Surface Generation Research Articles

Synthesis and Characterization of Biochars and Activated Carbons Derived from Various Biomasses

Reducing CO2 emissions is urgently needed to slow down the impacts of climate change. CO2 capture using an amine solution has been developed and implemented at pilot and commercial scales. However, amine scrubbing, in particular, produces a lot of degraded solvents as waste and is energy intensive. Solid sorbents have been used to overcome these drawbacks. In this work, waste biomass-derived carbon materials were developed and characterized. Advanced thermal chemical processes, i.e., hydrothermal and pyrolysis processes, were applied to produce materials from agrifood waste, such as soybean and okara. It was found that functional groups (-C=O and -OH) appeared in the synthesized materials, implying the generation of surface oxygenated groups. Preliminary results showed that synthesized activated carbons were obtained with good yields and relatively high surface areas, which may be applied as CO2 adsorption materials to solve CO2 emission problems.

Effect of side group modification on the glass transition and adhesion properties of polysiloxane at the atomic scale

Polysiloxane is a typical biomimetic dry adhesive, and polysiloxane-silica interface is a typical interface widely existing in test systems and wall-climbing robots. Studying the glass transition temperature (Tg) of polysiloxane and its adhesion properties on silica surfaces has important theoretical guiding significance and practical value for developing and applying a new generation of dry adhesion functional surfaces and devices. However, the effect of the type and content of side groups on the Tg and adhesion properties of polysiloxane is still unclear. Therefore, three side group combinations are included in the established modified polysiloxane models, with each type corresponding to five different side group contents. Molecular dynamics (MD) is used to investigate the effect of side group modification on the Tg of polysiloxane and the adhesion properties on the silica surface. The results show that, compared with polydimethylsiloxane (PDMS), introducing phenylmethyl or diphenyl into the polysiloxane increases the Tg in the studied range of side group contents. The introduction of diethyl decreases the Tg. The corresponding interfacial interactions are enhanced when the diethyl content is 2 %, 4 % and 10 %, the phenylmethyl content is 4–10 % and the diphenyl content is 2–10 %. The interfacial interactions are weakened at the unmentioned side group content. The ratio of van der Waals energy to the interfacial interaction energy is above 94.5 % in all interfaces, which means that van der Waals interaction dominates the interaction between polysiloxane and silica surface. The present model provides a deeper insight into polysiloxane, which may contribute to designing future bioinspired dry adhesives.

Methodology for Identifying Optimal Pedestrian Paths in an Urban Environment: A Case Study of a School Environment in A Coruña, Spain

Improving urban mobility, especially pedestrian mobility, is a current challenge in virtually every city worldwide. To calculate the least-cost paths and safer, more efficient routes, it is necessary to understand the geometry of streets and their various elements accurately. In this study, we propose a semi-automatic methodology to assess the capacity of urban spaces to enable adequate pedestrian mobility. We employ various data sources, but primarily point clouds obtained through a mobile laser scanner (MLS), which provide a wealth of highly detailed information about the geometry of street elements. Our method allows us to characterize preferred pedestrian-traffic zones by segmenting crosswalks, delineating sidewalks, and identifying obstacles and impediments to walking in urban routes. Subsequently, we generate different displacement cost surfaces and identify the least-cost origin–destination paths. All these factors enable a detailed pedestrian mobility analysis, yielding results on a raster with a ground sampling distance (GSD) of 10 cm/pix. The method is validated through its application in a case study analyzing pedestrian mobility around an educational center in a purely urban area of A Coruña (Galicia, Spain). The segmentation model successfully identified all pedestrian crossings in the study area without false positives. Additionally, obstacle segmentation effectively identified urban elements and parked vehicles, providing crucial information to generate precise friction surfaces reflecting real environmental conditions. Furthermore, the generation of cumulative displacement cost surfaces allowed for identifying optimal routes for pedestrian movement, considering the presence of obstacles and the availability of traversable spaces. These surfaces provided a detailed representation of pedestrian mobility, highlighting significant variations in travel times, especially in areas with high obstacle density, where differences of up to 15% were observed. These results underscore the importance of considering obstacles’ existence and location when planning pedestrian routes, which can significantly influence travel times and route selection. We consider the capability to generate accurate cumulative cost surfaces to be a significant advantage, as it enables urban planners and local authorities to make informed decisions regarding the improvement of pedestrian infrastructure.

