Metals Analysis: Future Trends

Source: Mikko Järvikivi, Global Head of Product Management - Hitachi High-Tech Analytical Science

From the rise of robots in the manufacturing process, to the fall in quality of raw materials from certain sources, our industry has never been a more challenging place to operate. And yet it’s never been more interesting and exciting. Here are just five areas that keep us talking at Hitachi High-Tech; highs and lows that are influencing the way we develop our technology to ensure a successful future for those working with metals, or in the metals industry.

1. 3D Printing in Metal

3D printing is here to stay, and the ability to ‘print’ in metals is moving far beyond prototype components, shifting to finished metal components that could potentially fail. Hailed as the new technique for fabrication, 3D printing is a disruptive technology that will change traditional methods in an exciting way. Having worked with the metals industry for many years, we get excited about advancement in technology and this is definitely up there. In the future, we believe that the analysis of finished products will be straightforward. However, it’s the testing of the raw materials that could make analysers your most valuable tools. Raw materials can include aluminium, cobalt, chrome, copper, stainless steel, titanium and tungsten. But for any of these to be used, they must first exist as pure elements or alloy powder. This ‘powder’ could be tested with an XRF (X-ray Fluorescence) metals analyser to ensure it’s of the quality you need before turning it into a vital component. Alternatively, stationary spark optical emission spectrometers (OES), like the OE750 and OE720 from Hitachi, can be used to test powders using a re-melting furnace. This provides the advantage to analyze C, P, S, B and N (if powder is nickel, cobalt or steel based), which XRF machines cannot analyse. WDXRF and combustion analysers are an alternative, but these can be up to three times more expensive than the OE750.

2. Metals Analysis and Big Data

resource for businesses in the last decade, and the metals industry is no different. While investment has been made into process control and optimisation, the industry has for many years lagged behind sectors, such as banking and media, in its adoption of new digital technologies. However, the pace is picking up with innovations in analytics, mobile solutions and automation delivering significant gains. For us, the speed, simplicity, and convenience of a metals analyser enabling a member of staff to take thousands of readings in a working day, means we also need to adapt to keep pace. Data and information is now an essential part of a complete metals analysis ‘toolkit’. Whether it is through the device being connected to the cloud, through the IoT, or installed within the instrument itself.

3. Why Sccuracy Matters

As global competition increases, or as is the current case, material shortages, there is no doubt that the quality of materials from some areas will decrease. In some countries, huge tax advantages are offered to manufacturers that add low-cost elements, such as boron to materials such as steel. The government of one of the world’s largest alloyed steel exporters supports it with a tax reduction of between three and nine percent. So, while someone else might be getting a tax break, you should be doing incoming inspection on the raw material being received, to ensure you’re not paying the cost. For this application, either a handheld XRF analyser such as the X-MET8000 or handheld laser analyser like the Vulcan, would be appropriate. However, when higher precision and accuracy is needed, our stationary optical emission analysers, such as the OE720 or OE750, would be the best choice to ensure you are getting the best price-quality ratio for your incoming raw materials verification.

4. Rise of the Robots

Robotics and artificial intelligence (AI) are at the heart of a new era in manufacturing - the drive to digitise industry. In many industries, robots and AI already take a crucial and prevalent role – improving accuracy and consistency, shortening throughput and enhancing product quality. The rise of the cobots, 24/7 factory floor and laboratory, and cloud robotics are all trends we’re seeing in metal manufacturing and how things are changing. We’ve also been increasing our research

into ways to help you with connectivity and automation to help optimize production. While the robot analyser that walks and talks is some way off, contact us in regards to the devices that can be integrated into your production process right now.

5. Materials and Their Impact on the Environment

Phrases like ‘green’ and ‘environmentally friendly’ are all too common nowadays, and our industry has never been more alert to these issues. While recycling scrap metal is a more environmentally friendly practice than extracting, processing and refining raw materials, it’s not without its downfalls.

Even very small amounts of additives or tramp elements, can cause serious issues later down the line and dramatically alter the quality and usability of metal. That’s why in order to create high-quality, reliable products in which the materials behave as expected, it’s crucial to control and measure tramp and trace elements in incoming raw materials - something that is only achievable with the right equipment. Our latest spark OES analysers, the OE750 and OE720, could be the answer to just that, also ensuring future flexibility as well. As metals analysis experts, our range of LIBS, OES and XRF means our PMI toolbox of metal composition testing analysers could be just the solution for you.

About Hitachi High-Tech Analytical Science

The Hitachi High-Tech range of X-ray, laser and optical emission spectrometer analysers provide superior analysis for incoming inspection, factory floor process control and NDT for final inspection to provide you with cutting-edge solutions. Their range includes: XRF (X-ray Fluorescence) is available in both benchtop and handheld formats, is ideal for measuring a wide range of elements and concentrations in many different materials, including metal alloys. XRF technology utilises an X-ray tube to induce a response from the atoms in the tested sample. This technique is ideal when you need low limits of detection for accurate grade separation. OES (Optical Emission Spectroscopy) is available in mobile and stationary formats. OES can analyse all the key elements at low limits of detection, like phosphorous, sulphur, boron – and carbon, starting with a detection limit of 30ppm. Compared to handheld XRF, the OES technique requires more sample preparation and a small but visible burn spot is left on the surface. LIBS (Laser Induced Breakdown Spectroscopy) is a fast, handheld format, ideal for the identification of different types of alloys. With a LIBS analyser, there are no X-rays as it uses a focused laser pulse to hit the sample surface, removing a very small amount of material for analysis. This means the LIBS burn mark is so small that it can often be used for finished goods.

100% Positive Material Identification

The Hitachi High-Tech range of metals analysers and technologies ensures: • Rapid, reliable material verification, even in the most demanding quality assurance and control applications • Meeting of standards, avoiding potentially devastating results for your customers, your company and even your reputation • Avoidance of costly reworks through incoming inspection of alloy material before the production phase • Avoidance of costly recalls by confirming chemical composition and material verification prior to shipment • Production lines kept running at optimum efficiency • Access to powerful data management and reporting

Read the metal. Reveal the quality.

Hitachi’s range of materials analyzers support the end-to-end metals production process from incoming inspection to final product assembly and finished goods testing to ensure product reliability, safety and regulatory compliance.

See the full range at: hhtas.net/read-the-metal

X-MET8000 - XRF VULCAN - LIBS MOBILE AND STATIONARY OES

Complete metals analysis you can count on.