Film Thickness Measurements Research Articles

Wide-area film thickness measurement method of water-lubricated polymer bearing based on ultrasonic reflection coefficient phase

Wide-area film thickness measurement method of water-lubricated polymer bearing based on ultrasonic reflection coefficient phase

Method for Extracting Optical Element Information Using Optical Coherence Tomography

This study examines the measurement of film thickness, curvature, and defects on the surface or inside of an optical element using a highly accurate and efficient method. This is essential to ensure their quality and performance. Existing methods are unable to simultaneously extract the three types of information: thickness, curvature, and defects. Spectral-domain optical coherence tomography (SD-OCT), a non-invasive imaging technique with imaging depths down to the millimeter scale, provides the possibility of detecting the optical element components’ parameters. In this paper, we propose an error correction model for compensating delay differences in A-scan, field curvature, and aberration to improve the accuracy of system fitting measurements using SD-OCT. During data processing, we use the histogram-equalized gray stretching (IAH-GS) method to deal with strong reflections in the thin film layers inside the optics using individual A-scan averages. In addition, we propose a window threshold cutoff algorithm to accurately identify defects and boundaries in OCT images. Finally, the system is capable of rapidly detecting the thickness and curvature of film layers in optical elements with a maximum measurement depth of 4.508 mm, a diameter of 15 × 15 mm, a resolution of 5.69 microns, and a sampling rate of 70 kHz. Measurements were performed on different standard optical elements to verify the accuracy and reliability of the proposed method. To the best of our knowledge, this is the first time that thickness, curvature, and defects of an optical film have been measured simultaneously, with a thickness measurement accuracy of 1.924 µm, and with a difference between the calibrated and nominal curvature measurements consistently within 1%. We believe that this research will greatly advance the use of OCT technology in the testing of optical thin films, thereby improving productivity and product quality.

Development of a sensor for liquid film thickness measurements during annular flow in microchannels

Development of a sensor for liquid film thickness measurements during annular flow in microchannels

Agent-based modeling system for real-time characterization of film thickness in digital twin coating

In the automated spraying workshop of ship segments, poor visibility caused by dust and fog hampers the effectiveness of the video monitoring system. The traditional method used during the automated spraying process fails to provide real-time measurement of film thickness and prediction of spraying quality, resulting in uneven film thickness and high rework rates. Robotic spraying technology also faces challenges, such as the time-consuming and labor-intensive process of building and computing a highly reliable Computational Fluid Dynamics (CFD) based spraying film-forming simulation model, which cannot be reflected in real-time during the spraying process. The digital twin characterization method, based on the agent model, offers a solution to these limitations and challenges, providing new ideas and approaches for improving and optimizing the spray film formation model. This paper presents the development of a real-time characterization system for sprayed film thickness based on digital twin technology. The spraying film thickness under different working conditions is obtained using Ansys-Fluent simulation software by varying the gun height and gun speed. The predictive model for spraying film thickness is then established using the obtained simulation data and the corresponding gun height and gun speed, employing the surrogate modeling method (BP neural network). The real-time characterization system for spraying film thickness is developed by combining C# and Unity3D. Finally, in order to ensure the accuracy of the predictive model, a spraying experimental platform is built to verify the accuracy of the predictive model.

Investigation of Water Film Dynamics on the Surface of an Airfoil in a High-Speed Flow and Subsequent Ligament Formation and Breakup from the Trailing Edge

Abstract In this work, the dynamics of a liquid film on the surface of NACA 0012 airfoil placed in a high-speed air flow is investigated. Experimental studies were carried out to assess the film thickness, droplet shedding, and the dynamics of the sheet. In the present work, air velocities up to 175 m/s were used with water films flowing between 1.4 and 2.6 cm2/s. The water was introduced on the airfoil via 26 holes each measuring of 0.5 mm holes separated by 1mm at 35 mm downstream of the leading edge of the vane. The results were obtained using four experimental tools. The first is a point measurement of the time-resolved film thickness using a confocal laser induced fluorescence method. Second is time averaged images of the film thickness on the entire vane surface. Third, high speed videos are obtained to study the accumulation and breakup of the liquid at the trailing edge of vane. Finally, laser diffraction and Phase Doppler interferometry were used to document the spray dynamics. The results illustrate that the average film thickness decreases with air velocity and increases with the water flow rate. Also, the dominant frequency of liquid film wave, ligament breakup length, drop size and spray concentration increase with the air velocity and is modestly affected by water flow rate. Finally, design tools are provided to predict the average film thickness and dominant frequencies of the film thickness, ligament breakup, spray concentration and droplet average size.

