4
6
Energy (keV)
8
10

7. EDS Simulation Results
“Use energy-dispersive X-ray spectroscopy (EDS)
simulation software to better understand ball coating”
1000
0 Angstroms C
100
100 Angstroms C
1000 Angstroms C
10
2000 Angstroms C
5000 Angstroms C
1
0
10
20
C/Coating 2 Ratio
30
M62 Coating 2 1000A C
Coating 2 Thickness (Angstroms)
Log (Coating 2 Thickness)
C/Coating 2 Ratio vs Coating Thickness
250
200
150
100
50
0
0
0.2
0.4
C/Fe Ratio
Knowing the C/Fe ratio can help
determine Ag thickness
0.6

8. Characterization of multilayer TZM sample
Purpose:
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

9. Characterization of multilayer TZM sample
EDS Compositional Line Scan Results

10. Characterization of multilayer TZM sample
EDS results
Element
C
Ti
Mo
Element
C
Ti
Wt%
3.9
61.6
34.5
Wt%
10.4
89.6

11. Phase Equilibria of the Ti-Mo-C System

12. Characterization of multilayer TZM sample
EBSD Results
Different Grains
Crystal Orientation

13. SolidWorks Simulation
X-ray Tube
Anode Tube Glass Insulator
Kovar
Borosilicate
glass
Kovar

14. SolidWorks FEA Results
Stress and Displacement (exaggeration)
Fixed location
Force applied
stress
Stress vs Time 1 cycle of use
time

15. FTIR Polymer Bag Results
12
1110
9
8
7
5
6
4

16. FTIR Polymer Bag Results

17. 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

18. Acknowledgments
• Michael Drory
• Rachel Wang