Focus Variation Microscopy Research Articles

Surface roughness analysis of medical grade titanium sheets formed by single point incremental forming

Single point incremental forming (SPIF) process has proven benefits in terms of formability, flexibility, and low cost as compared to conventional sheet forming, although it has some issues such as dimensional accuracy and low quality of surface finish for some materials. The SPIF is considered as a potential method of producing customised medical parts such as craniofacial implants using a titanium sheet. This investigation aims to analyse the overall surface roughness of grade 1 pure titanium along the wall of the hyperbolic truncated cone formed by the SPIF process with different forming parameters (i.e. forming tool diameter, step size, and feed rate). Focus variation microscopy was used to measure the surface roughness experimentally along the wall of the truncated cone. Abaqus/Explicit was used to predict the equivalent stress and equivalent plastic strain along the wall of the truncated cone part from the top to the fractured region to evaluate the relationship between the stress, strain, and roughness distribution. It was found that the surface roughness changes with the deformed part height and rough surface could be produced in the region of high equivalent stress and low equivalent plastic strain. Such a surface roughness and equivalent stress and plastic strain correlation has a clear implication to the design and the surface quality of sheet parts made by SPIF.

Resistance to fracture due to cyclic fatigue of stainless steel manual files and its association to surface roughness.

The aim of this study was to evaluate the possible association between the roughness of 5 brands of stainless steel endodontic files and their resistance to fracture due to cyclic fatigue. The study included five different brands of stainless steel endodontic files: SybroEndo Triple-Flex Files (Kerr, Glendora, USA), Ready Steel K-Flexofile (Dentsply Sirona, Ballaigues, Switzerland), Mani Flexile Files (Mani, Tochigi- Ken, Japan), FKG K-Files (FKG, La Chaux-de-Fonds, Switzerland) and Zipperer Flexicut Files (VDW, Munich, Germany). Twelve files per brand (total 60 files) were evaluated. File surface roughness over an area (Sa) was quantified using a focus variation microscope. Then the files were subject to a cyclical fatigue test to determine the number cycles to fracture due to fatigue and length of fractured fragment. Finally, fractographic analysis was performed using a scanning electron microscope. The electropolished Ready Steel K-Flexofile® files had the highest roughness according to Sa parameters, though they also had the highest resistance to fracture due to cyclic fatigue and the longest fractured fragment. Moderate positive correlation was found between fractured fragment length and roughness. The fractured surface showed characteristics of ductile fracture with cracks and plastic deformation. The electropolished stainless steel Ready Steel K-Flexofile® files were the most resistant to fracture due to cyclic fatigue even though they had highest surface roughness.

Surface Texture Characterization of Metal Selective Laser Melted Part With Varying Surface Inclinations

Abstract Additive manufacturing offers the advantage of infinite freedom to design and fabricate complex parts at reduced lead-time. However, the surface quality of additively manufactured parts remains well behind the conventionally processed counterparts. This paper aims to systematically investigate the impact of varying surface inclination angles with respect to the build direction on the resultant surface textures. A bespoke metal truncheon artifact with inclination angles varying from 0 deg to 180 deg was built by selective laser melting. Focus variation microscopy was used to measure the topography of inclined surfaces with a tilt angle of up to 132 deg. The measurement data were then analyzed to characterize the staircase effect and the particles adherent to the artifact surface. Areal surface texture parameters, including height parameters, spatial parameters, functional parameters, and feature parameters, were explored to quantify the general surface topography, the staircase effect, and the particle features. The areal surface texture characterization and particle analysis reveal the resulted surface topographies are strongly correlated with the surface inclination angles.

The impact of the retained austenite in the case-hardened steels on the crater wear formation of the PcBN tools