Ordering of oxygen vacancies in hydroxyapatite under electron irradiation

Understanding the mechanisms of radiation induced defect generation is essential for assessment of materials to be used in nuclear environments. In the current work, we investigate the effect of 10 MeV electron irradiation on the generation and possible ordering of defects/oxygen vacancies in hydroxyapatite (HAP) powders. Comprehensive analyses of X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), Electron Paramagnetic Resonance (EPR) and Raman spectra establish that (a) HAP has a high level of structural stability even after exposure to electron irradiation; (b) irradiation leads to the generation of surface defects/oxygen vacancy predominantly in the PO43− polyanion site, particularly in part of asymmetric bonding within the P–O bonds and (c) there is noticeable evidence for an ordered arrangement of oxygen vacancies within the HAP irradiated at 1 MGy dose. These radiation-induced defects, such as oxygen vacancies, can migrate within the HAP lattice, leading to formation of defect/oxygen vacancies clusters which ultimately results in the ordering tendency of oxygen vacancies within the lattice. The observed ordering, as evidenced by the photoluminescence intensities, aligns with the sequence HAP-1MGy > HAP-20MGy > HAP, providing further support for the presence of ordered oxygen vacancies.

OPTIMIZATION OF LASER PARAMETERS USING NSGA-II FOR THE GENERATION OF BIOINSPIRED SURFACE

OPTIMIZATION OF LASER PARAMETERS USING NSGA-II FOR THE GENERATION OF BIOINSPIRED SURFACE

Effect of crystal orientation on surface/subsurface damage characteristics of nano-cutting Ni-based single crystal superalloy

In ultra-precision machining, material anisotropy has an essential impact on surface generation and subsurface damage. In this work, the molecular dynamics method is applied to create the diamond nano-cutting models of Ni-based single crystal (NBSX) superalloy workpieces with different crystal orientations, and the surface/subsurface damage characteristics, crystal structure changes, cutting force, and atomic temperature and stress are discussed. The results show significant differences in surface/subsurface quality, crystal structure transformation, cutting force, atomic temperature and stress distributions and dislocation density obtained from nano-cutting workpieces along different crystal orientations. In four groups of workpieces, the surface/subsurface quality is used as an evaluation index, which shows that the [110](001) crystal orientation has the best cutting effect, and the [111](1‾ 10) crystal orientation is the worst cutting direction. This work reveals the damage generation mechanism of the machined surface/subsurface of NBSX superalloy on an atomic scale, which provides technical support for improving machining quality and optimizing machining parameters.

Subdivision Schemes Based on Weighted Local Polynomial Regression: A New Technique for the Convergence Analysis

The generation of curves and surfaces from given data is a well-known problem in Computer-Aided Design that can be approached using subdivision schemes. They are powerful tools that allow obtaining new data from the initial one by means of simple calculations. However, in some applications, the collected data are given with noise and most of schemes are not adequate to process them. In this paper, we present new families of binary univariate linear subdivision schemes using weighted local polynomial regression which are suitable for noisy data. We study their properties, such as convergence, monotonicity, polynomial reproduction and approximation and denoising capabilities. We establish conditions that connect the weight function with two essential properties: noise elimination and approximation capability. We propose a multi-objective optimization problem for improving these two capabilities and conclude that only some weight functions are Pareto optimal. For the convergence study, we develop some new theoretical results. Finally, some examples are presented to confirm the proven properties.

