Sequential Polishing Research Articles

Analysis of the effect of deep-profile compressive residual stress induced by laser peening on fatigue strength of 7075 aluminum alloy

The effect of laser peening-induced compressive residual stress on the fatigue strength improvement of A7075 specimens was investigated. Rotary bending fatigue tests and residual stress distribution measurements using the sequential polishing method were conducted on untreated, shot-peened, and laser-peened specimens. The results revealed that laser peening provides a deeper compressive stress and a deeper fracture origin, resulting in higher fatigue strength. Furthermore, controlling the laser parameters could extend the depth of the compressive stress layer by approximately 5 mm, indicating the possibility of applying laser peening to thicker materials to improve the fatigue strength.

Hybrid tools for improved removal and surface finish of metals and non-metals

Increasing productivity and surface quality in manufacturing is inevitable for the efficient use of resources. Precision smooth surfaces are generally achieved through sequential milling, grinding, fine-grinding, and polishing. This research aims to increase productivity through a shorter process chain. Hybrid tooling technology is presented where an elastic fine grinding tool is integrated with a conventional milling cutter or a grinding tool, in order to produce smooth surfaces on metal and non-metals. A hybrid milling cutter with an elastic tool could produce a low-waviness surface as compared to that of a milled-only surface. Surface roughness could be reduced by almost 50% using the hybrid milling tool on a steel workpiece. A monocrystalline silicon surface was machined with a hybrid grinding tool. Surface roughness of Ra ~ 100 nm could be obtained for hybrid tool in comparison to Ra ~ 200 nm with grinding only tool. The surface machined with a hybrid tool showed ductile mode cutting streaks, whereas, the ground surface was observed to be completely in brittle mode. Additionally, the hybrid tools also showed reduced machining vibrations due to the damping effect induced by the elastic tool member.

Possibilities of Duplex Plasma Electrolytic Treatment for Increasing the Hardness and Wear Resistance of a Commercially Pure Titanium Surface

The technology for duplex treatment of a commercially pure titanium surface is expected to increase hardness and wear resistance. This technology consists of sequential nitrocarburizing and polishing of the product in plasma electrolysis. The mechanism of duplex processing is revealed; it consists of strengthening the surface layers under diffusion saturation and controlled formation of the surface relief. The possibility of controlling the characteristics of the modified surface by combining various plasma technologies is shown. The morphological features of the surface and the surface layer after treatment were studied. The microhardness of the modified layer and the tribological properties of the surface were measured. It has been established that the samples with the highest surface layer hardness and a small thickness of the oxide layer on the surface have the highest wear resistance. After nitrocarburizing at 750 °C for 5 min, wear resistance increases by 4.3 times compared to pure material. If subsequent polishing is carried out at a voltage of 275–300 V for 3–5 min in chloride and fluoride electrolytes and 5–10 min in a sulfate electrolyte, then wear resistance can be further increased. This is achieved by removing the porous outer oxide layer.

Residual stress relaxation by bending fatigue in induction-hardened gear studied by neutron Bragg edge transmission imaging and X-ray diffraction

The compressive residual stress on the gear tooth’s surface, a vital parameter to control mechanical properties, such as strength, has a beneficial effect on the component’s fatigue life. A novel procedure, double induction quenching (DIQ), effective for improving the fatigue strength of gear products, has been used for producing gears with steep gradients of compressive residual stress generated in the tooth surface. We performed a Bragg edge imaging experiment at a pulsed neutron source to determine the spatial distribution of the {110} lattice spacing (d110) and the broadening of the {110} Bragg edge (w110) on the DIQ gear product after tooth-bending fatigue tests to which different loading cycles were applied. No significant difference occurred in the d110 and the w110 at Hofer’s critical section (tensile side) of the teeth with different loading conditions within the accuracy of data analysis. However, we detected a decrease in the w110 and changes in the residual lattice strain distribution in the axial direction (through the thickness) along the tooth root directions at the opposite side of Hofer’s critical section for both teeth after 3 × 105 and 8 × 105 cycles, relieving the compressive residual stresses during the fatigue process. The residual stress close to the gear tooth surface determined by X-ray diffraction using sequential polishing showed a slight relaxation and redistribution from the tensile side in the hoop direction, complementary to the neutron Bragg edge imaging information in the axial direction.

