Surface Finish Research Articles

Roller-Compacted Concrete Pavement, An Industry Perspective

This paper presents a summary of findings and experiences in implementing Roller- Compacted Concrete Pavement (“RCC Pavement”) at industrial distribution facilities. The author’s experiences in RCC Pavement involved defining and taking complete responsibility from concept to completion, including but not limited to, material selection, mixture design, structural design, production, transportation, placement and curing. Using ten-plus years of experience and incorporating pertinent research findings, processes and tests lead to the development of Quality Assurance (“QA”) Processes and Quality Control (“QC”) tests/observations. Continuous improvement has been made on developing a QC program. The author’s experiences involved the use of RCC Pavement as a finished surface and dictated a high performance RCC Pavement (compressive and flexural strength as high as 40 MPa and 5MPa, respectively after only 7 days); therefore, all placement utilized an ABG paver and vibrating screed with dual tamping bars to obtain high density RCC Pavement while minimizing roller displacement and maximizing smoothness and riding characteristics of the final RCC Pavement surface. Size of the projects has limited these experiences to production of RCC Pavement through the use of either a wetbatch concrete plant or a dry-batch concrete plan in conjunction with a horizontal shaft mixer.

Real time surface finish measurement of stepped holding shaft by automatic system

Real time surface finish measurement of stepped holding shaft by automatic system

Fine resolution satellite sea surface temperatures capture the conditions experienced by corals at monthly but not daily timescales

Abstract Water temperature is a strong driver of growth, survival, and local adaptation in corals, but our knowledge of the temperatures experienced by corals on reefs worldwide remains limited. While in situ temperature loggers can provide high quality data, they are relatively expensive to place and retrieve. Alternatively, remotely sensed sea surface temperature data are globally available but may be a biased representation of the temperatures experienced by corals. Here, we compared data from 314 temperature loggers on coral reefs to the ~ 1 km2 resolution remotely sensed Multi-scale Ultra-high Resolution Sea Surface Temperature (MUR) product from NASA. We found good agreement (Pearson’s r = 0.95) between maximum monthly mean temperatures calculated from remote and in situ data, with 84% of temperatures within 0.5 °C of each other. However, remotely sensed temperature did not effectively capture sub-diel temperature fluctuations and the highest peak temperatures that may be most dangerous for corals. Predictions of in situ temperatures were significantly but weakly improved by a consideration of reef geomorphology. Ultimately, we found that remotely sensed temperatures can accurately represent the monthly conditions experienced by most corals but should be used with caution at finer temporal scales.

Differences in time to surgery and defect sizes after Mohs micrographic surgery for black versus white patients with cutaneous squamous cell carcinoma.

Few studies have examined outcomes for Mohs micrographic surgery (MMS) for cutaneous squamous cell carcinoma (cSCC) in Black versus White patients. We compared time to surgery and defect sizes after MMS between Black versus White patients with cSCC. Patients with biopsy-proven cSCC treated with MMS at the Hospital of the University of Pennsylvania were identified from a prospectively maintained database (2006-2023). Our primary outcomes included time to surgery (days from the diagnostic biopsy to the first MMS) and defect size (final MMS defect surface area). Univariate and multivariate linear regression models were performed to compare outcomes between Black and White patients with adjustments for age, gender, and tumor location. We identified 8445 cSCC, including 8329 (98.2%) in White patients and 116 (1.4%) in Black patients. Mean time to surgery was 31% longer for Black (76 ± 3.9 days) versus White patients (58 ± 0.5 days) [p < 0.001]. Mean post-MMS cSCC defect size was nearly four times larger for Black (18.6 ± 1.2 cm2) versus White patients (4.8 ± 0.1 cm2) [p < 0.0001]. These differences remained significant when adjusted for age, gender, and tumor location [p < 0.0001]. In conclusion, Black patients with cSCC have significantly longer treatment delays and larger MMS defects than White patients. This study highlights the need for earlier diagnosis and more timely access to MMS for Black patients with cSCC.

