Groove Profile Research Articles

Effect of argon and nitrogen environments on the structure and properties of protective cermet coatings based on titanium borides obtained by electric arc surfacing

The aim of this work was to enhance the mechanical and tribological properties of an alpha titanium substrate by forming a protective cermet coating on its surface. In this study, protective cermet coatings based on titanium borides were prepared by electric arc surfacing in a protective environment. Two types of protective environment were investigated during the surfacing process: (i) inert (argon) and (ii) reactive (nitrogen). The characteristic zones of the deposited layer were established depending on the environment used, and the coating-substrate transition zone was thoroughly examined. It was demonstrated that the formation of the transition zone results from the mutual diffusion of the molten material of the electrode material and the substrate. For the first time, the formation of TiB2-TiN eutectic in the form of whiskers 4-20 μm wide and 100-300 μm long distributed in the matrix of the Ti(B,N)x solid solution was established when forming a protective cermet coating in a nitrogen environment. The presence of this TiB2-TiN eutectic led to a significant increase in the hardness of the coating, up to 4.4 times, from 350 to 1530 HV. Tribological tests of surfacing coatings were conducted, and both 2D and 3D profiles of the wear grooves are presented, providing insight into the wear mechanism. It was found that the wear resistance of the cermet coating obtained in a nitrogen environment increased by 5.2 times, while in an argon environment it increased by 3.1 times as compared to the substrate without the protective cermet coating. The results indicate the potential of the developed protective cermet coatings for use in abrasive operating conditions.

The ablation behavior of diamond/Cu composites by infrared nanosecond pulsed laser

This paper investigates the material removal behavior of diamond/Cu composites by multi-passes infrared nanosecond pulsed laser ablation, focusing on the formed surface cracks, periodic ripples, profile evolution and deposition. Combining nanosecond laser ablation experiments with simulations based on thermophysical properties is then undertaken to effectively reduce the maximum thermal stress and inhibit crack initiation and propagation. Three types of cracks were identified in nanosecond laser ablation, which were influenced by the diverse thermophysical properties of the material and the temperature gradient. The periodic ripples of 300–1800 nm on the sidewalls of the machined groove on diamond grains were induced when the laser fluence approached the ablation threshold, which did not even appear on the copper matrix as the thermal effects dominate. The groove profile showed a limited change as the ablation passes further increase to be over 40 due to the plasma shielding effect inside the groove, the laser defocusing phenomenon and the increased difficulty of sputtering the molten material. In addition, the different ablation mechanisms of diamond and copper resulted in the formation of overlapping deposition layers with changed surface characteristics at varying laser energy densities. The uneven island-like recast layer affected the uniformity of the ablated grooves, which was dependent on the material microstructure and accumulated laser energy.

Influence of beam polarization on underwater femtosecond laser machining of silicon wafer

This paper investigates the effect of polarization directions on underwater femtosecond laser machining of silicon wafer. Firstly, laser ablation in liquids produces laser-induced periodic surface structures (LIPSS) on both edges of the groove. The direction of LIPSS has direct correlation with the polarization of the laser beam. Secondly, the electric field intensity distribution within the groove is analyzed by numerical simulation employing the finite-difference-time-domain (FDTD) method. The simulation and experimental results reveal that the distribution of the inter electric field intensity within the grooves varies with polarization direction. As the angle between the polarization and scanning directions decreases, the peak electric field strength and groove depth gradually increase. Finally, changing the direction of polarization of the beam affects the symmetry of the groove profile. The groove profile produced by ablation is symmetrical when the beam polarization direction is parallel to the scanning direction. By modulating and optimizing the direction of polarization, grooves with large depth and symmetrical shape can be obtained.

A New Solution to the Grain Boundary Grooving Problem in Polycrystalline Thin Films When Evaporation and Diffusion Meet in Power Electronic Devices.

