Patent Abstract:
A method for producing an interferogram of an infrared translucent layer that is on a reflective substrate, comprising generating parallel infrared interferometer beams by means of an infrared interferometer, converging the parallel infrared interferometer beams into converging infrared interferometer beams, sending the converging infrared interferometer beams onto the infrared translucent layer to produce diffusely reflected infrared interferometer rays from above and below the infrared translucent layer, and making the diffusely reflected infrared interferometer rays into parallel reflected infrared interferometer rays.

Full Description:
FIELD OF THE INVENTION 
     A diffuse reflectance method and apparatus are used to determine thickness of an infrared translucent layer on a metal substrate. 
     BACKGROUND OF THE INVENTION 
     In a past, collimated beams, coming from an interferometer, were used to produce an interferogram of a relatively thick silicon layer that had been epitaxially coated onto a silicon wafer. A single angle of incidence was made with the silicon layer, by collimated interferometer beams. Reflections of the collimated beams were produced. Again, collimated interferometer beams were used in the past to form an interferogram. The interferogram was used to determine the thickness of the relatively thick silicon layer. 
     The present diffuse reflectance method and apparatus provide for an accurate measurement of thickness of a relatively thin infrared translucent layer on a metal substrate. An example of such a relatively thin translucent layer on a metal substrate is a thin beryllium oxide region that is formed into a beryllium metal part. 
     The present method uses diffuse reflectance to measure thickness of the relatively thin beryllium oxide region. Parallel infrared interferometer beams are emitted from an interferometer. A concave mirror is used to converge the parallel beams into converging infrared interferometer beams. Converging interferometer beams are sent onto both the beryllium oxide region and underlying beryllium substrate. Diverging infrared interferometer rays are diffusely reflected from the beryllium oxide region and beryllium substrate, after reflection of the converging infrared interferometer beams from the beryllium oxide region and from the beryllium substrate. 
     The diverging interferometer rays are collimated and analyzed by means of Fourier transform infrared spectroscopy. 
     A concave mirror is used in the present apparatus to collimate, that is make parallel, the diverging interferometer beams. 
     Different angles of incidence are made between the converging interferometer beams and a line perpendicular to the surface of the beryllium oxide region. 
     A movable mirror of the inteferometer is scanned and the overall intensity of interfereing diffusely reflected rays, coming from the beryllium oxide region and beryllium substrate, is detected. An inteferogram is produced by recording the intensity versus the increment amount of scan distance. Sidebursts occur in the interferogram due to reflections above and below the oxide region. An amount of displacement of a first sideburst, in the interferogram, from a centerburst, in the interferogram, is measured. The amount of displacement is indicative of the thickness of the beryllium oxide region. 
     The present diffuse reflection method and apparatus were used to measure the thickness of a beryllium oxide region that had been formed in a beryllium substrate. Beryllium oxide thicknesses ranging from 0.67 microns to 4 microns were measured. 
     A beryllium oxide region is formed in a beryllium substrate by oxiding the beryllium substrate. The beryllium oxide region could be a beryllium oxide region that was formed by oxidizing a beryllium part. 
     It is noted that when a beryllium substrate is oxidized, there is a less uniform interface region than the interface region that occurs when a silicon layer is epitaxially placed on a silicon wafer. 
     A prior art software program, that had been used in the prior art measurement of a thickness of a relatively thick epitaxial silicon layer coated onto a silicon wafer, was modified. The software was used to measure thicknesses of the silicon layers that had thicknesses that ranged from 25 microns to 150 microns. The prior art software program operated by subtracting an interferogram of the epitaxial layer under examination from an interferogram of a reference epitaxial layer of known thickness. The resultant subtracted interferogram was searched by the software until a first major sideburst was found. At this point, the program calculates the thickness of the silicon epitaxial layer, using the distance of the sideburst from a centerburst of the subtracted interferometer, and the refractive index of the silicon epitaxial material. 