The Impact of Upstream Static Deformation on Flow Past a Cylinder/Flare

Reynolds-averaged Navier–Stokes simulations are performed for supersonic turbulent flow over a cylinder/flare with upstream surface distortion representative of structural deformation induced via fluid–structural and fluid–thermal–structural behavior. Broad parametric analysis is carried out through the generation of Kriging-response surfaces from a database of general simulations. A posteriori simulations are then carried out at parametric combinations that correspond to extrema in the Kriging response surfaces to gain deeper insights into the interaction between the surface distortion and flow responses. Upstream distortions tend to decrease, rather than increase, the peak pressure and heat flux loads on the flare compared to an undeformed cylinder. Furthermore, decreases in these quantities reach up to O(10%) compared to up to O(1%) for increases. Integrated quantities over the flare are relatively insensitive to upstream distortion. The corner separation length is the most sensitive quantity to upstream distortion, with protrusions tending to increase the separation length and recessions reducing the separation length. Modifications in the separation length of up to 40% are observed. Reductions in peak loads tend to correspond to increases in the corner separation length. The movement of the surface distortion relative to the corner indicates a negligible impact beyond 1.5 distortion lengths from the corner, and the largest impact on the corner separation length occurs when distortion is directly adjacent. These results are an important step toward understanding and quantifying the impact of surface deformations on downstream components.

Research on the mechanism and application of wedge cutting blasting with hole-inner delay

To increase the efficiency of deep-hole blasting driving in mine rock tunnels, an innovative pattern of wedge cutting blasting with hole-inner delay was proposed. First, the blasting mechanisms of conventional and innovative wedge cutting patterns were theoretically investigated. The results showed that the resistance from large upper rock blocks and the clamping action from the surrounding rock were the major challenges of conventional cutting methods. For the innovative cutting pattern, under the conversion of the spatial distribution and release sequence of blasting energy, the first blasting of the upper charge can strengthen the breaking of the upper rock mass and create a new free surface, which provides favorable conditions for the delayed blasting of the bottom charge. Second, finite element models of two cutting patterns were established and solved, and the simulation results visually revealed the propagation of a stress wave. Critically, the stress strength in the upper cavity increased by 66–83% under the action of the upper charge, which was conducive to the breaking of the upper rock mass and the generation of a new free surface. Therefore, the rock mass in the bottom cavity can be readily broken and discharged. Ultimately, field applications were executed in a rock tunnel. Compared with a conventional cutting pattern, the proposed innovative cutting pattern can prominently increase the cycle advance and hole utilization and greatly reduce the unit consumption of explosives and detonators. This research confirms the usability of the innovative wedge cutting pattern with hole-inner delay in deep-hole blasting driving of rock tunnels.

Suppression of equilibrium magnetic islands by density profile effect in quasi-axisymmetric stellarator plasmas

In a quasi-axisymmetric stellarator, a significant bootstrap current will result in the generation of low-order rational surfaces and three-dimensional (3D) magnetic islands. In this paper, the influence of plasma density profiles on the equilibrium magnetic islands for the Chinese first quasi-axisymmetric stellarator (CFQS) is investigated using the HINT code. It is found that the flattening of the core plasma density profile leads to a significant suppression of magnetic islands. When the peaking factor of plasma density is 1.19, complete suppression of magnetic islands occurs while maintaining excellent integrity of the magnetic surface even with the volume-averaged plasma beta <β> increase up to 2%. On the other hand, during the transition of a plasma density profile from flat to hollow, there is a reversal in the core bootstrap current, resulting in reduction of rotational transform values to pass through the rational surface. Hence, formation of magnetic islands in the core region. Therefore, effective inhibition of CFQS’s magnetic islands can be achieved by appropriately controlling density profiles through methods like gas injection.

Theoretical and experimental investigation of ultrasonic cutting kinematics and its effect on chip formation and surface generation in high-frequency ultrasonic vibration-assisted diamond cutting

Ultrasonic vibration-assisted cutting (UVAC) is regarded as a feasible technology to machine difficult-to-cut materials. High-frequency ultrasonic vibration-assisted cutting (HFUVAC), with a working frequency of more than low and medium frequency (20–60 kHz), has been reported to improve material machinability and prolong tool life. This paper presents a comprehensive investigation of the ultrasonic cutting kinematics and the generated chip/surface formation process in HFUVAC of a 316l stainless steel workpiece. First, the ultrasonic cutting kinematics was analyzed and verified by comparing the experimental and theoretical surface texture under different nominal cutting speeds. Based on the ultrasonic cutting kinematics and the simulated strain/stress distributions, the chip and surface formation between conventional cutting (CC) and HFUVAC was analyzed. More importantly, the incremental cutting mode was defined when the cutting stroke, namely the effective cutting length in one vibration cycle was less than 800 nm. The results show that in the incremental cutting mode, defect-free surface was achieved due to suppressed large deformation and friction action. Finally, HFUVAC of the sinusoidal microstructure was performed under the incremental cutting mode, achieving optical requirements with nanometer-scale surface roughness and submicrometric form accuracy, which validates the technical feasibility in HFUVAC of micro-structured surfaces.