This paper constituted an extension of two previous studies concerning the mathematical development of the grain boundary grooving in polycrystalline thin films in the cases of evaporation/condensation and diffusion taken separately. The thermal grooving processes are deeply controlled by the various mass transfer mechanisms of evaporation-condensation, surface diffusion, lattice diffusion, and grain boundary diffusion. This study proposed a new original analytical solution to the mathematical problem governing the grain groove profile in the case of simultaneous effects of evaporation-condensation and diffusion in polycrystalline thin films by resolving the corresponding fourth-order partial differential equation ∂y∂t=C∂2y∂x2-B∂4y∂x4 obtained from the approximation ∂y∂x2≪1. The comparison of the new solution to that of diffusion alone proved an important effect of the coupling of evaporation and diffusion on the geometric characteristics of the groove profile. A second analytical solution based on the series development was also proposed. It was proved that changes in the boundary conditions of the grain grooving profile largely affected the different geometric characteristics of the groove profile.

Aluminum-Based Plasmonic Photodetector for Sensing Applications

Plasmonic sensors have great potential for widespread usage. However, the prohibitive cost of noble metals restrains the wider adoption of these devices. The aim of our study is to develop a cost-effective Al-based alternative to common noble metal-based plasmonic detectors. We considered a structure consisting of an n-type doped Si wafer with a shallow p-n junction and an overlying Al grating with a trapezoidal groove profile. The RCWA (rigorous coupled-wave analysis) method was used to numerically calculate the distribution of absorbed light energy in the plasmonic detector layers and to optimize the grating parameters. Based on the simulation results, experimental samples of plasmonic photodetectors with optimal grating parameters (period—633 nm, relief depth—50 nm, groove filling factor—0.36, and thickness of the intermediate Al layer—14 nm) were manufactured, and their properties were studied. For these samples, we obtained a polarization sensitivity value of Ip/Is = 8, an FWHM of the resonance in the photocurrent spectrum ranging from 50 to 100 nm, a sensitivity at the resonance maximum of Iph = 0.04–0.06 A/W, and an angular half-width of photocurrent resonance of Δθ = 5°, which are comparable to noble metal-based analogs. Our results may be used for creating cost-effective high-sensitivity plasmonic sensors.

Development of broadband high efficiency Mid-IR gratings for high-energy ultrafast lasers

Broadband high-efficiency diffraction gratings play a crucial role in the pulse stretcher and compressor of high-energy ultrafast lasers. Nevertheless, conventional grating manufacturing techniques, including mechanical ruling and holographic recording, face challenges in creating accurate blazed groove profiles necessary for the fabrication of broadband, high-efficiency mid-infrared gratings. In this work, we utilized combined electron-beam lithography and anisotropic wet etching technology to fabricate nearly perfect blazed grooves, producing high efficiency broadband mid-infrared (IR) grating for 4.3 µm 100 femtosecond laser. Global optimization was performed to achieve a design of > 90% efficiency over spectral range of 3.6 µm – 6.6 µm. Hybrid metal-dielectric coating (Au-Al2O3) is employed and optimized to minimize absorption and to enhance diffraction efficiency and laser-induced damage threshold (LIDT). Prototype gratings undergo testing at a desired application wavelengths of 4.3 µm in a tunable range of 0.2 µm, revealing that the optimal sample achieves a diffraction efficiency of 92%, closely approaching the theoretical value of 94.2%

Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium.

Die-sinking micro-electrical discharge machining (micro-EDM) is a potential method used to fabricate intricate structures without complex electrode motion planning and compensation. However, machining efficiency and poor discharge states are still bottlenecks. This study conducted a comparative investigation into the impact of ultrasonic vibration on die-sinking micro-EDM of polycrystalline diamond (PCD) and pure titanium (TA2). By adjusting discharge parameters, this study systematically evaluated the influence of ultrasonic vibration on these two materials based on discharge waveforms, motion trajectories, effective discharge counts and groove profiles. At an open-circuit voltage of 100 V, ultrasonic vibration promotes die-sinking micro-EDM of PCD. However, when the open-circuit voltage increases to 200 V, ultrasonic vibration exhibits inhibitory effects in general. Conversely, for TA2, ultrasonic vibration shows a promoting effect at both voltages, indicating the differences of ultrasonic vibration-assisted die-sinking micro-EDM on PCD and TA2. For PCD, ultrasonic cavitation improves the discharge gap environment, accelerating the removal of discharge debris. For TA2, due to its poor thermal conductivity, ultrasonic cavitation acts to break the arc, accelerating heat transfer. These research findings provide guidance for ultrasonic vibration-assisted die-sinking micro-EDM in industrial applications.

