材料試験と調査

Rimkus Materials Testing and Investigationチームは、材料故障解析、腐食調査、溶接エンジニアリングを専門としています。また、さまざまな専門的な材料試験、分析、およびコンサルティングサービスも提供しています。

包括的な故障解析を行うことで、材料故障の根本原因を特定し、冶金学的問題を解決し、将来の再発を防ぐための推奨事項を立てることができます。当社の材料専門家は、高度な分析機器と技術を使用して、試験結果を解釈し、クライアントに詳細な行動計画を提供することができます。

専門スタッフは、欠陥調査、熱処理プロセス、リバースエンジニアリング、コーティングとメッキ、ベンダーの資格、材料の選択など、材料工学の他の多くの分野も専門としています。

世界中の企業や業界が、Rimkus Materials Testing and Investigationの専門スタッフに頼って、迅速かつ正確な材料試験結果を提供しています。これらの業界には、モータースポーツ、自動車製造、配管(水システム)、海洋、化学および医薬品製造、発電およびユーティリティ、熱交換器、ボイラーなどがあります。

材料試験および調査ラボサービスの詳細については、以下をご覧いただくか、(704)663-5108または [email protected] に直接お問い合わせください。

また、Rimkusは、保険や訴訟に関連する重要な問題について、経験豊富なコンサルタントの専任チームを擁しています。詳細については 、材料科学およびエンジニアリングのページ をご覧ください。

当社の材料試験および調査サービス

Failure analysis is performed by systematically examining, testing, and analyzing components to identify the cause and sequence of events that lead to a product failure. This specialized testing can vary significantly depending on the result found.

This process typically involves the following steps:

  1. コンポーネント、そのアプリケーション、およびその履歴に関する情報の収集
  2. 詳細な目視検査
  3. コンポーネントと視覚的証拠の写真ドキュメンテーション
  4. 非破壊検査
  5. 低倍率立体視鏡検査または3Dイメージング
  6. 高倍率走査型電子顕微鏡(SEM)検査
  7. 元素分析分光/SEM
  8. 金属組織微量分析のためのサンプルの切片化
  9. メタログラフィー
  10. 硬さ試験
  11. 化学分析
  12. 機械的試験
  13. 詳細なエビデンスとデータレビュー
  14. 専門的な結論と意見の定式化
  15. 私たちの調査結果と推奨事項の相互運用性レポート

Fractured deisel marine engine intake valve received for Failure Analysis

Corrosion is a chemical reaction phenomenon that results in degradation of material and can lead to serious or catastrophic failures. Corrosion investigation engineering is the process of collecting corrosion failure samples and analyzing them to determine the source (root cause) and severity of the corrosion. Drawing from these analyses, we provide expert opinions and recommendations for corrosion remediation and prevention.

The Rimkus Materials Testing and Investigation team specializes in corrosion investigation engineering and the analytical techniques used to identify corrosion mechanisms. We have the expertise to recommend more corrosion-resistant alloys or coatings for a particular application or environment to prevent recurrent corrosion issues. Our energy dispersive X-ray spectroscopy (EDS) system can analyze corrosion deposits to identify the corrosive agent. We also have the expertise and capabilities to offer accelerated salt fog and other corrosion testing to determine the suitability of materials and coatings for specific environments.

Corrosion investigation

A significant amount of metallurgical engineering is needed to successfully produce sound weldments in mechanical and structural applications.

We can provide welder and welding procedure qualification testing to ensure compliance with a wide variety of industrial specifications such as those set by the American Welding Society (AWS) and the American Society of Mechanical Engineers (ASME).

We perform weld testing to evaluate the soundness, toughness, brittleness, hardness, and other properties of weldments before production begins. Our team also frequently investigates weld failures to determine the root cause of fracture or degradation of the weldment in the field.

Welder and Welding Procedure Qualifications:

  • ベンド試験
  • シャルピー衝撃(CVN)試験
  • 蛍光染料浸透剤
  • 目視検査
  • マクロエッチング試験
  • 引張強度

Weld engineering

Our scanning electron microscope (SEM), with the addition of the energy dispersive X-ray spectrometer (EDS), can examine and analyze samples at magnifications typically ranging from 5X to 20,000X. Using our state-of-the-art scanning electron microscope, our experts can analyze everything from microstructure and fracture surface to corrosion products, pitting, and impurities within the material.

