Surface Roughness Characteristics Research Articles

The Post-Processing of Additive Manufactured Polymeric and Metallic Parts

The traditional manufacturing industry has been revolutionized with the introduction of additive manufacturing which is based on layer-by-layer manufacturing. Due to these tool-free techniques, complex shape manufacturing becomes much more convenient in comparison to traditional machining. However, additive manufacturing comes with its inherent process characteristics of high surface roughness, which in turn effect fatigue strength as well as residual stresses. Therefore, in this paper, common post-processing techniques for additive manufactured (AM) parts were examined. The main objective was to analyze the finishing processes in terms of their ability to finish complicated surfaces and their performance were expressed as average surface roughness (Sa and Ra). The techniques were divided according to the materials they applied to and the material removal mechanism. It was found that chemical finishing significantly reduces surface roughness and can be used to finish parts with complicated geometry. Laser finishing, on the other hand, cannot be used to finish intricate internal surfaces. Among the mechanical abrasion methods, abrasive flow finishing shows optimum results in terms of its ability to finish complicated freeform cavities with improved accuracy for both polymer and metal parts. However, it was found that, in general, most mechanical abrasion processes lack the ability to finish complex parts. Moreover, although most of post-processing methods are conducted using single finishing processes, AM parts can be finished with hybrid successive processes to reap the benefits of different post-processing techniques and overcome the limitation of individual process.

Friction Coefficients Calculation via Surface Roughness Characterization for Tight Sedimentary Rocks

Friction Coefficients Calculation via Surface Roughness Characterization for Tight Sedimentary Rocks

The effects of resin infiltration on demineralized root surface: an experimental study.

The objective of this experimental invitro study was to investigate the effects of resin infiltration (RI) on surface roughness, microhardness, color and surface characteristics of artificially demineralized root surfaces. Forty-two root specimens prepared from freshly extracted intact human upper incisors were subjected to surface roughness, microhardness, and color tests. Profilometer was used to measure surface roughness and Vicker's Hardness tester was used to measure the changes in microhardness. The color measurements were performed by a spectrophotometer using the CIELAB parameters. Following measurements, specimens were divided into 3 groups (n=14): G1: intact root surfaces, G2: demineralized root surfaces and G3: Resin infiltrated root surfaces (Icon, DMG) following demineralization. Surface roughness, microhardness and color measurements were repeated in G2 and G3 after demineralization and RI. One specimen from each group was examined by SEM. Data were analyzed statistically (p<0.05). Application of RI to artificially demineralized root surfaces significantly decreased the surface roughness (p<0.001) and increased the microhardness (p=0.023). RI also affected the color of demineralized root surfaces. SEM examinations revealed that the porosities on demineralized root surfaces seemed to be sealed after RI. RI affected the surface roughness, microhardness, color and surface appearance of artificially demineralized root surfaces.

Effects of the Energy Density on Pores, Hardness, Surface Roughness, and Tensile Characteristics of Deposited ASTM 316L Specimens with Powder-Bed Fusion Process.

Powder bed fusion (PBF) is a typical metal-AM process. Studies on the process parameters are required to fabricate the desired shape without defects in the PBF process. The aim of this study is to investigate the effects of energy density on the pore, hardness, surface roughness, and tensile characteristics of deposited ASTM 316L specimens using a powder-bed fusion process. Twenty-seven types of specimens with different laser powers, scanning speeds, and overlap ratios were fabricated using the PBF process. The effects of the energy density on the porosity, hardness, surface roughness, tensile strength, and fracture properties of ASTM 316L specimens were examined. The relationships between these properties and energy density are discussed. A critical energy density level was suggested as 79 J/mm3 considering these characteristics. With the critical energy density level, relative density, surface roughness (Ra) and hardness were observed 99.5%, 1.2 μm, and 240 HV, respectively. Additionally, these characteristics were improved with increasing energy density. Five representative conditions were chosen to fabricate tensile specimens with the ASTM 316L powder through the PBF process. Tensile characteristics, including ultimate strength, yield strength, strain, and fracture shape, were examined for different energy densities. The best tensile characteristics were observed with the highest energy density level of 155 J/mm3.