Unconventional coil shape design of eddy current sensors and the effect of shape parameters on the micro/nano-scale metal film thickness measurement performance

Abstract The thickness of metal film is a critical parameter, especially in micro/nano-manufacturing, where high-precision measurement is essential. The eddy current method, a non-destructive testing technique, is well-suited for in-situ measurement of micro/nano-scale metal film thickness due to its superior performance. However, enhancing the measurement capabilities of eddy current sensors remains a significant challenge. In practical applications, thickness sensitivity and spatial resolution are two key performance indicators of eddy current sensors, and improving both simultaneously is difficult. While the sensitive element (coil) of an eddy current sensor has a substantial impact on thickness sensitivity, its effect on spatial resolution has received less attention.
This study establishes an eddy current coil model based on electromagnetic field theory, defining both thickness sensitivity and spatial resolution in the context of micro/nano-scale metal film thickness measurement. Two unconventional coil shapes are introduced, contrasting with the traditional cylindrical design, to investigate the influence of coil shape parameters, specifically the spatial distribution of the coil turns, on the key performance indicators. Simulation results are corroborated through experimental validation. Based on a series of calculations and analyses, an optimization method for coil shape parameters is proposed using a defined comparison factor that balances both thickness sensitivity and spatial resolution, which offers a promising approach for improving coil shape design.

Design of a high-performance surface plasmon resonance device for effective measurement of thin liquid film thickness

Design of a high-performance surface plasmon resonance device for effective measurement of thin liquid film thickness

High-accuracy ultrasonic measurement of oil film thickness in sliding bearings considering surface thin coating

Focusing on the difficulty and inaccuracy of separating reflected waves from overlapping echoes caused by coating when measuring the oil film thickness of coated sliding bearings using ultrasonic. This paper proposes a pseudo reflection coefficient (PRC) constructed using the overall reflected wave and reference wave. And a robust PRC model is constructed to simultaneously calculate the oil film and coating thickness. Acoustic simulations verify the accuracy of the method and reveal that the PRC model has better stability. Application experiments are conducted on an actual aviation fuel gear pump. The good consistency between theory and experiment has demonstrated the effectiveness of the method. In addition, the elastic deformation of the bearing is derived based on the minimum oil film thickness.

Characterization method of conductive film state of micro-cathode arc thrusters

Micro-Cathode Arc Thruster (μCAT) is an advanced electric propulsion system developed in the past decades to meet the maneuvering requirements of space microsatellites. However, the constraint on the its application is the short lifespan of the thruster. This is attributed to the conductive film, a key component of thruster discharge. In this study, we propose a measurement method for μCAT conductive film, and enables the evaluation of the evolution process of film thickness. The method is based on the four-probe resistivity testing theory and size effect fitting model, and establishes a method for characterizing the thickness and resistivity of μCAT conductive films. A comparison was made between the corrected resistivity test results of 1, 2, 5, and 10 μm film and the fitting results of the titanium film, revealing an error ofapproximately 10%. Additionally, a total of 2500 ignition experiments were conducted to verify the film thickness and resistance measurement of this method. This research serves as a valuable basis for the lifetime investigation of μCAT. Consequently, the thickness of the film progressively decreases with each discharge cycle, and the resistivity exhibits a corresponding increase due to the size effect. This method could be used as an effective method for exploring the μCAT lifespan and performance.

