Surface Roughness Parameters Research Articles

Evaluation of Macro- and Micro-Geometry of Models Made of Photopolymer Resins Using the PolyJet Method.

Additive manufacturing (AM) techniques are among the fastest-growing technologies for producing even the most geometrically complex models. Unfortunately, the lack of development of metrology guidelines for these methods, related to dimensional and geometry accuracy and surface roughness, significantly limits the commercialization of finished products manufactured using these methods. This paper aims to evaluate the macro- and micro-geometry of models manufactured using the PolyJet method from three types of photopolymer resins: Digital ABS Plus, RGD 720, and Vero Clear. For this purpose, test parts were designed and then manufactured on an Object 350 Connex3 3D printer. The Atos II Triple Scan optical system and the InfiniteFocusG4 microscope were used to evaluate macro- and micro-geometry, respectively. For both systems, measurement procedures were developed to obtain statistical results for evaluating geometric accuracy and surface roughness parameters. In the case of macro-geometry, for Digital ABS Plus and Vero Clear materials, 50% of the central deviations (between first quartile Q1 and third quartile Q3) lie within the range (-0.06, 0.03 mm) and for RGD 720 material within the range (-0.08, 0.01 mm). For micro-geometry, the arithmetic mean height (Sa) values for the Digital ABS Plus and Vero Clear samples were approximately 1.6 and 2.0 µm, respectively, while for RGD 720, it was 15.9 µm. The total roughness height expressed by reduced peak height (Spk) + core height (Sk) + reduced dale depth (Svk) for the Digital ABS Plus and Vero Clear samples was approximately 9.1 and 10.5 µm, respectively, while for the RGD 720, it was 101.9 µm.

Mechanical properties of 3D-printed resin denture teeth: An in vitro study.

The purpose of this study was to compare the wear, fracture strength, and mode of failure of various brands of 3D-printed resin denture teeth with prefabricated acrylic resin. Additionally, the study aimed to analyze the different modes of failure exhibited by these teeth. The study utilized 90 3D-printed and 30 prefabricated, 3D-printed resin teeth from three brands: L = Optiprint Lumina, A = ASIGA DentaTooth, P = Power resins, along with prefabricated acrylic teeth from M = Major Super Lux. Each of the 30 samples per main group was divided into two subgroups: The first subgroup samples (M1, A1, L1, P1) were subjected to thermal cycling and mechanical loading; M2, A2, L2, and P2 were not aged and tested directly. A scan of a prefabricated acrylic tooth was taken using an intraoral scanner, and then the STL file was printed using an Asiga 3Dprinter. The specimens underwent aging to simulate 5 years of clinical use with 10,000 thermal cycles and 1,200,000 dynamic load cycles on a chewing simulator. Surface roughness parameters (Rz, Ra, Rq) were measured using a 3D Optical Profilometer, fracture resistance was assessed using a universal testing machine, and SEM analysis was performed to observe failure modes. Statistical analysis using T-test, one-way analysis, and two-way analysis processed by the Statistical Package for Social Sciences (SPSS) software version 23.0 (SPSS: Inc., Chicago, IL, USA) was done with a level of significance set at <0.05. The results showed that the difference in surface roughness parameters (Rz, Ra, Rq) before and after aging for Group M, Group A, Group L, and Group P was statistically significant (p < 0.05). Two-way ANOVA for wear resistance between aging and groups on dependent variable Rz (p = 0.002), Ra (p = 0.001), Rq (p = 0.001) were significant. Multiple comparisons for surface roughness parameters showed Group A and Group L were lower than Group P and Group M (p < 0.05). For fracture strength, One-way ANOVA showed a significant difference between groups for fracture strength either without or after the aging procedure (p < 0.05). Multiple comparisons for fracture strength without aging showed no significant difference between Group M, Group A, and Group L (p > 0.05). After the aging procedure fracture strength for Group M was higher than Group A, Group L, and Group P (p < 0.05). 3D-printed resin teeth showed a greater and comparable wear resistance to prefabricated acrylic teeth. Fracture strength was comparable between prefabricated acrylic teeth and 3D-printed resin (Asiga and Lumina) before aging, but after aging 3D-printed resin teeth showed less fracture strength.

