Thermo Scientific Spark-DAT Software SuiteInclusion analysis in steel with the ARL iSpark OES spectrometer

Inclusion analysis with unparalleled speed

Real-time control and high throughput

Non-metallic micro-inclusions often have a negative impact on steel properties and the smooth running of the production process. The presence of inclusions increases cost due to the resultant de-classification of steel, process interruptions or scrapping. Effective and timely management of critical inclusions offers significant benefits.

For more than twenty years, Thermo Fisher Scientific has been a pioneer in ultra-fast analysis of non-metallic micro-inclusions by spark OES. Today, the Thermo Scientific™ Spark-DAT™ inclusion analysis methods are used by leading steel companies and enjoy growing popularity throughout the steel community.

The Thermo Scientific™ ARL iSpark™ high-performance OES metals analyzer enables fast assessment of inclusions in steel.

Inclusion analysis can be performed simultaneously with elemental analysis, allowing virtually real-time control of the inclusions and rapid corrective actions to be taken at different stages of the production process.

The unparalleled speed of analysis also provides a unique solution for high-throughput inclusion assessments, when large numbers of samples need to be analyzed quickly, for example in order to solve an urgent quality issue.

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Ultra-fast inclusion analysis with Spark OES

Thousands of high-frequency short single sparks are generated within a few seconds between the electrode and the metallic sample. These sparks hit randomly the metal sample surface, each ablating a small volume and generating light emission from the atoms that it contains.

The intensity of the emission is proportional to the amount of atoms. Therefore when an inclusion is part of the small volume, a light emission peak can be observed on the channels of the highly concentrated elements composing the inclusion.

The single spark signals are acquired separately and processed with proprietary Spark-DAT algorithms and dedicated mathematics in Thermo Scientific™ OXSAS™ analytical software. The results are then handled like conventional OES results for display, print, storage and transmission to statistical process control programs, LIMS or distant computers for special examination.

A steel sample with Al2O3 inclusions is sparked. The single spark A ablates a small volume containing an inclusion, while the single spark B ablates a small volume containing only steel. A peak is observed on the Al intensity run-chart at the position of single spark A, none at the position of single spark B.

Single spark data from the various element is processed in OXSAS with Spark-DAT algorithms to generate the output inclusion data of interest.

Spark-DAT algorithms

Al

Ca

Mg

S

O

Other Elements

Single Spark Data Inclusion data

External parameters

Spark-DAT Software Suite

The complete software suite for Spark OES inclusion analysisThe Spark-DAT Software Suite transforms the ARL iSpark into a full metals quality analyzer, able to report broad inclusion data within a few minutes, together with the most reliable bulk metal composition analysis.

It includes all relevant software modules and features, on-line and off-line, for analytical method development and set-up, in-depth investigation, inclusion control, and reporting of inclusion information:

• Spark-DAT: methods, features and algorithms in OXSAS analytical software used to setup and run inclusion analysis, and manage data treatment and results handling

• Spark Explorer: feature-rich standalone module for optimal set-up of method parameters and in-depth inclusion investigation

• Inclusions Report: comprehensive set of features to customize and generate the inclusion analysis report

• Ternary Diagrams: the software features to configure and generate the ternary phase diagrams of interest for the inclusion analysis report

• Statistical Process Control, the perfect module for most effective real-time control of inclusions.

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Spark-DAT

Breaking all limits of spark OES inclusion analysis

Key features of Spark-DAT: • Results display with unlimited number of components

• Algorithms process an unlimited number of elements

• Classification ranges editor, to manage e.g. SML (small, medium, large) type distributions or distributions in microns

• Recalculation of inclusion analysis results

• Generation of ternary phase diagrams and histograms

• Data transmission to statistical process control (SPC) software, LIMS systems or remote computers

• Three levels of Spark-DAT inclusion analysis: Basic, Standard and Advanced Inclusion Analysis.

In addition to controlling the ARL iSpark metals analyzer, managing all data treatments and handling results for standard bulk elemental analysis, OXSAS Analytical Software is at the heart of the inclusion analysis. Spark-DAT inclusion analysis is implemented, parameterized for acquisition and processing, and inclusion analysis results are analyzed in OXAS software.

The inclusion analysis is embedded in the standard OES analytical programs, so that it runs during the bulk elemental analysis.

Calculations involving statistical treatments of the single spark signals by specialized Spark-DAT algorithms output inclusion information (default or user-defined) that can be displayed with bulk elemental concentrations, sent to Statistical Process Control (SPC) software or compiled in the inclusion analysis report.

Results display showing 3-run analysis with mixed bulk elemental concentrations and inclusion information.

