Surface Roughness Research Articles

Influence of Binding Agent on the Cutting Performance and Friction Wear Characteristics of Catalytic Composite Abrasive Cluster

Abstract To improve the polishing efficiency and process stability of catalytic composite abrasive clusters (CCAC), CCAC containing different binding agent ratios was investigated. Five groups of CCAC with different binding agent ratios were prepared for friction chemical polishing of silicon carbide (SiC), respectively. Based on material removal rate (MRR) and surface roughness (Ra) as evaluation metrics, the polishing performance of five groups of CCAC were compared. Subsequently, wear experiments were carried by block shaped CCAC with diameter of 1.6 mm, as well as single crystal diamond (SCD) abrasives with the same particle size. The friction coefficient and the cross-sectional area at the worn area of wear were measured to evaluate the effect of binding agent content on the continuous cutting performance of the abrasive as well as on the tribological properties. The experimental results showed that #3 abrasive exhibited the highest machining efficiency (MRR reaches 330.535 nm/min) and better surface roughness (Ra reaches 22.741 nm). Excessive or insufficient bonding agent in CCAC will affect the processing performance of the abrasive. When the proportion of binding agent in the abrasive is 25%, CCAC has better processing ability and can realize efficient polishing of SiC wafers.

Human gingival fibroblast response on zirconia and titanium implant abutment: A systematic review.

The peri-implant region, where restoration interfaces with mucosal tissue, plays an essential role in overall implant success and is just as important as osseointegration. The implant abutment materials are in intimate contact with human gingival fibroblasts (HGFs). This study compares the proliferation of HGFs between zirconia and titanium abutments used in dental implants. An electronic search was performed using PubMed, EMBASE, and Web of Science databases. English articles based on in vitro studies testing HGFs proliferation on zirconia and titanium implant abutment materials were included. A quality assessment of the selected study was performed using the web-based Science in Risk Assessment and Policy (SciRAP) tool. The HGFs proliferation and cellular morphology tests on zirconia and titanium materials from the included studies were summarized, exploring the role of material surface characteristics. The electronic search yielded 401 studies, of which 17 were selected for inclusion. Zirconia exhibited comparable or superior efficacy in promoting the proliferation of HGFs compared to titanium. Observations on cellular morphology showed similar outcomes for both materials. Establishing a definitive relationship between contact angle, surface roughness, and their influence on cellular response remains challenging due to the varied methodological approaches in the reviewed studies. Based on the findings of this systematic review, zirconia shows comparable reliability to titanium as an abutment material for HGFs proliferation, with comparable or superior HGFs proliferative outcomes.

Axial behaviour of steel pipelines buried in sand: effects of surface roughness and hardness

Surface roughness and coating hardness of underground pipelines are expected to play decisive roles in their axial pullout behaviour, which is an important aspect of pipeline design. Existing guidelines and previous studies underestimated or ignored these effects, resulting in potentially unsafe design. To address this problem, in the current study, nine large-scale physical modelling tests were conducted on pipes in dry and dense sand. Five steel pipes with varying normalised roughness (0·04–1·01) and coating hardness (32·6–59·0 HRA) were used and instrumented with a novel type of film-like piezoresistive sensors for measuring soil–pipe contact pressure. The measured pullout resistance of rough pipes is 2·70–2·85 times that of smooth pipes, significantly greater than the value specified in current design guidelines (i.e. 1·17 times). This substantial increase stems from an increase in interface friction coefficient (accounting for 72–79%) and a contact pressure increase induced by constrained dilation and soil arching (contributing the remaining 21–28%). Regarding coating hardness, a critical hardness was observed (around 35 HRA). Owing to equivalent roughness from particle embedding, pipes with hardness below this value exhibited similar behaviour to rough pipes. Finally, a new and simple method was proposed for calculating the pullout resistance with consideration of the effects of roughness and dilatancy.