In Situ Measurement of Grease Capacitive Film Thickness in Bearings: A Review

In Situ Measurement of Grease Capacitive Film Thickness in Bearings: A Review

Study on Initial Corrosion Behavior of Arc-thermally Spray Zn, Zn–Al, and Al–Mg Coatings Exposed in Atmospheric Environment for One-Year

AbstractThis paper presents the results of a study comparing the initial corrosion characteristics of thermal spray coatings on Zn, Zn-Al, and Al–Mg thermal spray coatings after one year atmospheric exposure tests at two atmospheric environment sites. The thermal spray coatings were obtained by electroric arc spraying of various metals onto a carbon steel substrate. Atmospheric exposure tests were also conducted for outdoor accelerated exposure tests in which test specimens were applied with artificial seawater. The corrosion properties of these spray coatings were evaluated by surface analysis, film thickness measurements, cross-sectional analysis and anodic/cathodic polarization measurement. After one year of atmospheric exposure testing, white, granular corrosion products were observed on the surface of the Zn and Zn-Al thermal spray coatings, while no significant changes were observed in the Al–Mg thermal spray coating. Similar results were obtained for the surfaces of test specimens in atmospheric exposure tests with artificial seawater. The thickness of the thermal spray coating increased for the Zn thermal spray coating, while no significant change was observed for the other thermal spray coatings. Thus, differences in corrosion behavior were observed due to the composition of the thermal spray coatings. The initial corrosion behavior of the thermal spray coatings was also investigated based on the results of coating morphology and cross-sectional elemental distribution of the coatings.

Annular two-phase flow in a small diameter tube: OpenFOAM simulations with turbulence damping vs optical measurements

In this work, numerical simulations are performed to predict two-phase annular flow of refrigerant R245fa inside a 3.4 mm diameter vertical channel. The VOF (Volume of Fluid) method implemented in an OpenFOAM solver is used to accurately track the vapor-liquid interface. A 2D axisymmetric domain is considered and the Adaptive Mesh Refinement (AMR) method is applied to the cells near the liquid/vapor interface. The Reynolds-Averaged Navier Stokes (RANS) equations are solved and the k-ω SST model is adopted for turbulence modelling in both the liquid and vapor phase. Simulations are used to calculate instantaneous and mean values of the liquid film thickness at mass flux G = 100 kg m-2 s-1 and vapor quality ranging between 0.2 and 0.85. Numerical results are compared against measurements of the liquid film thickness taken during vertical annular downflow. Previous works from the literature and the deviations observed between present numerical and experimental results suggest the need for turbulence damping at the vapor-liquid interface by adding a source term in the ω equation. The simulations show that a low value of the turbulence damping parameter (e.g. 1) causes the average liquid film thickness to increase by 25 %–52 % compared to the non-damped scenario. The interface presents large amplitude disturbance waves in the non-damped case, whereas small ripple waves are predicted when turbulence damping is introduced. Furthermore, the difference between the application of a symmetric and asymmetric treatment for the source term is analysed. From the comparison between experimental data and numerical simulations, it emerges that the value of the correct damping source term to be applied is strictly dependent on the vapor quality.

Effects of hydrogen on the tribological performance of heavily loaded lubricated contacts

The objectives of this investigation were to experimentally characterize the effect of hydrogen on the tribological performance of heavily loaded lubricated contacts. In order to achieve these objectives, a ball-on-disk film thickness and traction measurement test rig and a four-ball wear tester were modified to introduce gaseous hydrogen into the lubricated contact. Using the ball-on-disk test rig, lubricant film thickness, and traction were measured operating in air, nitrogen, and hydrogen environments. The results indicate that hydrogen environment has no effect on the lubricant film thickness and traction coefficient. The wear performance of the lubricant was evaluated in air, nitrogen, and hydrogen environments using the four-ball tester according to ASTM D4172 standard. Wear scar dimensions were determined through optical profilometry and compared for each condition. The results demonstrated that the wear scar diameter is slightly higher in a hydrogen environment. Additionally, the effects of hydrogen embrittlement on the wear performance were investigated using the four-ball tester. The balls used in the four-ball tester were precharged with hydrogen in Ammonium Thiocyanate. Wear scar profilometry results showed significantly larger wear scars and excessive pitting on the worn surface of precharged specimens. Results from this investigation shows that a gaseous hydrogen environment has a negligible effect on friction and wear as compared to diffused hydrogen in the material.