The fracture surface topography revealed at increased magnification can reveal an exorbitant amount of information:

  • 応力のタイプ(引張、せん断、ねじり)
  • 破壊モード(延性、脆性、疲労、過負荷)
  • 破壊伝播の方向
  • 骨折開始の領域とメカニズム
  • 微細構造内の汚染
  • 腐食生成物および堆積物の元素分析
  • 非常に小さな部品の元素組成
  • 故障の原因となる製造または修理関連の要因
  • 障害の原因に関連するその他の要因

Rimkus Materials Testing and Investigationラボには、材料分析と腐食調査に特化した2つの商用SEM/EDSシステムがあります。

High magnification scanning electron microscope SEM image of a brittle transgranular cleavage fracture surface

Rimkus材料試験および調査の専門家は、次のようなさまざまな非破壊検査技術を利用しています。

  • エネルギー分散型分光法(EDS)
    • 走査型電子顕微鏡(SEM)
  • 高解像度の3D表面プロファイル
    • 3Dプロファイル測定
    • 表面仕上げ/粗さ
  • 液体浸透探傷試験(PT)
    • 表面に開いた材料欠陥を検出したり、開いた表面の亀裂を検出したりするために、さまざまなタイプの液体PT法が利用されています。赤色染料または蛍光浸透剤、ならびに様々なタイプの湿潤および乾燥現像剤が利用されます。
  • 磁粉探傷検査(MPI)
    • 強磁性体の表面および浅い表面下の不連続性を検出するプロセス
  • ポータブル硬度
    • ロックウェル、ブリネル、リーブ
  • 目視検査および低倍率検査
  • ポータブル蛍光X線(XRF)分光計

Florecent dye penetrant (FPT) inspection on a roller bearing after heat treat

Metallography is the study of the microstructures of metallic materials. The properties of a material and its performance in a specific application depend on its microstructure. Rimkus utilizes numerous types and magnification of high-resolution optical and digital microscopes during the metallurgical examination process.

Analyses of microstructure in cross-sectioned samples help determine material properties, fracture propagation, corrosion pitting morphology, heat treatment, quality and thickness of plating and coating, grain size, overheat damage, material contamination, flaw characteristics, weld quality, manufacturing design flaws, and defect mechanisms.

The Rimkus Materials Testing and Investigation team has advanced training and knowledge in metallographic preparation procedures/processes, from sectioning and mounting the specimen through the grinding and polishing stages to proper selection and etching techniques of the tested material. Our expert laboratory staff is looked upon to provide metallurgical samples preparation techniques and their subsequent interpretations to clients from across the country.

Metallurgical microstructure analysis of a cast iron graphite rosette

During manufacturing, defects can be introduced at several stages of processing. Supported by the necessary advanced analytical equipment, expert training, and experience, the Rimkus Materials Testing and Investigation experts perform high level defect investigation to identify the specific processing step in which a defect occurred. Our experts will not only interpret the results but can provide recommendations to prevent future defects.

By providing high-quality defect investigation along with other materials testing methods, our team can determine whether a product failed due to defects or flaws produced in the manufacturing process or if the failure was caused during normal or abnormal usage.

Metallurgical microstructure analysis stress corrosion cracking in austenitic stainless steel 316SS

Using a scanning electron microscope (SEM) with an energy dispersive X-ray spectrometer (EDS) is an advanced analytical technique that enables the operator to identify the chemical characterization/elemental analysis of materials. EDS analysis can identify the elemental composition of fine to microscopic particles or larger regions on the surface of samples.

During an SEM examination, the locations, deposits, or areas of interest are analyzed using an EDS attached to the scanning electron microscope. EDS microanalysis is performed by measuring the energy and intensity of the signals generated by a focused electron beam scanned across the specimen.

Elemental Dot Map

Element mapping measures the individual elemental distributions on the exposed surface of a sample. Typically, this technique produces an analysis of one field of view by utilizing the scanning electron beam in conjunction with the EDS detector, in a grid pattern to produce a map. This analysis is particularly valuable when identifying contamination, coating/plating layers, diffusion during welding, and corrosion products.

Energy dispersive spectroscopy elemental dot map

Rimkus experts have extensive mechanical testing experience to determine the compliance of materials to applicable standards and specifications. We have significant knowledge of mechanical testing methodology and are highly skilled in interpreting the results.

Our team can perform mechanical testing and materials testing as part of a quality assurance program, manufacturing engineering program, failure analysis, or for materials research and development. Tests can be performed to ASTM specifications or other industry-recognized standards.

In-house mechanical testing equipment is used for the following materials tests:

  • ベンド試験
  • 引張試験
  • 圧縮試験
  • CVN(シャルピーVノッチ)試験
  • 微小硬さ試験(ヌープ、ビッカース)
  • ロックウェル硬度
  • ブリネル硬度

Charpy v-notch specimens before and after impact testing

リバースエンジニアリングとは、部品の製造に使用された材料や加工を特定・分析し、同一の特性を持つ製品を作る方法です。化学組成、熱処理、コーティングの種類、コーティングの厚さなどの材料特性を決定することにより、リバースエンジニアリングを実現できます。

  • 化学分析
    • 材料の化学組成の特定
  • 金属組織学/微細構造評価
    • キャスト
    • 鍛造
    • 押し出し
    • 表面処理(窒化物、浸炭など)
  • 熱処理
    • 硬さまたは微小硬さトラバース
    • ケースの有効深さ
    • 微細 構造
  • コーティング
    • 鍍金
    • クラッド
    • アルマイト、リン酸塩、化成皮膜など

Close up of broken gear for reverse engineering

An invaluable component of a failure analysis or corrosion investigation is the chemical analysis of metals. Used for multiple purposes, chemical analysis is crucial in the identification of manufacturing difficulties, completion of quality control requirements, and reverse engineering of components that need to be recreated.