Study on the effects of ultrasonic vibration-assisted wire-EDM machining parameters on material removal rate and surface roughness of NiTiV shape memory alloy

Nickel-titanium (NiTi)-based shape memory alloys (SMAs) exhibit remarkable properties, making them increasingly demanding in various engineering and medical applications especially when these SMAs are manufactured with intricate shapes and sizes. This present study examines the machining of Ni50Ti48V2 SMA using ultrasonic-assisted WEDM with input parameters of pulse ON time (TON), pulse OFF time (TOFF), peek current (I), and servo voltage (SV) along with 20 kHz constant ultrasonic vibration on the responses of material removal rate (MRR) and surface roughness (Ra). RSM-BBD response surface methodology was used to conduct the experiments. It was inferred from analysis of variance (ANOVA) analysis, that as the peak current (I) and pulse ON time (TON) increased, the MRR increased by 65.76% and Ra decreased by 54.44%. The confirmation was carried out in USV-WEDM under optimal conditions, which shows that both the predicted and actual MRR and Ra are close to each other. When compared with conventional WEDM, the USV-WEDM shows significant improvement in MRR by 8.6% and also improved surface quality by 6.3%. The surface characteristics of Ni50Ti48V2 after machining were examined using field-emitted scanning electron microscopy, showing small irreularisation peaks and wavy surface topography at optimised parameter conditions. USV-WEDM showed a lower-order micro-hardness variation due to effective flushing of molten layer re-accumulation as compared to WEDM. When comparing the base and machined samples, the temperatures of austenite and martensite are nearly the same, indicating that shape memory effects are unaffected by the USV-WEDM process.

Fundamentals of simultaneous machining and coating (SMaC) through combination of extreme high-speed laser material deposition (EHLA) and turning

Simultaneous machining and coating (SMaC) is a novel hybrid technology developed by the Fraunhofer Institute for Laser Technology ILT that combines additive manufacturing through extreme high-speed laser material deposition (EHLA) with a simultaneously engaged turning process. In the present work, the parallelization of the two subprocesses is successfully demonstrated. For the first time, systematic investigations into the influence of residual heat from the deposition process on the machining process and the properties of the resulting coating, respectively, are conducted. The study specifically examines geometric deviations, surface roughness, and tool wear. One of the main parameters affecting the residual heat introduced into the turning process is the distance between the tool center points of the EHLA deposition head and the turning tool Δz. This parameter is identified as a primary factor influencing the dimensional accuracy of the coating geometry. The results show that SMaC not only offers potential for increasing the productivity of the process chain but also has a positive effect on the service life of the cutting tools involved, potentially improving the workability of hard coating materials. Improvements in terms of the attainable surface roughness are also observed. These investigations provide a basis for research into further aspects of the SMaC process, such as adaptive tool path control methods to enhance dimensional accuracy and the influence of induced compressive stresses in processing highly brittle coating materials.

Experimental evaluation of different coated cutting tools effects on machinability in turning of 17-4 PH stainless steel and optimization of the cutting parameters

Generally, coated cutting tools are preferred in machining of stainless steel. Especially, CVD coated cutting tools come to the forefront owing to its multilayer structure in the industry. In this study, the effects of CVD and PVD coated cutting tools on machinability were investigated in dry turning of 17-4 PH stainless steel. The cutting tools have exactly the same tool geometry. Based on the Taguchi L16 experimental design, experiments were performed for each coating type at different cutting speeds, feed rates and cutting depths. The evaluation parameters were selected as cutting force, surface roughness, tool life and chip formation. The effect ratio of input parameters to output parameters was evaluated with ANOVA and optimum cutting parameters were determined for each coating type with regression analysis. As a result of this study, PVD coated cutting tools showed superior performance than CVD coated cutting tools. It can be said that PVD coated cutting tools are a great alternative to CVD coated cutting tools in machining of 17-4 PH stainless steel.

Increasing the Wear and Corrosion Resistance of a CP-Ti Surface by Plasma Electrolytic Borocarburizing and Polishing

The paper examines the possibility of increasing the wear and corrosion resistance of a CP-Ti surface by duplex plasma electrolytic treatment (borocarburizing and polishing). The structure and composition of diffusion layers, their microhardness, surface morphology and roughness, wear resistance during dry friction and corrosion resistance in Ringer’s solution were studied. The formation of a surface-hardened layer up to 200 μm thick with a microhardness of up to 950 HV, including carbides and a solid solution of boron and carbon, is shown. Subsequent polishing makes it possible to reduce surface roughness and remove weak areas of the porous oxide layer, which are formed during high-temperature oxidation in aqueous electrolyte vapor during borocarburizing. Changing the morphology and structural-phase composition of the CP-Ti surface helps reduce weight wear by a factor of three (the mode of frictional interaction changes from microcutting to oxidative wear) and corrosion current density by a factor of four after borocarburizing in a solution of boric acid, glycerin and ammonium chloride at 950 °C for 5 min and subsequent polishing in an ammonium fluoride solution at a voltage of 250 V for 3 min.