Parametric optimization of abrasive waterjet machining for aluminum 7075/boron carbide/zirconium silicate hybrid composites

In the present work, an attempt was made to study the machining characteristics of Hybrid Metal Matrix Composites (HMMCs) using Abrasive Waterjet Machining (AWJM). For preparing the composites, Aluminum alloy 7075 is cast with boron carbide (B4C) and zirconium silicate (ZrSiO4) reinforcement by the method of stir casting. Experimental investigation of the machining parameters on Depth of Cut (DoC), Material Removal Rate (MRR), and Surface Roughness (SR) was done. The independent parameters include Abrasive Mesh Size (AMS), Abrasive Flow Rate (AFR), Water Jet Pressure (WJP), and Traverse Rate (TR). The results of experiments reveal that low TRs increase SR, while short AMSs, high flow rates, and large WJPs increase DoC and MRR. Surface maps made by SEM exposed information about the surface texturing and the material removal processes. It was found that the optimal DoC was achieved at an AMS 80#, AMS of 340 g/min, WJP of 200 MPa, and TR of 60 mm/min for both unreinforced Al and the composite of Al + 5% B4C + 5% ZrSiO4. The results enable the development of proper AWJM procedures for HMMCs to ensure better surface finish and workability. From the experiments, it was observed that while smaller mesh sizes and greater AFR will improve MRR and DoC, it can at the same time have a negative effect on the overall performance of Kerf Taper angle (KT) and Surface Roughness (SR).

Recent Contributions to the Development of Barrel End-Mill Machining Technologies for Titanium Alloys in the Aerospace Context

This study investigates the utilization of barrel end-mills in machining titanium alloys for aerospace applications. It involves a comprehensive review of the relevant literature and a preliminary experimental investigation, incorporating the influence of measurement direction on surface roughness and the behavior of cutting forces. The primary objective is to assess the performance and efficiency of these end-mills when machining challenging materials and to identify optimal cutting strategies. This paper emphasizes the significance of titanium alloys in the aerospace sector, due to their exceptional mechanical properties, and the problems encountered in their processing. It also highlights the advantages of barrel end-mills, such as enhanced accessibility and superior surface finish. Through a combination of literature review, practical experimentation under controlled conditions, and statistical analysis, this study investigates the surface roughness of the Ti-6Al-4V titanium alloy, confirming a significant difference between longitudinal and transverse roughness. The preliminary experiment revealed that the average values of longitudinal and transverse roughness were 0.237 µm and 0.263 µm, respectively. The coefficients of variation indicated a greater variation in longitudinal roughness (19.79%) compared to transverse roughness (18.61%). This study’s conclusions provide a solid foundation for future research into machining titanium alloys with barrel end-mills, contributing to the optimization of manufacturing processes and the enhancement of aerospace component performance.

A Radiation-Based Analytical Model for the Computation of Temperature in the Arc Column of Submerged Arc Additive Manufacturing (SAAM) Process

Abstract Submerged Arc Additive Manufacturing (SAAM) is an advanced Wire Arc-based Additive Manufacturing (WAAM) technique known for its uniform deposition structure, high deposition rate, and superior surface finish. However, it is difficult and expensive to experimentally investigate the arc column in SAAM due to its submerged nature under flux. This paper presents an effective alternative: developing a radiation-based analytical model to predict the complex temperature distribution within the SAAM arc column. It focuses on the radiation heat transfer phenomenon since the temperatures attained inside the arc column are beyond the melting temperature of the material involved, and the presence of granular flux and slag intensifies the effect of the same. The model incorporates key input process parameters like wire diameter, stick-out length, current, voltage, and travel speed alongside design parameters like bead width, penetration depth, and material reinforcement. The double ellipsoidal heat source model is the foundation for generating the temperature profile. The predicted temperature profile resembles the double ellipsoid in other arc welding-based additive manufacturing techniques. The model's predictions showed a deviation of approximately 14% from experimental results, validating its effectiveness. Extensive parametric studies were carried out using the developed model. It was observed that longer stick-out lengths dampened temperature variations, while higher currents confined the affected zone further. Increased travel speed reduces the heating and cooling rate, while voltage behaves the opposite way. This analytical approach offers a cost-effective alternative for optimizing process parameters to achieve desired dimensions and deposition quality.

