In today’s industrial and manufacturing world, producing high quality products is critical. Manufacturers are under constant pressure and use advanced technologies so they can be certain that their products perform reliably, satisfy their customers, and meet high quality standards. One of the key tools used by quality control (QC) experts is the Scanning Electron Microscope, or SEM. With an SEM, scientists and technicians can inspect the structures and material surfaces of a sample at the nano- and micro-scale.

Essentially, the SEM uses a beam of focused electrons to scan the surface of the provided sample. As the electrons come to interact with a sample’s atoms, they create signals that can be detected and then converted into images that are highly detailed. Unlike more traditional forms of optical microscopes, scientists and technicians in an SEM laboratory are  able to magnify an object up to hundreds of thousands times, thus revealing cracks, surface texture, composition, and contaminants in tremendous detail.

Why Companies Use SEM in Quality Control

One of the primary benefits of SEM is that it offers an unmatched imaging depth and resolution. A standard optical microscope is limited by light’s visible wavelength. SEM, on the other hand, utilizes an electron beam which lets it magnify an object by 500,000x with resolution that is below one nanometer. This helps QC teams see irregularities and defects that would otherwise be invisible to instruments that are light-based.

SEM resolutions levels are ideal for any manufacturers that produce high-precision components such as engine parts, medical implants, and semiconductors. This testing technology can also offer more than simply high-resolution images. When EDS, or Energy Dispersive X-ray Spectroscopy, is added QC departments can use this advanced technology to help determine elemental composition of contaminants, inclusions, and defects.

SEM’s Role in Quality Control Processes

SEM plays a key role in both reactive and proactive quality control. In reactive QC, scientists use SEM for root cause analysis. If a component fails during stress testing or in the field, technicians can use SEM to examine wear patterns, corrosion pits, or fracture surfaces at high resolution and magnification. Quality engineers are then able to understand failure points and mechanisms, and implement corrective action.

Proactive QC is used during the product development cycle. It allows technicians to verify consistency of coatings, material textures, and surface treatment. Designers and engineers can verify that products meet the intended specification, and will therefore be able to perform well in real-world conditions.

Industry Applications in QC Failure Analysis

Alloys and coatings are a key element of the steel industry. If a structure fails, detailed failure analysis is necessary to prevent future recurrence or accidents. SEM can be used to identify imperfections, contaminants or cracks in the steel coatings. Coatings are also critical in the medical field, especially for implants and devices. Testing a failed implant or device with SEM can save lives in the future.

In the semiconductor industry, the functionality and structure of components in chips are often analyzed with SEM. This testing methodology can help to pinpoint surface failures and  nonconformities inside the chip, and also study solder joints for porosity or leakage.

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