Rough Particles Research Articles

How Much Data Are Enough? Toward Statistically Robust Adhesion Experiments by Atomic Force Microscopy.

Direct force measurements by atomic force microscopy (AFM) have become an indispensable analytical tool in the last decades. Force measurements have been widely used for adhesion measurements, often in combination with the colloidal probe technique. For the latter technique, a colloidal particle is attached to the end of an AFM cantilever, proving great flexibility in terms of colloid/surface interaction to be studied. Interestingly, the question of how much data is necessary to obtain statistically reliable results has been addressed in this context only sparsely. By contrast, the value and necessity of determining and reporting distributions of adhesion forces has been widely accepted. Here, simple statistical methods of the experimental design have been applied to address this question. It has been demonstrated that it is possible to determine an optimal number of force curves even during data acquisition. This approach would be essential to prevent oversampling of data. Moreover, it allows to address questions like heterogeneity of the sample in a more reliable or less time-consuming way. In AFM measurements with colloidal probes, most statistical variation results from the surface roughness of the probe particle. In this case, the use of different colloidal particles is important, which can be achieved by techniques such as fluidic force microscopy (FluidFM). The latter enables to combine a real-time determination of the required data size and high-throughput techniques of unattended measurements, which will open new fields of analysis.

Effect of Roundness and Surface Roughness of Foundry Sand on the Temperature Change of Sand Cores for Aluminum Casting

Organic binder in sand cores, such as phenol-formaldehyde binder, rapidly decomposes above 550 K, releasing gases including volatile organic compounds (VOCs) and hydrocarbon gases. A rapid temperature rise in the core increases gas evolution during the casting process. The roundness and surface roughness of foundry sand particles influence temperature changes in sand cores. This study investigates how these factors affect temperature change in packed sand beds and cores and the gas porosity at the interface between the core and the A356 Al castings. Temperature changes were measured using three types of sand: angular artificial sand (AAS), natural sand (NS) with different roundness and surface roughness, and polished AAS with a smooth surface. Additionally, the temperature rise in cores was measured with varying proportions of AAS. Packed sand beds and cores with low roundness and rough surface morphology form macro and micro-gaps due to high porosity and surface roughness. These gaps, filled with interstitial gas of low thermal conductivity, hinder heat conduction. Delaying the temperature rise of the core could reduce weight loss from binder decomposition, thereby decreasing gas porosity at the interface between the A356 Al castings and the core. These findings on the effects of roundness and surface roughness on temperature changes in packed sand beds and cores provide methods for reducing gas emission during the casting process.

Optimizing Melamine Sponges Modified With Titanium Dioxide Nanoparticles for Environmental and Industrial Applications

ABSTRACTThis study explored the development and characterizations of a lightweight, cost‐effective, and easily accessible titanium dioxide (TiO2)/melamine sponge with outstanding hydrophobicity, oil absorption/separation, flame retardancy, durability, and electromagnetic wave absorption capacities. Commercial melamine sponges were modified using the silane coupling agent and TiO2 nanoparticles via a solution‐immersion method. Scanning Electron Microscopy revealed the structural integrity and surface morphology with increased surface roughness and uniform distribution of TiO2 particles. The hydrophobicity of the TiO2/sponge was confirmed by contact angle measurements, showing a high value of 145°. The oil absorption capacity and separation efficiency were also quantified, with the modified sponges able to absorb oils at 70 to 120 times their weight while maintaining a separation efficiency above 95% even after 10 reuse cycles. Additionally, the TiO2/sponge exhibited excellent flame resistance, strong mechanical abrasion resistance, and stability in saline environments. Electromagnetic absorption tests over the 2–18 GHz range showed efficient absorption, with reflection loss values below −10 dB at higher frequencies for thicker sponges. These results suggest that TiO2/sponge composites provide multifaceted enhancements, making them suitable for various environmental and industrial applications, including oil spill management and electromagnetic radiation mitigation.