Surface Roughness Evaluation of AZ31B Magnesium Alloy After Rough Milling Using Tools with Different Geometries

This paper presents the experimental results of a study investigating the impact of machining parameters on 3D surface roughness after rough, dry milling. The following 3D roughness parameters were analysed: Sa (arithmetic mean height), Sq (root mean square height), Sz (maximum height), Sku (kurtosis), Ssk (skewness), Sp (maximum peak height), and Sv (maximum pit height). Roughness measurements were made on the end face of the specimens. Additionally, 3D surface topography maps and Abbot-Firestone material ratio curves were generated. Carbide end mills with variable rake and helix angles were used in the study. Experiments were conducted on AZ31B magnesium alloy specimens using a contact-type profilometer. The machining process was conducted using the parameters of so-called high-speed machining. Three variable technological parameters were analysed: cutting speed vc, feed per tooth fz, and axial depth of cut ap. The results showed that the surface roughness of the rough-milled specimens depended to a great extent on the tool geometry and applied machining parameters. Feed per tooth was found to have the greatest impact on surface roughness parameters. Lower values of the analysed surface roughness parameters (and therefore higher surface quality) were obtained (in most cases) for the tools with a rake angle γ of 5° and a helix angle λs of 50°. The results provided both theoretical and practical knowledge about the achievable surface roughness after rough milling using tools with different tool blade geometry. It was shown that rough milling is an effective and efficient type of machining for the AZ31B alloy.

Effect of Shot‐Peening Process and Nanoparticle‐Added Lubricant on the Tribological Performance of Aluminium‐Based Sliding Bearing Material

ABSTRACTIn this study, it is aimed to increase the wear and fatigue performance of aluminium‐based sliding bearing material by using silver nanoparticles (AgNPs) added lubricant and shot‐peening process. The main purpose is to minimise the wear of the bearing material by penetrating AgNPs added lubricants into the rough surfaces formed by shot peening. Almen intensity, coverage and shot size parameters in the shot‐peening process were analysed in terms of hardness, surface roughness and fatigue strength. The shot‐peened aluminium bronze was subjected to wear experiments under dry, pure water and AgNPs added lubricant conditions. The wear test results were analysed in terms of friction coefficient, wear volume and surface roughness parameters, and the interaction of lubricant and shot‐peening parameters was evaluated. According to the results of the shot‐peening experiments, the Almen intensity was the most effective parameter in terms of hardness and surface roughness (91.62%). It was concluded that the hardness value was 8% higher at high Almen (12–14A) intensity compared with low Almen intensities, and the shot‐peening process could increase the fatigue strength by ~21 times. According to the wear tests, the most effective parameters were 4–6 Almen intensity and AgNP‐added lubricant.

Effect of raceway surface topography based on solid lubrication on temperature rise characteristics of HIPSN full ceramic ball bearings

PurposeThis study aims to understand the influence of raceway surface topography on the temperature rise characteristics of silicon nitride (Si3N4) full ceramic ball bearing and improve its service life.Design/methodology/approachThe arithmetic average height Sa, skewness Ssk and kurtosis Sku in the three-dimensional surface roughness parameters are used to quantitatively characterize the surface topography of the raceway after superfinishing. The bearing life testing machine is used to test the Si3N4 full ceramic ball bearing using polytetrafluoroethylene (PTFE) cage under dry friction conditions, and the self-lubricating full ceramic ball bearing heat generation model is established.FindingsWith the decrease of Sa and Ssk on the raceway surface and the increase of Sku, the average height of the raceway surface decreases, and the peaks and valleys tend to be symmetrically distributed on the average surface, and the surface texture becomes tighter. This kind of raceway surface topography is beneficial to form a thin and uniform filamentous PTFE transfer film with a wide coverage area on the raceway surface based on consuming less cage materials and improving the temperature rise characteristics of hot isostatic pressing silicon nitride full ceramic ball bearings.Originality/valueThe research results provide a theoretical basis for the reasonable selection of Si3N4 ring raceway processing technology and have important significance for improving the working characteristics and service life of Si3N4 full ceramic ball bearings under dry friction conditions.

