ARL iSpark 8860 Inclusion Analyzer

Importance of the topic

Modern steel production requires both rapid elemental analysis and reliable characterization of non-metallic inclusions to maintain product quality, avoid costly defects, and enable timely corrective actions. The ability to combine high-throughput elemental spectroscopy with advanced inclusion analytics in near-real-time supports process control, reduces customer complaints, and minimizes issues such as clogged submerged entry nozzles and impaired mechanical properties.

Objectives and overview of the product

The ARL iSpark 8860 Inclusion Analyzer is a turnkey analytical package designed to deliver simultaneous ultra-fast elemental analysis and detailed non-metallic inclusion characterization for steel. Objectives of the system are to provide: high-throughput inclusion data (up to ~30 samples per hour), advanced inclusion metrics (counts, coincidences, size distributions, concentration/volume fraction, and type), and the ability to determine ultra-low concentrations of light elements (N, and in specific configurations C and O) while maintaining the throughput and maintenance profile of a standard ARL iSpark optical emission spectrometer.

Methodology and used instrumentation

The analyzer performs spark optical emission spectrometry (OES) coupled with advanced inclusion detection routines (Spark-DAT). Key instrumentation and components included in the package:

• ARL iSpark base hardware with 1 m vacuum Paschen-Runge optics and photomultiplier tube (PMT) detectors.
• Two product variants: Fe1 (39 PMT channels including 1 VUV PMT for low N) and Fe2 (43 PMT channels including 4 VUV PMTs — one for Fe internal standard and three for low C, N, O).
• Special VUV optics with high-purity vacuum for sensitive detection of light elements.
• OXSAS software for instrument control and analysis.
• Spark Explorer — standalone software for graphical and statistical exploration of raw inclusion data.
• Inclusions Report module for dedicated inclusion reporting and customization.
• SPC (Statistical Process Control) software for online monitoring and control charts of both elemental and inclusion parameters.
• Sircal argon purifier and consumables specific to the package; calibration samples and consumables for setup.

Analytical approach: spark-induced emission acquires elemental spectra while advanced algorithms extract inclusion-related signals (peak events, coincidences) and compute inclusion metrics such as soluble/insoluble Al and B, counts, average sizes, distributions, concentration and volume fraction. Calibration sets target low-alloy steels and can be extended to many steel/iron grades using optional calibrations.

Main results and discussion (capabilities and performance)

The ARL iSpark 8860 offers a two-in-one solution providing both routine elemental OES and dedicated inclusion analysis in a single workflow. Principal capabilities and performance highlights:

• High throughput: inclusion and elemental data for up to thirty or more samples per hour, compatible with production needs.
• Comprehensive inclusion metrics: peak counts, coincidence counts, inclusion type (composition), number, average size, size distribution, inclusion concentration and volume fraction.
• Sensitive determination of light elements: ultra-low nitrogen detection in both Fe1 and Fe2; Fe2 also supports ultra-low C and O detection (with feasibility studies specified for certain oxygen determinations in Al-killed steels).
• Near-real-time output enabling corrective actions during production and significant cost savings by lowering defect rates.
• Software ecosystem: Spark Explorer for in-depth raw-data analysis, Inclusions Report for customizable reporting, and SPC for live process monitoring.
• Operational compatibility: same maintenance and ownership profile as standard ARL iSpark instruments; optional automation with ARL SMS sample handling systems for unattended operation.

Limitations and practical considerations:

• Oxygen determinations at ultra-low levels may require feasibility validation for specific steel types (e.g., Al-killed steels).
• Performance and detection limits for inclusions and light elements depend on calibration quality, sample preparation, and instrument configuration (choice of Fe1 vs Fe2).

Benefits and practical applications

Key practical advantages of deploying the ARL iSpark 8860 include:

• Faster decision-making: combined elemental and inclusion data per run shorten time to corrective interventions on the production line.
• Quality assurance and control: detailed inclusion statistics support product acceptance criteria, root-cause analysis and continuous improvement.
• Reduced downstream defects: monitoring inclusions reduces risk of nozzle clogging, mechanical failures, and customer returns.
• Flexible adoption: multiple calibration packages and software modules allow tailoring to a wide range of steel grades and production contexts.
• Process integration: SPC tools and automation options permit integration into plant-wide quality control and manufacturing execution systems.

Instrumentation used

Summary of instrument hardware and software provided in the standard package:

• ARL iSpark optical emission spectrometer with 1 m vacuum Paschen-Runge optics and PMT detectors.
• VUV optics assembly under high-purity vacuum (for Fe1/Fe2 light element channels).
• Fe1 configuration: 39 PMT channels (1 VUV channel for low N).
• Fe2 configuration: 43 PMT channels (4 VUV channels — Fe internal standard plus channels for low C, N, O).
• OXSAS control and data-processing software.
• Spark Explorer, Inclusions Report module, and SPC software.
• Sircal argon purifier, consumables, calibration samples and setup materials.

Future trends and potential applications

Expected developments and opportunities for inclusion analyzers in steel analytics include:

• Deeper automation and integration with plant control systems for continuous online monitoring and feedback loops to process control (closed-loop control).
• Enhanced data analytics: application of machine learning to inclusion event patterns and spectral signatures to improve classification, prediction of downstream failures, and automatic method optimization.
• Expanded calibration libraries to cover a broader range of alloys, sample geometries and small-sample analysis.
• Improved detection limits through additional VUV channels, optics optimization, and advanced signal processing to push sensitivity for C, N and O.
• Hybrid approaches combining OES inclusion analysis with complementary techniques (metallography, SEM/EDS, LECO inert gas analysis) to provide multi-modal inclusion characterization workflows.
• Increased emphasis on digital reporting, traceability, and regulatory/compliance-ready data outputs.

Conclusion

The ARL iSpark 8860 Inclusion Analyzer addresses a key industrial need by combining rapid, production-compatible elemental analysis with robust, advanced inclusion characterization. Its modular hardware (VUV-enabled PMT channels variants), comprehensive software (OXSAS, Spark Explorer, Inclusions Report, SPC), and calibration/training offerings position it as a practical solution for steelmakers aiming to reduce defects, improve product quality, and implement near-real-time process control. Adoption considerations should include validation for specific low-oxygen determinations and selection of the appropriate PMT/VUV configuration to match analytical targets.

References

The summary is based on the ARL iSpark 8860 product specification and package description provided by the manufacturer. No external academic references were supplied in the source document.