     Again, the prior art software program operated by subtracting an interferogram of the silicon layer under examination from an interferogram of a reference silicon layer of known thickness. The resultant subtracted interferogram was searched by the software until a first major sideburst was found. At this point, the program calculates the thickness of the silicon layer, using the distance of the sideburst from a centerburst of the subtracted interferometer, and the refractive index of the epitaxial silicon. 
     The prior art software program was modified in order to be used with the new method and apparatus. The modified software program can be used to measure the thickness of a relatively thin beryllium oxide region in a beryllium substrate. Such an oxide region might have a thickness from between 0.67 microns to 4 microns. A refractive index value of 1.8 was selected for a beryllium oxide region, in the modified software program. This value is used with the modified software program. 
     As part of its broad scope, a producibility program supported applications of new advancements from a wide range of technical disciplines to improvements of manufacturing and testing techniques for instruments. In this regard, steps were taken to prove that a nondestructive thickness measurement of beryllium oxide regions, in anodized beryllium components, was possible using diffuse reflectance Fourier transform infrared spectroscopy. Further steps were taken to demonstrate that the method could be readied for production use. By first demonstrating the interferometric principle with spectral patterns obtained from anodization regions of varying thicknesses, the modified prior art software program was incorporated into the disclosed method. 
     The modified software program enabled automated, nondestructive beryllium oxide region measurement by operators on a production line. The software program operated to the satisfaction of production and design engineers. 
     The disclosed diffuse reflection Fourier transform infrared spectroscopic method and apparatus, for measuring thicknesses of beryllium oxide regions, developed under the producibility program, can provide useful processing information about anodization region thickness and region uniformity, and to determine changes in the region&#39;s chemical composition. An implementation plan was developed by production engineers to determine how the disclosed method and apparatus, and the information that it generates, could be used. 
     When a group of beryllium components are manufactured, several production samples are routinely destroyed by an acid-etch technique wherein one obtains the thickness of the anodization, that is oxide, region, by etching away a small area of the oxide region and measuring the resultant hole with a form tally instrument. Aside from the destruction of useful hardware, there is some question regarding the accuracy of the acid-etch techniques. This issue warranted the use of an alternate thickness measurement method. 
     The disclosed diffuse reflectance method and apparatus will preserve hardware and improve the accuracy and efficiency for determining oxide region thicknesses. 
     SUMMARY OF THE INVENTION 
     A method for producing an interferogram of an infrared translucent layer that is on a reflective substrate, comprising generating parallel infrared interferometer beams by means of an infrared interferometer, converging the parallel infrared interferometer beams into converging infrared interferometer beams, sending the converging infrared interferometer beams onto the infrared translucent layer to produce diffusely reflected infrared interferometer rays from above and below the infrared translucent layer, and making the diffusely reflected infrared interferometer rays into parallel reflected infrared interferometer rays. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a gas bearing gyro rotor assembly. 
     FIG. 2 is optical ray diagram of an interferometer, with a moving mirror of the interferometer having a first position to provide destructively interfering beams. 