Phase Retrieval Algorithm for Surface Topography Measurement Using Multi-Wavelength Scattering Spectroscopy

We are currently developing a high-precision and wide-range in-process surface topography measurement system using the laser inverse scattering method. In the laser inverse scattering method, a monochromatic plane wave is illuminated perpendicular to the target surface and the surface topography is measured by retrieving the phase distribution of the reflected light. However, the dynamic range of this method is limited to the sub-micrometer range because of phase wrapping during phase retrieval. In this paper, we propose a laser inverse scattering method using a multi-wavelength light source based on the fact that the phase of light is inversely proportional to the wavelength with the propagation distance as a coefficient. We also constructed a surface profilometer based on the proposed method and measured the profile of a single rectangular groove with a width of 50 µm and a depth of 2 µm. The dimensions of the measured profiles agree well with the nominal dimensions of the rectangular groove.

Interface behavior and pore distribution of Ti6Al4V/CFRTP joints affected by groove profile

This study investigated the effect of groove profile on interface behavior, pore distribution, and bonding mechanism between Ti6Al4V (TC4) and carbon fiber reinforced thermoplastic (CFRTP). Using an ultraviolet picosecond laser system, grooves with varying depth-width ratios (R) and distances between adjacent grooves (T) were precisely etched on the TC4 surface. Experiment results revealed that grooves effectively impede bubble coalescence and growth, reduce pore defects at the grooves’ outer interface, and promote closer bonding between TC4 and CFRTP, thereby enhancing joint strength. In this study, grooves significantly improved joint strength by 40.2 % to 147.5 %, primarily due to increased mechanical interlocking and bonding area. Differences in joint strength among grooved joints are mainly attributed to variations in interface behavior and pore distribution caused by R and T. Appropriate R and T are crucial for inhibiting large-volume pores and reducing pores at the grooves’ outer. When R = 1/5 and T = 360 μm, the joint with small-volume pores, no pores at the grooves' outer, and the lowest porosity exhibits the highest strength (2830.3 N). Grooves showed no significant impact on chemical bonding (CTi0.42V1.58 carburization phase and TiOS). Furthermore, no significant effect of grooves on the chemical bonding (CTi0.42V1.58 carburization phase and TiOS).

Вплив тонких плівок Se на ефективність збудження поверхневих плазмон-поляритонів в срібних та алюмінієвих голографічних решітках

In this paper, we study the effect of thin selenium layers up to 3 nm thick on the efficiency of excitation of surface plasmon polaritons (SPPs). The Se layers were deposited by thermal evaporation in vacuum on the surface of silver and aluminum gratings. Gratings with a groove profile close to sinusoidal and a period equal to а = 694 nm were formed on chalcogenide photoresist films using interference lithography. Then they were coated with layers of the above metals with a thickness of 80–85 nm using thermal evaporation. Registration of SPP excitation on the gratings was carried out by measuring the angular dependences of the intensity of specularly reflected or diffracted p-polarized He-Ne laser radiation on a stand mounted on the basis of a G5M goniometer and a Fedorov table. An atomic force microscope was used to determine the shape of the groove profile and the depth of the grating relief. It has been found that for silver gratings with a relief modulation depth h/a less than the optimal value (which ensures maximum plasmon absorption, i.e., the maximum efficiency of SPP excitation), selenium deposition causes significant degradation of the plasmon resonance: a decrease in the depth of the minimum of the total reflection Rpt (i.e., a decrease in the efficiency of plasmon absorption), a shift of the Rpt minimum towards larger angles, and its widering. For silver gratings with h/a greater than the optimal value, a similar shift and widering of the plasmon resonance is also observed. However, at the same time, a significant deepening of the Rpt minimum is recorded, that is, an increase in the efficiency of SPP excitation. Such changes in the plasmon characteristics also appear on aluminum gratings, however, in this case the effect of the selenium layers is weaker by an order of magnitude. The obtained results allow us to propose a method of correcting the plasmonic characteristics of silver gratings in which the value of h/a is higher than optimal.