The finishing operation of transmission components in the automotive industry is widely performed by the hard part turning process, using polycrystalline cubic boron nitride (PcBN) as cutting tool material. Carburizing steels are used in shafts and gears, and after the heat treatment processes, the components have typically 10-30 vol% of retained austenite in the carburized layer. The hard-turning is essentially a process involving high temperatures. The temperature at the tool-chip interface typically reaches the austenitization temperature range of the machined steel. In carburizing steels, the consequence is the generation of crater wear in PCBN tools by the chemical wear mechanism. In this context, this research aims to determine the impact of the retained austenite in the carburized steels on the crater wear formation in the PcBN tools. The 18CrNiMo7-6 steel was used to manufacture the workpieces. During the heat treatment, two carbon potentials (0,64% and 0,72%) and two tempering temperatures (160 °C and 180 °C) were applied to reach two levels of hardness (710 HV and 740 HV) and amount of retained austenite (20% and 27%). To study the wear, hard-turning tests were performed, applying industrial cutting parameters. The PCBN inserts were analyzed by a focus variation microscope (FVM) and a scanning electron microscope (SEM). For the same level of hardness, an increased phase fraction of the retained austenite in the steel increases the crater wear of the PcBN tools. Two complementary hypotheses were framed to explain the results: i. the high fraction volume of retained austenite increases the overall oxidation potential of the iron on the steel, accelerating the chemical degradation of the cBN grains; ii. the high amount of retained austenite reduces the formation of the protective layer on the chip tool interface. The in-depth investigation of chemical degradation is a largely unexplored subject on the wear evaluation of the ultrahard cutting tool.

The crack surface morphology investigation of S355J2 steel after bending-torsion fatigue

The paper describes the analysis of crack surface morphology of S355J2 steel specimens after bending-torsion fatigue. These experimental investigations of the surface topography were carried out using the focus variation microscope, an optical 3D measurement device. Selected results of measured fracture surfaces for S355J2 steel were analysed according to the surface texture ISO 25178 standard. Differences in roughness values for different loadings were demonstrated. For profile Rx and areal Sx parameters, characteristic relationships of fracture zones have been demonstrated. It has been shown that roughness profile Ra for the rupture area is higher than for the propagation area, as well as increases after both the LCF and HCF tests and increases with the torsional loading level. However, Sa in the propagation area increases and the rupture area decreases.

Design of Industrial Standards for the Calibration of Optical Microscopes.

One of the most important fields of study in material science is surface characterization. This topic is currently a field of growing interest as many functional properties depend on the surface texture. In this paper the authors, after a short a review of different methods for surface topography characterization and the determination of the traceability problems that arise in this type of measurements, propose four different designs of material standards that can be used to calibrate the most common optical measuring instruments used for these tasks, such as measuring microscopes, metallurgical microscopes, confocal microscopes, focus variation microscopes, etc. The authors consider that the use of this type of standards (or others similar to them) could provide a step forward in assuring metrological traceability for different metrological characteristics that enables a more precise measurement of surface features with optical measuring instruments. In addition, authors expect that this work could lay the groundwork for the development of custom standards with specialized features tuned to gain a better metrological control when measuring specific geometrical surface properties.

Application of Focus Variation Microscopy and Dissolution Imaging in Understanding the Behaviour of Hydrophilic Matrices.

Hydrophilic matrix systems can be found in a wide range of extended release pharmaceutical formulations. The main principle of these systems is that upon contact with water, the hydrophilic component swells to form a hydrated gel layer which controls drug release. The following work demonstrates an explorative study into the use of dissolution imaging and focus variation microscopy with hydrophilic polymers. This study investigated the surface properties of xanthan gum (XG), polyethylene oxide (PEO), and hypromellose (hydroxypropyl methylcellulose, HPMC) compacts with each of these three hydrophilic polymers from one of each classification of natural, semi-synthetic, or synthetic polymer using a focus variation instrument. The auto correlation length (Sal) showed all surface profiles from the compacts displayed a value below 0.1 mm, indicating that only high frequency components (i.e., roughness) were considered and that the analysis had been successful. The developed interfacial area ratio (Sdr) displayed values below 5% in line with ISO guidelines for all the polymers studied with their texture aspect ratio values (Str) > 0.5, indicating uniformity of the surfaces of the produced compacts. Of the various parameters studied, areal material ratio (Smr2) predicted XG to wet and hydrate quicker than PEO, with PEO also wetting and hydrating quicker than the HPMC. The dissolution imaging and initial swelling studies proved to concur with the findings from the areal material ratio (Smr2) parameter, suggesting porosity was not an indicator for the ease with which water ingress occurs. This study suggests the Smr2 surface parameter to potentially predict wetting and initial hydration of hydrophilic polymers, however care should be taken as this study consists of a selected number of hydrophilic polymers.

