Showing papers on "Surface roughness published in 2016"

Drop Impact on a Solid Surface

Abstract: A drop hitting a solid surface can deposit, bounce, or splash. Splashing arises from the breakup of a fine liquid sheet that is ejected radially along the substrate. Bouncing and deposition depend crucially on the wetting properties of the substrate. In this review, we focus on recent experimental and theoretical studies, which aim at unraveling the underlying physics, characterized by the delicate interplay of not only liquid inertia, viscosity, and surface tension, but also the surrounding gas. The gas cushions the initial contact; it is entrapped in a central microbubble on the substrate; and it promotes the so-called corona splash, by lifting the lamella away from the solid. Particular attention is paid to the influence of surface roughness, natural or engineered to enhance repellency, relevant in many applications.

Mechanical behavior of additive manufactured, powder-bed laser-fused materials

Abstract: Mechanical behavior of four metallic alloys fabricated with layered, laser-heated methods of additive manufacturing (AM) was compared to that of similar alloys produced with conventional methods (wrought and machined). AM materials were produced by a leading commercial service provider, as opposed to incorporating material specimens produced by unique or specially-adapted equipment. The elastic moduli were measured in flexure, stress–strain characteristics were measured in tensile deformation, and fatigue strengths were measured in fully reversed bending. The effects of fabrication orientation, surface polishing, and hot isostatic pressing upon mechanical behavior were studied. The fatigue strengths exhibited by SLM AlSi10Mg and DMLS Ti6Al4V in the as-fabricated condition proved to be significantly inferior to that of conventional material. These lower fatigue strengths are a consequence of multiple fatigue cracks initiating at surface defects, internal voids and microcracks, and growing simultaneously during cyclic loading. Measured fatigue strengths of DMLS 316L and 17-4PH approached those of corresponding wrought materials when subjected to principal stresses aligned with the build planes. When cyclic stresses were applied across the build planes of the DMLS stainless steels, fatigue fractures often developed prematurely by separation of material. Post-processing the DMLS Ti6Al4V and SS316L with hot isostatic pressure elevated the fatigue strength significantly. Measurements of surface roughness with an optical profilometer, examinations of the material microstructures, and fractography contribute to an understanding of the mechanical behavior of the additive materials.

State-of-the-art in surface integrity in machining of nickel-based super alloys

Abstract: Nickel-based super alloys are gaining more significance, now-a-days, with extensive applications in aerospace, marine, nuclear reactor and chemical industries. Several characteristics including superior mechanical and chemical properties at elevated temperature, high toughness and ductility, high melting point, excellent resistance to corrosion, thermal shocks, thermal fatigue and erosion are primarily responsible for wide domain of application. Nevertheless, machined surface integrity of nickel-based super alloys is a critical aspect which influences functional performance including fatigue life of the component. This review paper presents state-of-the-art on various surface integrity characteristics during machining of nickel-based super alloys. Influence of various cutting parameters, cutting environment, coating, wear and edge geometry of cutting tools on different features of surface integrity has been critically explained. These characteristics encompass surface roughness, defects (surface cavities, metal debris, plucking, smeared material, redeposited material, cracked carbide particles, feed marks, grooves and laps), metallurgical aspects in the form of surface and sub-surface microstructure phase transformation, dynamic recrystallisation and grain refinement and mechanical characteristics such as work hardening and residual stress. Microstructural modification of deformed layer, profile of residual stresses and their influence on fatigue durability have been given significant emphasis. Future research endeavour might focus on development of new grades, advanced processing techniques of the same to ensure their superior stability of microstructure and thermo-mechanical properties along with advanced manufacturing processes like additive manufacturing to achieve highest level of fatigue durability of safety critical components while maintaining acceptable surface integrity and productivity.

Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V

Abstract: Additive manufacturing is increasingly considered for production of high quality, metallic, aerospace parts. Despite the high potential of this manufacturing process to reduce weight and lead time, the fundamental understanding of additive manufactured Ti–6Al–4V material is still at an early stage, especially in the area of fatigue and damage tolerance. This paper covers the effects of inherent surface roughness on the fatigue life. In the as built condition, metallic parts have a poor surface texture, which is generally removed in fatigue critical areas. It is shown that the fatigue properties of Ti–6Al–4V samples, produced by direct metal laser sintering and electron beam melting, are dominated by surface roughness effects. A simple model based on an equivalent initial flaw size is formulated.