Changing windstorm characteristics over the US Northeast in a single model large ensemble

Abstract Extreme windstorms pose a significant hazard to infrastructure and public safety, particularly in the highly populated US Northeast (NE). However, the influence climate change and changing land use will have on these events remains unclear. A large ensemble generated using the Max-Planck Institute (MPI) Earth system model is used to generate projections of NE windstorms under different shared socioeconomic pathways (SSPs) and to attribute changes to projected land use land cover (LULC) change, externally forced changes and internal climate variability. To reduce the influence of coarse grid cell resolution and uncertainties in surface roughness lengths, windstorms are identified using simultaneous widespread exceedance of local 99th percentile 10 m wind speeds (U99). Projected declines in forest cover in the NE and the resulting reductions in surface roughness length under SSP3-7.0 lead to projections of large increases in U99 and derived windstorm intensity and scale. However, these projected changes in regional LULC under SSP3-7.0 are unprecedented in a historical context and may not be realistic. After corrections are applied to remove the influence of LULC on wind speeds, regionally averaged U99 exhibit declines for most of the single model initial-condition large ensemble (SMILE) members which are broadly proportional to the radiative forcing and global air temperature increase in the SSPs, with a median value of −0.15 ms−1 °C−1. While weak cyclones are projected to decline in frequency in the NE, intense cyclones and the resulting windstorms and indices of socioeconomic loss do not. Where present, significant trends in these loss indices are positive, and some MPI SMILE members generate future windstorms that are unprecedented in the historical period.

Studies on surface roughness and axial thrust force of drilled holes in Mg-Zn-Ca bio-medical alloy

Mg-Zn-Ca alloy is a promising candidate for orthopaedic implants such as bone plates and screws, as it has a similar mechanical strength and elastic modulus to bone, and it degrades in the body without causing toxicity or inflammation. Drilling studies are necessary to optimize the drilling process parameters, to evaluate the machinability and surface integrity of Mg-Zn-Ca alloy, and to ensure the effective and efficient drilling for various applications in the medical and engineering fields. The present experimental study emphasizes the influence of Ca content, biofriendly coolants and their combined effect with standard drill bits on the surface quality and axial thrust force in the drilling operation of Mg-Zn-Ca alloy. The drilling parameters such as cutting speed, feed rate, standard tools, bio-compatible coolants were optimized with respect to the amount of Ca in the Mg-Zn alloy. The axial thrust force and average surface roughness of drilled holes were considered as response of the experiments. The drilled surfaces were measured for average surface roughness in the transverse direction along the centre path of the drilled hole and a qualitative analysis was also carried out using advanced confocal microscope. The results revealed that the cutting speed among continuous factors significantly influenced the axial thrust force and average surface roughness. The effect of categorical factors was assessed using a regression based ranking method. The results of statistical analysis revealed that high speed steel, and vegetable oil offered improved surface quality, whereas the coconut oil showed low axial thrust force. The liquid nitrogen showed high value of axial thrust force and average surface roughness due to the brittleness induced by cryogenic coolant before drilling operation.

Microstructure and mechanical properties of 3D‐printed zirconia bone scaffold: Experimental and computational analysis

AbstractMicroextrusion‐based additive manufacturing of zirconia‐based bioceramics is capable of fabricating design‐specific architectures with high mechanical strength properties and relative density. We developed a novel organic residue‐free binder system for zirconia paste printing (ZP2) with the shear‐thinning properties apropos to microextrusion‐based 3D printing. Based on thermogravimetric analysis, debinding protocol was established followed by high‐temperature heat treatment under four sintering conditions. Quantitative linear shrinkage (32.3%–42.7% ranging from in‐plane to vertical direction), density (83.3%–87.5%), and surface roughness (7.7–13.8 µm from the parallel to the perpendicular to the infill direction) as a factor of sintering conditions (1400°C–1500°C for 3–4 h) were analyzed. Whereas qualitative phase assemblage demonstrated “sintering condition independent” phase stability; grain growth and reduction in porosity were observed in the microstructure with increment in sintering temperature and hold time. Interestingly, at higher temperature and hold time, the compressive (46–72.4 MPa) and tensile strength (16.2–23.1 MPa) properties experienced a trade‐off between grain growth and reduction in porosity. The ZP2 scaffolds sintered at lower temperature and hold time qualified for the bone scaffold applications having interconnected porosities, biologically relevant surface roughness, and human bone mimicking mechanical properties. With a unique finite element analysis recipe, the mechanical behavior of the “life‐like” reconstructed computer aided design (CAD) geometries identical to real 3D‐printed‐sintered ZP2 scaffolds was quantitatively predicted.