Frictional effects on shear-induced diffusion in suspensions of non-Brownian particles

The shear-induced diffusivity of non-Brownian spheres in monodisperse suspensions undergoing viscous flow was calculated using simulations that account for particle roughness and friction as independent parameters. The diffusivity increases significantly as the friction coefficient is increased, and the effect is largest on rougher particles. Roughness reduces the transverse diffusivities relative to smoother particles for sufficiently concentrated suspensions of frictionless and low-friction particles. However, the diffusivity of roughened particles is larger than smoother ones at high values of the friction coefficient. The increase of the diffusivity with friction is associated with a significant broadening of the variance of the rotational velocities. The most prevalent observation, when correlating the microstructure to changes in diffusivity for frictionless particles, is that less diffusive systems, with larger roughness, form layers along the flow direction. These results confirm previous experimental and simulation results that roughness can decrease diffusivity at large concentrations using a more detailed model. Also, comparisons of the simulation results with previously published experimental measurements indicate that friction improves the alignment of the results with experiments.

Reusability of Ti-6Al-4V powder in laser powder bed fusion: Influence on powder morphology, oxygen uptake, and mechanical properties

The reusability of Ti-6Al-4V powder in laser powder bed fusion (L-PBF) processes is essential for achieving economic efficiency and maintaining consistent product quality. While powder reuse offers clear cost benefits, it also raises concerns about preserving material quality and consistency across multiple build cycles. This study, therefore, investigates the effects of repeated powder reuse on key parameters, including powder morphology, oxygen uptake, and mechanical properties. The results demonstrate that the repeated reuse of the powder results in a decrease in satellite particles and an increase in particle deformation. Oxygen content progressively increases with each cycle; however, smooth particles maintain relatively stable oxygen levels, whereas rough particles exhibit a more pronounced rise in oxygen content. Mechanical testing shows that as oxygen levels increase, tensile strength improves, yet elongation decreases. This observed increase in strength can be partially attributed to oxygen-induced phase transformations, where localized oxygen enrichment promotes the formation of the face-centered cubic (FCC) β phase, contributing to material strengthening. These findings emphasize the importance of optimizing powder reuse strategies, particularly in controlling oxygen levels, to achieve the optimal balance between strength and ductility in high-quality material properties.

Determination of interaction forces of (sub)-micron sized particles via the capillary rise method and colloidal probe atomic force microscopy: A combined approach

HypothesisThe adhesion forces of particles in the submicron range play a decisive role in many particle processes such as agglomeration. These forces are influenced by many factors such as particle size, surface roughness, and contact area. The quantification of these influences should be possible by linking adhesion forces, measured with colloidal probe atomic force microscopy (cp-AFM), and surface energy, measured with the capillary rise method, using different adhesion force models. ExperimentsSilica-silica (SiO2-SiO2), polystyrene-polystyrene (PS-PS) and mixed adhesive force contacts of micrometer-sized particles were measured by cp-AFM. The surface energy was determined by the capillary rise method using the Owens-Wendt-Rabel-Kaelble (OWRK) method. Various adhesive force models were used to link the experimentally measured forces. In the adhesive force models, the particle size, the distance between the particles, and the roughness were varied. FindingsAdhesion forces measured with the AFM can be linked to the OWRK method via adhesion force models such as the particle–particle Van-der-Waals (VDW) model, Rumpf’s roughness model, and a proprietary model for multiple particle–particle interactions with the surface energy. The main influencing factors are the substrate and particle roughness as well as their plastic or elastic behavior, which influences the contact area of the adhesive contact.

