The Application of Multivariate Statistical Process Control during Industrial Hot Isostatic Pressing Sintering Processes : A Case study at Seco Tools AB

Abstract: This Master's thesis focuses on improving the understanding and monitoring of the Hot Isostatic Pressing (HIP) sintering process used by Seco Tools AB to manufacture cemented carbides for cutting tools. While essential for producing cutting tools with superior hardness and toughness the HIP sintering process introduces a complex relationship between the selected process parameters and the achieved materials properties. With the goal of establishing batch process monitoring capabilities, this master thesis employs Multivariate Statistical Process Control (MSPC) strategies through the creation of Batch Evolution Models (BEMs) and Batch Level Models (BLMs) to monitor, predict end-product quality, and analyze the batch production HIP sintering process.  The developed models effectively account for significant variation in the HIP sintering process and demonstrate potential in identifying deviant batches. Enhancements to the models' performance are achieved through the incorporation of preprocessing, phase-specific variable selection, and specialized model training. These proposed enhancements yield discernible improvements, as evidenced by enhanced model fit and other statistical metrics.  Challenges arise when the models are tested with real-time data due to progressive changes in some tracked process variables. Block-scaling is applied to restore the real-time monitoring capabilities, but also introduces additional complexity to the models. In addition, this master thesis highlights the need for continuous and regular maintenance of these models to ensure real-time monitoring and anomaly detection capabilities. The models demonstrate varied effectiveness in predicting final product quality. For instance, they exhibit some potential in predicting Magnetic Saturation (MS), but their ability to predict Magnetic Coercivity (HC) seems nonexistent. Despite attempts to improve the predictive abilities the models are still not able to confidently predict these metrics. The master’s thesis highlights variability in powder contents and access to data of known quality nonconformities as potential areas for improving the predictive models.