Functional enhancement of hydroxypropyl cellulose‐based bionanocomposite films incorporating chitosan nanoparticles

SummaryThe aims of the present study were to investigate the effect of the incorporation of chitosan nanoparticles (ChiNPs) on the physicochemical properties and antifungal activity of hydroxypropyl cellulose (HPC) bionanocomposite films. The films of 4% HPC and ChiNP at various dosages (0%, 0.1%, 0.5%, 1%, 1.5%, 3% w/w of HPC) were prepared. Atomic force microscopy (AFM) verified the dispersion of spherical‐shaped ChiNP in a nanoscale size range (14.75–56.74 nm). Incorporation of nanofiller affected the functional properties by increasing the film–water contact angle to &gt;53°, improving the optical properties, and reducing water vapour permeability by 5.73–12.54%. These results were influenced by surface roughness and microstructure characteristics of a bionanocomposite film, which were confirmed using AFM and scanning electron microscopy (SEM). Tensile assays of the films showed slight increases in tensile strength from 8.87 to 11.08 MPa and Young's modulus from 0.10 to 0.15 GPa with increasing proportions of ChiNP (1.5%). An effective concentration of ChiNP of 1.5% (w/w of HPC) was able to improve the performance of HPC and offered antifungal activity against Botrytis cinerea, as confirmed through mycelial growth inhibition assays and by membrane integrity changes. The HPC/ChiNP bionanocomposite films may have potential applications for active packaging, particularly for fresh fruit commodities.

Sampling optimization for 3D surface measurement. Part I: Sampling area optimization based on areal texture parameter analysis

Surface roughness characterization is associated with sampling parameters during measurement, but little was reported on sampling scale selection for 3D surface topography measurement. This study aimed to optimize sampling areas for four surfaces with different surface height ranges for comparability and repeatability of areal texture measurement. Two kinds of isotropic and anisotropic 3D random surfaces were simulated and generated based on fast Fourier transform (FFT) and autocorrelation function. The availability of the two simulated surfaces was verified by actual surfaces machined using polishing and grinding. The surface heights parameters of Sq and Sz were selected as evaluation parameters to determine the optimal sampling areas based on the analysis for coefficients of variation of five typical areal texture parameters of Sq, Sz, Sku, Ssk, and Sal. For each surface, fifty sampling areas with different side lengths were selected to evaluate the response of Sq and Sz to the side length of sampling area. The results show anisotropic surfaces needed larger sampling areas than isotropic surfaces under the same roughness range. Four optimal sampling areas were determined corresponding to four different Sq ranges for isotropic and anisotropic surfaces, respectively. Finally, four surfaces corresponding to different Sq ranges were machined using four burs with different abrasive grits. Based on the recommended optimal sampling areas, their 3D surface topographies and areal texture parameters were measured. The minimum standard deviation (SD) analysis was performed on the measurement results, which verified the validity of the recommended optimal sampling areas. These optimal sampling areas provide practical guidance of standardizing sampling parameter selection for repeatability and comparability in areal texture parameters measurement of 3D surface measurements.

Utilisation of Paunch Waste as a Natural Fibre in Biocomposites.

Paunch is a fibrous solid residue consisting of partially digested feed from the stomachs of processed cattle. It is the largest untapped solid waste stream from animals at meat processing plants, and potentially a valuable source of fibres for the production of sustainable and potentially higher-value natural biocomposite materials. Paunch was obtained from the waste effluent of a red meat processing plant, and the fibre characteristics of the as-obtained material were studied and benchmarked against wood flour and ground buffel grass, with a view to evaluating the potential of paunch as a fibre for polymer composites. The ground paunch possessed a rough fibrous surface and fibre-like characteristics that were comparable to both wood flour and ground buffel grass, demonstrating their potential for use in composites. Without any pre-treatment or compatibilisation, composites of a representative biopolymer, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) and ground paunch were successfully produced for the first time via extrusion, with up to 50 wt% paunch content. Mechanical property analysis showed that, at 30 wt% content, PHBV/ground paunch composites yielded mechanical properties that were comparable to those of composites with ground buffel grass.