An investigation of drug compact topography as relates to intrinsic dissolution rates determined by dissolution imaging

The purpose of this study was to characterize compact surfaces (surface roughness) and study its potential importance to the intrinsic dissolution rate (IDR) as determined by dissolution imaging. To this end, the effect of varying compaction pressures and the use of two stainless-steel surfaces with different textures/roughness on the intrinsic dissolution were investigated. Ketoprofen (KET), paracetamol (PAR) and ibuprofen (IBU) were compacted and a focus variation microscope used to determine the surface topology of the compacts. IDR determination was conducted using a surface dissolution imaging apparatus with the flow-through set up in phosphate buffer at pH 7.2 and at 37 °C. The results indicated a general decrease in the surface area of the drug compacts with an increase in compaction force (p values < 0.05 for IBU and PAR but not KET). This change in surface area was measured using the Sdr parameter, which can be defined as the developed interfacial area. The smoother stainless-steel plate insert produced significantly smoother compacts for KET (Sdr decreased from 0.30% to 0.07%). However, PAR and IBU compacts showed an increase in their Sdr values from 3.94% to 17.90% and from 0.60% to 0.83%, respectively, suggesting the changes in surface properties to be drug specific relating to poor compaction properties and elasticity. The dissolution studies suggested that low compaction forces were not suitable for PAR. Overall changes in the surface topology did not have a significant effect on the obtained IDR values.

An Analysis of the Focus Variation Microscope and Its Application in the Measurement of Tool Parameter

Ultra-precision manufacturing is essential to the production of workpieces of the highest quality in terms of form accuracy, surface accuracy, and integrity. Compared with physical and chemical material removal methods, it has the advantages of high efficiency, high flexibility, and low cost. Because of the direct interaction between the workpiece and the tool during the process of ultra-precision manufacturing, the geometrical parameters of the tool directly affect the surface quality of the workpiece and need to be measured accurately and comprehensively. However, due to the large surface slopes of some tools, some three-dimensional measurement methods cannot measure their geometrical parameters because of limited maximum measurement angle. In this work, we build a focus variation system to make three-dimensional measurements of tools and extract their geometrical parameters. The data processing procedures and the selection of experimental parameters are analyzed in detail using simulations and experiments. Furthermore, we use a step height standard to verify the high accuracy of the measurement system and a roughened flat surface to evaluate the measurement noise and vertical resolution. Measurements of the parameters of a round nose cutting tool and the surface texture parameters of a grinding tool are conducted and indicate that the focus variation system is suitable for measuring the geometrical parameters of tools for ultra-precision manufacturing.

Analysis of Surface Microgeometry Created by Electric Discharge Machining.

The objective of this work is to study the geometric properties of surface topographies of hot-work tool steel created by electric discharge machining (EDM) using motif and multiscale analysis. The richness of these analyses is tested through calculating the strengths of the correlations between discharge energies and resulting surface characterization parameters, focusing on the most representative surface features—craters, and how they change with scale. Surfaces were created by EDM using estimated energies from 150 to 9468 µJ and measured by focus variation microscope. The measured topographies consist of overlapping microcraters, of which the geometry was characterized using three different analysis: conventional with ISO parameters, and motif and multiscale curvature tensor analysis. Motif analysis uses watershed segmentation which allows extraction and geometrically characterization of each crater. Curvature tensor analysis focuses on the characterization of principal curvatures and their function and their evolution with scale. Strong correlations (R2 > 0.9) were observed between craters height, diameter, area and curvature using linear and logarithmic regressions. Conventional areal parameter related to heights dispersion were found to correlate stronger using logarithmic regression. Geometric characterization of process-specific topographic formations is considered to be a natural and intuitive way of analyzing the complexity of studied surfaces. The presented approach allows extraction of information directly relating to the shape and size of topographic features of interest. In the tested conditions, the surface finish is mostly affected and potentially controlled by discharge energy at larger scales which is associated with sizes of fabricated craters.