A Review of Electroplastic Effect on Difficult‐to‐Machine Materials in Cutting Processing

Electroplastic effect refers to the role of pulsed current, material plasticity, and microstructural properties change, resulting in an increase in the plasticity of the material, the deformation resistance is reduced, and thus improves the processing performance of the phenomenon. This article summarizes the Joule thermal effect and a variety of nonthermal effects of the electrophysical effect mechanism, of which the nonthermal effects include pure electrophysical effect, magnetic field compression effect, and skin effect. The application of electroplastic‐assisted technology in cutting machining, such as turning, milling, drilling, and so on, and the potential application in other manufacturing processes are summarized. The limitations and shortcomings of the electroplastic‐assisted technology are analyzed, including the limitations of the required special equipment, machining platforms, and electric pulse parameters. The effects of different electric pulse parameters on the machinability of various types of difficult‐to‐machine metallic materials are summarized. The electric pulse parameters within a certain threshold range can promote the dynamic recrystallization of the workpiece, enhance the plastic deformation of the cutting zone, reduce the cutting force, improve the surface finish, and reduce tool wear. Finally, this article summarizes and looks forward to the electroplastic‐assisted cutting technology.

Low-carbon indoor humidity regulation via 3D-printed superhygroscopic building components

Indoor humidity can significantly impact our comfort and well-being, often leading to the use of mechanical systems for its management. However, these systems can result in substantial carbon emissions and energy precarity. This study offers an alternative: using low-carbon materials that naturally buffer moisture to passively regulate the indoor humidity. A geopolymer composite incorporating industrial waste is implemented via binder jet 3D printing technology. The superhygroscopic nature of the material, combined with the optimal geometry of 3D-printed components, unlocks remarkable potential for passive humidity regulation, achieving a moisture buffering value over 14 g·m⁻²·%RH⁻¹. The use of 3D-printed, geopolymer tiles for surface finishing in a library hosting 15 people was shown to improve annual indoor hygrometric comfort by up to 85%, a performance inconceivable with conventional materials and techniques. Additionally, the environmental impact of these tiles is significantly lower than that of a conventional dehumidification system. This study paves the way for merging highly hygroscopic, low-carbon materials with advanced manufacturing techniques to regulate indoor humidity levels and reduce our dependency on mechanical systems.

Effect of Surface Finishing and Nitriding on the Wetting Properties of Hot Forging Tools.

Lubrication is a critical aspect of the metal forming process and it is strongly influenced by the surface texture of the tool-forming surfaces. This study is focused on determining the effect of surface finish and heat treatment on wettability involving commonly used lubrication agents. Three different finishing states are evaluated (as-ground, as-polished and as-nitrided). Surface topography was measured using a focus variation microscope. Parametric evaluation was carried out according to ISO 25178, including fractal methods. The functional relations between the finish state and wettability, lubricating agent and wettability, selected surface parameters and wettability, as well as between finish state and selected surface parameters, were designated. The results showed that surface finishing treatments, particularly nitriding, influenced both surface roughness and wettability, with varying effects observed across different lubricants and droplet sizes. The findings provide valuable insights into the optimization of lubrication strategies for metal forming processes, highlighting the importance of tailored surface treatments for enhanced tool performance and longevity.

Optimization of cutting temperature and surface roughness in CNC turning of Ti-6Al-4V alloy using response surface methodology.

This study investigates the optimization of cutting conditions for machining titanium alloy (Ti-6Al-4V) using Response Surface Methodology (RSM), with the goal of minimizing tool-chip interface temperature and surface roughness. The research focuses on key cutting parameters to investigate the most effective combinations for enhancing surface finish and reducing thermal impact during machining. The present study deals with the dry turning of Ti-6Al-4V alloy with carbide alloy inserts in a way to utilize the Analysis of Variance (ANOVA) to develop predictive models for minimum surface roughness and optimum temperature. The findings reveal that both cutting speed and depth of cut are critical in determining machining outcomes. Specifically, a low cutting speed of 88m/min coupled with a high depth of cut of 0.20mm was found to elevate the cutting temperature to approximately 835°C, resulting a surface roughness of 0.59μm. Conversely, increasing the cutting speed to 120m/min while reducing the depth of cut to 0.10mm significantly lowered the temperature to around 607°C, resulting a surface roughness of 0.19μm; thus, thereby improving surface finish and reducing thermal stress on the tool. Additionally, a 27% reduction in cutting temperature and a minimum surface roughness of 0.19μm were achieved with optimal settings of 120m/min cutting speed, 0.08 mm/rev feed rate, and 0.10mm depth of cut. The study demonstrates the effectiveness of RSM in optimizing machining parameters for optimum temperature and better surface finish in the titanium alloy machining.