     FIG. 3 is optical ray diagram of an interferometer, with a moving mirror of the interferometer having a second position to provide constructively interfering beams. 
     FIG. 4 is optical ray diagram of an interferometer, with a moving mirror of the interferometer having a third position to provide destructively interfering beams. 
     FIG. 5 is an optical ray diagram of a diffuse reflectance Fourier transform infrared spectrometer that is being used to determine the thickness of a beryllium oxide region in a beryllium plate. 
     FIG. 6 is an optical ray diagram of converging interferometer beams that are impinging onto an anodized beryllium metal substrate. 
     FIG. 7 is an interferogram  50  of a beryllium oxide region whose thickness is to be determined, a reference interferogram  54  and a subtracted interferogram  58 . Interferogram  50  is examined to identify its centerburst and first sideburst by means of reference interferogram  54 . Subtracted interferogram  58  is made by subtracting the value of reference interferogram  54  from the value of interferogram  50 . 
     FIG. 8 is a gage that can be used to determine oxide thickness directly from an interferogram of the oxide. 
     FIG. 9A is an interferogram made by measuring intensity of a diffusively reflected interferometer beam coming from a 25 microinch thick beryllium oxide region, as a moving mirror of an interferometer, that produces the interferometer beam, is scanned from a position shown in FIG. 2 to a position shown in FIG.  4 . The interferogram of FIG. 9 is as interferogram  50  of FIG.  7 . 
     FIG. 9B is an interferogram made by measuring intensity of a diffusively reflected interferometer beam coming from a 50 microinch thick beryllium oxide region, as a moving mirror of an interferometer, that produces the interferometer beam, is scanned from a position shown in FIG. 2 to a position shown in FIG.  4 . 
     FIG. 9C is an interferogram made by measuring intensity of a diffusively reflected interferometer beam coming from a 75 microinch thick beryllium oxide region, as a moving mirror of an interferometer, that produces the interferometer beam, is scanned from a position shown in FIG. 2 to a position shown in FIG.  4 . 
     FIG. 9D is an interferogram made by measuring intensity of a diffusively reflected interferometer beam coming from a 100 microinch thick beryllium oxide region, as a moving mirror of an interferometer, that produces the interferometer beam, is scanned from a position shown in FIG. 2 to a position shown in FIG.  4 . 
     FIG. 9E is an interferogram made by measuring intensity of a diffusively reflected interferometer beam coming from a 400 microinch thick beryllium oxide region, as a moving mirror of an interferometer, that produces the interferometer beam, is scanned from a position shown in FIG. 2 to a position shown in FIG.  4 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     An anodized gas bearing gyro rotor assembly  10  is shown in FIG.  1 . The assembly  10  has two beryllium thrust plates  12  and  14 , a beryllium shaft  16 , and a rotor  18 , as shown in FIG.  1 . The plates, shaft and rotor have tight dimensional requirements, the dimensional requirements being on the order of several microinches. A microinch is symbolized by the letter u. Grooves  19  formed in the shaft  16  and grooves  19 A formed in plates  12  and  14 , allow a gas to pass between the shaft  16  and the rotor  18  and to thereby support rotor  18  away from shaft  16 .The beryllium plates  12  and  14 , and the beryllium shaft  16  are composed chiefly of beryllium metal. 
     The beryllium plates  12  and  14  and beryllium shaft  16  undergo a surface oxidation conversion reaction to yield topical beryllium oxide regions in the beryllium metal. A topical beryllium oxide region  20  is formed in plate  12 . Beryllium oxide region  20  is over beryllium metal  12 A of plate  12 , as shown in FIG.  6 . The thickness of the beryllium oxide region is unknown when formed. However to explain the present method, an interferogram  50  of FIG. 7 for a 25 microinch thick beryllium oxide region  20  is used. The beryllium oxide region  20  is an infrared translucent layer. The beryllium metal  12 A is a reflective substrate. A beryllium oxide region(not shown) is formed in beryllium plate  14 . A beryllium oxide region  21  is formed in beryllium shaft  16 . 