Removal of nutrients in sequential batch polishing ponds in the post-treatment of UASB reactor effluent

Resumo O lançamento indiscriminado de nutrientes em corpos hídricos pode levar ao processo de eutrofização desses corpos. Assim, deve-se buscar a remoção prévia de nitrogênio e fósforo. Uma alternativa que pode desempenhar satisfatoriamente esse papel são as lagoas de polimento de bateladas sequenciais (LPBS) no pós-tratamento de upflow anaerobic sludge blanket (UASB), uma vez que nessas lagoas o pH tende a se elevar, podendo acarretar a dessorção de amônia e precipitação de fósforo. Portanto, o presente trabalho objetivou aprofundar o estudo de UASB + LPBS abordando a importância do pH na remoção de nitrogênio e fósforo e avaliar a influência da profundidade e da temperatura no tempo de detenção hidráulica (TDH). Operou-se LPBS por 12 meses, na cidade de Campina Grande (PB), compreendendo os períodos quente (PQ) e frio (PF), com temperatura média de 25 e 21°C, nessa ordem, e avaliando quatro lagoas, L1, L2, L3 e L4, com profundidades de 0,2, 0,4, 0,6 e 1 m, respectivamente. O tratamento anaeróbio eficiente permitiu a elevação do pH nas LPBS em todos os períodos do ano, e o processo foi favorecido em menores profundidades. A remoção de amônia foi completa, independentemente da profundidade e do período do ano, com três, sete, 10 e 25 dias para o PQ e seis, 14, 18 e 27 dias para o PF. A remoção de fósforo ocorreu eficientemente, sobretudo quando se utilizaram lagoas mais rasas em ambos os períodos, embora o processo tenha sido favorecido no PQ, resultando em um menor TDH, o que demanda menor área nesse período.

Physical-Vapor-Transport growth of 4H silicon carbide single crystals by a tiling method

Increasing the diameter and reducing the dislocation density of 4H silicon carbide (4H-SiC) single crystals are the development tendency of 4H-SiC single-crystal substrate to reduce the cost of 4H-SiC based devices. In this work, we use the growth of a 100 mm 4H-SiC single crystal as an example to demonstrate that the tiling approach is attractive to enlarge the diameter of physical-vapor-transport (PVT)-grown 4H-SiC single crystals by a single growth period. By titling four pieces of 4H-SiC seed crystals, a 100 mm 4H-SiC boule without crystal deterioration is obtained by the PVT growth method. The shape of the growth interface is convex and complete after the PVT growth, indicating the tiling gaps between neighboring seed-crystal pieces are healed after the PVT growth of 25-mm thick 4H-SiC. Wafers are obtained after sequential slicing, lapping, and chemical mechanical polishing (CMP). The high-resolution X-ray diffraction (HRXRD) rocking curve measurements of the wafer at the latest growth stage indicate that the 4H-SiC crystal is basically healed, with mesoscopic boundaries being created at the central area of the wafer. Raman spectra indicate that the healing polymorph across the tiling gaps is 4H-SiC. We find that threading edge dislocations (TEDs) dominate the dislocation types in the 4H-SiC substrate wafers at the initial, middle, and latest growth stages. As the PVT growth proceeds, the density of dislocations in 4H-SiC wafers significantly decreases, as a result of the crystalline healing. Our work opens a pathway to enlarge the size of 4H-SiC single crystals in a single PVT growth period, which paves the way for the high-efficiency growth of large-size 4H-SiC single-crystals.

Influence of Surface Modifications on Bacterial Adherence to Implant Abutment Materials.

