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October 19, 2009 -- For wiring harness makers, creating micrographs, or cross-sectional views of crimped connections, with conventional methods and chemical etching can be time-consuming, and requires strict adherence to on-the-job safety regulations. Schleuniger says its MicroGraph System with a combined saw-polish process and electrolyte staining technology creates high-quality cross-sectional views in a fraction of the time needed with conventional methods.
The MicroGraph System can be used to saw, polish, stain (clean) and visually analyze crimps and other connections such as welded and spliced connections. The modular system is comprised of individual components that can be combined according to customer requirements.
Each connection to be tested (i.e. test sample) is secured in a sample holder. The holder is easily inserted into the saw and polish unit (SPU) using a tool-less, quick-change mechanism. Depending on the wire size, there are 2 different models of the SPU available (SPU 6 up to 10 AWG (6 mm sq.), and SPU 60 up to 2/0 AWG (60 mm sq.). The main advantage of both devices is that they combine the sawing and polishing processes in one unit. Test samples can be prepared in one step without having to remove the sample holder; which saves time when compared to using separate units. Both devices provide an excellent cutting surface even before polishing, notes the company. In many cases the polishing step is not required, thereby saving even more time. Sawing can be optimized further using different sawing blades for different materials or small wires down to 32 AWG (0.03 mm sq.).
After a sample is cut and polished, the surface of the sample is cleaned using the staining pen of the platform's ESU 6 electrolyte staining unit. According to Schleuniger, contrary to common etching methods, the ESU 6 doesn't use aggressive, acidic chemicals to remove dirt or impurities. The electrolyte staining process is environmentally-friendly and safer than traditional methods. The solution has a pH value of 7, the same as water, and the staining process requires a very low electrical current. Because the solution is not acidic, no toxic fumes are created during the process so a cut and polished surface can quickly be cleaned directly under the microscope. Results are immediately visible, and time-consuming re-working or waiting times are eliminated.
The entire sample holder can be quickly positioned under the zoom-optic of the MZU 1.3 MacroZoom unit for analysis. A 1.3 megapixel, USB 2.0 camera along with "pixel-fox" analysis and measuring software are included and can be installed on a standard PC. The optics and software can be calibrated according to international standards with an optional object micrometer. The software features numerous fixed zoom positions making the creation of high-precision cross-sectional pictures easy and repeatable.
In conclusion, Schleuniger maintains that the MicroGraph System provides extremely short processing times, high user-friendliness and comes at a substantially lower price than common laboratories. Systems can be set up on a table at a fixed location or using a mobile cart to bring the test equipment to the samples. In daily use, the platform may increase efficiency and lower costs typically associated with the creation of cross-sectional views, for increased productivity.
On the Web:
www.schleuniger-na.com
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