Tin Lodide Thin Films Growth via Plasma Enhanced Chemical Vapor Deposition and its Optimization Using V–I Probe Impedance Analyser for Optoelectronic Applications

AbstractTin(ii) iodide (SnI2) faces significant challenges in photodetector applications, primarily due to its sensitivity to moisture and degradation over time. Achieving uniform, high‐quality films with low impurity and defect levels is also a challenge. Potential solutions include advanced deposition techniques to improve film quality and stability, surface passivation and encapsulation, doping and alloying. In this study, SnI2 thin films have been deposited for the first time using plasma enhanced chemical vapour deposition (PECVD) technique to the best of our knowledge. Process parameters like deposition pressure and RF‐power have been optimised via non‐intrusive in‐situ V−I probe impedance analyser. SnI2 thin films have been deposited on glass & transparent conducting oxide (TCO) and p‐Si wafer at various RF‐power to make SnI2/p‐Si heterojunction followed by metallization to make Ag/SnI2/p‐Si/Ag heterojunction photodetector. Characterization techniques like thin film thickness measurement, UV‐Vis‐NIR spectroscopy, Photoluminescence spectroscopy, glancing incidence x‐ray diffraction (GIXRD), SEM and I−V measurements were carried out to study its optical, structural and electronic properties. Fabricated devices, Ag/SnI2/p‐Si/Ag heterojunction photodiode exhibits best critical performance for the film deposited at 150 W having rectifying ratio of 6.9×104 at 1.0 V and photo‐sensitivity of 1.6×104 at 100 mW/cm2 light intensity.

Evolution of liquid film in a crossflow tunnel: liquid film thickness measurement and effect of droplet impingement on film breakup

Abstract Liquid jet in crossflow tunnel has widespread applications in various industrial devices,
with the measurements of liquid film on the bottom surface pivotal in exploring relevant mechanisms
such as heat transfer and film breakup. This work reports the measurements of liquid film on the
bottom surface of a crossflow tunnel using the brightness-based laser induced fluorescence (LIF)
method under different flow conditions at ambient pressure and temperature. Film breakup
phenomena are observed downstream within the tunnel. Employing the shadowgraph method, two
distinct patterns of film breakup associated with the droplet impingement positions on the film wave
are identified, i.e., bag breakup and membrane breakup. The film thickness is subsequently calculated,
and jet impingement and spray impingement of injected liquid on tunnel bottom surface are classified
based on the centerline film thickness. A critical jet-to-crossflow momentum flux ratio (q) is determined to be proportional to the square of tunnel height. The averaged film thickness across the entire cross-section downstream at a distance of 50 mm from the nozzle is found to increase with the logarithm of q. Besides, the film boundaries are also identified under different flow conditions, which can be well predicted by a quadratic fit with the fitting parameters also correlated to the logarithm of q.

Enhancing the Range and Reliability of the Spacer Layer Imaging Method

The spacer layer imaging method (SLIM) is widely used to measure the thickness of additive and lubricant films, in lubricant development and evaluation, and for fundamental research into elastohydrodynamic lubrication and tribofilm formation mechanisms. The film thickness measurement, as implemented on several popular tribometers, provides powerful, non-destructive in-situ mapping of film topography with nanometre-scale height sensitivity. However, the results can be highly sensitive to experimental procedure, machine condition, and image analysis, in some cases reporting unphysical film thickness trends. The prevailing image analysis techniques make it challenging to interrogate these errors, often hiding their multivariate nonlinear behaviour from the user by spatial averaging. Herein, several common ‘silent errors’ in the SLIM measurement, including colour matching to incorrect fringe orders, and colour drift due to the optical properties of the system or film itself, are discussed, with examples. A robust suite of novel a priori and a posteriori methods to address these issues, and to improve the accuracy and reliability of the measurement, are also presented, including a novel, computationally inexpensive circle-finding algorithm for automated image processing. In combination, these methods allow reliable mapping of films up to at least 800 nm in thickness, representing a significant milestone for the utility of SLIM applied to elastohydrodynamic contact.Graphical abstract

A novel laser interferometric method for thin film thickness measurement in gas–liquid intermittent flow