Effect of Er,Cr:YSGG Laser Irradiation on the Surface Modification and Cell Adhesion on Titanium Discs: An In Vitro Study

This study evaluates the potential of erbium, chromium-doped:yttrium, scandium, gallium, and garnet (Er,Cr:YSGG) laser irradiation to modify the titanium surface for optimal seeding of fibroblasts and osteoblasts in the treatment of peri-implantitis. Titanium discs were treated using the Er,Cr:YSGG laser, an ultrasonic device with a stainless tip, or titanium scalers. Changes in surface properties were analyzed by profilometer and scanning electron microscopy (SEM). Murine fibroblast and osteoblast adhesion and proliferation were evaluated qualitatively and quantitatively at 24 and 72 h. Profilometric surface topography and SEM showed that titanium scalers and ultrasonic debridement techniques significantly changed the structure of the machined and rough titanium surfaces. The Er,Cr:YSGG laser irradiation, on the other hand, did not alter titanium microstructures. The Er,Cr:YSGG laser irradiation with the 40 Hz group showed a significantly higher attached fibroblast cell numbers than the titanium scaler group at 72 h after treatment (p = 0.023). Additionally, the number of the attached osteoblasts in the Er,Cr:YSGG laser irradiation with the 40 Hz group was significantly higher than that of the no-treatment groups 24 h after treatment (p = 0.045). The Er,Cr:YSGG laser effectively promoted adherence of fibroblasts and osteoblasts to the titanium surface without significantly altering the titanium surface, suggesting its superiority for treating peri-implantitis.

Modeling and Optimization of Sisal Fiber Degradation Treatment by Calcined Bentonite for Cement Composite Materials

ABSTRACT The treatment of sisal fiber by pozzolanic materials like kaolin and silica-fume has been explored; however, no study has modeled and optimized the effect of sisal fiber degradation treatment using calcined bentonite. Therefore, the present study investigate the effects of treating sisal fiber with different doses of calcined bentonite, bentonite calcination temperatures, and times on fiber breaking load, degradation resistance, and water absorption using the central composite design-response surface method (CCD-RSM). The best performance of the optimum treated sisal fiber selected from the CCD-RSM based on the established goal of maximizing breaking load and degradation resistance with minimum water absorption, it was obtained a calcined bentonite dose of 30.067%, a bentonite calcination temperature of 800°C, and a calcination time of 179.99 min. Based on these factors, experimentally found sisal fiber breaking load 12.87 N, degradation resistance 98.44%, and water absorption 39.05%, all are within the 95% confidence level compared to the optimum numerical suggested values. Hence, the optimum treated sisal fiber improved breaking load by 33.37% and degradation resistance by 98%, while it reduced water absorption by 60.95%, compared to raw sisal fiber. Besides these, the optimum treated sisal fiber exhibits higher surface roughness and lower porosity than the raw sisal fiber.

The Effect of Sodium Hexametaphosphate on the Dispersion and Polishing Performance of Lanthanum–Cerium-Based Slurry

A lanthanum–cerium-based abrasive composed of CeO2, LaOF, and LaF3 was commercially obtained. The effect of sodium hexametaphosphate (SHMP) on powder dispersion behavior was systematically investigated using the combined techniques of liquid contact angle, turbidity, zeta potential (ZP), scanning electron microscopy (SEM), powder X-ray diffraction (XRD) combined with Rietveld refinements, X-ray photoelectron spectroscopy (XPS), and polishing tests. The results indicated that the addition of 0.5 wt.% SHMP dispersant to the 5 wt.% lanthanum–cerium-based slurry produced the most stable suspension with a high turbidity of 2715 NTU and a low wetting angle of 45°. The as-obtained slurry displayed good surface polishing quality for K9 glass, with low surface roughness (Ra) of 0.642 and 0.515 nm (in the range of 979 × 979 μm2) at pH = 6 and 11, respectively, which corresponds to the fact that it has local maximum absolute values of ZP at these two pH values. SEM images demonstrated that after appropriate grafting of SHMP, the particle aggregation was reduced and the slurry’s dispersion stability was improved. In addition, the dispersion mechanism was explained based on the principle of complexation reaction, which reveals that the dispersant SHMP can increase the interparticle steric hindrance and electrostatic repulsions. In an acidic environment, steric hindrance dominates, while electrostatic repulsion prevails under alkaline conditions. As expected, this polishing slurry may find potential applications in manufacturing optical devices and integrated circuits.