The ablation behavior and modification mechanism of SiC under different laser energy

The laser modification pretreatment method is an effective way to address the machining difficulties of silicon carbide (SiC), a typical hard-to-machine material. Therefore, the ablation behavior and modification mechanism of SiC under different laser energy were explored in this paper. A new multi-scale model of laser irradiation SiC that couples heat transfer and fluid motion is first established. Then, a series of experiments is carried out to evaluate the model's accuracy, and the interaction between laser and SiC is discussed in detail. The results show that the dominant modification mechanism changes from coulomb explosion to multiphoton absorption, incubation effect, and heat accumulation with the laser energy increase. This leads the surface topography of SiC to transition from nanoparticle formation to disorder to a melting state. In ablative state, micro/nano porous and humps are formed at the edge of ablation groove due to surface tension, generation and rupture of bubbles, respectively. Furthermore, the surface roughness is not proportional to the laser energy due to the plasma shielding effect, and the surface roughness can be reduced by enhancing the flow of the molten material. Amorphous Si–O–C, Si and spherical SiO2 exist in deposition area, leading to SiC elastic modulus decreases from 347 GPa to 103.82 GPa, and the shear strength decreases from 20.9 GPa to 17.25 GPa. The results of this study can provide references for parameters selection and theoretical support for improving the machinability of SiC.

Surface and subsurface response to the in-situ laser assistance in ultra-precision diamond turning of SiCp/Al composites

This study focuses on the application of in-situ laser-assisted single-point diamond turning (ILAT) on SiCp/Al metal matrix composites (MMCs), renowned for their exceptional mechanical properties and difficult-to-cut nature. The surface and subsurface response to the in-situ laser assistance under a small uncut chip thickness (UCT) is investigated. The results demonstrate that appropriate laser energy can reduce subsurface crystal defects while maintaining surface quality during machining. As the laser power increases, the surface damage pattern shifts from cut-through to fracture, eventually leading to severe matrix deformation. Slight compressive stress is observed on the Al phase of surfaces machined with either conventional single-point diamond turning (SPDT) or ILAT. Al crystals near the machined surface and SiC particles in the SPDT sample exhibit a notable accumulation of dislocations. Laser assistance is beneficial for mitigating dislocations and improving the crystalline integrity of Al grains, while Al grains close to the machined surface in both SPDT and ILAT samples present comparable amounts of stacking faults. The findings enhance the understanding of surface and subsurface generation of SiCp/Al composites in ILAT, providing a reference for the application of ILAT on other MMCs.

Redox-driven surface generation of highly active Pd/PdO interface boosting low-temperature methane combustion

The supported Pd catalyst has been a benchmark for methane elimination. However, the active structures have been long under debate. Here, by the aberration-corrected high angle annular dark field scanning transmission electron microscopy, operando X-ray absorption spectroscopy and quasi in situ X-ray photoelectron spectroscopy, we revealed the two-dimensional metallic Pd bumps on the PdO surface (litchi-like structure) generated by the redox atmosphere under the lean condition as a highly active structure of the Pd/Al2O3 catalyst. The substantially increased Pd/PdO interfaces boost the methane combustion activity higher than the similar catalysts reported previously, and remarkably enhance the reaction rate by 15.5 and 10.7 times that of pure PdO or metallic Pd counterpart under lean condition at 300 °C, respectively. Density-functional theory calculations confirm the synergistic C–C bond activation of methane on the Pd/PdO interfaces. Our work provides new insight into the traditional understanding of the chemical state and particle size effects of the industrial Pd catalysts for methane oxidation.