Theoretical and experimental study on surface roughness of 316L stainless steel metal parts obtained through selective laser melting

Abstract: Purpose The purpose of this paper is to provide a theoretical foundation for improving the selective laser melting (SLM) surface roughness. To improve the part’s surface quality during SLM process, the upper surface roughness of SLM parts was theoretically studied and the influencing factors were analyzed through experiments. Design/methodology/approach The characteristics of single track were first investigated, and based on the analysis of single track, theoretical value of the upper surface roughness would be calculated. Two groups of cubic sample were fabricated to validate SLM parts’ surface roughness, the Ra and relative density of all the cubic parts was measured, and the difference between theoretical calculation and experiment results was studied. Then, the effect of laser energy density on surface roughness was studied. At last, the SLM part’s surface was improved by laser re-melting method. At the end of this paper, the curved surface roughness was discussed briefly. Findings The SLM upper surface roughness is affected by the width of track, scan space and the thickness of powder layer. Measured surface roughness Ra value was about 50 per cent greater than the theoretical value. The laser energy density has a great influence on the SLM fabrication quality. Different laser energy density corresponds to different fabricating characteristics. This study divided the SLM fabrication into not completely melting zone, balling zone in low energy density, successfully fabricating zone and excessive melting zone. The laser surface re-melting (LSR) process can improve the surface roughness of SLM parts greatly without considering the fabricating time and stress accumulation. Originality/value The upper surface roughness of SLM parts was theoretically studied, and the influencing factors were analyzed together; also, the LSR process was proven to be effective to improve the surface quality. This study provides a theoretical foundation to improve the surface quality of SLM parts to promote the popularization and application of metal additive manufacturing technology.

Influence of hatch spacing on heat and mass transfer, thermodynamics and laser processability during additive manufacturing of Inconel 718 alloy

Abstract: A transient three-dimensional powder-scale model has been established for investigating the thermodynamics, heat and mass transfer and surface quality within the molten pool during selective laser melting (SLM) Inconel 718 alloy by finite volume method (FVM), considering the powder-solid transition, variation of thermo-physical properties, and surface tension. The influences of hatch spacing (H) on the thermodynamics, heat and mass transfer, and resultant surface quality of molten pool have been discussed in detail. The results revealed that the H had a significant influence on determining the terminally solidified surface quality of the SLM-processed components. As a relatively lower H of 40 μm was used, a considerable amount of molten liquid migrated towards the previous as-fabricated tracks with a higher velocity, resulting in a stacking of molten liquid and the attendant formation of a poor surface quality with a large average surface roughness of 12.72 μm. As an appropriate H of 60 μm was settled, a reasonable temperature gradient and the resultant surface tension tended to spread the molten liquid with a steady velocity, favoring the formation of a flat surface of the component and an attendant low average surface roughness of 2.23 μm. Both the surface morphologies and average surface roughness were experimentally obtained, which were in a full accordance with the results calculated by simulation.

Finishing of Fused Deposition Modeling parts by CNC machining

Abstract: Fused Deposition Modeling is a filament extrusion-base Additive Manufacturing process that integrates Computer Aided Design system, material science, Computer Numerical Control and the extrusion process to fabricate physical parts without geometrical limitations. Notwithstanding the wide industrial diffusion, one of the most limiting aspects of this technology is the obtainable surface roughness. This limitation implies that secondary finishing operations are necessary in order to comply with the design requirements. Several efforts have been done in this field but a lack exists about Computer Numerical Control machining: the Fused Deposition Modeling mesostructure and the anisotropic surface morphology, which strongly depends upon the deposition angle, make very difficult the determination of the cutting process parameters. The aim of this work is to develop a methodology able to unlock the possibility to finish Fused Deposition Modeling parts by Computer Numerical Control machining. A variable cutting depth has been considered to avoid inner defects arising and to eliminate initial surface morphology. An experimental campaign allowed to determine how cutting depth should be set as a function of deposition angle. A particular virtual model offset permitted to generate in Computer Aided Manufacturing the machine code. A case study characterized by functional surfaces confirmed the applicability of the method to complex geometry: a great reduction of average roughness and a reliable uniformity of finished surfaces have been obtained. A methodology to improve Fused Deposition Modeling roughness has been developed.The finishing has been performed by Computer Numerical Control machining.A variable cutting depth as a function of the deposition angle has been determined.The surface inside a Pelton bucket has been successfully finished.

