Materials get complex.
Analysis gets simple.

ZEISS Materialography Solutions

zeiss.com

Mastering complexity
With microscopy solutions from ZEISSTasks in materialography are constantly changing andperformance requirements are increasing. Components are
becoming more complex, coatings ever thinner. Miniaturisationin electronics is progressing. New composite materials arebeing used especially in lightweight construction. Sustainable
materials and additive manufactured components pose
particular challenges in terms of material characterisation.
At the same time, error tolerances are decreasing, making more
precise analyses n­ ecessary.

AI-supported segmentation of an additive
manufactured gear wheel

Materials testing laboratories have to keep pace with these­developments. At the same time, they are under increasing timepressure. ZEISS offers materialographers an unrivalled depthof microscopes, software and services to effectively solve their
testing tasks. In addition, ZEISS microscopy solutions make itparticularly easy for all users, because thanks to deep learningalgorithms, results are more reliable, more accurate andavailable faster than ever before.

Materials testing in a time of change
Composite materials

Specific metals and alloys

Additive manufacturing

Composite materials continue to

The increasingly sophisticated use of

The new possibilities of additive

grow, especially in lightweightspecial metals or alloys makes it

manufacturing are accompanied byconstruction. The interfaces between

possible to find the optimum compro-

new typical component defects.

the bonded materials are often

mise between strength and weightZEISS Microscopy Solutions help

critical areas. Therefore, thesefor each component. In this context,

materialo­graphers to inspect 3D printed

must be checked particularly carefully.

materialography has the task ofmaterials, analyse defects in additive

analysing the characteristic properties

manufactured components andof specific materials.

determine the causes of defects.

Sustainable materials
For reasons of sustainability, forexample, metals are increasingly being

Miniaturised conductor paths

recycled or environmentally harmful

Miniaturisation in electronics continues

materials are being replaced by

to progress. With the right high-alternatives. Materialography helps

resolution microscopes, ever finerto ensure the integrity of sustainablestructures can be inspected quickly andmaterials.

reliably.

3

Flawless and efficient microscopy
From sample to result

In materialography, meaningful microscopy results are only

microscopes to make the entire analysis process reliable andguaranteed if the preceding process steps have also been

efficient: from sample extraction and preparation to image

carried out without errors. ZEISS provides suitableacquisition, image processing and evaluation.

Microscopy process

Microscopes
exemplary

Cut the sample

Fix the sample

Grinding / polishingEtching

Microscopy (image acquisition, processing and evaluation)

Stemi 508

Axioscope 5

Axio Imager 2

EVO

CrystalCT

Stereo microscope with 8:1 zoom

Semi-motorised light microscope

Microscope system for automatedmaterial analysis

Scanning electron microscopefor high-resolution imaging andelement characterisation

X-ray microscope for nondestructive 3D imaging

Resolution: 1 µm

Resolution: 0,7 µm

Resolution: 250 nm

Resolution: 2 nm

3D-Resolution: 40 nm

This becomes visible
Metal surface at 24x magnification

The bright field contrast image shows
scratches, stains, deformations and cracks ina perforated tensile sample

Dark-field contrast image of a Fosterit
coating

Automatic image segmentation withZEISS ZEN core

3D visualisation of the crystal structure oftitanium

Polarisation contrast image for testing theetching process

45

Exemplary microscopy programme for material labs
Comprehensive, reliable, supportive

01

6

Light microscopy

Checking theRepeated sample

Routine tasks

Large and heavy

Large sample fields,

Automated material analysis­s ampleanalyses,in the materials

samples

topography

Fully motorized microscope system

Stereo microscopes

topography­laboratory

Inverted microscope

Stereo zoom microscope

ZEISS Axio Imager Z2m

ZEISS Stemi 305/508

Automated digital

Reflected light

ZEISS Axiovert 5/7

ZEISS Axio Zoom.V16

microscope

microscope

ZEISS Smartzoom 5

ZEISS Axioscope

7

02

04

03

Scanning electron microscopy (SEM)

X-ray microscopy

Modular electron microscopy

High quality imaging

Non-destructive 3D X-ray imaging

Scanning electron microscope

Field emission scanning electron microscope

High-resolution X-ray microscope

ZEISS EVO product family

ZEISS Sigma product family

ZEISS CrystalCT

Further ZEISS technology for material analysis

Non-destructive 3D quality inspection

Optical 3D measurements of strain,

Industrial computer tomographdeformation and displacement

ZEISS METROTOM product family(e.g. tensile test)
3D camera measuring system ZEISS ARAMIS