Experimental study and modeling of extreme ultraviolet 4000 lines/mm diffraction gratings coated with periodic and aperiodic Al/Mo/SiC multilayers.

Multilayer coated diffraction gratings are crucial components for extreme ultraviolet (EUV) applications such as spectroscopy or spectro-imaging. However, for high groove density, the smoothening of the grating surface profile with multilayer deposition remains a limitation that requires further investigation. In this paper, we report on the design, characterization, and modeling of 4000 lines/mm diffraction gratings coated with periodic and aperiodic Al/Mo/SiC multilayers for EUV radiation. Two types of gratings with different groove depths are compared. Multilayer coatings were designed using a genetic algorithm to maximize the first-order diffraction efficiency in the 17-21 and 19-23nm wavelength ranges at normal incidence. Periodic and aperiodic multilayers with different numbers of layers were deposited by magnetron sputtering on the two types of fused silica gratings, and the grating groove profile evolution was measured by atomic force microscopy and cross-section transmission electron microscopy. The first-order diffraction efficiency was measured in the EUV at 5° incidence using monochromatic synchrotron radiation and modeled using the rigorous coupled-wave analysis method. The simulation models refined by using the Debye-Waller factor to account for the multilayer interfacial roughness show good agreement with experimental data. The results reported in this study will allow for designing efficient EUV multilayer gratings for high-resolution spectro-imaging instruments.

Analytical review of methods for determining the parameters of the groove profile of cable drums

Purpose. The primary goal of this study is to analyze current methodologies aimed at significantly improving the efficiency of using drums of mine hoisting machines and reducing the wear of hoisting ropes. The methods is based on the analysis of scientific works by leading experts in the field of mining engineering specializing in the development of mine hoisting machine designs. The literature review includes theoretical and practical aspects of drum design, analysis of different approaches for their rope capacity optimization, and methods to reduce rope wear during operation. Innovative technical solutions proposed in the works of domestic and foreign scientists are studied. Findings. The analysis of scientific works in the field of mine hoisting machines revealed certain shortcomings in approaches to designing and optimizing drum rope capacity. Often, the impact of dynamic loads and material wear during operation, as well as the specifics of drum operation in various mining conditions, is overlooked. This leads to increased risks of breakdowns and reduced safety of hoisting machines. Therefore, there is a need to develop new methodologies that take these aspects into account, ensuring improved quality and reliability of mine hoists. As a result of the study, an innovative drum design with a variable drum diameter was developed, allowing for increased rope capacity and reduced rope wear. The originality. It lies in the formulation of an optimization problem aimed at improving the design parameters of cylindrical drums for mine hoisting machines. This includes the development of innovative algorithms for determining the optimal characteristics of rope capacity, taking into account dynamic and safety factors. Practical implementation. The new drum design developed in the study significantly increases rope capacity, which is a critical aspect for enhancing the efficiency of mine hoisting machines. The optimization of the drum design also contributes to reducing energy consumption during operation, ensuring safer operation of hoisting machines.

Blazed Silicon Gratings for Soft X-Ray and Extreme Ultraviolet Radiation: the Effect of Groove Profile Shape and Random Roughness on the Diffraction Efficiency

Blazed Silicon Gratings for Soft X-Ray and Extreme Ultraviolet Radiation: the Effect of Groove Profile Shape and Random Roughness on the Diffraction Efficiency

Single-pass method for reconstruction of extreme UV spectra

This work is devoted to the development of a method for the reconstruction of plasma extreme UV (EUV) spectra recorded by a three frame grazing incidence spectrograph (GIS-3D). The spectrograph provides registration of radiation reflected from the diffraction grating (DG) on a three-frame detector based on a microchannel plate with a scintillator screen and registration on a CCD camera, with an exposure time of one frame of ∼1.5 ns. DG has a gold-coated spherical concave form with a radius of curvature of 2 m and dimensions of 30 × 40 × 10 mm3. In this case, radiation is incident on the DG at a grazing angle of 2°; the DG period is 1.66 µm. The new single-pass method for the reconstruction of plasma EUV spectra was developed, which solves the inverse problem of decomposing experimental signals into separate contributions from each of the diffraction orders, followed by the reconstruction of the true plasma spectrum. Using the developed method, the possibility of finding a close approximation to the shape of a DG groove profile based on a priori information about the recorded spectra was demonstrated. In order to test and demonstrate the efficiency of this method, several experimental EUV spectra obtained at the Z-pinch facility Angara-5-1 with a current of ∼3–4 MA through loads made of either tungsten wires or polypropylene fibers were reconstructed. In addition, to test the single-pass method, the transmittance of EUV in cold aluminum was measured in the wavelength range of 3–35 nm, and it has a good match with the Henke database.