Understanding and Controlling Cu-Catalyzed Graphene Nucleation: The Role of Impurities, Roughness, and Oxygen Scavenging.

Abstract: The mechanism by which Cu catalyst pretreatments control graphene nucleation density in scalable chemical vapor deposition (CVD) is systematically explored. The intrinsic and extrinsic carbon contamination in the Cu foil is identified by time-of-flight secondary ion mass spectrometry as a major factor influencing graphene nucleation and growth. By selectively oxidizing the backside of the Cu foil prior to graphene growth, a drastic reduction of the graphene nucleation density by 6 orders of magnitude can be obtained. This approach decouples surface roughness effects and at the same time allows us to trace the scavenging effect of oxygen on deleterious carbon impurities as it permeates through the Cu bulk. Parallels to well-known processes in Cu metallurgy are discussed. We also put into context the relative effectiveness and underlying mechanisms of the most widely used Cu pretreatments, including wet etching and electropolishing, allowing a rationalization of current literature and determination of the relevant parameter space for graphene growth. Taking into account the wider CVD growth parameter space, guidelines are discussed for high-throughput manufacturing of "electronic-quality" monolayer graphene films with domain size exceeding 1 mm, suitable for emerging industrial applications, such as electronics and photonics.

Machining Parameters Optimization of Titanium Alloy using Response Surface Methodology and Particle Swarm Optimization under Minimum-Quantity Lubrication Environment

Abstract: The present paper depicts an application of response surface methodology (RSM) and particle swarm optimization (PSO) technique for optimizing the machining factors in turning of titanium (Grade-II) alloy using cubic boron nitride insert tool under minimum quantity lubricant (MQL) environment. The three machining factors, i.e., cutting speed (Vc), feed rate (f) and side cutting edge angle (approach angle π), are designed as three factors by using RSM design, which is withal subject to several constraints including tangential force (Fc), tool wear (VBmax), surface roughness (Ra) and tool-chip contact length (L). The multiple regression technique was used to establish the interaction between input parameters and given responses. Moreover, the results have been presented and optimized process parameters are acquired through multi-response optimization via desirability function as well as the PSO technique. The lower values of Vc (200 m/min), f (0.10 mm/rev) and higher values of ϕ (90°) are the optimum machini...

Exponential roughness layer and analytical model for turbulent boundary layer flow over rectangular-prism roughness elements

Abstract: We conduct a series of large-eddy simulations (LES) to examine the mean flow behaviour within the roughness layer of turbulent boundary layer flow over rough surfaces. We consider several configurations consisting of arrays of rectangular-prism roughness elements with various spacings, aspect ratios and height distributions. The results provide clear evidence for exponential behaviour of the mean flow with respect to the wall normal distance. Such behaviour has been proposed before (see, e.g., Cionco, 1966 Tech. Rep. DTIC document), and is represented as , where is the spatially/temporally averaged fluid velocity, is the wall normal distance, represents the height of the roughness elements and is the velocity at . The attenuation factor depends on the density of the roughness element distribution and details of the roughness distribution on the wall. Once established, the generic velocity profile shape is used to formulate a fully analytical model for the effective drag exerted by turbulent flow on a surface covered with arrays of rectangular-prism roughness elements. The approach is based on the von Karman–Pohlhausen integral method, in which a shape function is assumed for the mean velocity profile and its parameters are determined based on momentum conservation and other fundamental constraints. In order to determine the attenuation parameter , wake interactions among surface roughness elements are accounted for by using the concept of flow sheltering. The model transitions smoothly between ‘ ’ and ‘ ’ type roughness conditions depending on the surface coverage density and the detailed geometry of roughness elements. Comparisons between model predictions and experimental/numerical data from the existing literature as well as LES data from this study are presented. It is shown that the analytical model provides good predictions of mean velocity and drag forces for the cases considered, thus raising the hope that analytical roughness modelling based on surface geometry is possible, at least for cases when the location of flow separation over surface elements can be easily predicted, as in the case of wall-attached rectangular-prism roughness elements.

