Measure Platinum, Rhodium and Palladium in Automotive Catalytic Converters

Automotive catalytic converters contain the precious metals Platinum, Rhodium and Palladium. The exact amount of these elements is important for the recycling industry to determine scrap values.

XRF Precious Metal Analysis for Automotive Catalysts

The European Directive on End-of-Life Vehicles (ELV 2000/53/EC) has the real effect that a huge number of different automotive catalytic converters are now recycled. The value of these used catalytic converters depends on the amount of precious metals they contain, making it important for the recycling industry to be able to determine precisely the content of Platinum, Rhodium and Palladium.

In comparison to analysis using traditional chemical methods, measurement of these three elements can be performed more quickly and accurately with the FISCHERSCOPE® X-RAY XDV®-SDD equipment.

To get the best measuring results the catalyst structures are first milled and pressed into pellets. The FISCHERSCOPE® X-RAY XDV®-SDD has a programmable measuring stage, which makes it easy to analyse a large number of samples (pellets) automatically.

The powerful WinFTM® analysis software provides accurate measurements of all three precious metals by their components.

Comparison of Measurement Results: XRF Analysis and Chemical Analysis of Platinum, Rhodium and Palladium

PLATINUM PALLADIUM PLATINUM
A1 ICP-OES XDV-SDD ICP-OES XDV-SDD ICP-OES XDV-SDD
A2 1065 1055 861 871 236 243
A3 1004 995 785 774 201 186
A4 770 741 1335 1315 125 100
A5 856 880 850 856 194 181
A6 1158 1142 806 815 180 177
A7 1071 1089 729 756 185 186
A8 1060 1057 761 747 189 189
A9 3112 3200 2830 2789 716 700
A10 975 996 887 884 177 172

Comparison of XDV-SDD and chemical analysis by ICP-OES for some automotive catalytic converters. Values in mg/kg.

XDV-SDD EDXRF

Precise measurements of extremely thin coatings (as low as nanometers) on complex geometry small and large samples. Ideal for PCB & ROHS.

Your Measuring Instrument for the XRF Analysis of Precious Metal Content in Catalysts

With its silicon drift detector (SDD), the programmable measuring stage and the powerful analysis software, WinFTM®, the FISCHERSCOPE® X-RAY XDV®-SDD is perfectly suited for the efficient, precise and convenient measurement of precious metal content in catalytic converters.

Inspection Plans for Car Paint Quality Control

For a variety of reasons, assessing the quality of paint coatings on car bodies is increasing in importance. Narrow tolerance limits and strong demand for smooth finishes require precise measurements of the coating thickness according to clearly defined testing procedures. In addition, the measurement results should provide clues for potential process optimizations. Therefore, consistent inspection procedures – regardless of who is doing the measuring – are also essential.

Paint finishes on car bodies must fulfill a range of criteria: Not only should they provide sufficient corrosion protection (therefore requiring at least a minimum thickness) while simultaneously containing costs (minimum material waste), the colour and texture must also be even and homogeneous. To check all these criteria systematically, test measurements should always be taken at the same spots, in the same way, regardless of who is currently executing the inspection.

Simplified surface development of a car body with defined measuring spots

Coating measurement according to pre-defined inspection plans with DUALSCOPE® FMP100 and Fischer DataCenter IP software

Using simplified surface development drawings, precise inspection specifications can be displayed for the examiner, showing exactly where the paint coating is to be measured. However, such sequences are often very complex and therefore susceptible to operator failure.

The FISCHER DataCenter IP (Inspection Plan) software makes it possible to create process-controlled inspection plans that can be loaded onto handheld DUALSCOPE® FMP100 measuring instruments. Enhanced by images and text, the inspection plan clearly guides the user step-by-step through the measurement tasks like a navigation system. The readings can then be down-loaded directly to the PC for easy evaluation, archival and printing (with customisable templates). For this purpose a wide variety of analysis and statistic functions, as well as supporting graphical displays, are available.

The Fischer DataCenter IP software and DUALSCOPE® FMP100 handheld instruments put powerful tools of strategic quality control directly into inspectors’ hands: Structured measurement recording and extensive evaluation options help to highlight potential improvements in production processes, while step-by-step guidance through the complete measurement cycle not only minimizes errors and increases consistency but also makes these instruments suitable for use even by non-technical staff. For more information please contact your local FISCHER representative.