The purpose of this study was to investigate the effects of various titanium and zirconia polishing protocols on the colonization of oral bacteria. Titanium and zirconia discs were divided into five groups: unpolished (control, UNP) and polished with Brownie only (BRO), Brownie plus Greenie (BPG), Brownie plus Greenie plus Supergreenie (BGS), and CeraMaster Coarse plus CeraMaster polishing tips (CER). The samples were sterilized and immersed in unstimulated saliva, then incubated in a liquid suspension of Streptococcus gordonii (S gordonii). The number of attached bacteria were counted 48 hours after the diluted suspensions were inoculated. Data were analyzed with ANOVA and Tukey test (P < .05). For titanium discs, the average number of bacteria from each group (CFU/mm2) was 1.51 x 103 for UNP; 3.71 x 103 for BRO; 5.65 x 103 for BPG; 8.99 x 102 for BGS; and 8.49 x 102 for CER. For zirconia, the averages were 2.87 x 102 for UNP; 3.16 x 102 for BRO; 3.50 x 102 for BPG; 1.83 x 102 for BGS; and 8.73 x 101 for CER. Inadequate polishing roughens surfaces and promotes microbial adhesion to titanium and zirconia. Sequential polishing to the finest-finish polishing tips minimizes bacterial adherence to abutment surfaces. Zirconia exhibited less bacterial adhesion than titanium.

Influence of Surface Characteristics of Different Implant Abutment Materials on Growth of Porphyromonas Gingivalis

The purpose of the present study was to determine the surface physicochemical properties of polished implant abutment materials and to investigate their relationship with the growth of Porphyromonas gingivalis in vitro. Four groups of the most popular prosthetic materials were used in this study: titanium alloy (Ti), yttria-stabilized zirconium oxide (3Y-TZP), polyether ether ketone (PEEK) composite, and poly(methyl methacrylate) (PMMA). The plate shape specimens (10 × 10 × 0.5 mm) were polished by applying sequential mechanical polishing. Measurements of water contact angle (WCA), surface free energy (SFE) and roughness were performed. Also, the growth of P.gingivalis was measured via counting colony-forming units to milliliter (CFUs/mL). The WCA means were significantly different among all groups, and the highest hydrophilicity was observed on the PEEK, whereas the lowest on PMMA surface. All measured surfaces had similarly low SFE values, but Ti, 3Y-TZP, and PEEK demonstrated more expressed polar parts. All means of roughness were beyond the micro-level and were lower than 0.2 µm. The highest CFUs/mL was assessed on the PMMA and it was significantly different from others, whereas the lowest was on 3Y-TZP. The surface roughness had a significant impact on CFUs/mL growth.

Unveiling surfaces for advanced materials characterisation with large-area electrochemical jet machining

Surface preparation for advanced materials inspection methods like electron backscatter diffraction (EBSD) generally involve laborious and destructive material sectioning and sequential polishing steps, as EBSD is sensitive to both sample topography and microstrain within the near-surface. While new methodologies, like focussed ion beam and femtosecond laser milling are capable of removing material in a layer-by-layer manner to enable the construction of tomographic datasets within the electron microscope, such techniques incur high initial capital cost for slow removal and reconstruction rates. In this study, ambient condition electrochemical slot jets are applied to rapidly etch (e.g. 31 s) large surface areas (e.g. 160 mm2) at controlled depths (e.g. 20 μm) with no in-process monitoring. Unveiled surfaces are conducive to measurement by EBSD (raw index rates between 75 and 95%), despite topographic anisotropy arising both from the process and the material. The mechanisms of topography formation during dissolution under the slot jet are analysed and understood. It is proposed that this slot jet method can be applied to create measurement surfaces for analysis with optical-based microstructural measurement routines reliant on topography and directional reflectance, at a significantly lower cost and time intervention than electron beam-based analysis methods.

