Skewed Surface Research Articles

Effect of the Surface Peak-Valley Features on Droplet Impact Dynamics under Leidenfrost Temperature.

This study explores the kinetic behavior of droplets impacting microtextured surfaces under a Leidenfrost temperature, employing high-speed photography and picosecond laser micromachining techniques. The investigation focuses on two types of microtextured surfaces with totally different surface peak-valley features: a negatively skewed surface with micropit arrays (Ssk < 0) and a positively skewed surface with micropillar arrays (Ssk > 0). The results indicate that both microtextured surfaces contribute to a higher Leidenfrost temperature compared with the original smooth surface, which is consistent with previous studies. However, it is worth noting that the Leidenfrost points of the micropit and micropillar surfaces showed opposite trends with the microtexture area occupancy. Specifically, the Leidenfrost temperature on micropit surfaces increases with greater micropit area occupancy, while it decreases on micropillar surfaces under similar conditions, which is mainly attributed to the differential impact of area occupancy on droplet heat transfer efficiency. When the microtexture area occupancy is 50%, it is worth noting that the micropit and micropillar surfaces have nearly same roughness (Sa), but the Leidenfrost temperature was notably higher on the micropit surface with negative skewness (Ssk < 0), which was related to differences in vapor flow dynamics. We further find that the Weber number (We) significantly influences the Leidenfrost point, with the droplet impact wall behavior going through the states of film bounce back, ejecting tiny droplets and bounce back, and ultimately droplet breakup as the We increases. The dynamic Leidenfrost point was found to be generally higher than the static point and increases with the We. Finally, we compare the cooling efficiency of these surfaces, and it is found that the micropit surfaces with a negative skewness exhibit superior heat dissipation performance under the same conditions, which proved that the negatively skewed surface may have great potential in high-density heat dissipation technology.

Evolution of tooth surface morphology and tribological properties of helical gears during mixed lubrication sliding wear

In mixed lubrication, the interplay of lubricant flows, solid asperity contact, and material wear between tooth surfaces creates complex and unpredictable contact states on tooth surface. To comprehensively understand the interaction between the lubrication and wear characteristics of the rough tooth surfaces of helical gears, this study established a mixed lubrication sliding wear calculation model for helical gears based on the mixed elastohydrodynamic lubrication model and Archard’s model. Specifically, the study aimed to examine the effects of surface topography features on average film thickness, contact area ratio, and accumulated wear at the meshing point. The findings demonstrated that the texture and power spectral density distributions of a non-Gaussian reconstructed surface closely resembled those of the actual ground surface. Furthermore, for non-Gaussian rough surfaces, a larger wavelength ratio enhanced microwedge motion, which increased film thickness and reduced wear. Additionally, a negatively skewed surface demonstrated better lubrication performance compared to both positively skewed and Gaussian surfaces. This improved performance is evident in the smaller contact area ratio and lower accumulated wear value of the negatively skewed surface.

Large eddy simulations of flow over additively manufactured surfaces: Impact of roughness and skewness on turbulent heat transfer

Additive manufacturing creates surfaces with random roughness, impacting heat transfer and pressure loss differently than traditional sand–grain roughness. Further research is needed to understand these effects. We conducted high-fidelity heat transfer simulations over three-dimensional additive manufactured surfaces with varying roughness heights and skewness. Based on an additive manufactured Inconel 939 sample from Siemens Energy, we created six surfaces with different normalized roughness heights, Ra/D=0.001,0.006,0.012,0.015,0.020, and 0.028, and a fixed skewness, sk=0.424. Each surface was also flipped to obtain negatively skewed counterparts (sk=−0.424). Simulations were conducted at a constant Reynolds number of 8000 and with temperature treated as a passive scalar (Prandtl number of 0.71). We analyzed temperature, velocity profiles, and heat fluxes to understand the impact of roughness height and skewness on heat and momentum transfer. The inner-scaled mean temperature profiles are of larger magnitude than the mean velocity profiles both inside and outside the roughness layer. This means, the temperature wall roughness function, ΔΘ+, differs from the momentum wall roughness function, ΔU+. Surfaces with positive and negative skewness yielded different estimates of equivalent sand–grain roughness for the same Ra/D values, suggesting a strong influence of slope and skewness on the relationship between roughness function and equivalent sand–grain roughness. Analysis of the heat and momentum transfer mechanisms indicated an increased effective Prandtl number within the rough surface in which the momentum diffusivity is larger than the corresponding thermal diffusivity due to the combined effects of turbulence and dispersion. Results consistently indicated improved heat transfer with increasing roughness height and positively skewed surfaces performing better beyond a certain roughness threshold than negatively skewed ones.