Multiscale evaluation of sand-geomaterial interface shear response in terms of material geometry effects

This study evaluates the effects of particle and surface geometric features on the interface shear behavior of sand-geomaterial. Particle shape and size were adjusted for the sand, and surface roughness form and height were set for the geomaterial part. 3D printing technology was used to produce geomaterials in the desired form. A custom-made transparent interface shear box was developed to perform digital image processing. For macroscale response, peak and residual strengths and dilation angle were measured. Sliding percentage and shear band thickness were determined from digital image correlation analyses for the mesoscale response. The experimental results showed that the macroscale response parameters increased as the overall regularity of the sand particles decreased. The increase in mean particle size and roughness height led to an increase in macroscale parameters. Digital image correlation analyses showed that the sliding percentage had an inverse correlation with the shear band thickness in terms of the particle shape and the roughness height effects. The roughness form controlled the trend of mean particle size effects on the sliding percentage. Overall, the mesoscale parameters revealed the traces of interlocking response, particle kinematics, and the failure mechanism in the interface region. Thus, a bridge was established between meso- and macro-scale responses.

Selective colonization of microplastics, wood and glass by antimicrobial-resistant and pathogenic bacteria.

The Plastisphere is a novel niche whereby microbial communities attach to plastic debris, including microplastics. These communities can be distinct from those found in the surrounding environment or those attached to natural substrates and may serve as a reservoir of both pathogenic and antimicrobial-resistant (AMR) bacteria. Owing to the frequent omission of appropriate comparator particles (e.g. natural substrates) in previous studies, there is a lack of empirical evidence supporting the unique risks posed by microplastics in terms of enrichment and spread of AMR pathogens. This study investigated selective colonization by a sewage community on environmentally sampled microplastics with three different polymers, sources and morphologies, alongside natural substrate (wood), inert substrate (glass) and free-living/planktonic community controls. Culture and molecular methods (quantitative polymerase chain reaction (qPCR)) were used to ascertain phenotypic and genotypic AMR prevalence, respectively, and multiplex colony PCR was used to identify extra-intestinal pathogenic Escherichia coli (ExPECs). From this, polystyrene and wood particles were found to significantly enrich AMR bacteria, whereas sewage-sourced bio-beads significantly enriched ExPECs. Polystyrene and wood were the least smooth particles, and so the importance of particle roughness on AMR prevalence was then directly investigated by comparing the colonization of virgin vs artificially weathered polyethylene particles. Surface weathering did not have a significant effect on the AMR prevalence of colonized particles. Our results suggest that the colonization of plastic and non-plastic particles by AMR and pathogenic bacteria may be enhanced by substrate-specific traits.

Visible-light photocatalytic performance of SrTiO3 nanoparticles modified with cobalt

In this article, an experimental study on the photocatalytic performance of SrTi1-yCoyO3 nanoparticles (with y = 0.0, 0.03, 0.06, and 0.09) synthesized by the Pechini-type sol-gel method is presented. The crystalline structure analysis revealed that all the samples exhibited the cubic perovskite phase of SrTiO3. In particular, the SrTi0.91Co0.09O3 sample was found to consist of rough spherical-like particles with an average size of 26 ± 0.5 nm. Cobalt ions with 2+ and 3+ oxidation states are responsible for modifying the electronic band structure of the semiconductor and a narrowing of optical band gap from 3.1 to 1.08 eV. The resulting Co-doped SrTiO3 nanoparticles exhibited photocatalytic activity under visible light due to their enhanced light absorption, effective charge transport and effective surface chemisorption. In particular, the SrTi0.91Co0.09O3 sample exhibited the highest photocatalytic activity with 91 % degradation efficiency of methylene blue dye within 120 min of simulated solar irradiation.