Experimental determination of solid-liquid interface energy for para- and diamagnetic solid solution in equilibrium with eutectic liquid under a high magnetic field

The solid-liquid interface energy (SLIE) of the Al-Cu and Bi-Cd systems under a high magnetic field (HMF) has been experimentally determined by a Bridgeman-type directional solidification furnace. The equilibrated grain boundary groove shapes for the paramagnetic solid α-Al solution and the diamagnetic solid Bi solution in equilibrium with the eutectic liquid under various HMFs were observed in Al-15.3at%Cu alloy and Bi-50at%Cd alloy. It can be found that the profiles of grain boundary grooves changed significantly under the action of the HMF. The Gibbs-Thomson coefficient and the SLIE for the solid α-Al and solid Bi solution in equilibrium with the eutectic liquid under various HMFs were obtained from obtained grain boundary groove shapes. The results show that the SLIE of the Al-Cu and Bi-Cd alloys increase and decrease under an HMF, respectively. The interaction theory of magnetic dipoles induced by an HMF can be responsible for the above experimental phenomena. Additionally, the results of the differential thermal analysis (DTA) and theoretical analysis indicate that the undercooling of the Al-15.3at%Cu and Bi-50at%Cd alloys increase and decrease under the influence of an HMF, respectively, which is ascribed to the existence of HMF-induced interface energy.

Thermal Fatigue Effect on the Grain Groove Profile in the Case of Diffusion in Thin Polycrystalline Films of Power Electronic Devices.

In a previous paper, we solved the partial differential equation of Mullins' problem in the case of the evaporation-condensation in electronic devices and gave an exact solution relative to the geometric profile of the grain boundary grooving when materials are submitted to thermal and mechanical solicitation and fatigue effect. In this new research, new modelling of the grain groove profile was proposed and new analytical expressions of the groove profile, the derivative and the groove depth were obtained in the case of diffusion in thin polycrystalline films by the resolution of the fourth differential equation formulated by Mullins that supposed y'2≪1. The obtained analytical solution gave more accurate information on the geometric characteristics of the groove that were necessary to study the depth and the width of the groove. These new findings will open a new way to study with more accuracy the problem of the evaporation-condensation combined to the diffusion phenomenon on the material surfaces with the help of the analytical solutions.

Effect of nanosecond pulsed laser parameters on texturing formation of metallic surface: Experiment and modelling

The laser ablation process is an indispensable tool in precision micromachining for fabricating micro/nanostructures with specific geometries and regulating physicochemical properties on target surfaces. However, the absence of studies on the effect of laser parameters on texturing formation and surface microstructure makes process control and the optimization of surface texturing challenging. In this study, a nanosecond pulsed laser process was employed to create the micro-texturing on the Al alloy surface, emphasizing the effect of process parameters on surficial grain structures and texturing formation. A three-dimensional (3D) heat transfer model based on the finite element (FE) method was developed to numerically visualize the shape-dimensional evolution of micro-texturing during laser ablation. A simplified but effective moving laser heat source model was proposed to predict the dynamic spatial and temporal distributions of heat generation and transfer. Material removal, which was dominated by surface evaporation in the pulsed laser process, was achieved using the element deletion method. Under various laser parameters, the model-predicted cross-sectional groove profiles agreed well with experimental measurements. In addition, the effects of laser power and scanning speed on the groove morphologies were investigated. The experimental findings and numerical models established in this study will provide guidance for precisely controlling pulsed laser parameters to achieve desired texturing structures and dimensions.