Effect of surface peak-valley features on the fluid flow performance in rough contact interface

In this work, two kinds of microtextured surfaces with different surface peak-valley features, namely positively skewed surface with micropillar array and negatively skewed surface with micropit array, are prepared to explore the effect of peak-valley features on the fluid flow performance in rough contact interface. The distribution and connectivity of microchannels is analyzed, and the physical mechanism of peak-valley features inducing different fluid flow processes is also derived through constructing a kinetic model of fluid spreading. It is found that when the surface skewness Ssk &amp;gt; 0, the positively skewed surface forms the void regions with better connectivity in the interface compared with the negatively skewed surface (Ssk &amp;lt; 0), despite both the surfaces having nearly the same roughness (Sa ∼ 3.6 mm). The formed microchannels are defined as crossed open microchannel and semi-closed microchannel, respectively, and the feature length of the microchannel decreases with the increase in load. The quantitative results of fluid flow demonstrate that the liquid has a better spreading and flow ability in the contact interface of the positively skewed surface. Even under the same microchannel feature length (nearly 48 mm), the fluid spread area ratio of the positively skewed surface has an order of magnitude higher than that of the negatively skewed surface. The mechanism of different flow characteristics induced by surface peak-valley features is believed as the variation of the microchannel shape, leading to the change in the capillary pressure at the meniscus. We believe the present work would lay a theoretical foundation for regulating the microscopic flow behavior in the contact interface.

Effects of surface morphology on the performance of water-lubricated thrust bearings

Purpose As the crucial support component of the propeller power system, the reliability of the operation of submersible pumps is influenced by the lubrication performance of water-lubricated thrust bearings. When the water-lubricated thrust bearings are under start-stop or heavy load conditions, the effect of surface morphology is crucial as the mixed lubrication regime is encountered. This paper aims to develop one mixed lubrication model for the water-lubricated thrust bearings to predict the effects of surface skewness, kurtosis and roughness orientation on the loading carrying capacity and tribological behavior. Design/methodology/approach This paper developed one improved mixed lubrication model specifically for the water-lubricated thrust bearing system. In this model, the hydrodynamic model was improved by using the height of the rough surface and its probability density function, combined with the average flow model. The asperity contact model was improved by using the equation for the Pearson system of frequency curves to characterize the non-Gaussian aspect of surface roughness distribution. Findings According to the results, negative skewness, large kurtosis and lateral surface pattern can improve the tribological performance of water-lubricated thrust bearings. Optimizing the surface morphology is a reasonable design method that can improve the performance of water-lubricated thrust bearings. Originality/value In this paper, one mixed lubrication model specifically for the water-lubricated thrust bearing with the effect of surface roughness into consideration was developed. Based on the developed model, the effect of surface morphology on tribological behavior can be evaluated. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2023-0247/

Suppressed Droplet Splashing on Positively Skewed Surfaces for High-Efficiency Evaporation Cooling.

Two types of functional surfaces with the same roughness but completely different surface topographies are prepared, namely positively skewed surfaces filled with micropillar arrays (Sa ≈4.4µm, Ssk >0) and negatively skewed surfaces filled with microcavity arrays (Sa ≈4.4µm, Ssk <0), demonstrating promoting droplet splashing. Remarkably, the critical Weber number for generating satellite droplets on the negatively skewed surfaces is significantly lower than that on the positively skewed surfaces, indicating that the negatively skewed surface with microcavity arrays is more likely to promote droplet splashing. It is mainly attributed to the fact that air on the negatively skewed surface can make the liquid film take on a Cassie-Baxter state on the surface so that the stabilizing capillary force of the liquid film exceeds the destabilizing stress of the air film. Moreover, the surface topography promoting droplet spreading and the mechanical properties of three-phase moving contact lines are analyzed from the perspective of microscopic interface mechanics. Finally, it is demonstrated the designed positively skewed surfaces can be employed for large-area heat dissipation by means of high-efficiency evaporation.