A study on the repeatability of electroformed electrochemical gas driven micro-pump, using the surface roughness of cathode electrodes

ABSTRACT The objective of this paper was to analyse the effect of the surface roughness of a deposited copper cathode on repeatability for the discharge flow rate of an electroformed micro-pump. For this purpose, a measurement set-up was assembled using a glass gauge with a threshold sensor. Each test cathode was fitted into the micro-pump and the flow rate was measured three times. The value of the standard deviation of the measured flow rate was calculated as a criterion for the repeatability of the prepared micro pump. Finally, the covariance value and correlation coefficient between each surface roughness parameter and standard deviation of flow rate were calculated and compared. The results demonstrated that the Rz surface roughness parameter has the strongest relation with micro-pump flow rate repeatability using covariance analysis. Also, the auto-correlation length (ACL) that can describe the surface roughness using a correlation function has the most linear relation among all surface roughness parameters with a flow rate based on correlation analysis. SEM analysis and hydrogen bubble illustration were also reported.

Synthesis, Structural, and Optical Properties of Modified Poly(vinyl Chloride) Thin Films by Ethylenediamine Loaded with Metal Oxide Nanoparticles

AbstractPoly (vinyl chloride) (PVC) films modified with ethylenediamine (en) and doped by nanoparticles (TiO2, ZnO, NiO, and MgO). A mixture of 0.5 g PVC/en dissolved in THF and 0.01 wt % of nanoparticles were used in doping PVC to produce the nanocomposite films. All modified PVC films were characterized by different analysis techniques such as Fourier Transform Infrared (FTIR), Nuclear Magnetic Resonance Spectrometer (NMR), diffusive reflectance spectroscopy (DRS), X‐ray diffraction analysis (XRD), and scanning electron microscopy (SEM). The DRS was used to analyse the scattered IR energy of the samples at wavelengths between (250–1350 nm). The optical properties and oscillator strength were also studied, the transmittance and reflectance values declined for the PVC films, and the absorption coefficient was observed between (79–89 %). The direct energy gap decreased from 4.6 to 1.9, and the indirect energy gap reduced from 4.3 to 1.9. The XRD exhibited a semi‐crystalline structure and the SEM test exhibited a porous structure of all samples. The Urbach energy was increased from 0.8772 eV to 14.712 eV, single oscillator energy ( ) was also increased from 6.38 eV to 13.69 eV and the dispersion energy increased from 23.40 eV to 70.63 eV. Moreover, the surface roughness parameters Ra and Rq of the PVC films in modified and doping were increased from 3.86 nm to 8.14 nm, and 5.08 nm to 10.10 nm respectively. So, PVC results show increased optical properties after modification with en and doping by NPs are used in the light conversion and aerospace industries.

Oil Plant Pomace as a Raw Material in Technology of Sustainable Thermoplastic Polymer Composites

The design of composites offers extensive opportunities for controlling parameters and utilizing diverse materials, including those sourced from recycling or waste streams. In this study, biocomposites were developed using high-density polyethylene (HDPE) and pomace derived from oilseed plants such as evening primrose, gold of pleasure, rapeseed, and sunflower seeds, mixed in a 1:1 ratio. These biocomposites were evaluated for their structural, mechanical, morphological, and thermal properties, as well as their vulnerability to overgrowth by cellulolytic fungi. The results indicate that incorporating plant waste into HDPE reduces thermal stability while increasing water absorption and thickness swelling. Additionally, the biocomposites showed enhanced fungal growth, which may improve their biodegradability. Notably, the PE_EP composite, derived from evening primrose pomace, did not show significant differences in surface roughness and MOE parameters compared to pure polyethylene. In the case of PE_R composite, an increase in MOE was observed while maintaining the MOR parameter compared to pure PE. Although generally the mechanical properties of composites were lower compared to pure polyethylene, the findings suggest that with further optimization, oil plant pomace can be a valuable raw material for producing biocomposites suitable for various industrial applications, thereby contributing to sustainability and effective waste recycling.