Material chemical composition analysis and verification ensures that each component or raw stock material is produced in accordance with the correct material alloy specification. Chemical composition analysis can be performed using various methods that compare results against the appropriate industry standards, such as ASTM, SAE, and more. Our team of experts routinely analyzes the alloying content of a wide range of materials including, but not limited to iron, steel, aluminum, copper, nickel, zinc, titanium, and lead.

For metals, the Optical Emission Spectrometry (OES) technique utilizes a high-energy spark created between an electrode and a sample of the material to be analyzed. The spark creates an emission of radiation from the excited sample surface with wavelengths characteristic of the elemental chemical composition. The spectrum of radiation is separated into the distinct element lines and the intensity of each line is measured. Finally, these are precisely converted into concentration values for each element present.

OES continues to be the reference technique for direct chemical analysis of solid metallic samples. The unmatched combination of accuracy, high speed, precision, stability, and reliability have made it an indispensable tool for production and verification of quality metal products.

Optical Emmisions Spectrometer OES elemental analysis of brass fitting

Field metallographic replication is a (semi) non-destructive test required in some applications where it is not possible to remove a component from service or the size of the components prohibits analysis in the laboratory.

Assorted replicating media techniques allow our experts to create a portable copy of the microstructure of interest while in the field. Replication involves removal of the material’s surface by lightly grinding, followed by polishing using fine grits.

Once the surface is properly polished and prepared, it is then etched with various acids to reveal the materials microstructure. The replicating media is then applied and allowed to cure. Once the replicating media is cured, it will be removed from the sample, returned to our laboratory, and analyzed using a variety of microscopes.

Replication can also be performed to replicate surfaces for surface finish or other testing, replicating shapes, corrosion pitting, cracking or any other surface that require imaging or measurements.

on site in-situ microstructure replication of a austenitic stainless steel tube sheet (heat exchanger)

With its 6 x 11-inch fully automated stage, the high-resolution Keyence VR enhances our capabilities for measuring and analyzing large samples. It can be utilized in nearly all industries and at every step of engineering, from research and development to production, and from quality control through analysis of failures and defect investigation.

The Keyence VR is just one of the many pieces of advanced technological and analytical equipment we utilize to assist customers in understanding their complex matters.

  • 複雑なプロファイルの測定
    • キーエンスVRは、任意の2Dまたは3Dオブジェクトまたは表面をスキャンし、任意のタイプの2Dおよび3D表面またはプロファイル測定を提供できます。また、非接触の表面仕上げと粗さの測定、および真の表面平坦性の評価も可能です。
  • 表面仕上げと粗さ
    • 表面仕上げおよび粗さ試験は、当社のラボで、または高解像度のゼロ収縮複製媒体を使用して現場で実施できます。
  • 製品の欠陥とフィットアップ
    • ゴム製ガスケットの取り付けが不適切だったのか、それともメーカーから不良品だったのか?ガスケットシートはガスケットの寸法と一致しましたか?キーエンスVRで得られた高解像度の3Dプロファイル計測値を用いて、これらの疑問に答えることができます。
  • 製造上の欠陥
    • キーエンスVRは、異常な摩耗傷跡、成形ライン、変形、ねじ山の損傷、または腐食孔食のコンポーネント(配管継手など)の評価に使用できます。
  • 環境屋根の損傷
    • 帯状疱疹への環境雹による損傷は、特徴付けと評価が難しい場合があります。キーエンスVRを使用することで、屋根板の損傷を評価、特徴付け、確認することができます。
  • 非破壊分析
    • ギアとブッシングの3Dプロファイル測定が、破壊試験なしで可能になりました。これにより、プロジェクトマネージャーは、摩耗パターンを迅速かつ効率的に、高い精度と再現性で評価することができます。
  • 射出成形金型の欠陥
    • 射出成形金型や金型は不適切に摩耗し、最終製品に欠陥を引き起こす可能性があります。これらの摩耗痕や欠陥を測定して、金型や金型の寸法を特徴付けて特定できるようになりました。

High resolution 3D surface roughness SA scan of a medical implant

当社の材料試験および調査の専門家

関連するケーススタディ

破砕されたインプットシャフト(上)と、同様のレース条件を経験した2つの比較シャフトの概要。

レースカーのトランスミッション入力シャフトの故障解析

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