Abstract In horizontal intermittent flow, the long bubbles move toward the center of the pipe due to inertia, forming the thin liquid film above the long bubbles. Accurate measurement of the liquid film thickness is crucial for heat and mass transfer. In this paper, laser interferometric technology is innovatively introduced to measure the film thickness of the intermittent flow, and the thin liquid film is detected with a resolution of 100 nm. Considering the curvature of the circular pipe wall, which leads to divergent reflected light, the effect of the pipe wall on the interference pattern is explored by the ray tracing technique. A two-dimensional interpolation phase retrieval algorithm based on light intensity is proposed to reconstruct the thickness of the liquid film, and the average error is less than 1.86%. Benefiting from the exceptionally high resolution, research is conducted on the thin liquid film at the top of the horizontal intermittent flow, revealing its dependence on the sub-regimes and gas–liquid velocities.

Experimental Investigation of Film Thickness in Wastewater Airlift Pumps by an Image Processing Method

The airlift pump is a key part of wastewater treatment and is employed as an innovative and feasible collection tool. However, as one of the key factors in the lifting capability of airlift pumps, film thickness in the gas–liquid two-phase flow operating in pumps is still an unknown topic because it is difficult to measure. This paper proposes a visualization method for measuring film thickness and investigates the film thickness when operating under gas flow with a high rate in airlift pumps using experiments. Firstly, a simulation experiment platform was built, and the images of the film structure were acquired by a high-speed camera. Then, image-processing technology and an image distortion correction were proposed to extract the gas–liquid interface for studying the thickness of the film. The experimental results demonstrated that a large film thickness ranging from 0.15 D to 0.24 D was found in airlift pumps and that its film thickness kept a constant value, even under a high gas superficial velocity, maintaining a large output liquid flow from airlift pumps. As wastewater was carried by wastewater treatment, a larger film thickness of the annular film will benefit the high lifting rate of wastewater. The works in this paper offer valuable insights for the higher performance of working airlift pumps and wastewater treatment efficiency.

Comparative Analysis Of Brightness-Based Laser-Induced Fluorescence (BBLIF) And Structured Planar Laser-Induced Fluorescence (S-PLIF) For Film Thickness Measurement In Two-Phase Flow

Improved understanding of the interactions between gas and liquid phases in gas sheared film flow is crucial for n improved capability to employ computational modelling in the future to optimize systems, thereby reducing environmental impact, increasing efficiency, and enhancing productivity. This abstract compares two techniques for measuring the thickness of the film in different regimes visible in a rectangular cross-section gas-sheared liquid film rig, namely previously published Brightness Based Laser Induced Fluorescence (BBLIF) data and Structured Planar Laser Induced Fluorescence (S-PLIF) from the current investigation. The study presents and compares examples at a specific liquid flow rate (8 litres per minute) for superficial gas velocities in the range 1 m/s to 10 m/s, noted as being in different flow regimes. The investigation reveals that the S-PLIF technique produces results that are within the uncertainty bands of the BBLIF data for most scenarios. However, in the transition regime, statistical variations emerge. The frequency content of the two film heights is analyzed using a Hilbert-Huang Technique. This shows clearer results for the S-PLIF than for BBLIF which is attributed to the erratic values that can occur in BBLIF when total internal reflection occurs. It is concluded that the S-PLIF technique demonstrates promise as a reliable method for determining film thickness which is highly advantageous as it can be applied to images obtained with seeded flow intended for PIV analysis. The S-PLIF film thickness data can be used for generating automated masks for PIV analysis concurrently conducted in both the gas and liquid phases. This advancement facilitates the enhanced capability to advance understanding of complex fluid dynamics and optimize system performance.

Effect of orientation and hardness of rubber tread block on the friction coefficient under glycerol lubrication and its underlying mechanisms

This study examines the influence of orientation and hardness of rubber tread blocks on friction under glycerol lubrication, focusing on negative fluid pressure. Measurements of fluid pressure, film thickness, and friction coefficient were conducted at the contact interface. Results showed that when tread blocks aligned parallel to the sliding direction, the friction coefficient increased by 57–191 %, attributed to either reduced film thickness or enlarged real contact area from greater negative fluid pressure. Conversely, with a perpendicular orientation, decreased hardness led to increased friction, due to thinner fluid films from enhanced negative pressure.