Utilization of multi-pass laser processing strategy for enhancing the capability of low power ns laser for machining of Ti-6Al-4V alloy

The present study aims to investigate the deep machining of Ti-6Al-4V alloy using a nanosecond (ns) laser through multi-pass and gas pressure. Experiments were conducted based on Full factorial design (FFD) by varying gas pressure and laser process parameters (LPP). Results showed that deeper grooves could be achieved through multi-pass laser scanning support with appropriate gas flow rate and laser parameters. A higher gas flow rate leads to more efficient removal of material and a faster machining rate. Further, the present findings revealed the substantial influence of laser power on the depth and width of the machined features, accounting for 41.28% and 7.11% of the variations, respectively. Moreover, power exhibited a significant impact on the taper angle (20.69%) and the heat-affected zone (HAZ) (12.04%) during the machining process. Additionally, the utilization of a multi-pass laser scan demonstrated a remarkable effect on the depth (1.89%), width (3.3%), HAZ (9.96%), and taper angle (8.78%). Furthermore, the assisted gas flow rate displayed a significant influence on the machined groove profile, that is, depth (41.97%), width (67.6%), HAZ (65.48%), and taper angle (30.15%). To achieve optimized results for high-depth machining with minimal defect, the present study recommends employing an average power of 40 W, an assisted gas flow rate of 25 L/min, and conducting four passes. These parameters develop laser machined surface with a high depth (~1499 µm) while simultaneously minimizing Taper (1.87°) and narrow HAZ (83 µm). Further, these conditions are suitable for laser cutting, trepanning, and surface texturing using a low-power laser system of Ti-6Al-4V alloy.

Shaped vibration cutting: A novel fabrication method for mid-infrared relief gratings with controllable profiles

Relief gratings are a particular group of diffractive gratings with a controlled profile, which can precisely modulate the intensity distribution of diffractive lights through its surface structure of depressions and elevations. The mechanical ruling is still one of the most dominant methods for fabricating relief gratings due to its accuracy and capacity to texture free-formed surfaces. However, the ruling has the drawbacks of low material adaptability and inflexible profile adjustability that restrict its wider application. This study invents a novel ruling process, i.e., shaped vibration cutting (SVC), which uses a controllable special-shaped vibration locus of a diamond cutting tool. The tool moves perpendicularly to the cutting plane, enabling the ruling-based fabrication of relief grating on difficult-to-cut materials with flexible control of the grating profile. Slope grooving tests with elliptical and triangular trajectories were performed on aluminum and silicon materials to explore the surface generation and defect formation mechanism comprehensively. The defect-less process window regarding the vibration trajectory, crossfeed, depth of cut, and ruling velocity was identified. Finally, mid-infrared relief gratings were successfully fabricated using the SVC process on aluminum without burrs and silicon in a ductile regime with a maximum depth of 2.3 µm, which outperforms the existing cutting-based texturing technique. To further demonstrate the process capacity of SVC in high material adaptability and flexible profile adjustability, multi-blaze gratings that have spatially varying groove profiles have been fabricated on bulk metallic glass.

Improving air-water two-phase flow pumping in centrifugal pumps using novel grooved front shrouds

The present investigations aim to improve the gas-liquid two-phase transport in centrifugal pumps using a novel front shroud design with macroscopic grooves. This increases the secondary flow strength and the two-phase mixing, boosting the performance. A total of 23 different circumferential and radial groove profiles were numerically investigated to identify the best configuration leading to the highest mixing efficiency. Three different loads were considered, i.e., part load, optimal point, and overload. Additionally, the performance of the novel designs was compared with that of the established alternatives, involving two different clearance gaps and/or an inducer. While circumferential grooves already lead to a slightly improved specific delivery work, radial grooves improve noticeably the pump efficiency and deliver a very high two-phase mixing compared to other traditional pump configurations. Under conditions of optimal loading, the utilization of circumferential grooves led to a phase mixing enhancement of approximately 19.5%, whereas the implementation of radial grooves exhibited a notable improvement in mixing efficiency by 64.8% compared to the standard gap. The radial design R14 is superior to all other designs regarding efficiency and phase mixing. It is therefore recommended for transporting gas-liquid two-phase flows.