Machine learning approach for the prediction of mixed lubrication parameters for different surface topographies of non-conformal rough contacts

PurposeThis study aims to use a machine learning (ML) model for the prediction of traction coefficient and asperity load ratio for different surface topographies of non-conformal rough contacts.Design/methodology/approachThe input data set for the ML model is generated using a mixed-lubrication model. Surface topography parameters (skewness, kurtosis and pattern ratio), rolling speed and hardness are used as input features in the multi-layer perceptron (MLP) model. The hyperparameter tuning and fivefold cross-validation are also performed to minimize the overfitting.FindingsFrom the results, it is shown that the MLP model shows excellent accuracy (R2 > 90%) on the test data set for making the prediction of mixed lubrication parameters. It is also observed that engineered rough surfaces with high negative skewness, low kurtosis and isotropic surface patterns exhibit a significant low traction coefficient. It is also concluded that the MLP model gives better accuracy in comparison to the random forest regression model based on the training and testing data sets.Originality/valueMixed lubrication parameters are predicted by developing a regression-based MLP model. The machine learning model is trained using several topography parameters, which are vital in the mixed-EHL regime because of the lack of regression-fit expressions in previous works. The accuracy of MLP with random forest models is also compared.

Effect of the surface peak-valley features on droplet splash dynamics

In this study, we fabricated two types of functional surfaces with the same roughness (Sa) but entirely opposite surface morphological features, which are defined as the positively skewed surface filled with protruding cylinder array (Ssk &amp;gt; 0) and the negatively skewed surface filled with circular pit array (Ssk &amp;lt; 0). The effect of surface morphology peak-valley features on droplet splash is analyzed, and the formation mechanism of the prompt splash and corona splash is also indicated based on the Kelvin–Helmholtz instability. Our results demonstrate that, under the same roughness conditions of Sa, the interaction between the liquid lamellae and the thin air layer is much stronger on the negatively skewed surface, which would inhibit droplet spreading and promote the generation of droplet splash. Increasing the depth of microstructures, resulting in more pronounced peak-valley features, has been found to facilitate both prompt and corona splash phenomena to some extent. Additionally, it is found that the ease of splash formation on each surface is related to the initial spreading speed variation, with the degree of reduction in the initial spreading speed indirectly reflecting the instability of the liquid lamellae. The findings from our study contribute to the development of advanced surface engineering strategies for controlling droplet splash and enhancing the performance of various industrial applications.

A numerical study on the impact of lubricant rheology and surface topography on heavily loaded non-conformal contacts

The increasing requirement of high-power density (power throughput/ weight) in modern day machines lead to thin film lubrication condition in various machine components (rolling element bearings, gears, cams, etc,) due to severe loading conditions. Surface roughness features and lubricant rheology plays a vital role in thin film lubrication, and significantly affects the lubrication performance and lifetime of machine components. The present work demonstrates surface topography and lubricant rheology effects on the traction coefficient for heavily loaded non-conformal contacts. The load-sharing concept considering elastic-plastic deformation of asperities, and Carreau shear-thinning rheological model is employed to describe the dry rough contacts and non-Newtonian behavior of lubricant. An influence of surface topography parameters such as roughness, skewness, kurtosis, and pattern ratio on the traction coefficient is discussed. From results, it is found that among different surface topographies, negatively skewed surfaces having isotropic surface pattern exhibit minimum traction coefficient. The load share function and the critical rolling speed are determined for various surface topographies which provides further insights into the surface topography effect on traction coefficient. The findings of present study are noteworthy as they provide a theoretical basis for an assessment of the lubrication performance of heavily loaded non-conformal contacts.

