Metrology, Volume 3, Issue 2 (June 2023) – 7 articles

As metal additive manufacturing has been increasingly accepted as a viable method of industrial manufacture, there has been a significant uptake in manufacturers wishing to verify and test their parts through analysis of part surface. However, various studies have shown that metal additive surfaces tend to exhibit highly complex features and, thus, represent a challenge to those wishing to undertake measurement and characterisation. Over the past decade, good practice in metal additive surface measurement and characterisation have been developed, ultimately resulting in the creation of a new standard guide, ASTM F3624-23, which summarises that good practice. Here, we explain the background and rationale for the creation of this standard and provide an overview of the contents of the standard. An example case study is then presented, showing the worked good practice guidance in a metal additive surface measurement and characterisation task, namely, a comparative measurement of an example surface using two different instruments. Finally, considerations for future versions of the standard are presented, explaining the need to develop further good practice for novel instruments and to focus on feature-based characterisation approaches. Full article

The Tsallis q-Gaussian distribution is a powerful generalization of the standard Gaussian distribution and is commonly used in various fields, including non-extensive statistical mechanics, financial markets and image processing. It belongs to the q-distribution family, which is characterized by a non-additive entropy. Due to their versatility and practicality, q-Gaussians are a natural choice for modeling input quantities in measurement models. This paper presents the characteristic function of a linear combination of independent q-Gaussian random variables and proposes a numerical method for its inversion. The proposed technique makes it possible to determine the exact probability distribution of the output quantity in linear measurement models, with the input quantities modeled as independent q-Gaussian random variables. It provides an alternative computational procedure to the Monte Carlo method for uncertainty analysis through the propagation of distributions. Full article

Additive manufactured surfaces, especially metal powder bed fusion surfaces, present unique challenges for measurement because of their complex topographies. To address these measurement challenges, optimisation of the measurement process is required. Using a statistical approach, sensitivity analyses were performed on measurement settings found on a commercial programmable array scanning confocal microscope. The instrument measurement process parameters were compared by their effects on three quality indicators: the areal surface texture parameter Sa, measurement noise, and number of non-measured points. An analysis was performed using a full factorial design of experiments for both the top and side surfaces of test surfaces made from Inconel 718 and Ti-6Al-4V using powder bed fusion. The results indicated that measurements of metal additive surfaces are robust to changes in the measurement control parameters for Sa, with variations within 5% of the mean parameter value for the same objective, surface, and measured area. The number of non-measured points and the measurement noise were more varied and were affected by the choice of measurement control parameters, but such changes could be predicted by the statistical models. The contribution offered by this work is an increased understanding of imaging confocal microscopy measurement of metal additive surfaces, along with the establishment of good practice guidance for measurements. Full article

The increasing demand for electric drives challenges conventional powertrain designs and requires new technologies to increase production efficiency. Hairpin stator manufacturing technology enables full automation, and quality control within the process is particularly important for increasing the process capacity, avoiding rejects and for safety-related aspects. Due to the complex, free-form geometries of hairpin stators and the required short inspection times, inline reconstruction and accurate quantification of relevant features is of particular importance. In this study, we propose a novel method to estimate the creepage distance, a feature that is crucial regarding the safety standards of hairpin stators and that could be determined neither automatically nor accurately until now. The data acquisition is based on fringe projection profilometry and a robot positioning system for a highly complete surface reconstruction. After alignment, the wire pairs are density-based clustered so that computations can be parallelized for each cluster, and an analysis of partial geometries is enabled. In several further steps, stripping edges are segmented automatically using a novel approach of spatially asymmetric windowed local surface normal variation, and the creepage distances are subsequently estimated using a geodesic path algorithm. Finally, the approach is examined and discussed for an entire stator, and a methodology is presented that enables the identification of implausible estimated creepage distances. Full article

Non-destructive measurements of high aspect ratio microscale features, especially those with internal geometries such as micro-holes, remain a challenging metrology problem that is increasing in difficulty due to the increasing requirement for more complexity and higher tolerances in such structures. Additionally, there is a growing use of functional surface texturing for improving characteristics such as heat transfer and wettability. As a result, measurement techniques capable of providing dimensional form and surface finish for these features are of intense interest. This review explores the state-of-the-art inspection methodologies compatible with high-aspect-ratio structures and their suitability for extracting three-dimensional surface data based on identified high-aspect ratio structure types. Here, the abilities, limitations, challenges, and future requirements for the practical implementation and acceptance of these measurement techniques are presented. Full article

Brazilian regulation requires the test methods for analysing the shrinkage factor, and the solubility ratio in crude oils must be estimated under the measurement conditions for appropriation. Since these physicochemical parameters depend upon the density, a Brazilian oil company proposed an adapted and more user-friendly methodology for adjusting the digital density meter under high pressure and temperature conditions. This study aimed to evaluate the metrological compatibility of this proposal by comparing it with the fit model presented by a manufacturer of a digital densimeter and with the tabulated reference values of fluid density. Since the density data behaviour presented non-normal distributions, the Wilcoxon signed-rank test showed metrological compatibility between the approaches studied in the pressure range from 0 psi to 1200 psi (8.273709 MPa) and the temperature range from 5 °C to 70 °C. Full article

The need to control the real-time location of assets is increasingly relevant worldwide. The Ultra-wideband (UWB) technology is an IoT solution for real-time locating systems (RTLS). The location of the asset is obtained by the signal exchange between a wireless tag (asset) and fixed anchors. The tag interacts with the fixed anchors, defining its position through the distances obtained by trilateration. This data is sent to the server through the gateway. It is well-known that this process has several sources of errors. However, the measurement uncertainty assessment of UWB technology is an important topic regarding its scope of use. This paper presents a task-specific measurement uncertainty evaluation for the UWB positioning system, according to the ISO GUM. It aims to propose a method to support decision-making regarding the possible uses of UWB technology. The position provided by the UWB is compared with reference points using Cartesian coordinates that are measured with a total station, providing metrological reliability. Using the information from the estimated uncertainty, one can define the minimum tolerance interval associated with UWB technology for a given use. A case study demonstrates the method. Full article