CarlBerk also assist our client in their quality control activity by offering high standard quality evaluation of the material, component or prototype before the large-scale production. To ensure the accuracy of the assessment, we design most suitable testing protocols and cross-check the results with complimentary technique(s) when necessary. Our failure analysis experience allows us to better relate the experimental results with product’s specific requirement and advise on preventing potential failure at early stage. Our quality evaluation service typically includes:
the initial concept validation, risk identification, vendor comparison, incoming material defect inspection, and so on. assist them in achieving high quality and reliable product.
Design review and risk identification with respect to specific geometrical design and material selection.
Compliance review on if specific material/component meet the specification required by client (e.g. surface roughness, coating thickness, material hardness, purity, etc.)
Example 1： Thermal Stress Induced Micro-Crack on Magnet Sidewall Surface
Fluorescent dye penetration test revealed the presence of surface cracks (~ 3 cm long) on the outer sidewall surface of incoming magnet purchased from vendor. The micro crack occurred near the centerline of outer sidewall surface and was likely resulted from imbalanced thermal expansion due to the temperature gradient within the magnet upon sudden temperature change. FEA simulation revealed that the hotter the magnet was when it was taken out from the furnace, the resulting thermal stress loaded on the magnet would be higher, so did the chances of forming surface crack.
Example 2: Comparison of Candidate Cells Sourced from Two Vendors
Even through the technical specification sheets looked similar, cells sourced from two vendors exhibit drastically different tolerance at elevated temperature. Detailed analysis of cell material revealed the different high temperature performance was correlated with different grade of LCO cathode materials used by the two vendors. In addition, CarlBerk provide more comprehensive comparison of two candidate cells from multiple aspects to assist client in cell selection.
Example 3: Surface Texture Analysis of Machining Marks Created by Different CNC Tooling
Surface roughness plays an important part in the functional performance of many engineering components. It affects the tightness of contact joints, positional accuracy, and component contact deformation. It also plays a vital role in the corrosion rate, residual stress, heat resistance, and friction resistance of the component. Surface texture evaluation thus allows a better understanding of how different tooling parameter (spindle speed, feed rate, depth of cut) could affect the final surface roughness and whether the surface quality are compliant to technical requirement.