Influence of skewed three-dimensional sinusoidal surface roughness on turbulent boundary layers

The impact of roughness skewness (ksk) on turbulent boundary layer (TBL) flow with a zero pressure gradient over three-dimensional (3D) sinusoidal rough surfaces was experimentally investigated using a single hotwire anemometer. Nine 3D sinusoidal profiles were manufactured with positive, negative, and zero roughness skewness values. Measurements were taken at three different freestream velocities for each surface and compared with smooth wall TBL results. This study covered a range of friction Reynolds numbers (Reτ) from approximately 1000 to 4000, with δ/k≈20 ± 2, where δ represents the local boundary layer thickness, and k is the maximum height of the roughness, measured from the valley to peak. The results indicate that the wall-unit normalized streamwise mean velocity profiles for all rough surfaces exhibit a downward shift compared to the smooth wall profiles. Surfaces with positive roughness skewness produced the highest drag, leading to the largest downward shift. The friction coefficient (Cf) decreased as ksk decreased. The percentage increase in Cf and ΔU+ (the roughness function) was much larger when moving from negative to zero roughness skewness than when moving from zero to positive roughness skewness. The small differences in turbulence intensity profiles and higher-order turbulence statistics in the outer region of the TBL support the outer layer similarity hypothesis for the roughness considered in this study. The autocorrelation study revealed that surfaces with positive roughness skewness tend to shorten the average length of turbulence structures in the near-wall region.

Scaling of the roughness effects in turbulent flows over systematically-varied irregular rough surfaces

To clarify the effects of surface topology on the scaling of roughness effects, we conduct experiments on turbulent rough-walled channel flows from transitionally to fully rough regimes. We considered three-dimensional irregular rough surfaces with different effective slope ES, skewness factor Sk, and fixed roughness height scales. The ES values are varied from 0.09 to 0.72 for positively and negatively skewed surfaces with Sk=±0.4. It is revealed that the transitional behavior to the fully rough regime is not influenced by Sk, but rather by ES. The transition to the fully rough regime for surfaces with ES≥0.18 is insensitive to the ES values, whereas wavy surfaces with ES=0.09 lead to a moderate transition. The equivalent sand-grain roughness ks steeply increases with increasing ES values from 0.09 to 0.36, whereas a further increase in the ES value does not significantly influence ks. It is also found that positively skewed surfaces with Sk=+0.4 yield larger ks values compared to surfaces with Sk=−0.4; this Sk effect is more pronounced for wavy surfaces with small ES values.

Mode-dependent H atom tunneling dynamics of the S1 phenol is resolved by the simple topographic view of the potential energy surfaces along the conical intersection seam.

Mode-dependent H atom tunneling dynamics of the O-H bond predissociation of the S1 phenol has been theoretically analyzed. As the tunneling is governed by the complicated multi-dimensional potential energy surfaces that are dynamically shaped by the upper-lying S1(ππ*)/S2(πσ*) conical intersection, the mode-specific tunneling dynamics of phenol (S1) has been quite formidable to be understood. Herein, we have examined the topography of the potential energy surface along the particular S1 vibrational mode of interest at the nuclear configurations of the S1 minimum and S1/S2 conical intersection. The effective adiabatic tunneling barrier experienced by the reactive flux at the particular S1 vibrational mode excitation is then uniquely determined by the topographic shape of the potential energy surface extended along the conical intersection seam coordinate associated with the particular vibrational mode. The resultant multi-dimensional coupling of the specific vibrational mode to the tunneling coordinate is then reflected in the mode-dependent tunneling rate as well as nonadiabatic transition probability. Remarkably, the mode-specific experimental result of the S1 phenol tunneling reaction [K. C. Woo and S. K. Kim, J. Phys. Chem. A 123, 1529-1537 (2019)] (in terms of the qualitative and relative mode-dependent dynamic behavior) could be well rationalized by semi-classical calculations based on the mode-specific topography of the effective tunneling barrier, providing the clear conceptual insight that the skewed potential energy surfaces along the conical intersection seam (strongly or weakly coupled to the tunneling reaction coordinate) may dictate the tunneling dynamics in the proximity of the conical intersection.