89

Your control centre for all tasks
The ZEISS ZEN core software

ZEISS ZEN core is the standardised solution for imaging,segmentation, analysis and data connectivity in yourmaterials laboratory or company. Because the user interface
can be configured according to the task at hand, eveninexperienced users can operate the software easily and safely.
Thanks to deep learning, ZEN core largely automates timeconsuming manual work steps such as segmentation. The
simple correlation of light, digital and electron microscopy
enables a deeper understanding of microstructure and failure
analysis. Several laboratory locations can be networked witheach other via ZEISS ZEN core.

With ZEISS ZEN core, different microscope types and laboratory
locations can be networked with each other.

10

11

ZEISS ZEN Connect

Different microscopes –one correlated evaluation
In many applications, it makes sense to
analyse the same sample with both an• Material apps

optical and an electron microscope. The• Developer toolkit

different magnification levels and contrasts

Correlation with light, digital

Tools for grain size analyses, cast

Programming of customised

together provide a deeper understanding

and electron microscopes

iron analyses, multiphase analyses,

macros in the Python programmingreference series comparisons and­language, control of ZEISS ZEN core

coating thickness measurements

via an API interfaceof the sample condition. With ZEISS ZEN
Connect, you can efficiently overlay

ZEN core tool kits

multimodal image data together and

ZEISS ZEN core has a modular

quickly switch from the overall view to a

structure and can be individually

high-resolution detailed display. All image

expanded with the tools you need.

AI application kit for segmentation,

Central SQL-based image databasedata, including that from third-party

Among other things, ZEISS offers

object classification and image

for intelligent data management

providers, can be conveniently aligned,these supplementary toolkits:

denoising, including training

with integrated user and accessinterfaces

management

overlaid and displayed in context with• AI toolkit• Data storageZEISS ZEN Connect.
• 2D toolkit image analysis

With ZEISS ZEN Connect, more information canbe obtained more quickly, for greater certainty in• Connect Toolkit

2D image analysis using automatic

ZEISS ZEN Connect allows you tomeasurement programmes, includingalign, overlay and correlateadvanced processing

multimodal image data fromdifferent microscope types.

microstructure evaluation.

Faster and more accurate ­testing

The latest deep learning models –using deep learning

locally or in the cloud

ZEISS ZEN core provides automated image

Depending on the respective micro-

analysis for particle and phase analysis.

structure for the analysis task, ZEISSDeep learning techniques significantly

ZEN core enables segmentation using

reduce the workload for these applicationsclassic machine learning or the latest

and always work reproducibly, according

deep learning technologies. The deep

to the same trained patterns, regardless oflearning models can be trained either

the user and location.

locally in ZEISS ZEN core or in the secure
ZEISS cloud environment.
Both semantic pixel-based segmentation,in which each pixel is assigned toa class, and object-based instancesegmentation, in which individual
objects are recognised and assigned
to classes, are possible.

12

The microscope image of an aluminium alloy is automatically segmented using deep learning. The

Automatic AI-supported determination of the grain boundaries of a ceramic, an austernite steel,algorithm reliably identifies individual grains. Touching and overlapping objects can be separated

a hard metal and a copper-based alloy sample. In this example, it was sufficient to train a deep

(instance segmentation).

learning model to reliably recognise the grain boundaries of all four materials.

13

Material characterisation with ZEISS ZEN core
Simple standard-compliant evaluation

Application

Grain sizes

Multiphase

Layer thicknesses

Cast ironNon-metallic inclusions

Grain size distribution

Phase fraction determination

Automatic edge detection

Size, shape and distributionof graphite particles

Quantity and size of oxides, sulphides,
nitrides and other inclusions

Technical ceramics, medical technology

Carbon fibre reinforced plastic, aerospace

Solar cell, renewable energies

Grey cast iron, plant engineering

Steel, plant engineering

Quantify the crystallographic

With this module, you can determine

Measure the thickness of coatings orAnalyse the shape and size of graphite

This module allows you to analyse

structure of your materials according

phases according to both their size

the depth of hardened surfaces in theparticles in cast iron fully automatically

non-metallic inclusions in steel in

to international standards.

and the percentage of the respective

cross-section of a sample. Evaluate

and determine the percentage oforder to assess steel purity. The

area. An important application is thecomplex coating systems either

graphite particles by area.

standards-based automated workflow

investigation of porosity.

automatically or interactively.

