in 

84000PELCO® Precision Thinning Tools
Materials Science Supplies Overview
Polishing Overview

PELCO® Dimpler™

Precision polishing system for TEM specimen thinning and site-specific analysis



PELCO Dimpler

The PELCO® Dimpler™ is the latest model in the evolu­tion of the Dimpler line formerly available from South Bay Technology and provides Automated Precision Thinning of Specimens for TEM Analysis, for deprocessing and failure analysis, and similar applications where targeted fine polishing is required. It is a precision electro-mechanical metallographic lapping in­strument that will continuously monitor and control dimpling parameters and accurately terminate at a preset specimen thickness. This electronic and mechanical integration has added repeatability and reliability to the dimpling process, as well as automation.

Active monitoring of the Z-position, feedback-controlled damping, and automated controls for determining termination of processing work together to provide repeatable, reliable results in sample preparation.


Z Position

The Z position is continuously monitored via a non-contact sensor. The digital display indicates the dimple depth in microns, and is updated once every revolution This negates any errosr due to tool run out, especially significant when using padded polishing tools. The termination depth can be set using the Z-position, allowing processing to stop when a specified depth of material is removed.


Termination

Process termination can be determined using the built-in timer, or by the Z Position. When using Z Position termination, the timer counts up to measure the total time elapsed until the Z Position is reached. This is useful for creating process recipies for various sampel types. Four factors improve the overall stability during processing, and the termination accuracy:

  1. Non-Contact Position Sensor
  2. Tool Phase Sensor
  3. No external measuring device
  4. Magnetically coupled arm damping

The Non-Contact Position Sensor measures the location of the fulcrum arm which corresponds precisely to the thickness of the specimen. This sensor has an accuracy of better than one micron. Since it is non-contacting there are no detrimental effects on the action of the fulcrum arm. The reaction time of the sensor is fast enough to terminate the dimpling process the first time the Tool Phase Sensor indicates that the Z termination set point has been reached. Specimen thickness is measured directly on the PELCO® Dimpler™ with the tool surface as the measuring point. The dimple depth and the Z termination set point are measured with the same reference. This prevents any measurement error from being translated directly to a termination error.


Damping

Damping of the arm is accomplished by using position information from the Non-Contact Position Sensor, processing it and feeding it back to the arm motor, which controls the up/down force of the arm. The position sensor and the processing circuit is fast enough to actively dampen any vibration the arm may experience. Since the damping force is magnetically coupled to the arm there is no mechanical play in the system, allowing damping response on the sub-micrometer level. Damping is adjustable from zero damping to stiff damping.

Damping offers three significant attributes:

  1. Vibrations that can crack thin specimens are greatly reduced.
  2. Keeps tools round, negating excess impacts, providing more accurate Z position control.
  3. Tool gently contacts the specimen when the arm is lowered.

Automated Controls

Automated features make the dimpling process more repeatable and easy to use. Tools are raised and lowered at the touch of a button; dimpling force, damping force, fine balance, and Z offset (termination point) all are set from the front panel.

Once dimpling has begun no monitoring is necessary. After the initial specimen thickness has been measured, the specimen is mounted and the user simply selects a dimple depth and begins dimpling. The precise Z position of the tool/surface interface is continuously displayed while dimpling with any tool. When the selected dimple depth is reached the PELCO® Dimpler™ controls will automatically raise the arm then stop the tool rotation, specimen rotation, and clock timer.


Working Interface

The working interface for the unpadded tools shows very high stability in terms of the ΔZ reading (change in the offset value), with any deviation usually the result of tilt in the mounted sample. Research has indicated that for padded tools, the working diameter is within the nap of the pad. In this case, the ΔZ between the working interface and the specimen is a function of dimpling load (force setpoint), tool speed, damping, and pad compliance. After the dimpling load, tool speed, and damping are selected, the working diameter will stabilize at the working interface of the pad. This working interface is monitored on the Z display and used as a reference location from which a specimen is to be dimpled further.


Specimen Mounting

Different mounts are available depending on the size and type of sample. TEM specimens are generally mounted on optically smooth sapphire flats. The low thermal mass of the flat reduces mounting and dismounting times and the smooth surface allows the dimpled specimens to be easily removed. The hardness of sapphire limits damage if specimens are accidentally perforated due to operator error. The retainer ring which secures the sapphire flat also serves as a slurry reservoir. This platen set is used with the traditional Dimpler tools. For larger specmens for surface analysis or delayering a separate, shorter magnetic base and platen set is used with larger diameter tools. These were developed for delayering and deprocessing.


Tools

The standard dimpling tools include flatting and dimpling tools, in both unpadded versions for faster material removal and padded versions for polishing. Tools are made from 316 Stainless steel. Flatting tools such as Tools li and 2i, and the Large Area Tools have a flat profile while Dimpling Tools such as 3i and 4i have a radiused profile to produce a pronounced dimple. The flatting tools will still produce a dimple with the lowest point at the center of rotation, but it will have a much shallower height differential across the dimple.

A variety of padded and unpadded tools are available to meet many dimple polishing process requirements. The 83031 standard tool set for 3mm samples contains 6 tools, part numbers 83010, 83016, 83015, 83012, 83013, and 83014. Available tools and specimen mounts are shown below.