Electromagnetic wave scattering simulation from precision grinding SiC surface under the influence of suspended micro-particles

ABSTRACT In a precision machining environment, suspended particles in the air have a non-negligible effect on visual roughness measurement results. To address this issue, this paper analyzes the influence of particles on the visual roughness measurement from theoretical derivation and numerical simulation, respectively. Firstly, based on the Lambert-Beer and the light scattering principles, the propagation equation of incident light under the joint action of suspended particles and rough surfaces is derived. Then, a numerical simulation model is designed, and the theoretical equations are verified by simulation experiments. The influence of particle material, particle size (D), particle concentration (N), light wavelength (λ), and SiC surface roughness (R a ) on the average electric field magnitude of the energy-acquisition boundary are analysed based on the simulation experiments. The theoretical derivation shows that the average electric field magnitude of the energy-acquisition boundary is mainly influenced by particle state and rough surface state. The simulation experiment results show that both the particle parameters and the rough surface parameters are consistent with the theoretical derivation. As R a increases, the effect of N on the measurement results decreases. The results reveal the influence mechanism of suspended particles on the visual roughness measurement results and provide a basis for improving visual roughness measurement accuracy.

Multi-objective Optimization of Process Parameters for Surface Quality and Geometric Tolerances of AlSi10Mg Samples Produced by Additive Manufacturing Method Using Taguchi-Based Gray Relational Analysis

AbstractIn this study, it has been focused on examining the effects of production parameters on quality parameters such as surface roughness and geometric tolerances in the production of AlSi10Mg samples by the additive manufacturing method. The experimental design has been prepared according to the Taguchi L27 orthogonal array. As a result, in the production of samples, increasing laser power (P) contributed positively to surface roughness and diameter change, and increasing scanning distance (SD) negatively contributed to circularity change and concentricity. Further, it has been determined that increasing the scanning speed (SS) negatively affects the concentricity change of the produced samples. The optimum production parameters for surface roughness and diameter variation has been determined as A1B1C3. The optimum production parameters for circularity variation and concentricity have been determined as A3B3C1 and A3B1C1, respectively. According to the ANOVA analysis results, the most effective parameters for surface roughness, diameter change, circularity change and concentricity have been 53.22% P, 62.45% SD, 37.23% SS and 40.41% SD, respectively. Furthermore, as a result of the gray relationship analysis (GRA) performed for the output parameters, the optimum production parameter has been determined as A2B1C3.

An Experimental Investigation Replicating the Surface Behavior of Ground Steel Gears in Mixed Lubrication Using Twin-Disk Testing Part 1: Running-in

ABSTRACT The surface of ground gear teeth is changed during the initial period of operation through a process termed running-in. During this process asperity peaks are plastically deformed and removed to better distribute the load across the surface, resulting in modification of the surface finish. In this work the influence of pressure, slide-roll ratio, and entrainment velocity on two-dimensional surface roughness parameters is evaluated through the running-in process using a full-factorial experimental programme. Hardened steel disks are used to simulate gear tooth contacts via the use of a twin-disk rig. Results showed that all three variables strongly influence the change in surface geometry, both individually and through both two- and three-factor interactions.

Process Parameter Effects on Powder Mixed EDM Machining Characteristics Using Biocompatible Ti-6Al-4V Alloy

This study examines how various process parameters affect the machining properties of a bio-compatible Ti-6Al-4V alloy using PMEDM with silicon carbide (SiC) powder. The parameters investigated include peak current, pulse on/off time, powder concentration, and voltage gap. The study analyzed their effects on material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and surface morphology. A central composite design was used in the tests to make empirical models that use response surface methods to link the process parameters to the machining results. It is found that the Pulse current and Ton influence the material removal rate and the surface roughness significantly. The powder concentration also impacts PMEDM's machining performance. The Scanning electron microscopic images reveal the effect of powder seen in the machined components. The crater, micro cracks and machining marks can be seen in the SEM images. The surface integrity is correlated with the output parameters of surface roughness. The developed mathematical models effectively predict and optimize the machining properties of Ti-6Al-4V alloy using PMEDM with SiC powder. This research offers valuable insights for applying PMEDM in the fabrication of biomedical implants and devices made from Ti-6Al-4V alloy.