Image, evaluation

Remarks

solution includes sample collection,
inclusion classification and inclusion
evaluation as well as results
documentation and archiving.

14

Example battery technology:

Example: Multiphasegrain size analysis of NCM

analysis of a thermal spray

cathode particles

coating

The only marginally visible grain

Thermal spray coatings improveboundaries of NCM cathodethe resistance of the substrateparticles can be revealed usingmaterial to corrosion, heat or

a ZEISS electron microscope

wear, among other things. The

with an Inlense-EsB detector.

porosity of a metallographicallyAn algorithm trained using

prepared sample can bedeep learning then automati-

easily determined using

cally and reliably segments themultiphase analysis. The

microscope image. The image

porosity determined allows

analysed in this way can be usedconclusions to be drawn about

to determine the particle size

the structure and hardness of

distribution, for example.

the spray coating.

15

Application example
GROB
Comprehensive quality
inspection for hairpin
stator production

Today, stators for electric car traction
motors are increasingly being produced
using the so-called hairpin technology.
The advantages over the standard
winding process are the compactness ofthe hairpin stators and the fact that
production can be better automated.
GROB is a leading manufacturer of
production systems for hairpin stators. To
ensure the quality of these systems, theGerman family-owned company utilises
various testing and measuring systems
from ZEISS.
16

Hairpin stator manufactured with GROB machines

17

ZEISS Axio Imager Z2m

Microscopictasks

Incoming inspection of copper
wire, quality inspection of
welding points

Benefits

Covers a wide range of tasks inquality assurance perfectly

Sample for incoming goods inspection

Checking the spot welds

Advantages and challenges ofwire is formed into a three-dimensional geometry using

Z2m to check the dimensional accuracy of the copper wire

ZEISS PRISMO verity, but this time with a tactile sensor. The

hairpin technology

special bending equipment. Up to 16 different geometries

and measure the thickness of the insulating enamel layer.

final step in the quality inspection is a complete optical scan

Hairpin technology is gaining ground in the automotive

can be built into one stator. In the next step, the plug-in

industry because, compared to stators wound with roundcoils pre-assembled into a hairpin basket are inserted into

After welding the hairpins and other components, the spot

wire, hairpin stators require less space and have a higher filla laminated core and finally the neighbouring hairpin ends

welds are randomly checked. GROB also uses the ZEISS Axio

GROB benefits from the combination of different ZEISS

factor, which also benefits the performance development

are welded and contacted with other electrical components,

Imager Z2m for this purpose. The welding points are criticalinspection systems. The standardised and simple ZEISSof the electric motor. Above all, however, the production ofusually using a laser welding process.

points of the construction. A single faulty contact impairs theoperating philosophy reduces the amount of training

function of the entire stator and can lead to failure.

required and speeds up work on the various systems. With

hairpin stators can be more automated and therefore moreof the finished stator in the ZEISS ATOS ScanBox.

economical. The biggest challenge of the process is ensuring

Microscopy by ZEISS

process reliability. Bending points and spot welds are the

The machine manufacturer GROB uses a ZEISS Axio Imager

Further measuring and inspection technology by ZEISS

easily combined into a coherent report. And in the event

most susceptible points of failure in the system and are

Z2m microscope to ensure the quality of its productionZEISS measuring and testing technology is used in many areasof quality problems, ZEISS provides an overarching contact

therefore of particular importance in quality assurance.

systems. On the one hand, the microscope is used forof quality assurance at GROB. In addition to the Axio Imager

partner who can provide neutral advice on the inspection

incoming inspection of the flat copper wire. The bending

Z2m, the laboratory equipment includes a ZEISS PRISMO

technologies used and assume overall responsibility.

Process steps in hairpin technology

behaviour of the wire depends primarily on its material

verity coordinate measuring machine and a ZEISS ATOS

In hairpin stators, the coil is made up of U-shaped wire

properties. A material defect can lead to dimensions not

ScanBox. The bending result of the hairpins is checked opti-

elements. Their shape is reminiscent of a hairpin, hence thebeing adhered to, welding points being set incorrectly andcally with the ZEISS PRISMO verity CMM. GROB also checks

name of the technology. To produce the hairpins, flat copper

the stator failing as a result. GROB uses the ZEISS Axio Imager

the weld seams of the assembled stator with the18

the ZEISS cross-device reporting, the partial results can be

19Application example
Smith & Nephew
Fully automated,
AI-supported testingof implant coatings

The medical technology company
Smith & Nephew manufactures artificial
hip and knee joints at its site in Aarau,
Switzerland. The implants enable patients
to move again without pain. How wellthey grow into the bone depends on their
coating. To ensure the quality of thecoating, Smith & Nephew uses
microscopy technology from ZEISS.
A rectangular sample plate is also coated and later
analysed microscopically.