The strength of an adhesive contact in the presence of interfacial defects

Adhesive contacts which possess a dominant stress concentration, such as at the contact edge in spherical junctions or at the detachment front in a peeling film, are well studied. More complex adhesive junction geometries, such as mushroom-shaped fibrils in bioinspired micropatterned dry adhesives, have exhibited a complex dependence of adhesive strength on the presence of interfacial defects within the contact. This has led to the emergence of statistical variation of the local behavior among micropatterned sub-contacts. In order to examine the interplay between geometry and interfacial defect character in control of the adhesive strength, the model system of a stiff cylindrical probe on an elastic layer is examined. Both experiments (glass on PDMS) and cohesive zone finite element simulations are performed, with analytical asymptotic limits also considered. The thickness of the elastic layer is varied to alter the interfacial stress distribution, with thinner layers having a reduced edge stress concentration at the expense of increased stress at the contact center. The size and position of manufactured interfacial defects is varied. It is observed that for the thickest substrates the edge stress concentration is dominant, with detachment propagating from this region regardless of the presence of an interfacial defect within the contact. Only very large center defects, with radius greater than half of that of the contact influence the adhesive strength. This transition is in agreement with analytical asymptotic limits. As the substrate is made thinner and the stress distribution changes, a strong decay in adhesive strength with increasing center defect radius emerges. For the thinnest substrate the flaw-insensitive upper bound is approached, suggesting that this decay is dominated by a reduction in the contact area. For penny-shaped defects at increasing radial positions, the adhesive strength for the thinnest substrates becomes non-monotonic. This confirms an intricate interplay between the geometry-controlled interfacial stress distribution and the size and position of interfacial defects in adhesive contacts, which will lead to statistical variation in strength when defects form due to surface roughness, fabrication imperfections, or contaminant particles.

Experimental study of influence of coal dust physical–chemical properties on indirect dust suppression effect

Indirect dust suppression parameters are one of the main indicators for evaluating the performance of dust reduction, and the physical and chemical properties of coal dust are important factors affecting the indirect dust reduction effectiveness. To clarify the influence of coal dust physical and chemical properties on the indirect dust suppression effect, atomic force microscope(AFM), laser particle sizer, infrared spectrometer were used to analyse raw coal dust characteristics (the particle size, roughness, adhesion force and functional groups) sampled from different mines, and sedimentation and agglomeration experiments were used to study the indirect dust suppression effect (the law of wettability and agglomeration) of the coal dust under different characteristics. The results showed that the median particle size of SY and DJH coal dusts was significantly lower than that of HL and YH coal dusts. The average roughness ranged from 1.10 to 2.62 nm, and the maximum roughness ranged from 7.18 to 26.7 nm. The coal dust had a small adherence force, and the agglomeration ability occurred by itself was difficult. Furthermore, the difference of the functional groups structure for four coal dusts was small, but it showed an obvious difference in the proportion of functional groups. As the decrease of particle size, the roughness of coal dusts increased, and its wetting velocity decreasing trend showed a power function. The higher the surface roughness of coal dust, the stronger the hydrophobicity of coal dust. With the hydroxyl proportion percentage increased, the coal dust wetting velocity increased linearly, and the increase of hydroxyl functional group proportion greatly promoted the agglomeration of fine particle coal dust. The agglomeration effect enhanced first and weakened after with coal dust particle size decreased, which reflected the fact that the large-size coal dust was more easily wetted by reagents, but it was difficult to form stable liquid bridges. Furthermore, the smaller size of coal dust showed a poorly wettability, it was unable to form effective agglomerates. Coal dust adhered to the surface of the droplets under the action of the liquid bridging force, and as the water evaporated, the coal dust formed stable solid bridges between them.

Laboratory Investigation of the Effect of Particle and Vegetation Roughness on Changes in Drag Force in an Open Channel

Laboratory Investigation of the Effect of Particle and Vegetation Roughness on Changes in Drag Force in an Open Channel

Evaluation of MSA mortar pore structure characteristics in water-saturated curing environment based on Talbot gradation theory