3D multiscale curvature analysis of tool edges as an indicator of cereal harvesting intensity

The adoption of an agricultural lifeway is considered one of the most significant cultural events in prehistory. Microwear analysis of stone harvesting tools is among the many approaches used to document the transition to agriculture in the Near East. Traditionally, these microwear analyses rely on the use of optical microscopy and visual-verbal descriptions of wear criteria. In addition to traditional optical microscopy, ongoing research into the applications of surface metrology for the characterization of microwear traces has contributed to the development of quantitative microwear methods. Despite significant research into the quantification of lithic microwear polishes, there has been comparatively little research on the quantification of tool edge angles to understand function. In this paper, we test a new method for the quantification of areal curvature of stone harvesting tool edges at multiple scales using data collected with focus variation microscopy. These calculations are based on curvature tensors of the measured surface topographies along tool edge cross sections. This method allows calculation of maximal and minimal curvatures at each location and scale. For this paper, we analyze a set of experimental microliths used as cereal harvesting tools using changes in multiscalar areal edge curvature to mathematically document harvesting intensity (duration of use). This experimental research presents a new method for documenting used stone tool edges that will contribute to our understanding of how harvesting tools were used, curated, and discarded in the past, giving insight into the food collection practices of early farmers.

On-machine focus variation measurement for micro-scale hybrid surface texture machining

Fast and accurate in-line areal surface topography measuring instruments are required to control the quality of microscale manufactured components, without significantly slowing down the production process. Full-field areal optical surface topography measurement instruments are promising for in-line or on-machine measurement applications due to their ability to measure quickly, to access small features and to avoid surface damage. This paper presents the development and integration of a compact optical focus variation sensor for on-machine surface topography measurement mounted on to a hybrid ultraprecision machine tool. The sensor development is described and a case study involving the on-machine dimensional measurement of the depth of hydrophobic microscale features, including microchannels and micro-dimples, is presented. Comparisons of results between the on-machine measurements obtained by the developed sensor and a desktop focus variation microscope are presented and discussed. The comparison results show that the developed focus variation sensor is able to perform on-machine dimensional measurement of microscale features within sub-micrometre accuracy.

Characterisation and correlation of areal surface texture with processing parameters and porosity of High Speed Sintered parts

High Speed Sintering is an advanced powder bed fusion polymer Additive Manufacturing technique aimed at economical production of end-use parts in series manufacture. Surface finish is thus of high importance to end users. This study investigates the surface topography of High Speed Sintered parts produced using a range of different energy-related process parameters including sinter speed, lamp power and ink grey level. Areal surface texture was measured using Focus Variation microscopy and the sample porosity was systematically examined by the X-ray Computed Tomography technique. Surface topography was further characterised by Scanning Electron Microscopy, following which the samples were subject to tensile testing. Results showed that areal surface texture is strongly correlated with porosity, which can be further linked with mechanical properties. Certain texture parameters i.e. arithmetic mean height Sa, root-mean-square Sq and maximum valley depth Sv were identified as good indicators that can be used to compare porosity and/or mechanical properties between different samples, as well as distinguish up-, down-skins and side surfaces. Sa, Sq and Sv for up- and down-skins were found to correlate with the above energy-related process parameters. It was also revealed that skewness Ssk and kurtosis Sku are related to sphere-like protrusions, sub-surface porosity and re-entrant features. Energy input is the fundamental reason that causes varying porosity levels and consequently different surface topographies and mechanical properties, with a 10.07 μm and a 30.21 % difference in Sa and porosity, respectively, between the ‘low’ and ‘high’ energy input.

Dataset and methodology on identification and correlation of secondary carbides with microstructure, wear mechanism, and tool performance for different CERMET grades during high-speed dry finish turning of AISI 304 stainless steel.

The aim of this research is to utilize reverse engineering approach for the identification of the elements and phases available in the commercial CERMET inserts with the help of characterization techniques such as Scanning Electron Microscope (SEM), Energy-dispersive X-ray spectroscopy (EDS), and X-Ray Deposition (XRD). Four commercial CERMET inserts were investigated in this research work, and the effect of the composition and phases are related to its tool wear mechanism and performance. Each CERMET insert is used to perform a turning process on a CNC lathe for machining stainless steel (SS) under the dry condition at a fixed cutting length interval. Once it completes machining for a fixed cutting length, the CERMET insert is taken out to investigate its wear mechanism with the help of SEM, EDS, XRD and using a focus-variation microscope (Alicona). A correlation analysis is performed to relate progressive tool wear mechanisms with elements and their relevant phases of various carbides. The approach of correlating wear property with the phase content will contribute to the understanding of the wear mechanism under such extreme machining conditions. It will serve as a reference for the improvement of the performance of these CERMET inserts for such harsh machining conditions by the development of protective coatings for these CERMET inserts based on the identification of the composition and phases that improves tool life and reduces wear. The data related research work can be found at “https://doi.org/10.1016/j.wear.2020.203285” [1].