Coupled Broad Ion Beam–Scanning Electron Microscopy (BIB–SEM) for polishing and three dimensional (3D) serial section tomography (SST)

Here we describe the first automated fully integrated in-microscope broad ion beam (BIB) system. Ar+-BIB has several advantages over Ga+ focused ion beam (FIB) and Xe+ plasma-FIB (PFIB) methods inducing less beam damage, especially for ion beam sensitive materials. It can mill areas several orders of magnitude larger (up to millimetre scale), and is not confined to the edge of the sample with associated curtaining issues. BIB is shown to have sputter rates up to five times higher than comparable FIB techniques. This new coupled BIB–SEM system (commercial name ‘iPrep™II’) enables in-microscope surface polishing to remove contaminants or damage for two dimensional (2D) imaging, as well as automated serial section tomography (SST) by milling and imaging hundreds of slices, cost and time efficiently. The milled slice thickness can be controlled from a few nanometers up to a micrometre. A novel sample transfer, handling and interlock system allows automated and sequential BIB polishing, scanning electron microscopy (SEM) and analysis by secondary electron (SE) imaging, electron back scatter diffraction (EBSD) and energy dispersive spectroscopy (EDS) for 3D microstructure analysis. Furthermore, insulating surfaces can be sputter coated after milling each slice to reduce charging during SEM analysis. The performance of the instrument is demonstrated through a series of case studies across the materials, earth and life sciences exploiting the imaging, crystallographic and chemical mapping capabilities. These include the study of butterfly defects in bearing steels, meta-stable intermetallic phases in bronze bearings, shale gas rock, aluminium plasma electrolytic oxide (PEO) coatings as well as liver and mouse brain tissues.

Residual Stress Distribution in Water Jet Peened Type 304 Stainless Steel

In materials with a surface treatment such as shot peening, the residual stress gradient in the surface layer is severe. When measuring the residual stress distribution near the surface with a severe stress gradient by the neutron diffraction method, the gauge volume must be removed from the measurement sample. However, when the gauge volume deviates from the sample, a pseudo peak shift occurs and accurate stress distribution cannot be evaluated. Therefore, it is necessary to evaluate the pseudo peak shift in advance under the same conditions, as in the case of actual residual stress measurement, using a sample in an unstressed state. In this study, the stress distributions in the surface layer of a type 304 stainless steel plate and bar with simulated stress-corrosion cracks which were subjected to water jet peening—giving a surface layer residual stress equivalent better than that of normal shot peening—were evaluated considering the pseudo peak shift. As a result, the residual stress distributions in the surface layer were measured in good agreement with the measurement result obtained by the sequential polishing X-ray diffraction method. It was clarified that the residual stress distribution in the near surface with steep stress gradient can be evaluated by the neutron diffraction method.

Graphite surface profile with different polishing treatment

Graphite is a fascinating material to study in nanotechnology. Surface profile and roughness of the graphite are some of the most important parameters to determine many physical and mechanical behaviors including friction or bonding condition. To acquire certain surface profile, mechanical polishing treatment is one of the easiest ways that can be applied. In this work, graphite is polished by three different grades of sandpapers (P800, P400, and P220) and cellulose-based paper. The surface properties are observed by a laser microscope and various surface roughness parameters were quantified. The sequential polishing process employed in this work is able to modify the surface roughness and might improve the physical properties. This work sheds light on the importance of the mechanical surface treatment on graphite.

Surface Topography, Gloss and Flexural Strength of Pressable Ceramic After Finishing-Polishing Protocols.