Submerged surface texturing of AISI 304L using the pulsating water jet method

Submerged jets have a variety of practical applications due to their versatility in providing efficient and environmentally friendly options for treatment in various industries. The physical background is based on the continuous water jet (CWJ) application powered via stagnation pressure. However, it is known that impact pressure is much more effective than static pressure. When the impact pressure is repeated with a high frequency per time unit, the erosive effects of water can be used even at pressures below 100 MPa, which is attractive from the point of view of the low demands of the hydraulic system. Surface modification utilising impact pressure can be achieved by employing the pulsed water jet (PWJ) method. The combination of parameters such as the traverse speed and trajectory pattern can control the number of water clusters impacting the material surface. So far, the field of application of PWJ for surface treatment has mostly been investigated water atmospheric conditions. This article focuses on the possibility of the surface modification of AISI 304L stainless steel using the PWJ method under submerged conditions. The results are compared to those obtained under atmospheric conditions. The reference samples were treated by the same technological conditions using a continuous water jet (CWJ). The affected surfaces were characterised using areal surface roughness parameters Sa, Sz, Sp, and Sv, and the surface topography and mechanism of erosion wear were evaluated by scanning electron microscopy. A significant increase in all roughness parameters was confirmed using the PWJ compared to the CWJ method (both in atmospheric and submerged conditions), which confirms the importance of using impact pressure. The surface treatment by PWJ under submerged conditions resulted in a decrease of the surface roughness parameter Sa by approximately 97% compared to atmospheric conditions at a traverse speed of 2 mm/s for perpendicular interleaved trajectory, nevertheless, the homogeneity of treatment over a larger area was improved.

Adverse effects of sterilization processes on the fundamental topographic properties of modified dental implant surfaces

The employ of sterilization processes are essential to investigate biomaterials aiming for experimental, preclinical, or clinical applications with biological tissues. However, responsive surface properties of biomaterials may be susceptible to sterilization processes, compromising important physio-chemical characteristics. For that reason, this in vitro study aimed to investigate the effects of three different processes for sterilization (humid heat under pressure, UVC-light exposure, and Gamma irradiation) on the major topographical properties of implant surfaces applied to dental bone-anchored implants and/or implant-abutments. Three groups of implant surfaces were developed: a smooth machined surface, a micro-texturized surface, and a hydrophilic micro-texturized surface. The implants were sterilized with three methodologies and characterized regarding surface morphology, elemental surface composition, roughness parameters, wettability characteristics, and compared to the samples as-developed. Surface morphology and roughness parameters were not modified by any of the sterilization processes applied. On the other hand, hydrophilic implants were negatively affected by autoclaving. After package opening, hydrophilic features showed to be sensible to atmospheric air exposition independently of the sterilization process performed. Our findings revealed significant chemical changes on the implant surfaces caused by autoclaving and UVC exposure; additionally, the results showed the importance of selecting an appropriate sterilization method when investigating hydrophilic implants so as not to generate imprecise outcomes.Graphical

Research on the correlation between roughness parameters and contact stress on tooth surfaces and its dominant characteristics

The contact performance of the tooth surface is a crucial factor affecting the operational lifespan of gears. There is a significant correlation between tooth surface topography and contact stress, as well as fatigue performance. To investigate the influence of different topography parameters on tooth surface contact stress, this paper performs analytical calculations on asperity contacts of rough tooth surfaces based on reconstruction modeling. Through efficient calculations, sufficient correlation analysis data is obtained. The neural network analysis method is used to measure the degree of influence of roughness parameters on tooth surface contact performance. Research on the correlation between micro-topography parameters and maximum contact stress on tooth surfaces, as well as regression analysis, is conducted. The results show that: (1) Considering rough surfaces, the tooth surface contact stress field exhibits two stress peaks in the near-surface layer and sub-surface layer, with a maximum Mises stress increase of up to 30 % compared to a smoother surface. (2) In the case of low roughness (Sa < 0.2 μm), the amplitude of the maximum Mises stress peak in the near-surface layer is close to that in the sub-surface layer. However, as the roughness amplitude increases, the amplitude of the near-surface stress peak increases sharply. (3) Ranking the roughness parameters based on their influence on contact stress, the main parameters characterizing contact performance are identified as Spk, Vmp, and Sq. The peak characteristics of the surface are the decisive factors affecting fatigue extremes, which are stronger than the traditional surface roughness parameter Sq. This paper establishes a direct correlation model between tooth surface topography parameters and contact stress, providing a foundation for simplifying stress calculations considering complex topographies and offering new insights for fatigue-resistant design of tooth surfaces.