20

21

ZEISS Axio Imager Z2m

Microscopic
tasks

Thickness, porosity, mean pore
length, mesh interface androughness of the titanium andhydroxyapatite coating

Benefits

Reproducibility, accuracy, 85 %time saving

ZEISS ZEN core sets 343 vertical lines fully automatically and calculates the

The prostheses are coated in the vacuum chamber at a temperature of up tocoating thickness from them

20,000 degrees Celsius

The use of artificial hip and knee joints is a success story ofIt’s the coating that counts

rameters of the coating: the coating thickness, porosity,

Porosity routinely according to standard

modern medicine. The prognosis for the frequently performed

An important step in the manufacturing process is theaverage pore length, mesh interface and roughness – andManual determination of porosity is very time-consuming andoperations is generally very good and promises significant

coating of the joint blanks with layers of titanium andthey do so particularly quickly, efficiently and reliably thanks

has therefore only been used in individual cases in Aarau.

pain relief and an improvement in movement functions.

hydroxyapatite - a bone substitute substance. The coating

to artificial intelligence. To determine the coating thickness,

With the ZEISS Axio Imager Z2m and ZEISS ZEN core, porosity

Patients not only regain their mobility with the implanted

ensures good ingrowth of the implant and extends its

50 vertical lines were previously drawn manually into theis now one of the parameters that are routinely recorded.

joints, but also a great deal of quality of life.

durability. It is applied using vacuum plasma spraying (VPS) in

microscope image at the Aarau site, the length values

A deep learning algorithm places horizontal lines in the empty

state-of-the-art vacuum chambers at temperatures of up to

determined were transferred to an Excel spreadsheet andspaces and determines the porosity in accordance with theProsthesis production with Swiss precision

20,000 degrees Celsius. The quality of the coating determines

then analysed. With the ZEISS ZEN core software, the layer

ASTM F1854 standard. If required, an evaluation inWith sales of over USD 5 billion, Smith & Nephew is one of

how stable the bond between the bone and the implant will

thickness is now determined fully automatically and moreaccordance with FDA 21 CFR Part 11 could also be

the world’s leading medical technology companies. Hip andbe. Smith & Nephew uses a ZEISS Axio Imager Z2m

accurately. Instead of 50 lines, the artificial intelligence

implemented.

knee implants are part of the Othopaedics segment of the

microscope to check compliance with the tolerance

sets 343 lines and delivers the result without operator

globally active group. They are manufactured to the highest

specifications.

intervention. Where the manual process took almost an hour,

User-friendly deep learning

the result is now available in around 6 minutes with ZEISS ZEN

The deep learning algorithms are trained by ZEISS as required.

Save time and increase quality

core - a time saving of 90%. Because operator influence isWith ZEISS arivis Cloud, a solution is also available for training

The ZEISS Axio Imager Z2m and the ZEISS ZEN coreeliminated, this result is also much more reproducible.

models for image segmentation yourself – in a very

quality standards at the Swiss site in Aarau.

microscopy software are used to determine many quality pa-

22user-­f riendly way and without programming knowledge.

23

Application example
SPC materials laboratory
Failure analyses on steel
components

What caused the crack in the pinion shaft? The SPC

Defects in the casting or forming of steel
can lead to corrosion, porosity, cracks
or breakage. The consequential costs ofsuch defects are often immense. The SPC
materials laboratory in southern Germany
investigates the causes of damaged steel
products. The materials researchers at
SPC use a digital microscope, an optical
microscope and an electron microscopefrom ZEISS as well as the microscopy
software ZEISS ZEN core.