Development of an Additive Manufactured Artifact to Characterize Unfused Powder Using Computed Tomography

Additive manufacturing (AM) is recognized as a core technology for producing high-value components. The production of complex and individually modified components, as well as prototypes, gives additive manufacturing a substantial advantage over conventional subtractive machining. For most industries, some of the current barriers to implementing AM include the lack of build repeatability and a deficit of quality assurance standards. The mechanical properties of the components depend critically on the density achieved. Therefore, defect/porosity analysis must be carried out to verify the components’ integrity and viability. In parts produced using AM, the detection of unfused powder using computed tomography is challenging because the detection relies on differences in density. This study presents an optimized methodology for differentiating between unfused powder and voids in additive manufactured components, using computed tomography. Detecting the unfused powder requires detecting the cavities between particles. Previous studies have found that the detection of unfused powder requires a voxel size that is as small as 4 μm3. For most applications, scanning using a small voxel size is not reasonable because of the part size, long scan time, and data analysis. In this study, different voxel sizes are used to compare the time required for scanning, and the data analysis showing the impact of voxel size on the detection of micro defects. The powder used was Ti6Al4V, which has a grain size of 45–100 μm, and is typically employed by Arcam electron beam melting (EBM) machines. The artifact consisted of a 6 mm round bar with designed internal features ranging from 50 μm to 1400 μm and containing a mixture of voids and unfused powder. The diameter and depth of the defects were characterized using a focus variation microscope, after which they were scanned using a Nikon XTH225 industrial CT to measure the artifacts and characterize the internal features for defects/pores. To reduce the number of the process variables, the measurement parameters, such as filament current, acceleration voltage, and X-ray filtering material and thickness were kept constant. The VGStudio MAX 3.0 (Volume Graphics, Germany) software package was used for data processing, surface determination, and defects/porosity analysis. The main focus of this study is to explore the optimal methods for enhancing the detection of pores/defects while minimizing the time taken for scanning, data analysis, and determining the effects of noise on the analysis.

The Optical Aspect of Errors in Measurements of Surface Asperities Using the Optical Profilometry Method

The paper presents the impact of lighting type and direction on measurements of surface asperities using focus-variation microscopy. Particular attention was paid to the direction of lighting when using a light ring. It was pointed out that the lighting direction directly affects the values of the parameters Rt, Rz, and Rc. The article also presents the impact of a light polarizer on the surface topography parameters. It has been shown that the positioning of a sample with a regular and directed structure relative to the optical axis of the light polarizer affects the accuracy of mapping surface asperities. The largest differences were observed for Rz and Rt parameters. A method of using an external polarizer mounted on a focus variation microscope lens was also presented. Keywords: surface topography,

Abrasive flow machining (AFM) finishing of conformal cooling channels created by selective laser melting (SLM)

Conformal cooling channels are widely adopted in the mold industry because of rapid and uniform cooling during injection molding. These complicated cooling channel geometries become feasible via selective laser melting (SLM) technology. However, the SLM fabricated internal channel surface shows high surface roughness of about 10 μm Ra. This rough surface can cause stress concentration, reducing the fatigue life of the mold. Therefore, the objective of this study is to investigate the surface finish of the SLM fabricated conformal channels by abrasive flow machining (AFM), which is widely used in the surface finishing of internal channels. To fulfill this objective, a combination of single/multiple and straight/helical channels for conformal cooling channel geometries are employed. Seven different types of conformal cooling channels (ø3mm) inside the bar are fabricated using SLM. The bar is put in the AFM fixture, and the internal channels are polished by flowing AFM media (ULV50%-54) through the channel at the same extrusion pressure of 80 bars for ten cycles. Fourteen bars (seven before AFM and seven after AFM) are machined to have the internal channel surfaces exposed for surface roughness measurement. Surface topographies of the exposed surfaces of seven types of internal channels are obtained using focus variation microscopy. The areal roughness parameters, such as arithmetical mean height (Sa) on the internal channel surfaces before and after AFM. By comparing SLM as-built conformal channel surfaces with AFM finished ones, AFM is shown to be effective in improving all SLM conformal cooling channels’ arithmetical mean height, Sa. Areal roughness parameters, such as developed interfacial area ratio (Sdr), root mean square gradient (Sdq), reduced peak height (Spk), reduced valley height (Svk), and skewness (Ssk), on those internal surfaces, were found to be sensitive to surface finishing by AFM.