Simultaneous enhancement of build rate and microstructure in SS316L additive manufacturing through in-situ laser remelting

The build quality in Laser-Directed Energy Deposition (L-DED) is crucial for industrial production but is often compromised at higher build rates. Higher deposition rates in L-DED typically lead to poor surface finish, high porosity, and solute segregation at grain boundaries. This study investigates in-situ laser remelting with positive defocus to enable a substantially higher deposition rate, i.e., 25 g/min compared to the preferred 7 g/min, in building SS316L components using the powder-based L-DED technique while maintaining the desired build quality. It is shown that laser remelting significantly improves surface finish, reduces porosity by up to 83%, increases microhardness by up to 34%, and eliminates solute segregation compared to the as-deposited case. The effect of specific laser remelting parameters and underlying mechanisms are further investigated via specially designed experiments. The results indicate that employing the highest linear energy density through maximum laser power (2000 W) and minimum scan speed (400 mm/min) yields minimum porosity. On the other hand, employing the lowest linear energy density through minimum laser power (500 W) and maximum scan speed (1000 mm/min) yields the highest microhardness due to grain refinement. An analytical model is utilized to provide insights into the process-structure–property relationship based on experimental measurements of cooling rate, grain size, and microhardness. In conclusion, this research demonstrates the potential of in-situ laser remelting to significantly enhance both build rate and quality in L-DED, offering a promising approach for large-scale part production through periodic laser melting during deposition.

Effects of plasma electrolytic polishing on surface finish and mechanical properties of Ti6Al4V diamond lattices with a specific relative density

Effects of plasma electrolytic polishing on surface finish and mechanical properties of Ti6Al4V diamond lattices with a specific relative density

Optimized hot injection and HCl purification for high quality Cu2ZnSnS4 nanoparticles.

Cu2ZnSnS4 (CZTS) is a narrow band gap, non-toxic, and environmentally friendly semiconductor with important properties for photovoltaic and electro-/photo-catalytic applications. In this study, we report on the synthesis of CZTS nanoparticles (NPs) by a simple and promising hot-injection technique using environmentally friendly, earth-abundant, and low-cost copper and zinc acetates in combination with tin chloride and elemental sulphur. Oleylamine was used as solvent and capping agent. The influence of injection temperatures on the crystalline size, morphology and crystal structure were studied. The formation of detrimental phases has been investigated, as well as their removal by using an HCl treatment during the purification step of the CZTS NPs synthesis process. Raman spectroscopy, X-ray diffraction (XRD), energy-dispersive X-ray spectroscopy (EDX), transmission electron microscopy (TEM), and scanning electron microscopy (SEM) analyses were used to investigate the formation mechanism of the CZTS NPs. The experimental results showed that the injection temperature influences the NPs growth. Thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS) and infrared spectroscopy (FTIR-ATR) analyses were used to confirm the removal of both organic traces and detrimental phases. It was found that HCl treatment plays a key role in the successful removal of impurities without altering the final crystalline composition profile or NPs surface.

Laser polishing of additive manufactured stainless-steel parts by line focused beam: A response surface method for improving surface finish

Laser polishing of additive manufactured stainless-steel parts by line focused beam: A response surface method for improving surface finish

Experimental investigation on surface finishing of CaF2 via core–shell composite magnetic particles

Experimental investigation on surface finishing of CaF2 via core–shell composite magnetic particles

3D printed microfluidic devices produced by material extrusion: effect of ironing parameters on mixing efficiency and gradient generation

Purpose This study aims to describe the effect of ironing process parameters on mixing efficiency and gradient generation in Y-micromixers and microfluidic gradient generators (MGGs), respectively. Design/methodology/approach Material extrusion (MEX) enables the production of miniaturized devices with the advantage of lower manufacturing costs and higher design freedom. However, surface finishing is the most important drawback when it comes to microfluidic applications where flow splitting is not required. First, the effect of ironing line spacing (LS) and speed (IS) on mixing efficiency in Y-micromixers was experimentally investigated. Then, the best ironing settings were chosen to further study the spatial stability of the normalized concentration gradient in MGGs. Findings Lower ironing LS and IS enhance the microchannel surface smoothness. The best combination of ironing parameters (lowest values of LS and IS) leads to an increase in mixing length of 191% at Q = 10 µL/min and 198% at Q = 20 µL/min, with respect to a similar Y-micromixer geometry where ironing was not performed. These findings were applied in the production of a MGG, showing that the normalized concentration gradient in the crosswise flow direction does not depend on the streamwise position when ironing is performed. Originality/value To the best of the authors’ knowledge, for the first time, the possibility of optimizing ironing parameters to enhance the surface roughness in MEX microfluidic devices has been investigated. Ironing of the channel bottom surface allows to reduce ridges-induced flow convection, thus delaying mixing in Y-micromixers and achieving stable concentration gradient in MGGs.