­m aterials laboratory determined the cause of the defectusing ZEISS microscopy solutions

24

25

ZEISS Smartzoom 5

ZEISS Axio Imager Z2m

ZEISS EVO 15

Microscopic
tasks

Localisation and rough determination of the cause of damage

Microscopic
task

Detailed determination of thecause of failure

Microscopictask

Chemical determination ofcontaminants

Benefits

Fast results thanks to automated functions and smart user
guidance

Benefits

High-resolution images withlarge image area

Benefits

Additional information on­q uality optimisation

The ZEISS Smartzoom 5 quickly provided the first­v aluable clues as to the cause of the damage

Steel is the material of the industrial revolution and has

Failure analysis of a pinion shaft

Recognising the cause of defect

Providing reliable results

been a basic material of industrial progress ever since.

One example from SPC’s day-to-day work is a cast steel pinion

In order to analyse the microstructure in more detail, SPC took

SPC was also able to determine for the steel producer that the

Whether in the automotive industry, mechanical engineering,shaft. After casting, a complete batch of pinion shafts wasanother sample, ground it and etched it with acid. Under the

impurities were within the standard required by the customer.

shipbuilding, aerospace, electrical industry or construction –torn open lengthways. The steel trader commissioned SPC tohigh-resolution ZEISS Axio Imager Z2m wide-field microscope,

However, as a hole was drilled in the centre of the axle, whichsteel is omnipresent and remains indispensable.

analyse the damage.

‘segregation’ had taken place near the central axis, i.e.

placed particular stress on the material, it broke. According tocontamination; in addition, SPC saw non-metallic inclusions

laboratory manager Schaupp, the pinion manufacturer shouldHigh demand and more complex requirements“At first glance, the fracture looked to us as if it had beenof foreign material. This caused the steel to become brittle.

have set tighter tolerances for the steel supplied due to thisMaterials laboratories such as SPC are directly confronted

caused by defect to the surface of the raw part duringwith developments in the steel industry. The challenges facing

hardening,” reports laboratory manager Thomas Schaupp,

Determining impurities

steel producers and steel processors are more diverse than“therefore a crack from the outside inwards.” But a closer

Using the ZEISS EVO 15 scanning electron microscope, theFast results with ZEISS microscopy solutions

ever. In view of supply bottlenecks on the steel market, thelook revealed a dark discolouration in the centre of the axle.

­e xperts at SPC were also able to determine the chemical

Two points are essential for SPC’s customers: the reliability

composition of the impurities. The microscopy method of energyof the result and the fastest possible analysis. In the case ofneed for quality measures to minimise rejects is growing. At

hole.

the same time, there is increasing time pressure to quickly

Localising the cause of damage

dispersive spectroscopy (EDX) revealed: In the steel of thethe pinion shaft, SPC was able to deliver a detailed andidentify the causes of defects. This makes microscopy

Using the ZEISS Smartzoom 5 digital microscope, SPC was

pinion shaft, there were non-metallic inclusions with highreproducible result within a few days. The microscopy

solutions that deliver fast and reliable results for eachquickly able to confirm this finding: The microscope image

concentrations of manganese and sulfur near the central axle, as

solutions from ZEISS played a decisive role in this. The use ofindividual case all the more important.

showed oxidation of the steel in this area – known as scaling.

well as segregations of sulfur and phosphorus.

various microscopes – from digital to electron microscopes –The cause of the damage could therefore be clearly localised

enabled SPC to proceed effectively step by step. In each step,in the core of the component.

further information could be obtained to precisely determine
the cause of the defect, building on the previous results.

26

27

The ZEISS Smartzoom 5 revealed weakening­o xidation in the core of the component

Using the ZEISS EVO 15 scanning electron microscope, SPC was also able to determine the chemical composition of the impurities

Software for greater effectiveness
Using the ZEISS ZEN core software, SPC was able to easily
correlate the results of light and electron microscopy andanalyse them together. ZEISS hardware and software are
optimally harmonised. ZEISS ZEN core supports users withsimple user guidance and numerous automated functions
during image acquisition, processing and evaluation. This
reduces the influence of the individual user and improves
reproducibility.
Cloud-based database
SPC uses a cloud-based database from ZEISS to provide its
customers with complete, transparent and convenient
Under the wide-field microscope ZEISS Axio Imager Z2m
impurities in the joints of the crystal lattice became visible

material analysis results. “Sending PDFs by email is no longer
in keeping with the times,” says Laboratory Manager Thomas
Schaupp, “in times of digitalisation, we and our customers
expect solutions like this.”28

29

Investigating the crystal
structures of metals
X-ray microscope
ZEISS CrystalCTZEISS CrystalCT is the first commerciallyavailable computer tomography system thatvisualises crystallographic grain structures.
It takes the examination of polycrystalline
materials such as metals, alloys andceramics to a new level. This was madepossible by newly developed diffraction
contrast methods. In addition, ZEISSCrystalCT eliminates sample size limitations
and enables a wide variety of sample
types to be analysed quickly and nondestructively.