To investigate the impact of aggregate gradation on the pore structure of manufactured sand aggregate (MSA) mortar and its fractal characteristics under water-saturated curing conditions. The static pore structure characteristics of the pore structure of MSA mortar with 10 aggregate gradations were explored. The analysis is based on the Talbot gradation theory, the NMR technique, and fractal theory. The surface area and roughness of aggregate particles contribute to a reduction in the porosity of MSA mortar. The aggregate gradation is quantified using the Talbot index. The correlation characteristics and intrinsic relationships between Talbot index and different pore structure parameters, such as total porosity, pore gradation, pore fractal dimension and permeability of MSA mortar, are analyzed. Two pore division methods are employed to explore the interrelationships among pore types, fractal dimensions and Talbot index. Additionally, A correlation model between Talbot index and permeability is developed to investigate the intrinsic correlation of parameter variations from a microscopic perspective. It is found that aggregate gradation is optimal with a Talbot index of 0.4, leading to the highest number of micropores and the lowest number of larger pores, thereby enhancing resistance to seepage and dissolution. Furthermore, The contribution of pore size, content and type to permeability varies with different aggregate gradations. Overall, this study serves as a valuable guide for the design and durability evaluation of mortar concrete projects in water-saturated curing environments.

Towards 3D determination of the surface roughness of core–shell microparticles as a routine quality control procedure by scanning electron microscopy

Recently, we have developed an algorithm to quantitatively evaluate the roughness of spherical microparticles using scanning electron microscopy (SEM) images. The algorithm calculates the root-mean-squared profile roughness (RMS-RQ) of a single particle by analyzing the particle’s boundary. The information extracted from a single SEM image yields however only two-dimensional (2D) profile roughness data from the horizontal plane of a particle. The present study offers a practical procedure and the necessary software tools to gain quasi three-dimensional (3D) information from 2D particle contours recorded at different particle inclinations by tilting the sample (stage). This new approach was tested on a set of polystyrene core-iron oxide shell-silica shell particles as few micrometer-sized beads with different (tailored) surface roughness, providing the proof of principle that validates the applicability of the proposed method. SEM images of these particles were analyzed by the latest version of the developed algorithm, which allows to determine the analysis of particles in terms of roughness both within a batch and across the batches as a routine quality control procedure. A separate set of particles has been analyzed by atomic force microscopy (AFM) as a powerful complementary surface analysis technique integrated into SEM, and the roughness results have been compared.

Experimental study on improving the performance of imitation earthen site soil in carbon dioxide environment

This study aims to explore the performance of lime-treated soil for repairing the lime soil of the earthen city wall of Kaifeng and to standardize the construction technology of lime-treated soil. The research comprehensively considered factors such as carbonation time, lime particle size, aging conditions, and lime content, and conducted various tests and analyses including triaxial mechanical properties, surface crack analysis, particle size distribution, pH measurement, composition analysis, and electron microscopy on different samples. The results indicate that the significant effect of high-concentration CO2 carbonation enhances the chemical reactions of lime soil, and an appropriate carbonation process can strengthen the bonding and density between soil particles. Under the maintenance condition of 5 % CO2, with increasing carbonation time, the crack ratio, average crack length, and average crack width of the samples decreased. Cohesion and internal friction angle of the samples exhibited an initial increase followed by a decrease, while shear strength of the samples increased by 22.93 %–75.09 %. The lime particle size has a critical impact on the formation of cracks in lime soil. With increasing lime particle size, the crack ratio, average crack length, and average crack width of the samples increased. Cohesion and internal friction angle of the samples gradually increased with increasing lime content. The increase in crack ratio, average crack length, and average crack width during natural curing of lime-treated soil samples was proportional to the lime content. Appropriate carbonation time, smaller lime particle size, and curing conditions with 5 % CO2 contribute to improving the particle size distribution of lime-treated soil samples, reducing surface cracks, and enhancing performance. However, prolonged carbonation may lead to larger lime particle size, resulting in rough and loose particles, disorganized arrangement of CaCO3 crystals, and the inability to form a cross-linked network skeleton, causing a reduction in shear strength of the samples. These research findings provide important theoretical basis and construction technology guidance for the application of lime-treated soil combined with CO2 carbonation in repairing earthen city walls.