     The beryllium oxide regions are thin enough to allow infrared light to pass there through. Infrared light is reflected by the beryllium metal that is beneath the beryllium oxide regions. 
     The beryllium oxide regions are fabricated with the intent that the depth of each of the beryllium oxide regions be approximately 65 microinches (u″). 
     Nondestructive type testing, by the present method and apparatus, of the thicknesses of the beryllium oxide regions of the gas gyro assembly  10 , is desirable. For, the gas gyro assembly  10  is one of the most critical and costly components of a pendulous integrating gyro accelerometer. 
     Nondestructive measurements of the thicknesses of the beryllium oxide regions are performed by the present diffuse reflectance Fourier transform infrared spectroscopy (DRFTIS) method and apparatus. The principle behind such nondestructive measuements is based on the wave nature of light. DRFTIS makes use of the surface reflectance properties of the underlying beryllium, the reflectance properties of the beryllium oxide region, and the refractive index value of a beryllium oxide region. 
     In FIGS. 2,  3  and  4  a generic layout of optics for a Michelson infrared interferometer  25 , plus a concave converging mirror  40 , are shown. An infrared light source  26  sends a beam  28  of infrared light toward a beam splitter  30 . The beam splitter  30  splits beam  28  into infrared interferomter beams  32 A and  32 B. The infrared interferometer beam  32 A is reflected by fixed mirror  37  and passes through beam splitter  30  toward concave mirror  40 . The infrared interferometer beam  32 B is reflected by movable mirror  38  and is reflected by beam splitter  30  toward concave mirror  40 . Infrared interferometer beams  32 A and  32 B are parallel before reaching mirror  40 . 
     The paths of the parallel infrared interferometer beams  32 A and  32 B are toward concave mirror  40 . The concave mirror  40  reflects infrared interferometer beam  32 A, to produce infrared interferometer beam  44 A. The concave mirror  40  reflects infrared interferomter beam  32 B, to produce infrared interferometer beam  44 B. The concave mirror  40  causes infrared interferometer beams  44 A and  44 B to converge toward each other. 
     Interferometer  25  has a fixed, that is stationary, mirror  37 . Interferometer  25  has a movable mirror  38 . The mirror  38  is continuously moved, that is scanned, as shown by FIGS. 2,  3  and  4 , to produce an interferogram of a beryllium oxide region, as further described below. 
     FIGS. 2,  3  and  4  respectively show infrared interferometer configurations for destructive interference, for constructive interference and for destructive interference. The movable mirror  38  is scanned from the configuration of FIG. 2 to the configuration of FIG. 4 to produce an interferogram. 
     A diffuse reflectance Fourier transform infrared spectroscopic apparatus  39  is shown in FIG.  5 . The apparatus  39  includes a beryllium thrust plate  12  that has a beryllium oxide region  20 . The apparatus  39  could alternately be made to include an alternate component, such as beryllium shaft  16  that has a beryllium oxide region  21 , in place of beryllium thrust plate  12 . 
     In FIG. 5, parallel infrared interferometer beams  32 A and  32 B, that are emitted by th interferometer  25 , are directed by flat mirror  41  and flat mirror  42  toward concave mirror  40 . Concave mirror  40  reflects the parallel infrared beams  32 A and  32 B, coming from the interferometer  25 , and produces converging infrared interferometer beams  44 A and  44 B. Infrared interferomter beams  32 A and  32 B converge toward each other due to reflection of the beams  32 A and  32 B by concave mirror  40 . 
     The converging infrared interferometer beams  44 A and  44 B, coming from the concave mirror  40 , are sent onto thrust plate  12 . The thrust plate  12  reflects infrared interferometer beam  44 A to produce diffuse reflected infrared interferomter rays  45 A and  46 A. The thrust plate  12  reflects infrared interferometer beam  44 B to produce diffuse reflected infrared interferometer rays  45 B and  46 B. 
     A concave collecting mirror  43  collects and collimates, that is makes parallel, the diffuse reflected infrared rays  45 A,  46 A,  45 B and  46 B. Diffuse reflected infrared rays  45 A,  46 A,  45 B and  46 B are collected and collimated, as shown in FIG.  5 . Again, a concave collecting mirror  43  collects and makes parallel the diffuse reflected infrared rays  45 A,  46 A,  45 B and  46 B. 