Optimization of process parameters to minimize circularity error and surface roughness in fused deposition modelling (FDM) using Taguchi method for biomedical implant fabrication

Fused Deposition Modeling (FDM) has emerged as a pivotal additive manufacturing technology that enables the creation of complex geometries with high precision and repeatability, particularly in the fabrication of biomedical implants. The functional additive manufacturing components, such as custom prosthetics, dental implants, and surgical guides, are expected to have dimensional accuracy and superior surface finish to ensure biocompatibility, osseointegration, and optimal tissue-implant interaction. This study aimed to optimize the FDM process parameters to minimize circularity error and surface roughness (Ra) using the Taguchi method, with a focus on biomedical implant fabrication. The printing temperature, printing speed, and layer thickness were identified as significant factors affecting circularity and Ra. Orthogonal arrays of Taguchi L9 were devised with three levels of each factor. Circularity and Ra were measured on the printed specimens, which included biomedical implant prototypes. The signal-to-noise (S/N) ratio response analysis determined the optimal parameter combinations. Results showed that the most dominant factor for circularity error reduction was build orientation, while layer thickness had the highest influence on Ra. The confirmation runs validated that the Taguchi-optimized parameters reduced the circularity error by 42% and Ra by 67% compared to default settings. Therefore, the Taguchi method proved effective in identifying the ideal process combinations for biomedical implant fabrication. The findings can help FDM users in the biomedical sector minimize dimensional errors and improve surface finish quality, ultimately enhancing the performance and reliability of medical implants.

Pengembangan dan Evaluasi Printer 3D FDM Berbasis Linear Slider MGN12 untuk Meningkatkan Kepresisian pada Aplikasi Ergonomi dan Industri

Three-dimensional (3D) printing technology, particularly the Fused Deposition Modeling (FDM) method, plays a crucial role in modern industrial design and ergonomics research. One of the primary challenges in this application is ensuring high precision, operational stability, and reducing mechanical wear to support the sustainability and efficiency of the printing process. This study introduces the development of a 3D printer based on FDM, utilizing the MGN12 linear slider as a replacement for conventional roller bearings. This innovation is designed to improve printing accuracy, optimize component durability, and maintain long-term operational quality. Empirical testing was conducted to compare the performance of the linear slider system and roller bearings in terms of dimensional accuracy, surface finish, printing speed, and mechanical durability. The results show that the linear slider system achieves dimensional accuracy of up to ±0.02 mm, better than the ±0.12 mm of the roller bearing system. The average surface roughness also decreased to 3.2 µm, compared to 5.6 µm in the roller bearing system. At high printing speeds (150 mm/s) with a layer height of 0.01 mm, the roller bearing system exhibited greater inconsistency, producing an average layer height of 0.04 mm, while the linear slider maintained high layer consistency. Additionally, the linear slider system reduced noise levels to 45 dB and significantly minimized mechanical wear, thereby reducing the need for regular maintenance. The findings of this study indicate that although the initial investment in linear slider technology is higher, it provides a significant improvement in 3D printing performance. This technology is highly relevant for industrial applications requiring high precision, process efficiency, and system reliability.

Experimental Studies into the Super Finishing of Nitronic-60 by One - Way Extrusion Honing Process

Abstract: The surface requirements of engineering components used varies widely depending on where the components surface is being applied for. Fabrication of surfaces with desired characterises on materials possessing high hardness is the need of the hour to effectively overcome the contemporary application challenges. The required surface generation of these difficult to cut material possessing intricate and unable to reach geometries could not be met by conventional finishing processes. So, several non-conventional finishing processes have been developed over the years to meet the ever-growing requirements of the industry, among them, Extrusion Honing or Abrasive Flow Machining where a flexible media loaded with abrasive particles acting as cutting tool can be successfully used to fine finish the surface. In the present study, the abrasive loaded flexible cutting media is extruded using one-way extrusion honing process and the effect of this on the surface characterises of Nitronic-60 is studied. The surface roughness is examined using a stylus type surface measuring instrument and the surface texture of the specimen before and after the process is analysed using SEM images. The results shows a significant enhancement in surface finish using EH/AFM process and the process found quite capable in removing the surface irregularities and producing surface with enhanced overall surface integrity.