Reconstruction Of The Shape Of Irregular Rough Particles From Their Interferometric Images Using A Convolutional Neural Network

We have developed a convolutional neural network (CNN) to reconstruct the shape of irregular rough particles from their interferometric images. The CNN is based on a UNET architecture with residual block modules. The database has been constructed using the experimental patterns generated by perfectly known pseudo-particles programmed on a Digital Micromirror Device (DMD) and under laser illumination. The CNN has been trained on a basis of 18000 experimental interferometric images using the AUSTRAL super computer (at CRIANN in Normandy). The CNN is tested in the case of centrosymmetric (stick, cross, dendrite) and non-centrosymmetric (like T, Y or L) particles. The size and the 3D orientation of the programmed particles are random. The different shapes are reconstructed by the CNN with good accuracy. Using three angles of view, the 3D reconstruction of particles from three reconstructed faces can be further done.

Spreading dynamics of a microgel particle-laden thermosensitive polymer drop along smooth and nanofiber surfaces

The research focuses on the influence of 300-μm microgel particles in an aqueous solution of a thermosensitive biopolymer on the spreading and deformation of 3.7-mm drops. The drops impact a smooth hydrophilic and a rough hydrophobic surface. A mass fraction of microgel particles varies in a range of 0–0.2. A universal physical model of the spreading of thermosensitive polymer drops laden with microgel particles along surfaces with significantly different roughness is proposed. It explains the strong inhomogeneity of the contact line stretching due to the deceleration of the continuous phase flow by microgel particles and the increased flow vorticity because of the addition of the surface roughness factor. The validity of the proposed physical model is proven by qualitative and quantitative assessments of the contact line deformation when spreading. An empirical expression for the maximum spreading factor is derived, taking into account the properties of liquids, wall roughness, and microgel particle concentration; it reliably predicts when Re≈110−3100, the surface roughness is 0.5–125 nm, Ca=4.5×10−7, and the number of microgel particles in drops is up to 100. The expression was successfully tested during the modeling of arbitrary surface roughness and the increased concentration of microgel particles relative to those considered in experiments during the formation of a biopolymer layer. When developing the method of additive manufacturing of a functional layer, a practical correlation was established between the volume content of microgel particles, acting as potential containers for living cells, in a drop and the area of the biopolymer layer.

Dynamics of particle-laden turbulent suspensions: Effect of particle roughness

Dynamics of particle-laden turbulent suspensions: Effect of particle roughness

Microphysical Characterization of Boundary Layer Ice Particles: Results from a 3-Year Measurement Campaign in Interior Alaska

Abstract A three-winter study has been conducted to better understand the relationship between atmospheric conditions and ice fog or diamond dust microphysics. Measurements were conducted east of downtown Fairbanks in interior Alaska during nonprecipitating conditions. Atmospheric conditions were measured with several weather stations around the Fairbanks region and two meteorological temperature profiler instruments (ATTEX MTP-5HE and MTP-5PE). Near-surface ice particle microphysical observations were conducted with the Particle Phase Discriminator mark 2, Karlsruhe edition (PPD-2K), instrument, which measures particles from 8 to 112 μm (sphere equivalent). Panoramic camera images were captured and saved every 10 min throughout the campaign for visual assessment of atmospheric conditions. Machine learning was used to classify both cloud particle microphysical characteristics from the PPD-2K data and to categorize boundary layer conditions using the panoramic camera images. For panoramic camera images, data were categorized as cloudy, clear, fog, snowing, and a nearby power plant plume. For the PPD-2K machine learning study, the scattering pattern images were used to identify rough surface, pristine, sublimating, and spherical particles. Three additional categories were used to identify indeterminant or saturated images. These categories and categories derived from weather station data (e.g., temperature ranges) are used to quantify ice microphysical properties under different conditions. For the complete microphysical dataset, pristine plates or columns accounted for 15.5%, 16.3% appeared to be sublimating particles, and 43.4% were complex particles with either rough surfaces or multiple branches. Although the temperature was as warm as −20°C during measurements, only 1.3% of the particles were classified as liquid. Significance Statement Boundary layer ice particles are frequently present in the near-surface atmosphere when surface temperatures drop below −20°C. Substantial human impacts can occur due to visibility degradation and deposition of particles on surfaces. Understanding particle shape, size, and phase (liquid or solid) is important for understanding those impacts. This study presents the results of a 3-yr measurement campaign in Fairbanks, Alaska, in which we relate ice particle characteristics to lower atmospheric conditions. Results should improve weather forecasting and hazard prediction.