     The parallel infrared rays  45 A,  46 A,  45 B and  46 B are reflected by flat mirror  47 . The parallel rays  45 A,  46 A,  45 B and  46 B are then reflected by flat mirror  48  into a detector  49 . 
     A varying signal is generated by detector  49 , as movable mirror  38  of interferometer  25  of FIG. 5 is scanned from the position shown in FIG. 2 to the position shown in FIG.  4 . The strength of the signal from detector  49  is dependent on the amount of energy in the detected interfering infrared rays  45 A,  46 A,  45 B and  46 B, as movable mirror  38  is scanned. That is, the strength of the signal is proportional to the overall strength of the reflected interfering infrared rays  45 A,  46 A,  45 B and  46 B. 
     The signal is sent from detector  49  to a recorder  49 A and recorder produced a trace proportional in height to the strength of the signal. A controller  49 B coordinates the scanning of mirror  38  with the position of a trace in recorder  49   a . The trace is interferogram  50 , as shown in FIG.  7 . 
     As shown in FIG. 6, the converging beam  44 A produces rays  45 A and  46 A. Converging beam  44 B produces rays  45 B and  46 B. Rays  45 A and  45 B are produced, respectively, as a result of beams  44 A and  44 B being reflected from the top of beryllium oxide region  20 . Rays  46 A and  46 B are produced, respectively, as a result of beams  44 A and  44 B being reflected one or more times from beryllium metal  12 A that is under the oxide region  20 . 
     Rays  45 A and  46 A are parts of beam  44 A. Rays  45 B and  46 B are parts of beam  44 B. The collected rays  45 A,  46 A,  45 B and  46 B are together detected by detector  49 . 
     The collected rays  45 A,  45 B,  46 A and  46 B are all collected by detector  49 . An interferogram  50 , shown in FIG. 7, is produced due to their interference at the oxide region  20  and underlying beryllium  12 A, as mirror  38  of interferometer  25  is scanned inward toward the beamsplitter of interferometer  25 . The movable mirror  38  of the interferometer  25  is scanned to produce a set of intensities in detector  49 . This set of intensities is interferogram  50 . 
     The intensity produced by the interference of rays  45 A,  45 B,  46 A and  46 B is essentially zero when the moving mirror  38  is at the three halves point, in distance, to the beamsplitter  30 , with respect to the distance of beamsplitter  30  to mirror  37 . This arrangement is shown in FIG.  2 . At the three halves mark, the IR rays  45 A and  46 A are a half cycle out of phase with respect to IR rays  45 B and  46 B, thereby leading to total destructive interference (minimum energy throughput). This interference produces the left end of interferogram  50  of FIG.  7 . 
     The rays  45 A,  46 A,  45 B and  46 B interfere to produce a maximum intensity in detector  49 , known as a centerburst  53 , when the mirrors  37  and  38  of interferometer  25  are equidistant from the beamsplitter  39 , as shown in FIG.  3 . This interference produces the center burst  53  of interferogram  50  of FIG.  7 . 
     The intensity produced by the interference of rays  45 A,  45 B,  46 A and  46 B diminishes to zero as the moving mirror  38  approaches the halfway point, in distance, to the beamsplitter  39 , with respect to the distance of beamsplitter  39  to mirror  37  as shown in FIG.  4 . At the halfway mark between the moving mirror  38  and the beamsplitter  39 , the IR rays  45 A and  46 A are again a half cycle out of synchronization with rays  45 B and  46 B, thereby leading to total destructive interference (minimum energy throughput). This interference produces the right end of the interferogram  50  of FIG.  7 . 
     Diffuse reflectance Fourier transform infrared spectrometry is generally discussed. However there is no teaching or suggestion of transmission of diffuse infrared beams through a translucent oxide region, nor of a subsequent formation of a high-information interferogram, nor of a subsequent determination of a thickness of the translucent oxide layer. Such a discussion is at pages 194 to 202 of a book entitled “Fourier Transform Infrared Spectrometry” by Peter R. Griffiths and James A. de Haseth. Principals of interferometry are discussed in that book. That book was published by John Wiley &amp; Sons, New York, in 1986. The teaching of that book are incorporated herein by reference. 