This study evaluated the effect of different finishing-polishing protocols on surface roughness, gloss, morphology and biaxial flexural strength of pressable fluorapatite glass ceramic. Thirty ceramic discs (12x1 mm) were produced and divided into five groups (n=6): CT: control (glaze); DA: fine grit diamond bur; DG: DA + new glaze layer; DP: DA + felt disk with fine grit diamond paste; DK: DA+ sequential polishing with silicon abrasive instruments, goat hair brush and cotton wheel. The specimens were analyzed for surface roughness (Ra) under profilometry and atomic force microscopy (AFM). Gloss was measured with spectrophotometry and micromorphology with scanning electron microscopy (SEM). Flexural strength was assessed by biaxial flexural strength test. Data were analyzed using one-way ANOVA and Tukey's post hoc test (a=0.05). DK showed the lowest surface roughness values and DA presented the highest in the perfilometer analysis. No significant differences were observed in the AFM for the CT, DG and DK groups, which presented the lower surface roughness; DA and DP had the higher Ra values. The DA, DP and CT showed the lowest surface gloss values, and the reflectance was significantly different from those observed for DK and DG groups. SEM analysis revealed the smoothest surface for DK group, followed by DG and CT groups; DA and DP groups exhibited variable degrees of surface irregularities. No significant differences were observed among groups for the biaxial flexural strength. The polishing protocol used in DK group can be a good alternative for chairside finishing of adjusted pressable fluorapatite glass ceramic surfaces.

Stress-driven grain boundary movement during nanoindentation in tungsten at room temperature

Nanoindentations were performed in the vicinity of grain boundaries (GBs) in polycrystalline tungsten at room temperature, observing in some cases a secondary pop-in (known as GB pop-in) in the load–displacement curve. The dislocation microstructure in the plastic zone of the residual impression was analysed using sequential polishing, electron channelling contrast imaging (ECCI) and electron backscatter diffraction (EBSD) analysis on and below the surface. For some indentations, the interaction of the dislocations within the plastic zone and the GB leads to a localized GB movement on or below the surface. The occurrence and magnitude of GB movement are found to be strongly influenced by misorientation between the adjacent grains, the orientation of the indenter, as well as the applied load and the distance to the GB. The results show that the localized GB movement under an inhomogeneous stress field at room temperature is a possible deformation mechanism for tungsten.

Indentation size effect and dislocation structure evolution in (001) oriented SrTiO3 Berkovich indentations: HR-EBSD and etch-pit analysis

In the present work, the dislocation structure evolution and indentation size effect in (001) oriented STO have been studied by using sequential polishing, chemical etch-pit technique and high-resolution electron backscattered diffraction (HR-EBSD) analysis via Berkovich nanoindentation experiments. Nanoindentation load-displacement curves show multiple pop-in events, which relate to nucleation and extension of dislocation pile-ups around the residual impression. Sequential polishing and etching revealed the three-dimensional dislocation etch-pit structure at various sub-surface depths. The dislocation densities are determined for a 5 mN and 10 mN indentation below the surface via HR-EBSD and etch-pit analysis. With HR-EBSD, the lattice rotation and thereby GND densities are determined, while the etch-pit technique revealed the total dislocation density. Based on the independently measured dislocation densities, we clearly show a depth dependent dislocation density, where both total and GND densities increase with decreasing indentation depths. The higher dislocation densities below smaller indents explain the observed size dependency of the hardness in STO, which also sheds light on the extraordinary combination of high indentation hardness and low yield strength in STO.

Correlative Fluorescence and Electron Microscopy in 3D-Scanning Electron Microscope Perspective.

The ability to correlate fluorescence microscopy (FM) and electron microscopy (EM) data obtained on biological (cell and tissue) specimens is essential to bridge the resolution gap between the data obtained by these different imaging techniques. In the past such correlations were limited to either EM navigation in two dimensions to the locations previously highlighted by fluorescence markers, or subsequent high-resolution acquisition of tomographic information using a TEM. We present a novel approach whereby a sample previously investigated by FM is embedded and subjected to sequential mechanical polishing and backscatter imaging by scanning electron microscope. The resulting three dimensional EM tomogram of the sample can be directly correlated to the FM data. © 2017 by John Wiley & Sons, Inc.