Acclimatize experimental approach to adjudicate hydraulic coefficients under different bed material configurations and slopes with and without weir

The primary purpose of this study was to evaluate the hydraulic coefficient of coarse aggregate grain size beds and hydraulic parameters under random and perpendicular bed configurations, as well as to explore the discharge coefficient for rectangular weirs. The research objectives were to compare flow resistance coefficients, evaluate the discharge coefficient for rectangular weirs, investigate the relationship between roughness coefficient and hydraulic parameters, and validate the theoretical hydraulic equation for the rectangular weir. This was achieved by analysing different bed configurations, bed slopes, and 20 and 30-mm bed materials. Sieve analysis was conducted on bed materials using American-standard sieves to determine their particle size distribution. The experiment was performed in a rectangular flume measuring 12 m in length, 0.31 m in width, and 0.45 m in depth. In a laboratory experiment, water was pumped into a flume using centrifugal pumps, and a rectangular weir was attached downstream for discharge measurement. The experiment investigated factors such as Manning roughness coefficient, bed material geometry, bed slope, and weir shapes. Approximately 1680 tests were conducted to analysed the impact of these factors on discharge and the coefficient of discharge. The average Manning's roughness coefficients for a grain size of 20 mm were 0.019 (with weir) and 0.019 (without weir) in a random bed configuration, and 0.028 (with weir) and 0.027 (without weir) in a perpendicular flow bed configuration. For a grain size of 30 mm, the coefficients were 0.023 (with weir) and 0.022 (without weir) in a random bed configuration, and 0.033 (with weir) and 0.026 (without weir) in a perpendicular flow bed configuration. The presence of a weir has affected Manning's roughness coefficients and discharge coefficients. With a weir, the roughness coefficients have generally been higher compared to without a weir, indicating increased roughness in the channel. The discharge coefficient for a rectangular weir with a grain size of 20 mm ranged from 0.39 to 0.84 (random bed) and 0.27 to 0.68 (perpendicular flow bed), while for a grain size of 30 mm it ranged from 0.31 to 0.81 (random bed) and 0.23 to 0.48 (perpendicular flow bed). The discharge coefficients have varied depending on the grain size and bed configuration, reflecting different flow efficiencies over the weir. Rough particles influenced flow and Manning's roughness coefficient value, then reduced discharge and velocity values. Under two bed configurations and slopes, beds with a grain size of 30 mm have higher roughness coefficients compared to those with a grain size of 20 mm. The models have shown that the roughness coefficient is inversely proportional to the discharge and directly proportional to the tailgate water levels. The coefficient of roughness and discharge coefficient are mainly influenced by the channel slopes, bed roughness, bed grain size, and bed configuration. A randomly configured bed with a 20 mm grain size gravel bed is preferred over a perpendicular bed configuration to handle high discharges. Using a 20 mm grain-size gravel bed in open-channel flow is more suitable than a 30 mm grain-size bed. Relying on the constant friction factor, Manning's n, is not recommended as it may result in design errors. These findings have the potential to improve hydraulic engineering design practices, enhancing the accuracy and efficiency of open-channel flow systems.