     In the past, when the beryllium oxide region  20  undergoes analysis by a split IR beam, in a nondiffuse reflectance mode, information imputted into an interferogram is restricted to information of the topical features, i. e. the top, of beryllium oxide region  20 . 
     However, as herein disclosed, when the beryllium oxide region  20  undergoes analysis, by scanning movable mirror of interferometer  25 , in a diffuse reflectance mode, shown in FIG. 5, a more detailed interferogram  50  is produced. This interferogram  50  has more information in it, that is information of the thickness of very thin beryllium oxide region  20  of FIGS. 1 and 6. 
     In FIG. 6 the angles of incidence of each of converging beams  44 A and  44 B are shown. In FIG. 6, such light incidence angles are shown as forty-five degrees and twenty degrees, respectively. The angle of reflection of rays  45 A, and  46 A has a value dependent on the angle of incidence of beam  44 A. The angle of reflection of rays  45 B, and  46 B has a value dependent on the angle of incidence of beam  44 B. In FIG. 6 such angles of reflection are shown as approximately forty-five degrees and twenty degrees, respectively. Angles of incidence, from ten degrees to eighty degrees, can be used for the disclosed diffuse reflectance Fourier transform infrared spectroscopic method and apparatus. 
     Although converging beams  44 A and  44 B are shown as being sent onto the oxide region  20  in the apparatus of FIG. 6, nonparallel diverging beams could be sent onto the oxide region  20 , by means of a convex mirror in place of concave mirrir  40 . Diffuse reflected rays produced by the nonparallel diverging beams would also be diverging. These latter diffuse reflected rays could be made to be parallel, by means of a concave mirror, in a similar manner that concave mirror  43  of FIG. 6 collects diffuse reflected rays  45 A,  46 A,  45 B and  46 B and makes them parallel. 
     Again, an interferogram  50 , that has information of the thickness of beryllium oxide region  20 , is shown in FIG.  7 . The interferogram  50  is a result of IR beams  44 A and  45 A having very different angles of incidence, as they pass into and through the beryllium oxide region  20  and are reflected from the beryllium metal  12 A. The interferogram  50  of FIG. 7 is the same as the interferogram of FIG.  9 A. 
     A first sideburst  52  of the interferogram  50  is produced as a result of interference of rays  46 A and  46 B. The first sideburst  52  has information of the thickness of region  20 , when first sideburst  52  is taken with centerburst  53 . The first sideburst  52  is shown in FIG.  7 . 
     In FIG. 7, the first sideburst  52  of interferogram  50  is displaced from the centerburst  53  of interferogram  50  by 10 points. 10 points is proportional to the thickness and average refractive index of the beryllium oxide region  20  of FIG.  6 . This point difference is used to determine the thickness of region  20 . The first sideburst  52  of FIG. 7 is due to interference between the IR rays  46 A and  46 B that are reflected from the beryllium metal subsurface  12 A. 
     In the initial step of the disclosed thickness measurement technique, reference interferograms of various thicknesses of beryllium oxide, from 25 to 160 microinch thick regions, are used to identify first sideburst  52 . These reference interferograms are used as references against which the interferogram  50  is compared. Interferogram  50  of region  20  is compared against such reference interferograms until a near match is found. The matching technique is described below, to identify first sideburst  52 . 
     A beryllium oxide region that is somewhat thicker that region  20 , such as a 150 microinch thick region, would increase the distance traveled by the IR beams  44 A and  44 B through such a thicker region. 
     A reference interferogram  54 , shown in FIG. 7, is produced using a 150 microinch thick beryllium oxide region. A sideburst  55  of reference interferogram  54  is shown in FIG.  7 . Further a centerburst  56  of reference interferogram  54  is shown in FIG.  7 . 
     In FIG. 7 the reference interferogram  54  of a 150 microinch thick beryllium oxide region, is used as one of the reference interferograms against which the interferogram  50  is compared to identify which arc of interferogram  50  is the first sideburst, that is sideburst  52 . 