Investigation of plastic strain rate under strain path changes in dual-phase steel using microstructure-based modeling

Micromechanical-based finite element simulations were carried out to investigate the transient plastic strain rate evolutions of ferrite and martensite dual-phase steel during strain path changes. A representative volume element (RVE) was generated through a three-dimensional (3D) reconstruction of microstructure images which were acquired from sequential polishing of a small material volume. The 10 × 10 × 10 μm3 3D RVEs consisted of martensite islands embedded in a ferrite base matrix. Each phase was assumed to exhibit distinct mechanical properties but the grain and phase boundary effects were ignored in this work. The effective mechanical properties for the constituent phases were assumed to be well defined by the von Mises or Hill 1948 yield criteria, the associated flow rule, and an empirical isotropic hardening equation based on chemical composition. This model was applied to investigate the transient behavior of the r-value (Lankford coefficient) in uniaxial tension when the loading direction changed. In addition to monotonic tension, compression-tension, and tension-orthogonal tension, sequences were considered. The simulation results captured well in a qualitative manner the experimental r-value evolutions in terms of a temporary transition and asymptotic limit. The evolutions of stress states in ferrite and martensite were analyzed to explain the r-value behavior that resulted from three factors: (1) r-value differences between ferrite and martensite, (2) martensite configuration-induced stress state in phases, and (3) stress partitioning and its evolution during non-proportional loading. Finally, an analytical relationship between the stress evolution in the constituent phases and the relevant r-value changes is suggested.

3D Dislocation structure evolution in strontium titanate: Spherical indentation experiments and MD simulations

AbstractIn the present work, the dislocation structure evolution around and underneath the spherical indentations in (001) oriented single crystalline strontium titanate (STO) was revealed by using an etch‐pit technique and molecular dynamics (MD) simulations. The 3D defect structure at various length scales and subsurface depths was resolved with the help of a sequential polishing, etching, and imaging technique. This analysis, combined with load‐displacement data, shows that the incipient plasticity (manifested as sudden indenter displacement bursts) is strongly influenced by preexisting dislocations. In the early stage of plastic deformation, the dislocation pile‐ups are all aligned in 〈100〉 directions, lying on {110}45 planes, inclined at 45° to the (001) surface. At higher mean contact pressure and larger indentation depth, however, dislocation pile‐ups along 〈110〉 directions appear, lying on {110}90 planes, perpendicular to the (100) surface. MD simulations confirm the glide plane nature and provide further insights into the dislocation formation mechanisms by tracing the evolution of the complete dislocation line network as function of indentation depth.

D-Shaped Polarization Maintaining Fiber Sensor for Strain and Temperature Monitoring.

A D-shaped polarization-maintaining fiber (PMF) as fiber optic sensor for the simultaneous monitoring of strain and the surrounding temperature is presented. A mechanical end and edge polishing system with aluminum oxide polishing film is utilized to perform sequential polishing on one side (lengthwise) of the PMF in order to fabricate a D-shaped cross-section. Experimental results show that the proposed sensor has high sensitivity of 46 pm/µε and 130 pm/°C for strain and temperature, respectively, which is significantly higher than other recently reported work (mainly from 2013) related to fiber optic sensors. The easy fabrication method, high sensitivity, and good linearity make this sensing device applicable in various applications such as health monitoring and spatial analysis of engineering structures.

Single-mode D-shaped optical fiber sensor for the refractive index monitoring of liquid

A new fabrication method is introduced for the production of D-shaped optical fiber. A mechanical end and edge polishing system with aluminum oxide polishing film is utilized to perform sequential polishing on one side (lengthwise) of single-mode optical fiber in order to obtain a D-shaped cross section. Adjusting specific mechanical parameters allows for control of the volume of the D-shaped zone, while the fiber surface smoothness is governed by selection of polishing film grit size. To meet the accuracy and repeatability requirements, optical power loss is monitored during the entire polishing process in situ and in real time. This proposed technique possesses advantages of rapidity, safety, simplicity, repeatability and stability with high precision in comparison with contemporary methods for production. Sensor performance tests on the fiber reveal a linear response with linearity up to R2 = 0.984 for surrounding refractive index in the range of 1.320–1.342 refractive index, which corresponds to different concentrations of the glucose solution test environment. The produced D-shaped optical fiber has potential sensing and monitoring applications in chemical, environmental, biological and biochemical fields.