Numerical simulation and experimental validation on the mechanism of crater evolution in electrical discharge micromachining

The plasma-material interaction and evolution mechanism of a solitary crater governs the nature of the surface, either plain or textured, created through the electrical discharge micromachining (EDMM) process. Therefore, it is indispensable to understand the fundamentals of a single crater evolution, which involves melt pool hydrodynamics and material vaporization under intense plasma pressure. The plasma pressure during the workpiece heating phase alters the vaporization phenomenon and melt ejection, warranting an in-depth understanding. In light of this, the current work proposes a two-dimensional (2-D) multiphysics numerical model of the melt pool hydrodynamics during EDMM. The model incorporates thermal evolution along with the effects of active plasma pressure during the heating phase of the substrate with the help of a coupled thermo-fluidic model. The simulation results reveal the predominant role of plasma pressure on the crater morphology evolution, plasma flushing efficiency (PFE) and recast layer thickness (RLT). The predicted single crater profile is validated using single-spark experiments with reasonable agreement. Thereafter, the formation mechanism of a single crater has been extended to multi-crater creation for textured surface generation.

Non-destructive measurement of MUCT in micro-milling using surface topography generated by bi-planer size effects

In mechanical micro-cutting, a Minimum Undeformed Chip Thickness (MUCT) is desired to ensure chip formation by the round-edged tool. Although the MUCT controls several machinability, productivity, and sustainability attributes, its measurement using output responses is a challenging task. This article, for the first time, demonstrates a non-destructive methodology to measure MUCT in micro-milling using the topographical pattern that inherently remains embedded on the micro-milled floor surface in the form of a microscopic step at the ploughing-shearing transition boundary. Simultaneous action of two Size Effect phenomena that occur concurrently in two mutually perpendicular planes owing to rounded-nose and rounded-edge produce microscopic step during surface generation. A methodology to quantify MUCT using this inconsistent surface topography is also demonstrated. MUCT remains within 36–41 % of the edge radius during dry micro-milling of Ti-6Al-4V using TiAlN-coated WC-6Co tool. The same reduces to 33–40 % of the edge radius when cutting fluid is delivered through sustainable Minimum Quantity Lubrication (MQL) strategy. Proportionality between MUCT and edge radius remains valid during abrasive wear regime of the cutting tool. Tool wear significantly deteriorates surface quality, causing Ra roughness to increase from 40 to 350 nm when adhesion deposits on cutting edge. Consequently, the proposed surface-dependent methodology fails to provide precise MUCT data when cutting tool experiences aggressive wear.

A numerical method for generation of shot peened surfaces

Shot peening is a widely utilized surface modification technique, and the surface morphology of the treated materials plays a crucial role in determining their friction and fatigue properties. Surface morphology generation is a pivotal process in simulating shot-peened surface friction and other performance characteristics. However, there are limited available methods for shot-peened surfaces until now. In this paper, we present a method that directly specifies the height probability distribution and power spectrum to generate shot-peened surfaces. Compared to methods that specify height parameters, this method has more flexibility. This approach replaces the traditional Johnson transformation method with an optimization algorithm to generate height data that follows a high probability distribution, while the power spectrum is derived from the Fourier transform of an exponential autocorrelation function. The results show that this approach can generate shot-peened surfaces using any conventional height parameters, with a maximum difference in height parameters between the reconstructed surface and the original surface of no more than 18.63%. Compared to the Johnson transformation method, this method significantly reduces the errors in skewness and kurtosis of the generated surface. It offers rapid surface generation for shot-peened surfaces, leading to significant time and cost savings in experiments.

Diamond machining of additively manufactured Ti6Al4V ELI: Newer mode of material removal challenging the current simulation tools