     FIG. 7 shows a subtracted interferogram  58 . The subtracted interferogram  58  is formed by subtracting the value of the reference interferogram  54  from the value of interferogram  50 , at each point along the horizontal axis of FIG.  7 . 
     A center burst  59  and a first side burst  60  of subtracted interferogram  58  are shown in FIG.  7 . In the preferred initial thickness determination step the shape of the reference interferogram  58  is used to identify first sideburst  52 . 
     In the final step of the disclosed thickness measurement technique, the distance between first sideburst  52  and centerburst  53  is measured. The measured distance allows one to determine the exact thickness of beryllium oxide region  20 . 
     The matching technique can be adjusted if the index of refraction of region  20  is not exactly the same as the index of refraction of the beryllium oxide regions that are used to produce the reference interferograms. An adjustment factor can be multiplied by the measured distance to find a second order thickness of region  20 . The adjustment factor would be the refractive index of the regions generating the reference interferograms, divided by the refractive index of the region  20 . 
     To prove out the interferogram mechanism for an anodic region, numerous thrust plates, and shafts, with a wide range of known oxide regions having thicknesses from 25 u″ to 150 u″, were prepared. Interferograms for these regions are shown in FIGS. 9A to  9 E. These interferograms prove that a sideburst of an interferogram moves away from the centerburst of that interferogram, as the thickness of the region, being measured, becomes greater. 
     In the disclosed measurement technique, one compares an interferogram of a first order known thickness, with a set of reference interferograms of various regions having known thicknesses, in order to determine a second order known thickness. The range of known thicknesses should include the first order known thickness. 
     As an alternate first order measurement technique, a thickness value of a known thickness of a standard interferogram that has a sideburst-centerburst distance that is approximately the same as the sideburst-centerburst distance of the interferogram of the unknown thickness, could be taken as the first order thickness value of the unknown thickness. 
     Several interferograms, made from thrust plates with various thicknesses of beryllium oxide regions are shown in FIGS. 9A to  9 E. Arrows designate the first sidebursts, verifying the proposed interaction of the IR beams  32 A and  32 B with the beryllium subsurface. While a spectroscopist would be able to determine the thickness of the anodization region of any shaft or plate by inspection of the interferometers of FIGS. 9A to  9 E, an automated means of interpreting the spectra was necessary if the technique were to be useful in a production environment. 
     An implementation plan can be used to determine how the information generated by diffuse reflectance Fourier transform infrared spectroscopy, DRFTIR, can be applied in production. When implemented, the method will find many uses in production in addition to routine oxide thickness evaluation. For example, such uses are: 
     (1) Nondestructive evaluation of finishing effects and the uniformity of an anodization region; and 
     (2) Detection of changes in the chemical composition of an anodization region based on refractive index and key absorbances in the infrared spectrum. 
     Straight specular Fourier transform infrared spectroscopy had previously demonstrated its usefulness in other areas of online production use such as nondestructive gas bearing lube analysis. 
     Diffuse reflectance Fourier transform infrared spectroscopic analysis of anodization region thickness is another step forward in providing noncontact, nondestructive tools to access important parameters that give meaningful information to the production engineer about manufacturing processes. On-Line DRFTIR implementation can be used, in production activities, for anodize thickness measurement. 
     The plate and shafts prepared with different coating thicknesses were tested by using diffuse reflectance Fourier transform spectroscopy and a shellscript program, as shown below. A comparison of the coating thicknesses for shafts and thrust plates, as determined by three techniques (DRFTIR, Acid-Etch and Time/Current measurements), is presented in Table 1, as follows: 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Comparison of Anodize Coating Thickness Values By 
               