Classification ranges editor with examples for SML distribution and size distribution in microns.

Spark Explorer

Investigate and optimize

Inclusions Report The right zoom on the inclusions

The Thermo Scientific™ Spark Explorer™ is the most comprehensive software tool for in-depth study of single spark data and for adjustment of methods and algorithm parameters for optimal on-line inclusion analysis.

Independent of OXSAS, it can be used during idle time of the ARL iSpark spectrometer, or on a separate computer, for investigation of a quality or production issue, or to double-check ambiguous inclusion analysis results.

The Spark-DAT Inclusions Report gathers all the information you need on your inclusion analysis in a single document. OXSAS allows to select and customize different information fields, such as general information on sample and analysis, important cleanness indicators, summaries of bulk elemental analysis, inclusion concentrations, inclusion size distribution, histograms and ternary phase diagrams.

The perfect tool for validation, documentation and archiving of your inclusion analysis results, it will also deliver most of the necessary information for investigation and inclusion problem solving.

Simultaneous display of run chart, S-chart and intensity histogram.

Overview of run charts and intensity histograms of Al, Ca and Mg in three samples.

Comparison of run charts of different elements in different samples.

Key features of the Spark Explorer:• Screening of single spark data of the

different elements

• Simultaneous display of run chart, intensity histogram and S-chart

• Overview of all chart types for unlimited samples, runs and elements

• Comparison of run charts of unlimited elements and samples

• Real-time computation of key parameters, e.g. peak threshold, peak count and insoluble ratio

• Graphical optimization of peak threshold for on-line analyses with highlighting of peaks

• Printout of report and export of charts to image files

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Ternary Diagrams

Follow inclusions modifications

Statistical Process Control

Efficient real-time inclusion control

Ternary phase diagrams are used to represent the composition distribution of important inclusions systems based on three chemical components, e.g. Al2O3–MgO–CaO or Al2O3–CaS–CaO. They allow metallurgists to understand inclusion systems and their modification, often induced by process condition change or steel treatment (e.g. Al and Ca additions).

The ternary phase diagrams are fully configurable in OXSAS and displayed in the Inclusions Report. Fixed custom size classes in mm are represented by dots of different colors. The average composition is displayed in percent of the three components and it is also indicated by a dot on the ternary diagram.

Statistical Process Control (SPC) helps ensure that steel manufacturing process runs stably and efficiently, that it produces a minimum of non-compliant product and causes a minimum of time loss and costly rework or scrap. It allows early detection and prevention of problems, rather than their correction.

Statistical Process Control is the application which benefits the most from the unmatched speed of the ARL iSpark inclusion analysis.

Significant changes or overshoots of specification can be detected using simple parameters (such as peak counts) or more advanced parameters (e.g. Total Oxygen Content). Real-time control charts give the best insight to monitor process and quality in term of inclusions.

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SPC run chart of Al peaks count. One sample (#17th on the chart) was not compliant, with a number of Al peaks above the user specified limit (USL).

Example of ternary phase diagram for inclusion system Al2O3-MgO-CaO.

There are two different types of Spark-DAT inclusion analysis methods. The standard methods are performed on single spark data only. The information delivered allows to easily classify samples as clean or dirty or to get warning of a process problem caused by inclusions (e.g., nozzle clogging) from Statistical Process Control. In the advanced methods, external parameters are also taken into account, such as the bulk elemental concentration of the inclusion elements, allowing more quantitative or specific inclusion information to be obtained.

Find out more at thermofisher.com/ispark

Standard methods deliver information such as:• Single element peak counts, e.g., Al peak count, to evaluate the amount of

aluminum type of inclusions • Multi-elements peak coincidence counts, e.g., Al and Ca coincidence count,

to evaluate the amount of Ca aluminate type of inclusions• Classification as small, medium and large inclusions (SML distribution)

Advanced methods deliver information such as:• Size and size distribution of inclusions in microns• Total oxygen content down to ppm levels• Inclusion concentration in the bulk metal sample• Inclusion area fraction

Customization and training Get the best out of your ARL iSparkCustomization of your ARL iSpark metals analyzer and training by our specialists are recommended for Standard Inclusion Analysis and Advanced Inclusion Analysis. Our Thermo Training Institute offers a series of training courses on inclusion analysis with the ARL iSpark. Ask your sales representative for detailed information about this.

Spark-DAT inclusion analysis options Inclusion analysis for everyone’s needs

Depending on your needs, select Basic Inclusion Analysis or Standard Inclusion Analysis option, both packaged with standard treatment methods only, or Advanced Inclusion Analysis, packaged with standard and advanced methods. Ask your sales representative for detailed information about our inclusion analysis options.

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