How the Epsilon 1 shines a light on aluminum inclusions
In the bustling world of aluminum production, quality is key. But as any expert knows, solving quality issues during production can be like a detective mystery! The culprits: tiny interloper particles called inclusions, often titanium borides and alumina particles that get in during the production process.
Production intruders: titanium borides and alumina particles
Typically, we rely on high-tech ‘detectives’ to identify these intruders: scanning electron microscopes (SEM). These investigative tools scrutinize the material, unveiling the sources of inclusions. But there’s a slight problem – these machines are like having Sherlock Holmes on speed-dial, which is a luxury not always available! When the specialist microscopes aren’t available, due to maintenance or breakdowns, it’s very challenging to track down the source of inclusions. So, how can we keep the quality of our aluminum products in check when our trusted detectives are absent?
New method, trusted technology
Enter: energy-dispersive X-ray fluorescence (EDXRF). EDXRF is a well-established technology, but a new method using the Epsilon 1 spectrometer has been developed by Hussain Al Halwachi, Senior Chemist at Aluminum Bahrain (Alba), to measure inclusions in aluminum where SEMs are unavailable.
Think of EDXRF as a specialized flashlight – revealing hidden inclusions through X-ray elemental analysis. The method is a bit like a detective checking for fingerprints, as it looks for the tell-tale peaks that indicate the presence of an element that doesn’t belong.
In Al Halwachi’s paper, Identifying borides inclusion in aluminum melt using EDXRF for small spot
analysis, he discovered that the award-winning Epsilon 1 can successfully identify and measure the first common ‘intruder’, titanium boride inclusions in aluminum melts. Not only can it identify them, but it can also confirm the root cause by quantifying the titanium values above and below the PoDFA filter area and comparing the measurements.
Overcoming the challenges of the case
Our new hero does have some limitations. The alumina particles – the second type of ‘intruder’ – can’t easily be caught using EDXRF. The overlap of aluminum peaks intensities from the sample and the alumina inclusion is similar to overlaying two sets of fingerprints; they’re so similar that they become indistinguishable. However, in the case of a customer complaint around inclusions, where no borides are found, alumina would be the next most obvious culprit.
Boron is actually difficult to measure with EDXRF due to its low atomic weight, but this represents less of a problem. As the chemical formula for borides is Al(Ti,V)B2 or TiB2, it’s possible to track titanium or vanadium and deduce the borides from those measurements.
Real value – and more to come
Despite these limitations, the Epsilon 1’s ability to detect titanium boride inclusions offers real value for producers. When the usual analytical machines are unavailable, the Epsilon 1 can provide a reliable alternative, ensuring that this common type of inclusion doesn’t sneak past your quality control measures and jeopardize the quality of the final product.
Acting as a backup ‘forensic flashlight,’ EDXRF shines a light on the issue of inclusions. It’s an effective tool to guide us toward improving aluminum production quality. Yet, the mystery isn’t entirely solved. As with all thrilling whodunits, the story continues – with further research already in the pipeline to refine the method.
In this ongoing investigation, we’re continually refining our techniques, improving our tools, and inching closer to ensuring consistently high-quality aluminum production. And as with any good detective story, we’re eagerly awaiting the next chapter. Stay tuned!
Find out how the Epsilon 1 could take the mystery out of your aluminum processes – contact us today for a demo! Check out the Epsilon 1 in more detail and download a brochure here.
Reference
Al Halwachi, H. (2022). Identifying borides inclusion in aluminum melt using EDXRF for small spot analysis. Proceedings of the Liquid Metal Processing & Casting Conference 2022