COATING THICKNESS (DFT) GAUGES

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Wide range of handheld dry film thickness gauges (DFT) for the measurement of coating thickness on ferrous and non-ferrous substrates

Measuring Duplex Coatings in the Automotive Industry

For automotive manufacturers, it is of increasing importance to control the quality of the paint processes in order to ensure effective corrosion protection while reducing costs. Especially in EDP (electrophoretic deposition) processes, this requires adherence to tight tolerance limits, which in turn, requires careful monitoring. But the measurement task itself should also be fast and cost-effective; the instrument must be able to measure lacquer atop various base materials (mainly galvanized steel or aluminum) without refitting or recalibration.

To measure lacquer coatings on both steel and aluminum with the same instrument and without having to change probes, it is necessary to utilize different methods. Furthermore, when the steel is galvanized, the Zn coating must be measured separately in order to determine the thickness of the lacquer coating above it. Especially for this purpose, FISCHER has developed the PHASCOPE® PMP10 DUPLEX and the ESG20 probe, uniting three measurement methods in one system for testing the thickness of each layer precisely and accurately.

PHASCOPE® PMP10 DUPLEX.

For a typical lacquer/Zn/Fe combination, the Zn layer is measured through the lacquer using the phase sensitive eddy current method (employing lift-off-compensation). At the same time, the overall coating thickness (Zn+ lacquer) is measured using the magnetic induction method; the thickness of each individual layer is derived from this and displayed on the instrument.

For coating systems on aluminum, the amplitude sensitive eddy current method is used. A special conductivity compensation feature ensures that the various conductivities of different Al alloys exert no influence on the measurement of the lacquer layer. Without any additional calibration, the coating thickness can be measured precisely and reproducibly in one pass even when the substrate changes, as the probe automatically identifies what the base material is.

Typical measurement tasks in the automotive industry. MS = magnetic induction method, WS PS = phase sensitive eddy current method, WS AS = amplitude sensitive eddy current method.

Especially with costly EDP coatings, very small tolerances – often of just ± 2 µm – must be met in order to ensure the minimum thickness for effective corrosion protection while minimising the amount of material consumed. This is why it is necessary to measure the Zn layer underneath the paint to determine the real thickness of the lacquer, since even minor variations in the Zn coating could erroneously indicate a (non-existent) flaw in the paint process.

The PHASCOPE® PMP10 DUPLEX, together with the ESG20 probe, was developed especially to meet the requirements of the automotive industry. Its three different measurement methods make it possible to measure lacquer coatings precisely, in one operation, whether on galvanized steel or on aluminum. Your local FISCHER representative will gladly provide you with further information.

Measure CDP Coatings Inside Car Body Parts

Simple Coating Thickness Measurement of CDP in Hard-to-Reach Spots in Car Bodies

In the automotive industry, the anti-rust warranty has become an important hallmark of car quality. Particularly in hard-to-reach areas such as the cross beams and pillars of the steel car body, specified tolerances for CDP coating thicknesses must be ensured, because in these areas, corrosion can proceed long undetected.

Modern car bodies are usually protected from rust with a primer coat applied by cathodic dip painting (CDP). Until now, it was not feasible to measure the coating thickness inside the hollow parts without destroying the entire car body. Common practice has been to dismantle random car bodies for spot-checking of these hidden areas. This approach carries a very high cost and makes systematic, real-time quality control more or less impossible.

For exactly this purpose, FISCHER has developed the V3FGA06H “cavity probe” which, due to its design, can be inserted into almost any opening in cross beams or pillars for accurate and non-destructive measurement of the CDP coating thickness – on the inside.

DUALSCOPE® FMP100 and cavity probe V3FGA06H for measurement of CDP coatings on car bodies.

The magnetic inductive probe with its wear resistant tip has been optimized for all typical CDP coatings thinner than 25 μm (including Zn). It has a specially curved, slim shape and fits through small openings in the car body to measure the thickness of lacquer coatings in what was once inaccessible areas. Its small, flexible, attached head with three-point support guarantees precise positioning and repeatable measurements even inside the cross beams and on curved surfaces.

Insertion of the V3FGA06H probe into a hollow car body part to measure the CDP coating on the inside.