Crystal structure of an aluminium-copper alloy,

Crystal structure of titanium, used for example as

Crystal structure of an ultra thin oriented

used for example in aircraft construction due toa base material for implants

electrical steel sample, used for example inelectric motors, transformers or generators

its low specific weightZEISS CrystalCT

Diffraction contrast make theRepresentative data for virtual

crystal structure visible

material testingZEISS CrystalCT utilises two different

Virtual material testing speeds up theimaging techniques: the establisheddevelopment of new materials

tomography technique using absorption

enormously. In order to create thecontrasts and a new technique thatcomputer models as realistically as

uses diffraction contrasts for imaging.

possible, a large amount of real test

This Diffraction Contrast Tomography

data is required. Conventional destructive(DCT) was developed by ZEISS in

methods for grain characterisation

partnership with Xnovo Technology.

are very time-consuming and onlyThis makes it possible for the first time

provide a small amount of data. ZEISS

in a commercially available CT device

CrystalCT, on the other hand, captures

to image the grain structure of metals,

much larger sample volumes andalloys and ceramics in three dimensions.

delivers a data-illustrated digital image

Diffraction contrast tomography alsoof the three-dimensional crystal

enables in-situ 4D studies to analyse thestructure – in a fraction of the time.

effects of different conditions over time.

The new type of diffraction contrast

The innovative diffraction-contrast tomography

tomography eliminates volume limitationsof ZEISS CrystalCT significantly increases theand makes it possible to analyse a large

1
Non-destructive CrystalCT
Volume: >>(1000)3 µm3 and more
Isotropic voxels: up to 2 µm
Voxel aspect ratio = 12
Non-destructive DCT
Volume: >>(1000)3 µm3Isotropic voxels: up to 2 µm
Voxel aspect ratio = 1

1

3
PFIB + EBSD
Volume: >>(250)3 µm3Layer thickness: 0.2 - 5 µm
Voxel aspect ratio ≥ 50
4Ga-FIB + EBSD
Volume: >>(100)3 µm3Layer thickness: 10 nm
Voxel aspect ratio ≥ 12
34

analysable sample volume

number of different sample types. This

30

Inspection tasks

Analysing crystal and microstructures in metals and alloys

Benefits

Fast examination, large sample
volume, unique technology tovisualise crystal structure

makes ZEISS CrystalCT the ideal data
provider for virtual material testing.

31

ZEISS METROTOM provides information on geometry, cavities and internal structures

Non-destructive
X-ray inspection of­entire components
Computer tomograph
ZEISS METROTOM
With a computer tomograph fromZEISS, you can perform even complex
measuring and inspection tasks efficiently
and non-destructively with just one
X-ray scan. The standardized acceptance,
the precision mechanics used and thesophisticated calibration procedure
guarantee the traceability of the system.
Linear guides and rotary table fulfil thehighest demands on accuracy.

3D inspection of a light metal component with ZEISS METROTOM

Measure and analyse entire

Full CT data analysis in 3D

the analysis with CAD data. This means­components

The easy-to-use ZEISS INSPECT X-Ray

that the quality of your component

ZEISS METROTOM is an industrial

analysis software, which is also suitable

can be precisely determined andcomputer tomograph for measuring

for beginners, enables complete CT

documented - all in just one piece ofand testing complete components

data analysis in 3D. Geometries, cavities

software.

made of plastic or light metal. Hidden

or internal structures and assembly

structures, which can only be inspected

situations can be precisely analysed.

with conventional measurement

Even the smallest defects can betechnology after the complex

visualised using individual sectional

layer-by-layer destruction of theimages and can be automaticallycomponent, can be visualised andevaluated using a wide range of criteria.

analysed by ZEISS METROTOM in the

You can also load volume data from

simplest possible way.

several components into a project,
perform a trend analysis and compare

ZEISS METROTOM

Application example:

previously necessary are no longer

Testing of cast raw parts fornecessary with ZEISS METROTOM. The

process optimisation

computer tomograph eliminates the

The Austrian printing and injectionneed for destructive testing procedures.

