Let’s take a look at some of the equipment we use to determine the material make up of cables and cable components and to measure and monitor factors like volatile and organic content, atomic composition, decomposition and oxidation, curing reactions, heat flow, and other material behavior under various conditions.
n this tour of the New England Wire Technologies Material Analysis Testing Lab, design engineer Tom Paquet highlights the advanced analytical instrumentation used to ensure material compliance, investigate component failures, and support customer validation programs. The laboratory works in direct collaboration with customers to co-develop specialized testing protocols for research and development, first-article inspection, and production quality control.
Key analytical capabilities and equipment include:
- Scanning Electron Microscopy (SEM) & Energy Dispersive Spectroscopy (EDS): Enables high-magnification surface imaging far beyond optical microscopy limits. The integrated EDS detects characteristic X-ray emissions to identify elemental composition and relative concentrations, which is critical for wire break analysis, particulate inclusion mapping (such as identifying iron-chromium contaminants), and raw material verification.
- Cooling Cross-Section Polisher (CCP): Utilizes an argon ion beam to finely mill sample cross sections without mechanical distortion, ensuring clean, pristine surfaces for SEM imaging.
- Vapor Pro Moisture Analyzer: Selectively measures moisture content in polymer extrusion compounds and textile fibers. Precise moisture quantification prevents processing defects like bubbles, voids, and poor dielectric performance.
- Fourier Transform Infrared Spectrophotometer (FTIR): Leverages characteristic molecular bond vibrations and extensive spectral libraries to identify unknown polymers, evaluate substance concentrations, and detect chemical contaminants.
- Thermogravimetric Analysis (TGA): Measures sample mass changes as a function of temperature and time in air or nitrogen atmospheres. It determines volatile content, decomposition kinetics, thermal oxidation, and residual ash content (indicating inorganic mineral filler levels).
- Rotational Rheometer: Evaluates polymer melt flow characteristics, tracks curing and crosslinking mechanisms, and measures finished jacket behavior under thermal stress or fluid immersion.
- Differential Scanning Calorimeter (DSC): Measures heat flow to determine melting points, crystallization behavior, heat capacity, and glass transition temperatures ($T_g$) to optimize extrusion parameters and verify thermoplastic insulations.
- Autoclave Environmental Chamber: Simulates pressurized steam sterilization cycles and high-pressure, high-temperature environments to validate medical cables and accelerated aging performance.
- X-Ray Fluorescence (XRF) Analyzer: Delivers non-destructive elemental identification of bulk metal and polymer samples using primary X-ray excitation.
Key Technical Takeaways
- Microscopic Failure Analysis: SEM and EDS allow microscopic examination of wire breaks and elemental identification of sub-surface inclusions (such as iron or chromium).
- Ion Beam Sample Prep: The Cooling Cross-Section Polisher (CCP) uses an argon beam to prevent mechanical deformation during sample cross-sectioning.
- Process Quality Control: Vapor Pro moisture analyzers prevent extrusion voids by confirming compound dryness before melt processing.
- Polymer Characterization: FTIR, DSC, and TGA collectively confirm polymer identity, glass transition temperatures ($T_g$), melting profiles, and mineral filler ratios.
- Environmental & Medical Simulation: Autoclave chambers evaluate real-world steam sterilization resistance and accelerated environmental aging.
Material Analysis Testing Lab Tour Transcript
Welcome to the Material Analysis Testing Lab
I’m Tom Paquet, design engineer at New England Wire. Today we’d like to show you around our material analysis testing lab. We utilize state-of-the-art equipment and instrumentation to ensure compliance and provide the highest quality products. We work closely with customers to co-develop test methods for validation programs and first article production. Let’s take a look.
Scanning Electron Microscope (SEM) & Energy Dispersive Spectrometer (EDS)
The Scanning Electron Microscope, or SEM, enables observation of samples at far higher magnification than is possible with optical microscopy. The SEM is also equipped with an energy dispersive spectrometer, or EDS. The EDS uses characteristic X-ray emissions to indicate which elements are present in the sample and their relative amounts. New England Wire Technologies uses the SEM EDS for failure analysis, for example to aid in the examination of wire breaks, contaminant identification, and identification of materials in customer samples.
Here we see an example of what can be observed using the SEM, with EDS mapping on a sample that was prepared using the CCP. Wire breaks were observed during drawing. The structure of the breaks indicated that they were most likely caused by inclusions. An intact inclusion was located near one of the breaks. The inclusion was cross-sectioned and mapped, the EDS revealing that the inclusion was composed of iron and chromium.
Cooling Cross-Section Polisher (CCP) & Moisture Analysis
The Cooling Cross-Section Polisher, or CCP, uses an argon beam to finely mill samples for better imaging in the SEM.
The Vapor Pro is a moisture analyzer. It selectively measures the moisture content of extrusion compounds and fibers. Absorbed moisture can cause both processing difficulty and defects in the final product. New England Wire Technologies uses the Vapor Pro to aid in the development of appropriate tracking conditions for each step of manufacturing.
FTIR Spectrophotometry & Thermogravimetric Analysis (TGA)
The Fourier Transform Infrared Spectrophotometer, or FTIR, uses characteristic bond vibrations in conjunction with both internal and commercial libraries to identify compounds. New England Wire Technologies uses the FTIR to aid in the identification of materials used in customer samples. It is also used to estimate the relative concentrations of substances and to examine contaminants.
The Thermal Gravimetric Analyzer, or TGA, monitors sample mass as a function of time and temperature. The sample can be run in either air or nitrogen. New England Wire Technologies uses the TGA to determine the volatile content of material, at what temperature and rate volatilization takes place, to examine the decomposition and oxidation of materials, and to determine the residual mass after the sample has been reduced to ash, which can be an indicator of inorganic content like mineral filler. This information aids in identification of customer samples as well as new product and process development.
Rheometry & Differential Scanning Calorimetry (DSC)
The Rheometer is used to examine mechanical properties of polymeric materials. New England Wire Technologies utilizes the Rheometer to study the flow characteristics of polymer melts and solutions, characterize curing and crosslinking systems, and probe the behavior of finished jackets with temperature and fluid immersion.
The Differential Scanning Calorimeter, or DSC, measures heat flow into or out of a sample. It is used to measure heat capacity, exothermic or endothermic reactions, and thermodynamic transitions like melting or the glass transition. It is used to aid in the selection of processing conditions during development, and to aid in identifying thermoplastic insulation materials by melt point.
Autoclave Environmental Testing & X-Ray Fluorescence (XRF)
The Autoclave is a pressurized steam heater with control of cycle time, temperature, pressure, and cycle count. It is used to replicate customer conditions, for example sterilization cycles, and to carry out certain accelerated aging tests.
The X-Ray Fluorescence Analyzer, or XRF, is used to aid in sample identification for bulk samples. The XRF uses characteristic X-ray emissions to indicate which elements are present in a sample and their relative amounts. It works on a similar principle to the EDS, but the excitation is carried out by X-rays instead of an electron beam.
We hope you enjoyed a peek inside our facility. If you have any questions or need assistance with creating your testing methods, please contact us at newenglandwire.com.