Cytotoxicity and antibacterial susceptibility assessment of a newly developed pectin–chitosan polyelectrolyte composite for dental implants

Biopolymers such as chitosan and pectin are currently attracting significant attention because of their unique properties, which are valuable in the food industry and pharmaceutical applications. These properties include non-toxicity, compatibility with biological systems, natural decomposition ability, and structural adaptability. The objective of this study was to assess the performance of two different ratios of pectin–chitosan polyelectrolyte composite (PCPC) after applying them as a coating to commercially pure titanium (CpTi) substrates using electrospraying. The PCPC was studied in ratios of 1:2 and 1:3, while the control group consisted of CpTi substrates without any coating. The pull-off adhesion strength, cytotoxicity, and antibacterial susceptibility tests were utilized to evaluate the PCPC coatings. In order to determine whether the composite coating was the result of physical blending or chemical bonding, the topographic surface parameters were studied using Fourier transform infrared spectroscopy (FTIR) and atomic force microscopy (AFM). PCPC (1:3) had the highest average cell viability of 93.42, 89.88, and 86.85% after 24, 48, and 72 h, respectively, as determined by the cytotoxicity assay, when compared to the other groups. According to the Kirby–Bauer disk diffusion method for testing antibacterial susceptibility, PCPC (1:3) showed the highest average diameter of the zone of inhibition, measuring 14.88, 14.43, and 11.03 mm after 24, 48, and 72 h of incubation, respectively. This difference was highly significant compared to Group 3 at all three time periods. PCPC (1:3) exhibited a significantly higher mean pull-off adhesion strength (521.6 psi) compared to PCPC (1:2), which revealed 419.5 psi. PCPC (1:3) coated substrates exhibited better surface roughness parameters compared to other groups based on the findings of the AFM. The FTIR measurement indicated that both PCPC groups exhibited a purely physical blending in the composite coating. Based on the extent of these successful in vitro experiments, PCPC (1:3) demonstrates its potential as an effective coating layer. Therefore, the findings of this study pave the way for using newly developed PCPC after electrospraying coating on CpTi for dental implants.

An Experimental Study in Laser-Assisted Machining of AerMet100 Steel.

To solve the problems of poor surface quality and low tool life in conventional machining (CM) of AerMet100 steel, an experimental study was conducted in laser-assisted machining (LAM) of AerMet100 steel. The effects of laser power, cutting speed, feed rate, and depth of cut on the surface roughness of AerMet100 steel were studied based on a single-factor experiment. The degree of influence of each factor on the surface roughness was evaluated by analyses of variance and range in the orthogonal experiment, and the combination of process parameters for the optimal surface roughness was obtained. The order of influence was as follows: laser power > cutting speed > depth of cut > feed rate; the optimal combination of process parameters was laser power 200 W, cutting speed 56.5 m/min, feed rate 0.018 mm/rev, and depth of cut 0.3 mm. Compared to CM, the surface morphology of the workpiece under the optimization of LAM was relatively smooth and flat, the surface roughness Ra was 0.402 μm, which was reduced by 62.11%, the flank wear was reduced from 208.69 μm to 52.17 μm, there were no tipping or notches, and the tool life was significantly improved. The study shows that the LAM of AerMet100 steel has obvious advantages in improving surface quality and reducing tool wear.

Comparative Analysis of Microabrasive Film Finishing Effects across Various Process Variants.