moulding company TCG UNITECHZEISS METROTOM delivers comprehen-uses a ZEISS METROTOM 1500 in thesive results quickly with just one 3D

immediate vicinity of its 20 die castingscan. TCG UNITECH also uses the 3D

machines in production. This enables

X-ray machine to design cast blanks

quality fluctuations to be detected

via reverse engineering and whenquickly and reliably. If porosity is

introducing new series components.

detected, for example, the ZEISSZEISS METROTOM delivers fast results

METROTOM indicates whether it is due

for validation with the customer andto air inclusions or shrinkage. With thisthus accelerates the release for series

important information, employees can

production.

immediately adjust the casting process

32

Inspection task

Non-destructive testing of
hidden structures

Benefits

Reliably replaces manytime-consuming inspection
procedures with a 3D scanand provides a comprehensive
digital image

parameters to avoid rejects. Manytime-consuming inspections that were33

Colour plots provide an intuitive
understanding of the longitudinal strain
distribution investigated with ZEISSARAMIS

Optical analysisof tensile tests
3D-sensor ZEISS ARAMISZEISS ARAMIS provides a deeper andmore precise understanding of material
properties during tensile tests. Using
high-resolution or high-speed cameras,
the optical 3D sensor provides the exact
coordinates of the sample surface overtime without contact and thus thederived measured variables of strain,
displacement, velocity and acceleration.
The visualisation of the strain distribution
gives you a quick overview of the force
effects on the material surface. You canalso use the image data from ZEISSARAMIS to determine material
characteristics and validate numericalsimulations.

Application example: Validation

was to use the data from ZEISS ARAMIS

preparation effort, a large numberof numerical models for bolt

to check numerical models of materialof samples could also be analysed

connections

behaviour. Thanks to the graphicallyefficiently.

With regard to the use of bolts in thevisualised high-resolution image data,

aerospace industry, bolt connections

strain peaks could be precisely localised

on CFRP components were analysed inand the behaviour of the sample

a tensile test. The aim of the research

intuitively illustrated. Due to the low

Contactless strain distribution

measuring principle with camera

measurement with ZEISS ARAMIS

technology, ZEISS ARAMIS offers

The measurement of inhomogeneousenormous flexibility in terms of sample

strain distributions is not possible withmaterial, sample shape and temporalconventional tactile strain measurement

measurement resolution.

The analysis of a tensile test with ZEISS ARAMIS provides aprecise understanding of the deformation behaviour of thematerial under test

Optical 3D sensor ZEISS ARAMIS

technology. The ZEISS ARAMIS optical
3D sensor delivers thousands of measured

Analyse strain and temperaturestrain values and visualises the strain

distribution synchronously

distribution on the surface of the material

By combining ZEISS ARAMIS with asample in easy-to-understand colour

thermographic infrared camera, thediagrams. Even the strain behaviour

strain and temperature distribution in

shortly before the material sample fails

the sample can be analysed separately

Recording the strain behaviour of a open holeis reliably recorded by ZEISS ARAMIS.

but synchronously. In a tensile test, fortension specimen with ZEISS ARAMIS

example, this makes it possible toInspection task

Investigate deformation
behaviour in detail

Benefits

Complete analysis of strain
behaviour, high data density,
low sample preparation effort,easy-to-understand colour
plots.

The complete picture -determine when the deformation isquick and easy

elastic (causes cooling) and when it is

Measure thousands of strain data points

plastic (causes heating). The combined

without contact. Save time and money

data can also be used to validate

on sample preparation. Material samples

numerical simulations.

only need to be prepared with a black
and white random colour pattern. Thereis no need to spend time attachingstrain gauges that only provide one
data point. Thanks to the non-contact

34

35

info.metrology.de@zeiss.com
www.zeiss.de/imt

Carl Zeiss
Industrial Quality Solutions, LLC
6250 Sycamore Lane North
Maple Grove, MN 55369/USA
Phone: +1 800 327-9735
Fax: +1 763 533-0219
info.metrology.us@zeiss.com
www.zeiss.com/metrology

EN_60_010_0066I Printed in Germany CZ-04/2024
Subject to change in design and scope of delivery and as a result of ongoing technical development.

Carl Zeiss IQS Deutschland GmbH
Carl-Zeiss-Straße 2273447 Oberkochen, Deutschland
Tel.: +49 7364 20-6337
Fax: +49 7364 20-3870