Study on surface integrity and ductile cutting of PV polycrystalline silicon and wear mechanisms of electroplated diamond wire

This study aimed to evaluate and better understand the mechanical and crystalline responses of polycrystalline silicon sawn by diamond wire sawing. To simplify the multi-wire sawing kinematic, an endless wire saw with a single looped diamond wire welded was used. The wire cutting speed and feed rate were varied in order to evaluate the characteristics of surface morphology, surface roughness, and subsurface damage. The analysis of brittle-ductile transition and residual stress of the sawn surface and silicon chips were performed with Raman spectroscopy. The wear and failure mechanism of the diamond wire were analyzed. The results showed that sawn surface is composed of brittle and ductile regions and the predominance of one of these directly affected the surface roughness Ra. The ductile cutting mode induced the predominance of microgrooves and ploughing over the sawn surface and led to formation of an amorphous layer with residual compressive stress around of − 192.3 MPa. Micro-cracks in subsurface were identified and it reached a minimum depth of 7.2 ± 1.6 µm. Chip fragments and elongated chips were observed and latter is practically amorphous. The wire wear analysis indicated that during the cutting there is deformation of the Ni-layer, exposed grits, and grit pullout. The main wear mechanisms are Ni-matrix removal and abrasive wear of the diamond grit. A better surface quality of polycrystalline silicon was obtained on increasing wire cutting speed and decreasing feed rate. Thus, the looped diamond wire sawing allows to reach a high surface quality of the silicon wafer, since the material removal occurs more in ductile cutting mode, generating a smooth surface with shallow subsurface damage.Graphical abstract

AFM and EIS investigation of the influence of pH on the corrosion film stability of Al4Cu2Mg8Si7 intermetallic particle in aqueous solutions

The stability of corrosion films on the Q-phase (Al5Cu2Mg8Si6) under different pH environments ranging from pH 1 to pH 13 in 0.1 M NaCl solution has been investigated using Atomic Force Microscopy (AFM) and Electrochemical impedance spectroscopy (EIS). The magnitude of Rct and Rf of Q-phase was noted to vary with pH. At pH 4 and 6, the values of Rct and Rf were higher by about 3 orders of magnitude than the values at pH 1 and 13. This indicates better protection of the metal towards corrosion under neutral conditions. The polarization resistance (Rct + Rf) obtained from the fitting parameter is observed to follow the order pH 6 > pH 4 > pH 10 >> pH2 > pH12 > pH13 > pH 1. The EIS response showed a capacitive behavior. From surface topography and cross section topography characterization there were significant differences in the surface characteristics of Q-phase under different pH values. The microscopic topographic analysis suggests copious accumulation of corrosion products in near neutral environments and the lowest surface roughness was observed in the alkaline environment. Quantitative surface roughness characterization shows that a maximum surface roughness was at pH 2 which decreases with increased basicity of the environment. Results indicate that the corrosion film stability decreases with increased deviation from the neutral pH environment.

The effect of ceramic surface structure modification method on the ignition and combustion behavior of non-metallized and metallized gel fuel particles exposed to conductive heating

The study explores the effect of roughness characteristics of ceramic surfaces processed by diamond abrasives (ground and polished) and laser radiation on the consistent patterns and characteristics of the ignition and combustion of non-metallized and metallized gel fuel (GF) particles based on oil-filled cryogels exposed to conductive heating. Ceramics were produced from SiC F1200 powder using spark plasma sintering. It was established that when combustible liquid droplets in a normal state, as well as metallized and non-metallized GF particles are ignited and burned on a ceramic surface, the ignition delay times can be controlled by the characteristics of the heating surface roughness. Laser surface treatment of ceramics was shown to be a high-potential technique to control the ignition delay times of combustible liquid droplets (±48 %), as well as metallized and non-metallized GF particles (±35 %). A reduction in the ignition delay times of liquid fuels, when using laser surface treatment of ceramics, calls for developed, multi-level roughness with Sdr more than 6.3 %. To decrease the ignition delay times of GF on a ceramic surface by using laser treatment, it is necessary to create a texture with roughness parameters Sdr, Sq, Sz close to the respective characteristics of a polished (molecularly-smooth) heating surface. Evidence was provided that laser surface treatment of ceramics is more promising than mechanical processing using diamond abrasives, which is the most common method currently used in mechanical engineering. This is explained by the fact that laser surface treatment of ceramics creates conditions for enhancing the dispersion of GF melt droplets when ignited, as well as reduces the burnout time by creating a layered multimodal texture of the heating surface, characterized by more developed roughness as compared with the texture resulting from the mechanical processing by means of diamond abrasives.