The paper investigates various methods of microfinishing and arrives at the best technique to produce a very smooth surface. Various setups, with and without oscillation, were developed, together with a microfinishing attachment used on conventional lathes and milling machines. The workpiece material used was an amorphous nickel-phosphorus Ni-P alloy. The surface roughness parameters, such as Sa, Sv, and Sp, were measured with the TalySurf CCI6000 instrument. For the measurement of the surface protrusions, an "analysis of islands" technique was used at various levels of cut-off. The 2BA method-machining below the workpiece axis with oscillation-turned out to be the most effective method applied because it had the highest density of protrusions while having the smallest value of surface roughness. Non-oscillation with the machining zone below the axis also becomes effective, indicating that repositioning can compensate for a lack of oscillation. Already, the very compact surface structure achieved with minimized depths in the valleys by the 2BA method supported the improvement in tribological performance and increase in load-carrying capacity, together with lubricant retention enhancement. These results show that the microfinishing process can be optimized by parameter tuning, and also, non-oscillating methods could come to be a practical alternative, probably reducing the complexity of equipment and cutting costs. Further studies need to be aimed at the scalability of these methods and their application to other materials and fields.

Characterization of surface asperities to understand its effect on fatigue life of electron beam powder bed fusion manufactured Ti-6Al-4 V

Surface asperities play a leading role in determining the fatigue life of as-built Ti-6Al-4 V components manufactured by electron beam powder bed fusion (PBF-EB). Several roughness parameters are available to characterize the surface asperities This study focuses on identifying the surface roughness parameter that correlates best with fatigue life. To this end, several fatigue test specimens were manufactured using the PBF-EB process and utilizing different contour melting strategies, thus producing as-built surfaces with varying roughness. The focus variation microscopy technique was employed to obtain surface roughness parameters for the as-built surfaces. Selected specimens were characterized using x-ray computed tomography (XCT). Tomography can detect surface-connected features obscured by other parts of the surface that are not visible through optical microscopy. The fatigue life of all specimens was determined using four-point bend testing. Through regression model analysis, maximum pit height (Sv) was identified as the statistically significant roughness parameter with the best fit affecting fatigue life. The fracture zone was closely inspected based on the data collected through XCT prior to fatigue tests. This led to another estimate of the worst-case value for the statistically significant roughness parameter Sv. The Sv parameter values obtained from optical microscopy and XCT were used as the initial crack size in a crack growth model to predict fatigue life. It is observed that life estimates based solely on optical measurements of Sv can be overly optimistic, a situation that must be avoided in predictive design calculations.

Study on the surface layer properties of magnesium alloys after impulse shot peening

Shot peening is a commonly used method of finishing machine elements in the manufacturing process. One variation of shot peening is the impulse shot peening. This paper presents the influence of impulse shot peening technological conditions on the surface roughness (parameters Ra and Rt), topography, and microhardness. The FEM was used to determine the S11 stresses. In the experiment and simulation tests, AZ31 and AZ91HP magnesium alloy samples were used. Variable parameters in the impulse shot peening process were impact energy E (15–185 mJ), ball diameter d (3–15 mm), and impact density j (3–44 mm−2). As a result of the tests carried out, it was found that after impulse shot peening, the surface topography is change, microirregularities are flattened, and numerous depressions are formed, which can be potential lubrication pockets. The 2D surface roughness parameters for most impulse shot peening conditions are lower than for the pre-machining. The roughness parameters for magnesium alloy AZ91HP are lower than for AZ31. This is most likely due to the lower elongation A. The microhardness after impulse shot peening increased by 20 to 87 HV. As a result of FEM of the impulse shot peening, compressive stresses S11 were created in the surface layer. The depth of occurrence of S11 stresses is from 1.5 to 3.5 mm, and their values for the AZ91HP magnesium alloy samples are 10 to 25% lower than for the AZ31 alloy samples. The most favorable results of the tested properties of the surface layer were obtained for E = 100 mJ, d = 10 mm, and j = 11 mm−2. The abstract serves both as a general introduction to the topic and as a brief, non-technical summary of the main results and their implications.