The V3FGA06H probe works with FISCHER’s FMP series instruments, which are equipped with a USB port that makes it convenient to transfer measurement results to a computer for evaluation, recording and storage using FISCHER DataCenter software. A combination of the DUALSCOPE® FMP100 gauge and FISCHER DataCenter IP (Inspection Plan) allows the user to create inspection plans on a PC and transfer them back to the instrument, providing visually aided guidance though a defined measurement task.

With the cavity probe V3FGA06H and easy-to-operate FMP instruments from FISCHER the thickness of CDP coatings in difficult to access cavities such as inside door sills, brackets or reinforced parts can be measured quickly, accurately and, above all, without dismantling. Your local FISCHER representative will be happy to answer any questions you may have.

Measure Nikasil Coatings on Aluminum Automotive Cylinders

Precise Coating Thickness Measurements inside Cylinder Barrels with FISCHERSCOPE® MMS® PC2

Automotive cylinders are subject to extreme mechanical wear. A way of protecting aluminum cylinders is to plate the contact surfaces with Nikasil®, a hard coating technology used to improve the tribological characteristics of the cylinder parts and to optimize the heat transfer. It is often used for high-end engine components of premium car brands and in motor sports.

Nikasil® (from the German for Nickel-Carbide-Silicon – Nickel-Karbid-Silizium) is an electroplated nickel matrix with embedded silicon-carbide particles. Its amazing tribological characteristics make Nikasil® the ideal contact surface for pistons and rings; it is therefore used on high-end engine parts to minimize the friction within the engine block. The Nikasil® coating is appropriate for two- and four-stroke aluminum cylinder walls or sleeves and is used in a variety of automotive engines ranging from classic cars to the latest Formula 1 vehicles.

Cylinder block made of aluminum coated with Nikasil®. Coating thickness approx. 20 – 50 µm.

In practical use the cylinder walls or sleeves are electroplated with a layer of Nikasil®, typically between 80 and 180 µm thick. Afterwards, the coating thickness is controlled using the custom-configured table-top FISCHERSCOPE® MMS® PC2, further outfitted with a NICKELSCOPE® module and the probe ENW3. Overall, this specialized instrument employs the magnetic measurement method (hall effect).

In the next step the cylinder barrels are milled and honed to improve their sliding characteristics. A final coating thickness somewhere in the range of 25 to 50 µm is aimed for, which requires extremely narrow tolerances to be met in the measurement procedure.

The probe ENW3 is the centerpiece of the measurement system and is used both after the electroplating process as well as after honing. Its angled form helps the user to reach even difficult-to-access places.

Measuring inside cylinder barrels or sleeves can also be automated. To this end, the FISCHERSCOPE® MMS® PC2 can be equipped with a digital I/O module to control up to six probes at once; measurement values are collected and transferred to the instrument simultaneously, making it possible to take multiple measurements with high frequency for quality control purposes in a running production line.

For precise thickness measurement of Nikasil® coatings the FISCHERSCOPE® MMS® PC2 – equipped with the NICKELSCOPE® module and the ENW3 probe – is the perfect choice for professional quality monitoring of Nikasil® coatings. Even automated measurements with multiple probes are feasible. Please contact your FISCHER representative for more information. 

COATING THICKNESS (DFT) GAUGES

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Wide range of handheld dry film thickness gauges (DFT) for the measurement of coating thickness on ferrous and non-ferrous substrates

Measurement of Thick NiP Coatings on Automotive Parts

Precise Coating Thickness Measurement of NiP with Fischer Handheld Gauges and Probes

In the automotive industry, the plungers used inside the solenoid valves of automatic transmission gearboxes must fit smoothly into their through-holes to an accuracy of just a few µm, in order to prevent oscillations that would lead to jamming or canting. To meet these tight tolerance limits, the plungers must be coated very evenly, which requires strict quality control.

In the manufacture of parts in the automotive and machine-building industries, adhering to extremely tight tolerance limits is necessary to guarantee the components’ proper functioning. That is why electroless metal platings like electroless nickel are being used more and more frequently, as they enable a very even coating: The layer builds up more homogeneously and with less variation in thickness than electroplated coatings, which tend toward excessive coating thicknesses on edges and corners.

In this example, steel plungers for solenoid valves are coated with approximately 60-70 µm of NiP containing at least 10% phosphorous. Afterwards, the parts are ground to an accurate fit; the end thickness of the coating is approximately 50 µm, which must be within a tolerance range of ± 4 µm. This layer is itself non-magnetic and can, for purposes of incoming inspection and/or after grinding, be measured with the magnetic induction method using the DUALSCOPE® FMP100 and the FGAB 1.3 probe.

SAMPLE COATING THICKNESS STANDARD DEVIATION
Unground plunger 67 µm Ø 3 µm *
Finished plunger 50 µm Ø 0.3 µm *
Control of the measurement system variation by repeated measurements on a single measurement spot 0.03 µm

Measurement results of a quality inspection * 10 readings taken on different measurement spots per sample.

The DUALSCOPE® FMP100 and FGAB1.3 probe are employed in conjunction with a V12 BASE stand, which makes it possible to replicate the measurement procedure with consistent probe positioning and angle. This minimizes operator influence and produces extremely repeatable results, as shown in Table 1: The standard deviation for the measurements of the coating after grinding is, on average, just 0.3 µm, and the variation of the entire measurement system itself is only 0.03 µm, which is negligible. Therefore the measurement device capability even for the required tight tolerances is fulfilled.

The DUALSCOPE® FMP100, together with the probe FGAB1.3 and the stand V12 BASE, forms a reliable control system that can precisely and accurately measure NiP coatings on automotive components with minimal variation. This allows both monitoring of quality specifications and adherence to very tight tolerance limits – and therefore, the avoidance of potentially costly warranty claims. For further information please contact your local FISCHER representative.

COATING THICKNESS (DFT) GAUGES

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Wide range of handheld dry film thickness gauges (DFT) for the measurement of coating thickness on ferrous and non-ferrous substrates

Measure Sprayable Acoustic Material Coatings (SAM) with Fischer

Coating Thickness Measurement of SAM (Sprayable Acoustic Material) with Probe FA14

In the automotive industry, a great deal of effort goes into reducing vehicle weight by using lighter components. An example is the use of SAM (sprayable acoustic material) coatings in vehicle interiors. These locally applied insulation layers replace the larger and heavier soundproofing mats previously used. However, in order to meet the targets for sound protection, weight, clearance and cost, the thickness of these coatings must be carefully monitored.

In addition to its light weight, sprayed-in acoustical insulation has the further advantage that it can be applied precisely and selectively by robots, allowing a full automatic manufacturing process. Typically, these SAM coatings are between 2 and 4.5 mm thick, very often located in places that are difficult to reach, and found on top of either aluminum or steel – that is, on both ferrous and non-ferrous substrates.

Developed by FISCHER for just this measurement task, the FA14 probe employs the eddy current method, which is effective for measuring non-conductive coatings of up to 5 mm thickness on conductive base materials.

But above and beyond these fundamental specifications, the FA14’s compact elbow design also makes it possible to take accurate readings even in very close areas: The sensor has an external casing with a total diameter of 20 mm, and its field focus is optimized such that measurements can be taken – without edge influence – on spots no bigger than the probe itself.

Of course, as do all FISCHER eddy current probes, the FA14 compensates for conductivity. In practice, this means that differences in the conductivity of the base material, e.g. when various aluminum alloys are used, exert no influence on the coating thickness measurement. The probe of FA 14 can be connected to the handheld instruments of the FMP-family, either DUALSCOPE® or ISOSCOPE® models.

MEASURING POINT TARGET MIN (MM) TARGET MAX (MM) ACTUAL (MM)
MP1 2.7 3.5 2.8
MP2 2.7 3.5 2.9
MP3 2.7 3.5 3.1
MP4 1.7 2.5 2.0
MP5 2.7 3.5 2.9
MP6 2.7 3.5 2.9
MP7 3.7 4.5 3.7 !
MP8 1.7 2.5 2.1

Example of typical measurement values from quality control of SAM coatings on eight predefined measuring points, where MP7 is outside the tolerance.

With the handheld instruments of the FISCHER FMP-family and the specially developed FA14 probe, SAM coatings can be measured accurately and easily even in hard-to-reach areas and on varying base materials (aluminum or steel). Your local FISCHER representative will gladly answer further questions.

COATING THICKNESS (DFT) GAUGES

Explore Further

Wide range of handheld dry film thickness gauges (DFT) for the measurement of coating thickness on ferrous and non-ferrous substrates