non-contact photothermal multilayer thickness measurement christian
TRANSCRIPT
Non-Contact PhotothermalMultilayer Thickness Measurement
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Christian Florin (flo-ir)
Andor Bariska, Dr. Nils Reinke, Prof. Dr. Beat Ruhstaller (ZHAW)
Application (Samples only)
Method
Application
Ultrasonic Eddy Current
Mechanical Photometric(Interferometry)(Ellipsometry,..)
Photo-Thermal
Construction engineering (Coatings on concrete, stone,wood and roofs)
Transportation(Automotive, Marine, Aircraft, Railway)
Chemistry, Medical(Medical patches, skin thicknessFunctional layers)
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Properties of Thickness Measurement Technologies
MethodProCons
Ultrasonic Eddy Current
Mechanical Photometric(Interferometry)(Ellipsometry,..)
Photothermal
Pro • low-cost• broad appli- cation experience• multilayer resolution
• low-cost• broad appli- lication experience
• simple technology• broad appli- lication experience• calibration free
• non- contact• multilayer resolution
• non-contact• independent of coating and substrate
material• multilayer resolution
Con • contacting• contact medium• > 20µm
• contacting• requires ferritic substrate• no multilayer resolution
• contacting• time consuming• destructive• no multilayer resolution
• transpar- ent and smooth materials only• < 10µm
• little practical experience• new technology
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Market Potential
Market potential
Application
Photothermal thickness measurement method
Construction engineeringMarket VolumeImportanceCustomers
232
TransportationMarket VolumeImportanceCustomers
233
Chemistry, MedicalMarket VolumeImportanceCustomers
321
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
1 = small 2 = medium 3 = big (Based on a marketing study from 2006/2007)
Measuring Principle
• Heating of a coating system (single or multilayer coating) with optical pulse
• Non-contact measurement of IR radiation from the surface with high time resolution (<0.1ms)
• Post-processing of the acquired data to determine coating thickness
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Development of an Idea to a CTI-Project
• Experimentally detected dependency of IR-radiation from layer thickness (Christian Florin 2000 - 2003).
• Price holder "Swiss Technology Award 2004" for photothermal non-destructive measurements. (Startup Label, 2004).
• Verification of the photothermal effect to multilayer coatings for thickness measurement (2006, Arsenco AG).
• CTI suggests academic partner ZHAW School of Engineering for a follow-up project to develop photothermal technology (2007).
• The ICP Institute for Computational Physics and IDP Institute for Data Analysis and Process Design joined their complementary forces for this challenging project.
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Industrial Project Partners
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
• flo-ir• Specialized in consulting on IR measurements for non-
destructive testing & evaluation and process control. • Experience goes back to 1984• Swiss Technology Award 2004
• Five additional industry partners:• Thickness measurement and process control for coating and
plastic foils production industry• Multilayer lacquering in automotive industry• Food packaging industry
Academic Project Partners
• ICP Institute of Computational Physics• Applies and develops numerical modeling software to solve multi-
physics problems
• Optics lab equipped for high-speed IR measurements
• IDP Institute of Data Analysis and Process Design• Applies physical and statistical modeling to extract information from
measurements
• Develops data analysis methods
• History of successful partnerships for R&D projects between institutes
• Supported by School of Engineering mechanics workshop for prototype fabrication
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Example Result
Ceramic Plate with multiple concrete coatings
1. layer 2. layer 3. layer 4. layer 5. layer 6. layer
Signal vs. time curve
(log-lin plot)
Relative layer
thickness20 % 88 % 100 % 125 % 132 % 179 %
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Project Successes
• ZHAW produces first prototype:
• Mobile, robust device (Laptop-controlled automation and data acquisition)
• Software with newly developed model-based algorithms to determine layer thicknesses from measurements
• Experience of flo-ir with project partners confirms wide applicability of measurement principle
• Cooperation initiated by CTI continues beyond the project to develop this promising new technology
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Commercial Development
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch
Introduction to the market:• Test measurements in the practice. (Phase 1)• Installation of basic equipment at key customers.
(Phase 1 / Phase 2)• Training and conferences for non-contact thickness
measurement. (Phase 1 / Phase 2)
• Acquisition of technically competent sales partners. (Phase 2 / Phase 3)
1 2 3 4 5 6 7 11 128 9 10
m
Phase 1Phase 1
Phase 2Phase 2
Phase 3Phase 3
Continuing Cooperation
• Measurement series with the prototype and lead customers• flo-ir will promote the measurement technique in the market• Further development of hardware and software at ZHAW• Possible new CTI project with focus on
• modified prototype for specific application markets• extended analysis models• refined experimental techniques
www.flo-ir.ch www.icp.zhaw.ch www.idp.zhaw.ch