Modeling the Maximum Spreading of Liquid Droplets Impacting Wetting and Nonwetting Surfaces

Abstract: Droplet impact has been imaged on different rigid, smooth, and rough substrates for three liquids with different viscosity and surface tension, with special attention to the lower impact velocity range. Of all studied parameters, only surface tension and viscosity, thus the liquid properties, clearly play a role in terms of the attained maximum spreading ratio of the impacting droplet. Surface roughness and type of surface (steel, aluminum, and parafilm) slightly affect the dynamic wettability and maximum spreading at low impact velocity. The dynamic contact angle at maximum spreading has been identified to properly characterize this dynamic spreading process, especially at low impact velocity where dynamic wetting plays an important role. The dynamic contact angle is found to be generally higher than the equilibrium contact angle, showing that statically wetting surfaces can become less wetting or even nonwetting under dynamic droplet impact. An improved energy balance model for maximum spreading ratio i...

The Effect of Hydrofluoric Acid Etching Duration on the Surface Micromorphology, Roughness, and Wettability of Dental Ceramics.

Abstract: The current laboratory study is evaluating the effect of hydrofluoric acid etching duration on the surface characteristics of five silica-based glass ceramics. Changes in the pore pattern, crystal structure, roughness, and wettability were compared and evaluated. Seventy-five rectangularly shaped specimens were cut from each material (IPS e-max™, Dentsply Celtra™, Vita Suprinity™, Vita mark II™, and Vita Suprinity FC™); the sectioned samples were finished, polished, and ultrasonically cleaned. Specimens were randomly assigned into study groups: control (no etching) and four experimental groups (20, 40, 80 and 160 s of etching). The etched surfaces’ microstructure including crystal structure, pore pattern, pore depth, and pore width was studied under a scanning electron microscope, and the surface roughness and wettability were analyzed using a non-contact surface profilometer and a contact angle measuring device, respectively. The results were statistically analyzed using one-way analysis of variance (ANOVA) and the post hoc Tukey’s test. The results showed a significant change in the pore number, pore pattern, crystal structure, surface roughness, and wettability with increased etching duration. Etching for a short time resulted in small pores, and etching for longer times resulted in wider, irregular grooves. A significant increase in the surface roughness and wettability was observed with an increase in the etching duration. The findings also suggested a strong association between the surface roughness and wettability.

Performances of Al2O3/SiC hybrid nanofluids in minimum-quantity lubrication grinding

Abstract: The present research investigated the lubrication performances of Al2O3/SiC nanofluid minimum-quantity lubrication (MQL) grinding in accordance with recent technologies used in conducting minimum-quantity lubrication grinding with nanofluids. The mean grain size of the Al2O3 and SiC nanoparticles (NPs) was set to 50 nm, and the difficult grinding Ni-based alloy was used as the workpiece material in the experiment. Grinding force was measure by using a three-component dynamometer and then used to calculate grinding force ratio (R). Workpiece surface roughness was measured by a roughness tester. Five groups of NPs were mixed with synthetic lipids at a mass fraction of 6 %. The lipids were then used as the grinding fluid for the nanofluid MQL grinding. Results showed that, compared with pure SiC NPs, pure Al2O3 NPs obtained lower R = 0.3, lower specific grinding energy (U = 75.93 J/mm3), and lower surface roughness (Ra = 0.386 μm), indicating better lubrication performance. The mixed NP consisting of Al2O3 and SiC NPs achieved even lower R and surface roughness than pure NPs because of the “physical synergistic effect.” The optimal ratio of the effect of mixed NPs was explored based on this finding. The Al2O3/SiC (2:1) mixed NPs obtained the smallest R = 0.28 and specific grinding energy (U = 60.68 J/mm3), thus indicating the best lubrication performance. Therefore, 2:1 is the optimal ratio for mixed NPs.