83050
Standard Base, Platen, Ring,
and Sapphire Flat,
for use with Standard Tools
83050
Standard Platen Set
(#83027)
83050
Adjustable Platen Set
(#83032)
83050
Large Area Platen
with Base (#83007/83040)


83050
Standard Base, Adjustable Platen,
Ring, and Sapphire Flat,
for use with Standard Tools
  83050
Tool 1i
(#83010)
83050
Tool 2iT
(#83014)
83050
Tool 2iM
(#83013)
  83050
(#83011)
83050
(#83036)
83050
(#83038)
83050
(#83037)
  83050
Tool 3i
(#83012)
83050
Tool 4iT
(#83016)
83050
Tool 4iM
(#83015)
  83050
(#83039)
83050
(#83044)
83050
(#83045)
83050
(#83047)
  STANDARD TOOLS   LARGE AREA TOOLS




PELCO® Dimpler™ & Tools Specifications


Z Offset Accuracy: 1 micron
  Range: 2000 microns
Z Termination Accuracy Tools 1i / 3i: <± 1 micron
  Tools 2i / 4i: <± 2 microns
Tool Force Range: 1 - 200 grams
    1 gram steps
Balance Sensitivity: 1 gram
  Range: 50 grams
Tool Speed 100 - 600 RPM
Specimen Platen Speed 10 RPM
Tool Shaft 0.5 micron TIR
  Tools 1i / 3i: <± 1 micron TIR
  Tools 2i / 4i: <± 2 microns TIR
Platen Surface < 0.5 micron TIR
Dimensions Length: 68.6cm
  Width: 35.6cm
  Height: 33cm
  Weight: 32kg
Electrical Universal AC Input:100-240VAC, 50/60Hz




83050  

PELCO® Video Alignment Microscope (VAM)

The PELCO® Video Alignment Microscope is an essential accessory for the PELCO® Dimpler, particularly for deprocessing/delayering and site-specific polising applications. It allows easy targeting of an area of interest, and precise control of the position, size, and shape of the bottom of the dimple or thin area of the specimen. It is particularly useful for selective surface polishing and delayering applications, where the low point and planarity of the polished area must be controlled to reveal the feature of interest. The VAM consits of a microscope optical system with a TFT display, a post corresponding precisely to the base mount on the PELCO® Dimpler that is aligned to the optic axis of the microcope, a reticle to allow precise targeting of a particular area using the adjustable base, and an X-Y stage for precision alignment to the area of interest.

Prod # Description Unit Price Order / Quote
83050 PELCO® Video Alignment Microscope each P.O.R.
Qty:




PELCO® Dimpler™ Ordering Information

PELCO® Dimpler™ ships without tools or platen sets. Please choose appropriate Platen Set and Tools when requesting your quote.

Prod # Description Unit Price Order / Quote
84000 PELCO® Dimpler™ precision specimen thinning and polishing each P.O.R.
Qty:





PELCO® Dimpler™ Tools & Accessories Ordering Information

Prod # Description Unit Price Order / Quote
83031 Standard Tool Set for 3mm Samples each $410.00
Qty:
83027 Standard Platen Set (with through-hole) each 567.00
Qty:
83032 Adjustable Platen Set each 535.00
Qty:
83002 Standard Platen (with through-hole) each 145.00
Qty:
83004 Adjustable Platen, Fits PELCO® 15000 Lapping Fixture each 125.00
Qty:
83007 Magnetic Base for Large Area Tool each 225.00
Qty:
83003 Slurry Retainer Ring for Standard and Adjustable Platens each 110.00
Qty:
83001 Sapphire Flat each 75.00
Qty:
83040 Platen for Large Area Tools each 70.00
Qty:
83008 Magnetic Base for Standard and Adjustable Platen each 225.00
Qty:
83010 Tool li, Flatting each 60.00
Qty:
83015 Tool 4iM, Dimpling, Padded (low nap rayon) each 70.00
Qty:
83012 Tool 3i, Dimpling each 70.00
Qty:
83016 Tool 4iT Dimpling, padded, nonwoven each 70.00
Qty:
83013 Tool 2iM padded, low nap rayon each 70.00
Qty:
83014 Tool 2iT, padded, nonwoven each 70.00
Qty:
83011 Large Area, Tool li, 0.125" width each 75.00
Qty:
83039 Large Area Tool, Padded, 0.125" width each 95.00
Qty:
83036 Large Area Tool, 0.25" width each 75.00
Qty:
83044 Large Area Tool, padded, 0.25" width each 105.00
Qty:
83038 Large Area Tool, Counterbored 2 sides, 0.25" width each 95.00
Qty:
83045 Large Area Tool, Counterbored 2 sides, Padded, 0.25" width each 105.00
Qty:
83046 Large Area Tool, Counterbored 1 side, Padded, 0.25" width each 105.00
Qty:
83037 Large Area Tool, 0.5" width each 145.00
Qty:
83047 Large Area Tool, Padded, 0.5" width each 126.00
Qty:

Prod # Description Unit Qty Price Order / Quote
83064 Repadding Strips for li Tools pkg/10 1-4 $19.80
Qty:
5+ 18.70
83061 Repadding Strips for 1/8" Large Area Tools pkg/10 1-4 22.86
Qty:
5+ 21.59
83062 Repadding Strips for 1/4" Large Area Tools pkg/10 1-4 24.66
Qty:
5+ 23.29
83063 Repadding Strips for 1/2" Large Area Tools pkg/10 1-4 34.56
Qty:
5+ 32.64
83060 Repadding Roller Tool Kit each 1+ 120.00
Qty: