Surface Conditioning Research Articles

Surface conditioning in machining: optimizing component performance through advanced process modeling and control

This Special Issue showcases a broad spectrum of fundamental research targeting the in-line measurement and assessment of surface conditions in machining operations. It presents and discusses various measurement approaches, including those based on acoustic emission, micromagnetic fields, the Seebeck effect, and other techniques. These methods are explored for their effectiveness in assessing and ensuring the quality of machined surfaces. The collected research delves into surface modeling techniques and investigates diverse strategies for predicting the effects of process parameters on surface integrity. It also focuses on the strategic selection of these parameters to enhance final component performance. There is a significant emphasis on the evolution of in-process control methods, which are crucial for elevating the quality and functionality of machined surfaces and facilitating unmanned manufacturing. These advancements are instrumental in improving manufacturing efficiency and augmenting the quality of the final products.

Evaluation of methods to counteract multipactor phenomena in X-band waveguides

This study investigates multipactor mitigation techniques in X-band geometries, focusing on surface modifications, surface conditioning, and additive manufacturing. Surface modifications include geometric alterations such as dimpled surfaces. Experimental results demonstrate that 3D-printed copper test pieces can achieve a multipactor onset threshold comparable to traditionally machined test pieces with appropriate sample preparation. Surface conditioning, involving rapid successions of pulses, is explored for its mitigative potential. Among assessed techniques, dimpled configurations demonstrated superior multipactor hold-off compared to non-modified components. Additionally, the conditioning of test pieces significantly increased the single-pulse threshold.

Ultrasonic testing and surface conditioning techniques for enhanced thermoplastic adhesive bonds

Ultrasonic testing and surface conditioning techniques for enhanced thermoplastic adhesive bonds

The Surface Roughness of Contemporary Indirect CAD/CAM Restorative Materials That Are Glazed and Chair-Side-Finished/Polished.

The surface roughness (Ra) of indirect computer-aided design/computer-aided manufacturing (CAD/CAM)-fabricated dental restorations is crucial for their long-term durability. This study intended to evaluate the Ra of five different types of contemporary indirect CAD/CAM restorative materials with varying compositions that were glazed and finished/polished. A total of 75 specimens, disc-shaped (10 mm × 2 mm), were obtained from five materials (n = 15) (Tetric CAD, IPS e.max CAD, IPS e.max ZirCAD, CELTRA Duo, and Vita Enamic) and fabricated by CAD/CAM. One of the two surfaces for each specimen was subjected to glazing, while the other surface was subjected to finishing/polishing. The Ra of the two surfaces in micrometers (μm) was evaluated using a Profilometer, while the surface topography was examined using a scanning electron microscope. Using SPSS, the Kruskal-Wallis, post hoc Conover, and Mann-Whitney tests were used to statistically evaluate the data. A comparison of the Ra for the finished/polished surfaces of the five test materials showed significant differences (p < 0.0001). Among the finished/polished surfaces, the mean rank values of Vita Enamic were significantly higher than the other four test materials (p < 0.0001). A comparison of the Ra of glazed surfaces among the five study materials revealed significant differences (p < 0.0001). The Ra for the IPS e.max ZirCAD material was significantly higher than the rest of the four materials (p < 0.001). A comparison of the Ra for two types of surface conditioning within each of the five test materials showed a significant difference (p < 0.05). Only for IPS e.max ZirCAD was the Ra of the glazed surface significantly higher than the finished/polished surface (p < 0.0001). Significant variations in the surface roughness (Ra) were exhibited between the finished/polished and glazed surfaces of the five test materials. Hybrid ceramics showed the highest Ra values for the finished/polished surfaces, and zirconia exhibited the highest Ra values among the glazed surfaces among the tested materials. The Ra values of either finished/polished or glazed surfaces of the test materials were within the clinically acceptable range (0.2-0.5 μm), except for the glazed surface of the zirconia ceramics (0.84 μm).

Surface conditioning of artificial caries lesions with Er, Cr:YSGG laser before resin infiltration: an in vitro study

Surface conditioning of artificial caries lesions with Er, Cr:YSGG laser before resin infiltration: an in vitro study

The effect of pulsed Er,Cr:YSGG laser scanning on the adhesion strength of lithium disilicate to tooth dentin

This study examined how Er,Cr:YSGG laser surface conditioning affected the adhesion of lithium disilicate ceramic to the dentin tooth structure. Forty samples were divided into four groups (n=10). The first group was untreated, whereas the second was etched with hydrofluoric acid. The third group was treated for 2 minutes with a 7 W, 25 Hz Er,Cr:YSGG laser. The fourth group received the same Er,Cr:YSGG laser treatment at 5 W. The untreated group had the lowest shear bond scores. Laser-irradiated Group 3 at 7 W had a higher maximum shear bond strength than the hydrofluoric acid-etched group. The laser-irradiated groups also had a more uniform, non-invasive surface roughness pattern. The samples were tested by atomic force microscopy, scanning electron microscopy, and a universal shear bond testing machine. Surface treatment with the Er,Cr:YSSG laser at 7 W improves lithium disilicate ceramic adhesion to dentin. The laser outperforms hydrofluoric acid as the gold standard.

Electrodeposited hydroxyapatite coating on titanium after ultrashort-pulsed laser processing for a novel surface of endosseous implants.

Ceramic endosseous implant coatings have gained esteem due to their favorable osteoinductive and osteoconductive properties. However, such a layer may be prone to failure under in vivo conditions, which necessitates its modification. The aim of the present study was to modify an electrodeposited hydroxyapatite (HA) coating on titanium (Ti) with ultrashort-pulsed lasers for the incorporation of the ceramic into the sample surface and the texturing of the metal surface. The obtained surface was planned for application on the endosseous implant surface to enhance osseointegration. To our knowledge, such laser modification of a HA coating has not been performed previously. Four different HA coatings were created (A-D). Each coating was conditioned with 4 different laser irradiations (1-4 to 4-4), carried out using different power, velocity and frequency settings. The surface features of the laser-irradiated coatings were analyzed. The laser modifications of the HA coatings resulted in 2 kinds of surfaces. Laser-induced periodic surface structure (LIPSS) texturing could be observed on quadrants 1-4 to 3-4, with parallel grooves and HA crystals melted and sintered into spherical structures. The 4-4 laser surface conditioning did not altered the needle-like morphology of the HA coating. The LIPSS-fusion modification decreased the water contact angle of the samples. The ultrashort-pulsed laser modification of the HA coating for regimes 1-4 to 3-4 resulted in the LIPSS texturing of the Ti surface with HA sinterization. Further biological analyses are necessary to evaluate the cell and tissue response to such laser-modified HA coating on Ti.

Effect of zirconia surface conditioning before glazing on the wear of opposing enamel: an in vitro study.

This in vitro study aimed to evaluate the wear of natural teeth opposing 3mol% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP) with different surface conditions. Sixty 3Y-TZP specimens were randomly assigned to six groups (n = 10), differing in surface condition. In three groups, the samples underwent glazing-with the glaze applied to roughened (i.e., 106-µm-grit diamond-finished), as-sintered, and polished zirconia. The three remaining groups consisted of unglazed specimens: solely polished samples and diamond-finished samples (106-µm-grit and 46-µm-grit) without further conditioning. Two-body wear was evaluated at extracted, non-carious molars (n = 60), which served as antagonists in chewing simulation (10,000 masticatory cycles, 49N load). As a control, natural teeth with intact enamel surfaces were tested against natural molars (n = 10). All samples were 3D-scanned before and after the chewing simulation (7 Series, Straumann). Volume loss was calculated (Inspect Software, GOM), and statistically analyzed (SPSS Statistics 24, IBM). Volume loss of the natural antagonists decreased in the following order: 106-µm-grit diamond-finished zirconia (4.6 ± 2.5 mm3), glazed 106-µm-grit diamond-finished zirconia (3.8 ± 1.1 mm3), glazed as-sintered zirconia (3.5 ± 0.9 mm3), 46-µm-grit diamond-finished zirconia (1.7 ± 0.6 mm3), control (1.6 ± 0.7 mm3), glazed polished zirconia (1.4 ± 0.5 mm3), and solely polishing (0.4 ± 0.2 mm3). Even when polishing the surfaces before glazing, volume loss was not mitigated to the same extent as after polishing alone. The zirconia surface condition beneath the glazing influences antagonist wear. Although polishing before glazing resulted in acceptable levels of antagonist wear, this approach did not yield as favorable results as polishing alone. For operators favoring glazing, pre-polishing the zirconia surface could be advantageous to reduce wear.

Methodology for soft-sensor design and in-process surface conditioning in turning of aluminum alloys

Surface properties significantly influence the performance of machined parts. However, they cannot be measured directly during machining. For surface conditioning based on a soft sensor, it is necessary to monitor process characteristics like temperatures and forces, which influence the surface state. Soft-sensor development in machining requires a robust methodology, which is adaptable to different materials and machining processes. In addition, a measurement system that combines hardware sensors to measure temperatures and process forces has to be implemented into the machine tool. In the present study, a suitable methodology is proposed and tested using a tool-workpiece thermocouple and a dynamometer to determine the thermomechanical workpiece load during turning of the aluminum alloys EN AW-2017 and EN AW-7075. Experimental investigations are performed according to a D-optimal statistical design of experiments. For this, the machining parameters cutting speed, feed, depth of cut, as well as the flank wear land width are varied on four levels. Subsequent measurements of residual stresses and the surface roughness are used to correlate the surface state with input parameters and their resulting thermomechanical workpiece load by multiple regression based on analysis of variance (ANOVA). It is found that the methodology is applicable and allows for the prediction of surface states. The developed soft sensors enable an in-process control of machining parameters, which enables a robust prediction and targeted conditioning of the addressed surface properties during machining.

Properties of Nanohybrid Dental Composites-A Comparative In Vitro Study.

(1) Background: the current study investigated three nanohybrid composites: two commercial products ClearfilMajestyTM (CM) and HarmonizeTM (HU), compared with an experimental product PS2. (2) Methods: Two sample types were molded using Teflon dies. The first sample type was represented by standard discs (20 mm diameter and 2 mm thickness) (n = 60, 20/each material), used for surface conditioning investigation, specifically roughness monitoring and color stability analysis using AFM and the CIELab test, respectively. The second sample type was a standard cylindrical specimen (4 mm diameter and 6 mm height) for compression testing (n = 60, 20/each material). After complete polymerization, the samples were ground with sandpaper and further polished. The filler size and distribution in the polymer matrix were investigated with SEM. Data were statistically analyzed using the Anova Test followed by Tukey's post hoc test on the Origin Lab 2019 software produced by OriginLab Corporation, Northampton, MA, USA. (3) Results: A mono-disperse system was identified in HU samples, while CM and PS2 revealed both nano- and microfiller particles. The samples' observation after immersion in coffee and tea indicated that a lower roughness combined with optimal filler lamination within the polymer matrix assured the best color preservation. The compression strength was lower for the HU sample, while higher values were obtained for the complex filler systems within CM and PS2. (4) Conclusions: the behavior of the investigated nanohybrid composites strongly depends on the microstructural features.

Digital process twins: a modular approach for surface conditioning and process optimization

Digital process twins: a modular approach for surface conditioning and process optimization

Effects of Surface Textures Created Using Additive Manufacturing on Shear Bond Strength Between Resin and Zirconia.

This investigation aimed to assess the impact of additive manufacturing-generated surface textures on zirconia bond strength. Zirconia samples (n = 144) fabricated using digital light-processing (DLP) technology were categorized into 6 groups according to the type of surface conditioning (group NN: no designs, no air abrasion; group NY: no designs, with air abrasion; group GN: groove designs, no air abrasion; group GY: groove designs with air abrasion; group HN: hexagon grid, no air abrasion; group HY: hexagon grid, with air abrasion). Composite resin cylinders were cemented to the treated zirconia surfaces with dual-curing, self-adhesive resin cement (Clearfil SA Luting). The shear bond strength (SBS) was tested after water storage for 3 days or 3 days with an additional 10,000 thermocycles. The zirconia samples fabricated using DLP technology have high accuracy. The SBS of the NY, GY, and HY groups did not significantly differ after 3 days, and neither did the SBS of the NN, GN, and HN groups. The NN, NY, and HY groups exhibited reduced SBS compared to their initial values following artificial aging, while the SBS of the remaining three groups were not diminished. The GY group obtained the highest SBS value after aging. Printing grooves with air abrasion can improve the bond strength.

Evaluation of the Color of Zirconia in Different Substrates of Osseointegrated Implants, Thickness of Materials and Types of Resin Cements.

Objectives: To evaluate the impact of surface conditioning of titanium, zirconia thickness, and cement type on the final color of zirconia luted to the titanium. Methods: A total of 192 grade 5 titanium specimens with the final dimensions 10 mm × 10 mm × 2 mm were fabricated and subjected to four different surface conditioning including, that is, sandblasting, etching, and anodization. In addition, 192 zirconia specimens with the same dimensions as the titanium specimens but altered thicknesses of 0.7 (n = 96) and 1.0 (n = 96) mm were fabricated using 5Y-TZP zirconia. Color as expressed by L ∗ (lightness), a ∗ (red-green axis), and b ∗ (blue-yellow axis) of titanium and zirconia specimens as well as the joined titanium-zirconia complex, total assembly (Panavia V5 clear, PC; opaque, PO, each n = 96) were determined under standardized conditions using a spectroradiometer (SpectraScan P-650). Color differences were calculated using the ΔE 00 formula. ANOVA supplemented with post hoc Tukey test for group comparisons was compiled to estimate possible effects of titanium conditioning, zirconia thickness, and type of cement used on the final zirconia color (SPSS Ver. 28; α = 0.05). Results: All investigated factors affected the zirconia color of the total assembly (p < 0.001). Using PO mean values of all groups were still close to baseline colors (ΔE 00 between 5.5 and 6.2). When using PC, the final color was significantly altered, irrespective of the other parameters. Specimens luted with PO appeared lighter, less reddish (a ∗ was affected predominately by sample thickness), and more bluish, while luting with PC resulted in reduced lightness combined with large shifts along the red and yellow axes. Significance: Color changes of zirconia luted to titanium are primarily affected by the color of the substrate if a translucent cement was used. Vice versa, the application of an opaque cement effectively masked the dark substrate color. Substrate color and choice of cement have to be taken into consideration when performing shade selection.

Surface microstructuring by Ultrasonic Vibration Assisted Deformational Machining (UVADM) – Simulation and experimental results

Polymer-metal hybrids are a lightweight solution for many industrial applications, especially in the automotive or aircraft sector. However, due to their poor chemical bonding the manufacturing of such compounds requires the use of adhesive layers or the conditioning of the metallic surface to achieve form closure and high joint strength. Ultrasonic Vibration Assisted Deformational Machining (UVADM) is a novel process that generates functional microstructures with high production rates, aiming to form defined burr structures with undercuts, that have a significant impact on the interlaminar strength of polymer-metal hybrids (PMH). A 3D FEM simulation using Abaqus/Explicit software was applied to design and analyze process conditions including tool geometry. Material deformation was described by the Johnson-Cook model. Simulation results were validated experimentally using two different MCD tools. For the UVADM experiments, specimens of the aluminum alloy EN AW-6082 were used. In the tests, a constant ultrasonic frequency (20.42 kHz), machining speed (100 m/min and 200 m/min), and peak-to-peak amplitude (7 µm) were used. Geometrical surface properties were analyzed by optical methods and SEM. The study demonstrates a conformity between simulated and experimental results, highlighting the potential of UVADM for an increased productivity in the surface conditioning for polymer-metal hybrids.

Experimental Investigation on the Surface Integrity in Micromilling AISI H11 Tool Steel

The surface integrity of machined components affects their fatigue performance and service life. Thus, with a view to sustainability and resource efficiency, aspects that influence the nature of the workpiece surface and sub-surface are increasingly considered in the process design, such as the resulting microhardness or the residual stress state. In this context, micromilling offers the possibility to positively influence the sub-surface properties due to the low thermal impact as well as concentrated mechanical load during machining. In order to gain a deeper understanding of the potential of micromilling for surface conditioning, experimental investigations were carried out on samples of the hot work tool steel AISI H11 in hardened condition. Cutting forces and surface topography were measured at different feed per tooth. The depth-dependent microhardness and residual stresses were determined after machining and analyzed taking into account the engagement situation and cutting forces. As the results show, micromilling can induce high compressive residual stresses as well as increase surficial microhardness while achieving low roughness topographies. This represents a great potential for improving component properties regarding tribological performance as well as fatigue behavior.

Revealing the characteristics of biofilms on different polypropylene plastic products: Comparison between disposable masks and takeaway boxes

The increasingly severe plastic pollution issue was intensified by the enormous plastic emissions into ecosystems during the Covid-19 pandemic. Plastic wastes entering the environment were swiftly exposed to microorganisms and colonized by biofilms, and the plastic-biofilm combined effects further influenced the ecosystem. However, the non-woven structure of disposable masks discarded carelessly during the COVID-19 pandemic was different from those of plastics with flat surface. To reveal the potential effects of plastic structure on colonized biofilms, white disposable surgical masks (DM) and transparent takeaway boxes (TB), both made of polyethylene, were selected for the incubation of organic conditioning films and biofilms. The results indicated that the non-woven structure of disposable mask was destroyed by the influence of water infiltration and biofilm colonization. The influence of surface structure on conditioning films led to a relatively higher proportion of tryptophan-like substances on DM than those on TB samples. Therefore, biofilms with significantly higher microbial biomass and carbon metabolic capacity were formed on DM than those on TB samples owing to the combined effects of their differences in surface structure and conditioning films. Moreover, abundant functional microorganisms associated with stress tolerance, carbon metabolism and biofilm formation were observed in biofilms on disposable mask. Combining with the results of partial least squares regression analysis, the selective colonization of functional microorganisms on disposable masks with uneven surface longitudinal fluctuation was revealed. Although the predicted functions of biofilms on disposable masks and takeaway boxes showed more similarity to each other than to those of free-living aquatic microorganisms owing to the existence of the plastisphere, biofilms on disposable masks may potentially trigger environmental risks different from those of takeaway boxes by unique carbon metabolism and abundant biomass.

Electrolyte Flow through Porous Carbon Electrodes Under Compression in the Hydrogen-Bromine Redox Flow Battery

The conditions of electrolyte flow affect the performance of redox flow batteries through the combined effect of pumping energy and electrode overpotential. In the hybrid hydrogen-bromine flow battery the conditions of electrolyte flow depend on the trans-membrane pressure exerted by hydrogen gas in the membrane electrode assembly, which has a compressive effect on the liquid side electrode.This study aims at characterizing the effect of hydrogen pressure on flow characteristics and investigate its effect on transport behavior. We selected two types of porous carbon electrodes, carbon paper and carbon cloth, with and without surface conditioning, and study liquid flow at the compression ratios expected in a hydrogen-bromine cell under increasing operation pressure.Combination of electrode characterization with electrolyte velocity measurements obtained by particle image velocimetry in flow-through configuration allow characterization of liquid flow through porous electrodes, and attempt to relate it to electrode morphology. Electrochemical testing is then is used to reveal the effect of electrode compression on electrochemical active surface area, estimated by the capacitance of the double layer, and cell polarization.The velocity field is revealed to be highly dependent on the fiber structure of the electrode and surface conditioning. The effect of compression manifests early and impacts the uniformity of flow through the porous structure. Additionally, the changes in active area and cell resistance result in a complex combination of factors that determine cell polarization. Figure 1

Surface conditioning of zirconia ceramic by enhanced ultrasonic vibration-assisted burnishing

Surface conditioning of zirconia ceramic by enhanced ultrasonic vibration-assisted burnishing

Is dentin analogue material a viable substitute for human dentin in fatigue behavior studies?

This study aimed to compare the fatigue performance of a lithium disilicate ceramic cemented on different substrates (human dentin and glass fiber-reinforced epoxy resin - GFRER), treated with different types of conditioning (CTR - without surface conditioning; HF5 - 5% hydrofluoric acid; HF10 - 10% hydrofluoric acid; H3PO4 - phosphoric acid 37%; SAND - sandblasting with aluminum oxide). The occlusal surface of human molars (DENT group) (n = 15) was ground for dentin exposure and the root portion was cut, then the dentin slice (2.0 mm thick) was conditioned with 37% phosphoric acid and a dual-curing dental adhesive was applied. The GFRER in a round-rod format was cut into discs (Ø = 10 mm, 2.0 mm thick). Lithium disilicate glass ceramic blocks (IPS e.max CAD, Ivoclar, Schaan, Liechtenstein) were shaped into a cylinder format and cut, resulting in 90 discs (Ø = 10 mm, 1.5 mm thick). The substrate materials of each group were etched according to the groups and the ceramic was etched with 5% hydrofluoric acid for 30 s. A silane coupling agent was applied over the cementation surface in ceramic and GFRER surfaces and a dual cement was used for cementation (ceramic/GFRER or dentin). The disc/disc sets were submitted to thermocycling (25,000 cycles + storage for 6 months), and then tested in step-wise accelerated cyclic fatigue test. The failure pattern and topography were analyzed and the roughness and contact angle were measured before and after surface treatment. The DENT group presented the lowest load to failure values and number of cycles to failure in fatigue (637.33 N; 118.333), showing no statistical similarity with any of the other tested groups (p < 0.05). The topographic analysis showed that all proposed surface treatments modified the substrate surface when compared to the CTR group. All of the fractographical inspections demonstrated failure by radial crack. Considering the roughness analysis, the post-etched DENT group showed similar roughness to all groups of GFRER materials with their surface treated, except for SAND, which showed greater roughness and statistically different from the other groups. The DENT group (49.5) showed statistically different post-conditioning contact angle values from the HF10 group (96.5) and similar to the other groups. The glass fiber-reinforced epoxy resin was not able to simulate the results presented by the human dentin substrate when cemented to lithium disilicate regarding fatigue failure load and number of cycles for failure, regardless of the surface treatment. Lithium disilicate cemented on dentin analogue overestimates the load values for fatigue failure.

Surface Conditioning Effects on Submerged Optical Sensors: A Comparative Study of Fused Silica, Titanium Dioxide, Aluminum Oxide, and Parylene C

Optical sensors excel in performance but face efficacy challenges when submerged due to potential surface colonization, leading to signal deviation. This necessitates robust solutions for sustained accuracy. Protein and microorganism adsorption on solid surfaces is crucial in antibiofilm studies, contributing to conditioning film and biofilm formation. Most studies focus on surface characteristics (hydrophilicity, roughness, charge, and composition) individually for their adhesion impact. In this work, we tested four materials: silica, titanium dioxide, aluminum oxide, and parylene C. Bovine Serum Albumin (BSA) served as the biofouling conditioning model, assessed with X-ray photoelectron spectroscopy (XPS). Its effect on microorganism adhesion (modeled with functionalized microbeads) was quantified using a shear stress flow chamber. Surface features and adhesion properties were correlated via Principal Component Analysis (PCA). Protein adsorption is influenced by nanoscale roughness, hydrophilicity, and likely correlated with superficial electron distribution and bond nature. Conditioning films alter the surface interaction with microbeads, affecting hydrophilicity and local charge distribution. Silica shows a significant increase in microbead adhesion, while parylene C exhibits a moderate increase, and titanium dioxide shows reduced adhesion. Alumina demonstrates notable stability, with the conditioning film minimally impacting adhesion, which remains low.