Microcrystalline and nanocrystalline structure of diamond films grown by MPCVD with nitrogen additions: Study of transitional synthesis conditions

This research explores the complex influence of nitrogen concentration and substrate temperature on the resultant properties of polycrystalline diamond (PCD) films grown by microwave plasma chemical vapor deposition (CVD). In particular, we investigated the growth parameters to find the exact conditions for changing the morphology of the resulting film from microcrystalline (MCD) to nanocrystalline (NCD). A series of 2 µm-thick polycrystalline diamond films was grown on Si substrates in methane-hydrogen–nitrogen gas mixtures with varied: (i) nitrogen concentration (0–2 %) and (ii) substrate temperature (700–1050 °C). Comprehensive characterization techniques, including scanning electron microscopy (SEM), micro-Raman spectroscopy, and X-ray diffraction, were employed to assess the morphological, structural, and spectroscopic properties of the films. The study reveals that even minor additions of nitrogen significantly modulate secondary nucleation, impacting both film morphology and phase composition. Furthermore, substrate temperature emerges as another critical parameter, influencing the growth kinetics and crystallite size. The comparison of the characteristics of grown PCD films allowed us to find conditions for the formation of NCD films with minimal surface roughness and maximal growth rate: nitrogen concentration [N2] ≈ 0.2–0.5 % and temperature T ≈ 850–900 °C. These findings can be used to optimize the CVD synthesis parameters of PCD films for applications as protective or friction-reducing layers, as well as for superhard cutting tools and optical devices.

Aged Microplastics and Antibiotic Resistance Genes: A Review of Aging Effects on Their Interactions

Background: Microplastic aging affects the dynamics of antibiotic resistance genes (ARGs) on microplastics, yet no review presents the effects of microplastic aging on the associated ARGs. Objectives: This review, therefore, aims to discuss the effects of different types of microplastic aging, as well as the other pollutants on or around microplastics and the chemicals leached from microplastics, on the associated ARGs. Results: It highlights that microplastic photoaging generally results in higher sorption of antibiotics and ARGs due to increased microplastic surface area and functional group changes. Photoaging produces reactive oxygen species, facilitating ARG transfer by increasing bacterial cell membrane permeability. Reactive oxygen species can interact with biofilms, suggesting combined effects of microplastic aging on ARGs. The effects of mechanical aging were deduced from studies showing larger microplastics anchoring more ARGs due to rough surfaces. Smaller microplastics from aging penetrate deeper and smaller places and transport ARGs to these places. High temperatures are likely to reduce biofilm mass and ARGs, but the variation of ARGs on microplastics subjected to thermal aging remains unknown due to limited studies. Biotic aging results in biofilm formation on microplastics, and biofilms, often with unique microbial structures, invariably enrich ARGs. Higher oxidative stress promotes ARG transfer in the biofilms due to higher cell membrane permeability. Other environmental pollutants, particularly heavy metals, antibacterial, chlorination by-products, and other functional genes, could increase microplastic-associated ARGs, as do microplastic additives like phthalates and bisphenols. Conclusions: This review provides insights into the environmental fate of co-existing microplastics and ARGs under the influences of aging. Further studies could examine the effects of mechanical and thermal MP aging on their interactions with ARGs.

Synthesis, structural characterization, thermal analysis and anticorrosion properties of novel AZO-based imidazo[1,2-a]pyridine derivatives: Experimental study and theoretical approaches