Effect of high skewness and kurtosis on turbulent channel flow over irregular rough walls

The skewness of the roughness height distribution is one of the key topographical parameters that govern roughness effects on wall-bounded turbulence. In this paper mathematical bounds for realisable values of skewness and kurtosis are discussed in the context of irregular multi-scale rough surfaces, which are representative of typical forms of engineering roughness. The properties of a set of irregular rough surfaces fully covered by roughness features with very high positive and negative skewness and high kurtosis are investigated using direct numerical simulations of turbulent channel flow at . While an increase of the roughness function is observed at moderate skewness values in line with empirical predictions and previous results for moderately skewed surfaces, the roughness function saturates at extreme values of skewness. Overall, the roughness effect is found to be more sensitive to skewness over the negative skewness range compared to the positive skewness range. Surface pressure statistics show that for surfaces with extreme skewness fully covered by roughness features extreme pits or peaks do not dominate the roughness effect and that surrounding roughness features (‘background’ roughness) retain a significant influence. This is because, while extreme roughness features emerge as skewness approaches high positive or negative values, they tend to be sparse decreasing their overall impact on the wall-bounded flow.

Prediction of electrical resistance of laser-welded copper pin-pairs with surface topographical information from inline post-process observation by optical coherence tomography

Laser welding of copper hairpins is required to produce a conductive connection in electric stators. Past manufacturing processes introduce misalignments that lead to poor weld connections with increased electrical resistance. In this work, we discuss correlations between the electrical resistance of the weld connection and possible misalignment types. Misalignments lead to a deformed surface topography of the weld. We correlate inline measurements of the weld topography by optical coherence tomography (OCT) with misalignment types and hence erroneous weld connections. We identify a connection between surface topographical weld features with the electrical resistance of the weld. As a result, a quantified separation of process results is possible with a surface topographical feature of the hairpins that allows for concluding the electrical resistance of the pin-pair connection. Correlation coefficient is identified as the most relevant feature indicating a linear trend in the height profile. Reference measurements with a symmetrical weld pearl show a correlation coefficient of around 0, whereas misalignments with a skewed surface topography show increased absolute correlation coefficient values up to 0.75. The identified correlation between the electrical resistance and different misalignment types can be depicted with the correlation coefficient for the given boundary conditions. Defective weld results with electrical resistances above 6 µΩ can be identified with feature values above 0.5, whereas reference welds with an electrical resistance below 5 µΩ can be identified with an absolute correlation coefficient below 0.2.

MICROPOLAR FLUID LUBRICATION OF FINITE ROUGH POROUS JOURNAL BEARING WITH SQUEEZING EFFECT

In this paper, a theoretical analysis of the effect of surface roughness on the squeeze film lubrication of finite porous journal bearings with micropolar fluids is studied. A more generalized form of surface roughness is mathematically modeled by a stochastic random variable with non-zero mean, variance and skewness. The generalized average Reynolds type equation is derived for the squeeze film lubrication of finite rough porous journal bearings with micropolar fluids as lubricant. The closed form expressions are obtained for the fluid film pressure, load carrying capacity, journal centre velocity and locus of the journal centre. The cases of a constant applied load and an alternating applied load are analyzed under a cyclic load the micropolar fluids provide a reduction in the journal centre velocity. Further, it is numerical computations of the results show that the negatively skewed surface roughness pattern increase fluid film pressure, load carrying capacity and decreases the journal centre velocity. Where as adverse effects were found for the positively skewed surface roughness pattern. The effect of porous parameter causes reduction in fliud film pressure, load carrying capacity and enhances the journal centre velocity.

Exploration and tuning of Al2O3/Mo composite for enhancement of anti-corrosion and tribological characteristics in zinc phosphate conversion coatings

Recently, phosphate conversion coatings have been modified by transition/non-transition metal oxide with distinguished characteristic features such as corrosion resistance, wear resistance, lubrication and adhesion. The present paper explores the development of Al2O3/Mo composite incorporated zinc phosphate coatings on galvanized steel for achieving higher corrosion-resistant characteristics with an added advantage of tribological performance. Incorporation of Mo leads to the phase transformation from γ to α-Al2O3, which ensures the subsequent crystallization of alumina particles by the anisotropic grain growth of Mo content. Particle size, elemental composition and morphology of the Al2O3/Mo composite are tuned for retaining the stable crystalline alpha phase of the composite. The optimum concentration of the tuned content of Al2O3/Mo composite in the phosphating solution can effectively perform as an active nucleating source for the establishment of more compact, homogeneous and dense zinc phosphate crystal growth and coverage in the galvanized steel surface by significantly reducing the activation energy during the phosphating process. The resultant composite phosphate coating ensures the formation of a large quantity of crystalline hopeite rich phase compared to other coatings, which effectively acts as an insulator during the electrochemical reaction by imparting a corrosion-resistant barrier between the substrate and corrosive media. Uniform distribution of composite particles at the grain boundaries and at the bulk grain composition is also achieved. Lower average surface roughness (Sa), root mean square surface roughness (Sq), maximum height (St), surface skewness (Ssk) and higher surface kurtosis (Sku) values are acquired for better anti-corrosion properties with excellent tribological performance. The higher Rp and Rct values with lower Cdl and corrosion rate values of the tuned composition of Al2O3/Mo composite based zinc phosphate coating confirms the better porosity and thereby enhances the corrosion-resistant performance due to the sealing action of the composite.