               
                 DRFTIR, Acid-Etch and Time/Current Measurements* 
               
             
          
           
               
                 CURRENT/TIME 
                   
                 DRFTIR PROGRAM 
                   
                 ACID-ETCH 
               
             
          
           
               
                 Microns 
                 u inches 
                   
                 Microns 
                 u inches 
                   
                 Microns 
                 u inches 
               
               
                   
               
             
          
           
               
                 THRUST PLATES 
               
             
          
           
               
                 0.635 
                 25 
                   
                 0.67 
                 27 
                   
                 0.79 
                 31 
               
               
                 1.27 
                 50 
                   
                 1.46 
                 58 
                   
                 1.27 
                 50 
               
               
                 1.905 
                 75 
                   
                 1.81 
                 72 
                   
                 1.80 
                 71 
               
               
                 2.54 
                 100 
                   
                 2.28 
                 91 
                   
                 2.38 
                 95 
               
               
                 3.175 
                 125 
                   
                 2.60 
                 104 
                   
                 2.98 
                 119 
               
               
                 3.81 
                 150 
                   
                 3.78 
                 151 
                   
                 3.62 
                 143 
               
             
          
           
               
                 SHAFTS 
               
             
          
           
               
                 0.635 
                 25 
                   
                 0.68 
                 27 
                   
                 0.71 
                 28 
               
               
                 1.27 
                 50 
                   
                 1.26 
                 50 
                   
                 1.45 
                 58 
               
               
                 1.905 
                 75 
                   
                 1.80 
                 75 
                   
                 2.10 
                 84 
               
               
                 2.54 
                 100 
                   
                 2.89 
                 115 
                   
                 2.84 
                 114 
               
               
                 3.175 
                 125 
                   
                 3.04 
                 122 
                   
                 3.05 
                 122 
               
               
                 3.81 
                 150 
                   
                 3.96 
                 158 
                   
                 4.11 
                 164 
               
               
                   
               
               
                 *Site of DRFTIR analysis may not be the same as site where acid etch occurred.  
               
             
          
         
       
     
     The DRFTIR results agreed reasonably with the acid/etch method, with only two samples showing a discrepancy greater than 10 microinches. The observed differences may by due mainly to the changes in the refractive index of the coating. This seems to be a function of the thickness. Hypothetically, the refractive index of the coating decreases with increasing coating thickness (n=2.1 for 25 microinches vs. n=1.8 for 150 microinches). 
     An accurate epilayer thickness calculation by the prior art software program was dependent on an accurate value for refractive index as well as an optimal reference thickness. The interferogram for the reference region is subtracted from the sample&#39;s interferogram as part of the prior art program, in a manner somewhat similar to that used to produce the difference interferogram  58  as shown in FIG.  7 . 
     Because the anodization region is so thin, the reference thicknesses had to be very close to the sample thickness, for the the disclosed method to be effective. When working with such thin regions, the prior art program could not discern the position of the first sideburst  52  when using a reference sideburst that was too remote from the sample sideburst. For example, the step of using a 240 u″ reference for a 75 u″ oxide region was not effective in finding the first sideburst. u″ refers to a microinch unit of measure. 
     In FIG. 8 a gage is shown. The gage is one example of a calibration standard to be used to determine the thickness of the infrared translucent. This gage could be used in the thickness measurement technique. This gage presents the results of the point distance between a first side burst and a center burst of each of several interferograms of FIG.  9 . With this gage one can determine the thickness of a region by measuring the point distance between the center burst and the first side burst of the region&#39;s interferogram. One measures the point distance between a sideburst and a centerburst for an interferogram, and compared the point distance to the same point distance on the gage, and reads off the thickness value shown on the gage. This thickness value is taken as the thickness of the region under investigation. Again, one compares that measured distance on the gage, to find a corresponding thickness for that region, on the gage. 
     The values shown on the gage can be programmed into a computer, as an set of equations that provide thickness over the point range shown in FIG.  8 . Then by putting the measured point distance taken from an interferogram of a region under investigation into the computer, the thickness of the region under investigation will be provided as an output, by the computer. 
     A shellscript calls out the appropriate reference interferograms and refractive index settings for use in a successive set of exclusion windows. In the first sideburst identity search step, the program gradually searches each window for the sideburst of interferogram  50  that is observed to be closest to the centerburst. When the first sideburst  52  is located, the program calculated the thickness of the beryllium oxide region, e.g. region  20 , and reports the thickness of the beryllium oxide region. 
     If the operator has a general idea of the thickness of the beryllium oxide region and inputs the information into the FTIR computer when asked by the shellscript program, the computer will determine if the appropriate first sideburst for that thickness is present in the corresponding exclusion window, within two minutes. If the first sideburst is not observed, the program informs the operator that the proposed thickness is inaccurate and asks if the operator wants to proceed with the determination of the true thickness. This takes about fifteen minutes while the computer searches through each exclusion window. The program gives the operator control over the direction of analysis. 
     While the present invention has been disclosed in connection with the preferred embodiment thereof, it is understood that there may be other embodiments which fall within the spirit and scope of the invention as defined by the following claims.

Technology Classification (CPC): 6