technical industrial problem solving and failure ...€¦ · • problem solving • consultancy...
TRANSCRIPT
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
1 www.lpdlabservices.co.uk
Technical Industrial Problem Solving and
Failure Investigation at LPD Lab Services Dr Stephen Jenkins – Managing Director / Principal Scientist
Composites / Advanced Engineering Show 2013 (NEC) - 13th November 2013
RAPRA Session Invited Speaker
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
2 www.lpdlabservices.co.uk
Who are LPD Lab Services?
• Mix of analytical industrial chemists, materials scientists / engineers, physicists
(Over 180 man-years experience – 9 technical staff)
• Access to Consultants and Trusted Partner Laboratories
• Diverse product and process manufacturing knowledge.
• Experienced and pragmatic problem solvers.
• Used to providing quick and effective solutions to deal with unusual problems
• Diverse laboratory equipment – right tools for job!
• Skilled in bespoke sample preparation without interfering with physical and
chemical structures.
• Flexible / proactive approach to scope of work.
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
3 www.lpdlabservices.co.uk
Introduction to Specialities of LPD Lab Services
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Specialties:-
• Physical Analysis
• Chemicals Analysis.
• Materials analysis and materials engineering
• Surface analysis
• Bespoke tests and measurements
• Problem Solving
• Consultancy
• Reverse Engineering / Deformulation
• Product and process development.
Key Factors –
Competent, Experienced, Fast, Adaptable and communicative
Turn complex data into understandable practical information.
Accreditations –
ISO 17025:2005 (laboratory)
2766
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
4 www.lpdlabservices.co.uk
Problem Solving Approach – Beyond a Test House
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Normal test
house Sample
Measurement
Advise on
containment
actions
Explain
interpretation
clearly
Plan suitable
response
Plan work
Problem
Definition
Advise on
Solutions
Consultancy
Conduct work
Problem Solving Methodology:-
• 6 Sigma
• 8D
• Kepner Tregoe (KT)
Support specialising in:-
• Product development.
• Competitor benchmarking.
• Industrialisation and Ramp up
• Production Rejects
• Field Failure – Customer return.
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
5 www.lpdlabservices.co.uk
In House Laboratory Techniques
Surface Analysis / Surface Science.
•XPS, SIMS, AES, Contact Angle.
Scanning Electron Microscopy (SEM) / EDX
Optical Microscopy / Image Analysis
Chemical Analysis
•FTIR, AAS, XRF, ICP-MS GC, GC-MS, HPLC, IC, UV/Vis-(NIR) TGA, Wet Chemical
Mechanical Properties
•Tensile and hardness testing
Optical SEM
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
6 www.lpdlabservices.co.uk
Particle Contamination Identification and Elimination
• Particle contamination is problematic for many industries.
• Isolating and characterising the particles (with Optical Microscopy, SEM / EDX, FTIR
and SIMS) can yield a likely source.
Perform this work on virtually any type of sample, including:
• Liquid samples – suspended particles (in raw materials or process chemicals).
• Filters / Membranes.
• Product surfaces and under transparent polymer layers
eg Pre-preg surfaces, in laminated structures.
Charred pollen grain
found to block a filter.
Metal oxide particle with
characteristic machine marks
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
7 www.lpdlabservices.co.uk
Buried Particles in Laminate
Particle identification, isolation, characterisation and type matching in a laminate.
SEM/EDX showed particles in raw and finished laminate materials chemically and
physically similar (iron oxide + other elements) to confirm supplier was source.
Adhesive
Plastic film
Paper
Very fine dark
powder
contaminant with
no mechanical
strength at
interface
Unpigmented Polymer
Different
polymer
Optical Microscopy
• Dismantle laminate under microscope.
OR
• Solvent removal of over-layers without disturbing physical
and chemical structure so causal link can be proved. 150µm diameter particle
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
8 www.lpdlabservices.co.uk
Materials Problems with Composites, Plastics and Coatings?
Plastic Moulding Cracking Over Life
Moulding conditions can leave residual stress:
Relieved over life giving cracking (Environmental Stress Cracking - ESC)
• Solvent or cleaning agents give polymer chains mobility – Cracks.
• Affected by filler contents, filler types, size shape and distributions (Optical microscopy, SEM, PSD)
• Polymer crystallinity.
Shrinkage
• Mobile species like plasticisers or low molecular weight polymer can leach out under heat.
• Change mechanical properties.
• Cause delamination.
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
9 www.lpdlabservices.co.uk
Materials Problems with Plastics and Coatings?
Depolymerisation / Degradation
• Stabiliser concentration problems – Material less robust.
• Hydrolysis (FTIR).
• Oxidation (FTIR).
• Free radical attack (FTIR).
• Attack by mobile metallic ions (AAS).
• Chlorine embrittllement in Polyacetal (IC, SEM/EDX, SIMS)..
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
10 www.lpdlabservices.co.uk
Mechanical Property or Moulding Distortion Issues
• Wrong Volume fraction of reinforcement fibres (TGA).
• Insufficient ‘Size’ applied - Poor matrix – fibre load transfer.
• Moulding conditions left short fibre incorrectly distributed.
• Excess mould release agent.
• Plasticisers leaching out to surface – (XPS or SIMS).
• Contaminants at Pre-preg interface (SEM, FTIR or Surface Analysis).
• Depolymerisation – Chain Scission.
• Environmental Stress Cracking (ESC).
• Hydrolysis Moisture attack so polymer changes - FTIR, XPS, SIMS, TGA.
• Discolouration and UV radiation attack FTIR, SIMS.
• ‘Size’ effects diffusion rates as fast path to interior.
• Temperature and humidity affects
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
11 www.lpdlabservices.co.uk
Delamination in Products
SIMS or XPS determination of residual mould
release agents or plasticisers surface
segregating giving delamination problems
Delamination:
• Incomplete Resin Curing.
• Weak boundary layers – Residual release agents, interfacial or particle contamination.
• Poor surface treatments (eg Corona discharge)
• Coatings cured too fast during application or mix wrong (FTIR/XPS and look at recipe and process.)
• XPS, FTIR and SEM to check for residual release films.
• Poor cleaning.
• Water Ingress.
• Corrosion Issues.
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LPD Lab Services
Tel: +44 (0)1254 676074 Fax: +44 (0)1254 278845 Philips Road Blackburn Lancashire BB1 5RZ UK
12 www.lpdlabservices.co.uk
Summary and Final Comments
LPD Lab Services Ltd
www.lpdlabservices.co.uk
Tel. 01254-676074
Effective Problem Solving Needs…
• Experienced analytical staff to recognise failure mechanisms.
• Combine interpretation from multiple techniques.
• Act as extra R&D manpower / consultants for customer.
• Actively input into product and process modifications.
• Add value input when analysts have close understanding of the product
and design requirements.
• Adaptable and react fast.
Any Questions?