Correlation approach for quality assurance of additive manufactured parts based on optical metrology

Surface topography and surface finish are two significant factors for evaluating the quality of products in additive manufacturing (AM). AM parts are fabricated layer by layer, which is quite different from traditional formative or subtractive methods. Despite rapid progress in additive manufacturing and associated optical metrology for quality control and in-situ monitoring, limited research has been conducted to investigate the reliability of 3D surface measurement data. The surface topologies scanned by multiple optical systems demonstrated significant differences due to varying sampling mechanisms, resolutions, system noises, etc. The 3D datasets should be trustworthy in order to extract parameters for quality assurance or feedback control from 3D surface measurements. In this paper, we set up new standards to evaluate the reliability of 3D surface measurement data and analyze the variation in the topographical profile. In this study, two non-contact optical methods based on Focus Variation Microscopy (FVM) and Structured Light System (SLS) were adopted to measure the surface topography of the target components. The two optical metrology systems generated two entirely different point cloud datasets. Statistical methods were applied to test the difference between the data obtained from the two systems. By using data analytics approach for comparison, it was found that the surface roughness estimated from the point cloud data sets of FVM and SLS has no significant difference, though the point cloud data sets were completely different. This paper provides standard validation approach to evaluate the plausibility of metrology data from in-situ real-time surface analysis for process planning of AM.

Utilization of the focus variation method for determining the wear volume in the pin-on-disk sliding test

Abstract The measurement of wear volume in tribological tests is a critical step in wear characterization. There are many methods and instruments for wear volume measurement reported in the literature and most of them have already been commercialized. These commonly determine wear volume by means of tactile or optical methods, requiring costly and/or specifically developed instruments. In this study, an alternative method for determining wear volume, obtained after a sliding test with a pin-on-disk type apparatus, using focus variation microscopy is reported. A reflective-type light microscope, equipped with a digital camera, together with a range of computer software was used for the line profiling of wear scars, rather than a specialized focus variation microscope. In this study the relatively “shallow” depth of field at the high magnification of the light microscope was precisely used for determining surface line profiles on both slightly and heavily worn specimen surfaces after a series of tribological wear tests. Results of the study method were compared with both profilometric measurements obtained from a 3D optical microscope and with those obtained using a previously reported method. This comparison showed that the method under development and tested in this study yielded successful measurements, comparable to those obtained using the much more expensive 3D optical microscope.

Effect of Feedstock Properties on Extrusion of High Aspect Ratio Microbi-Lumen Tubes

Abstract The micro-extrusion of feedstock is a promising and emerging technology for manufacturing very high length to thickness aspect ratio metallic microcomponents which are not feasible for conventional metal processing methodologies or commonly used feedstock processing technologies. Extrusion of high aspect ratio microcomponents using metallic feedstock confronts the challenges of achieving a continuous extrusion without any breakage, the geometrical accuracy, surface finish and structural properties for the component which are required for the micro-application, during micro-extrusion process. The type of metallic powder, powder size, type of binder, and binder properties are very decisive in making the extrusion process feasible for the micro-application. The influence of feedstock properties on micro-extrusion of high aspect ratio microcomponents are still unknown in case of micro-extrusion of feedstock. In this research work, the effect of type of feedstock on micro-extrusion is studied by extruding microbi-lumen tubes using biocompatible steel feedstocks AISI316 L and 17-4PH at two different aging states (no aging and 1.5 years aging). The geometrical features of the extruded bi-lumen tubes, surface roughness and structural properties are analyzed using three-dimensional (3D) focus variation microscopy, differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). The analysis showed that feedstock type affects the feasibility of extrusion and geometrical size to a great extent. An average Sa roughness deviation from 1.73 to 4.57 μm was observed for feedstocks 17-4PH and AISI316 L. The study also confirms that binder properties and aging of the feedstocks also have to be taken into account for maintaining the surface finish and structural properties in case of metallic feedstock extrusion of high aspect ratio bi-lumen tubes.