Single point diamond machining (SPDM) produces smooth machined surfaces that other production methods cannot match. While the mechanics of machining of cast alloys with SPDM is well-explored, the realm of SPDM for additively manufactured parts remains largely uncharted. This work reveals new insights into the surface generation process of an additively manufactured titanium alloy, specifically, a Ti6Al4V Extra Low Interstitials (ELI) alloy workpiece. Our examination of the chip morphology unveiled a distinct mode of chip removal, previously unrecorded in existing literature. During SPDM of additively made Ti6Al4V ELI workpiece, identification of numerous pores and discontinuities in the chips flowing on the tool rake face, indicating periodic intermittent cracking during the material's plastic flow was seen. To examine this phenomenon, a finite element analysis (FEA) model was developed. While the FEA model can well explain the machining mechanics and chip morphology of SPDM of cast Ti6Al4V ELI reported in the literature, it failed to describe the chip morphology that are obtained during machining of additively made workpiece in this work. This disparity underscores the need for innovative simulation approaches tailored for additively manufactured components. The experimental observations in this study highlight a unique form of chip formation in contrast to conventional Ti6Al4V alloy machining processes. At lower feeds, there was a presence of short, discontinuous chip formation with tearing at the outer periphery. Conversely, at higher feeds, a long, continuous ribbon-like chip formation was observed. In addition, some typical additive manufacturing defects appear on the machined surface and chips. Through optimisation of the SPDT parameters, a surface roughness (Ra) value of about 11.8 nm was achieved on additively manufactured Ti6Al4V ELI workpiece. This work provides a fresh perspective on the mechanics of SPDM for additively manufactured components, offering a stepping stone for subsequent studies.

A hybrid statistical morphometry free-form deformation approach to 3D personalized foot-ankle models

Foot and ankle joint models are widely used in the biomechanics community for musculoskeletal and finite element analysis. However, personalizing a foot and ankle joint model is highly time-consuming in terms of medical image collection and data processing. This study aims to develop and evaluate a framework for constructing a comprehensive 3D foot model that integrates statistical shape modeling (SSM) with free-form deformation (FFD) of internal bones. The SSM component is derived from external foot surface scans (skin measurements) of 50 participants, utilizing principal component analysis (PCA) to capture the variance in foot shapes. The derived surface shapes from SSM then guide the FFD process to accurately reconstruct the internal bone structures. The workflow accuracy was established by comparing three model-generated foot models against corresponding skin and bone geometries manually segmented and not part of the original training set. We used the top ten principal components representing 85 % of the population variation to create the model. For prediction validation, the average Dice similarity coefficient, Hausdorff distance error, and root mean square error were 0.92 ± 0.01, 2.2 ± 0.19 mm, and 2.95 ± 0.23 mm for soft tissues, and 0.84 ± 0.03, 1.83 ± 0.1 mm, and 2.36 ± 0.12 mm for bones, respectively. This study presents an efficient approach for 3D personalized foot model reconstruction via SSM generation of the foot surface that informs bone reconstruction based on FFD. The proposed workflow is part of the open-source Musculoskeletal Atlas Project linked to OpenSim and makes it feasible to accurately generate foot models informed by population anatomy, and suitable for rigid body analysis and finite element simulation.

Catalytic ozonation of reverse osmosis concentrate from coking wastewater reuse by surface oxidation over Mn-Ce/γ-Al2O3: Effluent organic matter transformation and its catalytic mechanism

Degradation of organics in high-salinity wastewater is beneficial to meeting the requirement of zero liquid discharge for coking wastewater treatment. Creating efficient and stable performance catalysts for high-salinity wastewater treatment is vital in catalytic ozonation process. Compared with ozonation alone, Mn and Ce co-doped γ-Al2O3 could remarkably enhance activities of catalytic ozonation for chemical oxygen demand (COD) removal (38.9%) of brine derived from a two-stage reverse osmosis treatment. Experimental and theoretical calculation results indicate that introducing Mn could increase the active points of catalyst surface, and introducing Ce could optimize d-band electronic structures and promote the electron transport capacity, enhancing HO• bound to the catalyst surface ([HO•]ads) generation. [HO•]ads plays key roles for degrading the intermediates and transfer them into low molecular weight organics, and further decrease COD, molecular weights and number of organics in reverse osmosis concentrate. Under the same reaction conditions, the presence of Mn/γ-Al2O3 catalyst can reduce ΔO3/ΔCOD by at least 37.6% compared to ozonation alone. Furthermore, Mn-Ce/γ-Al2O3 catalytic ozonation can reduce the ΔO3/ΔCOD from 2.6 of Mn/γ-Al2O3 catalytic ozonation to 0.9 in the case of achieving similar COD removal. Catalytic ozonation has the potential to treat reverse osmosis concentrate derived from bio-treated coking wastewater reclamation.