In this study, innovative AZO-based imidazo[1,2-a]pyridine derivatives were synthesized using simple and efficient synthetic approach enabling large-scale production. Thermal analysis highlights their suitability for potential applications requiring resistance to moderate temperatures. These compounds were investigated as corrosion inhibitors for MS in a 1 M HCl-medium. Corrosion inhibition studies, including weight loss, PotentioDynamic polarization and electrochemical impedance spectroscopy methods, revealed that AZOs exhibited maximum corrosion inhibition efficiencies reaching 96.13 % and 94.07 %, respectively, at a concentration of 10−3 M and a temperature of 298 K, with both compounds acting as mixed-type inhibitors. The study also delved into the influence of temperature and immersion time on inhibitory performance, revealing stable inhibition within the temperature range of 298–328 K. The calculated standard free energy of adsorption was −42.06 and −40.62 kJ/mol for AZO 1 and AZO 2, respectively, suggesting mixed-type adsorption, with adsorption behavior following the Langmuir isotherm. Morphological analysis through SEM and AFM, showed a reduction in surface roughness in the presence of the inhibitors, while water contact angle measurements indicated a significant increase in surface hydrophobicity. UV–visible and FT-IR analyses confirmed the interaction of AZOs with the MS surface, suggesting the formation of a protective layer composed of adsorbed AZO molecules. Furthermore, computational investigations employing DFT, Monte Carlo, and Molecular Dynamic simulation revealed the formation of coordinate bonds between the studied inhibitors and the metal surface, confirming adsorption on the metallic surface. These findings align well with experimental outcomes, and a possible corrosion inhibition mechanism process was discussed.

Enhanced electrical and mechanical properties of additively manufactured pure copper with green laser

The effort to improve the additive manufacturing (AM) of copper, which is essential in various industrial sectors, has led to the exploration of green laser powder bed fusion (GL-PBF). By using a high-energy green laser, we overcome the challenges posed by the high reflectivity of copper, which has previously hindered achieving the desired component densities and functionalities through AM. This study uncovers the key role of GL-PBF process parameters on the densification, microstructure, surface roughness, mechanical properties, and electrical conductivity of pure copper parts. Our findings demonstrate that optimizing GL-PBF parameters can achieve copper components with over 99.9 % relative density and 98 % international annealed copper standard (IACS) electrical conductivity. The combination of comprehensive experiments and finite element modeling also reveals how the critical role of defect morphology in affecting electrical conductivity. This work contributes to the broader application of AM technologies, especially for high-reflectivity metals, and also provides new insights into how these defects affect conductivity and should be controlled during the AM process.

Investigating the role of extracellular polymeric substances produced by Parachlorella kessleri in Zn(II) bioremediation using atomic force microscopy

Microalgae, such as Parachlorella kessleri, have significant potential for environmental remediation, especially in removing heavy metals like zinc from water. This study investigates how P. kessleri, isolated from a polluted river in Argentina, can remediate zinc. Using atomic force microscopy (AFM), the research examined the interactions between Zn particles and cells grown with different nitrogen sources—nitrate or ammonium. The results showed that cells grown with nitrate produced extracellular polymeric substances (EPS), while those grown with ammonium did not. Raman spectroscopy revealed distinct metabolic responses based on the nitrogen source, with nitrate-grown cells showing altered profiles after zinc exposure. Zinc exposure also changed the surface roughness and nanomechanical properties of the cells, particularly in those producing EPS. AFM force spectroscopy experiments then confirmed strong Zn binding to EPS in nitrate-grown cells, while interactions were weaker in ammonium-grown cells that lacked EPS. Overall, our results elucidate the critical role of EPS in Zn removal by P. kessleri cells and show that Zn remediation is mediated by EPS adsorption. This study underscores the significance of regulating nitrogen sources to stimulate EPS production, offering insights that are essential for subsequent bioremediation applications.

Effect of Laser Powder Bed Fusion Parameters on the Evolution of Melt Pool, Densification, Microstructure, and Hardness in 420 Stainless Steel Parts

Laser powder bed fusion (LPBF) involves depositing, melting, and solidifying metal powder particles layer by layer to create 3D components. In this study, a deep fundamental understanding on how process parameters—laser power, scan speed, and hatch spacing—affect the melt pool, densification, microstructure, hardness, and thermal behavior of 420 stainless steel (420SS) parts produced by such technology is provided. The conducted investigation considers five levels of laser power and hatch spacing, and four scan speeds. Optimal single tracks, based on geometry and profile, are achieved with laser powers between 40 and 80 W and a scan speed of 10 mm s−1. In the multitrack analysis, it is indicated that a dense, smooth surface is obtained with a hatch spacing of 250 μm, corresponding to an overlapping rate of ≈30%. The 420SS samples show high densification (≈99%) and low surface roughness (≈3.62 μm). The microstructure consisted of martensite laths and retained austenite. The hardness and thermal conductivity of the samples are measured at 540 HV and 15.3 W m−1 K−1, respectively. In this study, the understanding of the process–structure–property relationships in LPBF of 420SS is expanded.

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.