A Simple Empirical Model for the Radar Backscatters of Skewed Sea Surfaces at X- and Ku-Bands

A Simple Empirical Model for the Radar Backscatters of Skewed Sea Surfaces at X- and Ku-Bands

Effects of surface texture parameters of cutting tools on friction conditions at tool-chip interface during dry machining of AISI 1045 steel

Abstract Dry machining is one of the essential steps towards achieving sustainable manufacturing processes. Sustainable dry machining can be further enhanced by using surface textured cutting tools where the micro-capillary networks on cutting tool surfaces are exploited for tribological benefit in the absence of cutting fluids. This paper presents the results of an experimental study in which rake surfaces of uncoated carbide cutting tools are textured at different levels, and orthogonal machining is performed on AISI 1045 steel under dry machining condition. The results show that skewness, kurtosis, and other surface texture parameters on the rake surface significantly influence the machining forces via altering friction conditions at the tool-chip interface. Further, the orientation of the cutting tool’s surface texture pattern has a strong effect on the capability of the surface micro-capillary network to allow atmospheric air, which must serve as a lubricant in dry cutting, to access portions of the tool-chip contact zone.

Surface Water Temperature Heterogeneity at Subpixel Satellite Scales and Its Effect on the Surface Cooling Estimates of a Large Lake: Airborne Remote Sensing Results From Lake Geneva

AbstractThe dynamics of spatial heterogeneity of lake surface water temperature (LSWT) at subpixel satellite scale O(1 m) and its effect on the surface cooling estimation at typical satellite pixel areas O(1 km2) were investigated using an airborne platform. The measurements provide maps that revealed spatial LSWT variability with unprecedented detail. The cold season data did not show significant LSWT heterogeneity and hence no surface cooling spatial variability. However, based on three selected daytime subpixel‐scale maps, LSWT patterns showed a variability of &gt;2 °C in the spring and &gt;3.5 °C in the summer, corresponding to a spatial surface cooling range of &gt;20 and &gt;40 W/m2, respectively. Due to the nonlinear relationship between turbulent surface heat fluxes and LSWT, negatively skewed LSWT distributions resulted in negatively skewed surface cooling patterns under very stable or predominantly unstable atmospheric boundary layer (ABL) conditions and positively skewed surface cooling patterns under predominantly stable ABL conditions. Implementing a mean spatial filter, the effect of area‐averaged LSWT on the surface cooling estimation up to a typical satellite pixel was assessed. The effect of the averaging filter size on the mean spatial surface cooling values was negligible, except for predominantly stable ABL conditions. In that situation, a reduction of ~3.5 W/m2 was obtained when moving from high O(1 m) to low O(1 km) pixel resolution.

The influence of roughness distribution characteristic on the lubrication performance of textured cylinder liners

PurposeThe purpose of this paper is to investigate the coupling mechanism of the roughness distribution characteristic and surface textures on the cylinder liner.Design/methodology/approachThe cylinder liner-piston ring lubrication model with non-Gaussian roughness distribution surface was proposed in this paper to find the optimum cylinder liner surface. The motored engine tests were carried out to verify the simulation results.FindingsThe calculation and experiment results show that the large negative skewness surface has the optimal lubrication performance in the un-textured liner, while in the textured liner, the small negative skewness surface is more appropriate, which means surface textures couple with small negative skewness surface can improve the lubrication performance.Originality/valueAlthough there are some works related to liner surface roughness and textures, the combine of roughness distribution and surface textures is not usually taken into account. Therefore, this research is different from others, as the present model considers with real non-Gaussian roughness distribution liners.