Impact of thermocycling on surface roughness, microhardness and optical properties of three different lithium disilicate ceramics

ObjectivesThis investigation was carried out to examine the influence of thermocycling aging on the surface roughness (Ra, µm), color parameters (L*, a*, b*), lightness change (ΔL*), chroma change (ΔC*ab), color change (ΔE), and microhardness (VH) of three lithium disilicate ceramics. Materials and methodsForty-five specimens were prepared from three lithium disilicate materials (n = 15)—e.max CAD (EC), e.max Press (EP), and GC Initial LiSi Press (LP) ceramics—with dimensions of 6.0 × 1.2 × 16.0 ± 0.2 mm following the manufacturers’ instructions. All specimens were exposed to 5000 thermal cycles with bath temperatures ranging between 5 °C and 55 °C. Data of surface roughness, color parameters, and microhardness were obtained using an optical profiler, a spectrophotometer, and a Vickers hardness tester, respectively. One-way ANOVA, a post-hoc Tukey’s test, and a paired sample t-test were implemented for statistical analysis (p ≤ 0.05). ResultsFor surface roughness, insignificant differences were reported between the materials either before or after thermocycling (p > 0.05) while each material displayed a significant increase after being subjected to thermocycling (p < 0.05). For color parameters, LP showed significantly lower L* and b* after thermocycling while EC presented a significant reduction in a* in comparison with other materials (p < 0.05). EP showed a significant decrease in ΔL*, ΔC*ab and ΔE compared with other materials (p < 0.05). Regarding microhardness, LP showed significantly increase value in comparison with other materials (p < 0.05). ConclusionsThermocycling had a major impact on the surface roughness, microhardness and optical characteristics of the tested materials. E.max Press displayed less changes in (ΔL*), (ΔC*ab) and (ΔE), while GC LiSi Press had better behavior in terms of microhardness.

Comparison of Correlation between 3D Surface Roughness and Laser Speckle Pattern for Experimental Setup Using He-Ne as Laser Source and Laser Pointer as Laser Source.

Correlation between 3D surface roughness and characteristic features extracted from laser speckle pattern was done using an inexpensive laser pointer and a digital single lens reflex (DSLR) camera in previous research work. There had been no comparison work done between the experimental setup which uses a laser pointer, which has a diode laser as the laser source, and the experimental setup, which uses a He-Ne laser as the laser source. As such, in the current work, a comparison study between two experimental setups was carried out. One experimental setup was using a He-Ne laser, spatial filter, and charged coupled device (CCD) camera, while another experimental setup was using a laser pointer and DSLR camera. The laser beam was illuminated at angles of 30°, 45°, and 60° from the horizontal. When a laser beam falls on the surface, the beam gets scattered, and the scattered beam undergoes interference and produces speckle patterns which are captured using a camera. Using a Matlab program, the gray level co-occurrence matrix (GLCM) characteristic features, such as contrast (GLCM), correlation (GLCM), energy (GLCM), entropy (GLCM), homogeneity (GLCM), and maximum probability, and non-GLCM characteristic features, such as mean, standard deviation (STD), uniformity, entropy, normalized R, and white-to-black ratio (W/B), were extracted and correlated with 3D surface roughness parameters. The coefficient of determination (R2) was determined for each case. Compared to the setup using a laser pointer, the setup using a He-Ne laser gave better results. In the setup using the He-Ne laser, there were correlations with a coefficient of determination R2 ≥ 0.7 at illumination angles of 30°, 45°, and 60°, whereas in the setup using a laser pointer, there were correlations with R2 ≥ 0.7 at illumination angles of 30° and 45°. Mean characteristic features had more correlations with R2 ≥ 0.7 in the case of the angle of illumination of 45° (7 out of 36 correlations) and 60° (11 out of 82 correlations), while R-normalized characteristic features had more correlations with R2 ≥ 0.7 in the case of the angle of illumination of 30° (9 out of 38 correlations) for the setup using the He-Ne laser. Correlation (GLCM) had more correlations with R2 ≥ 0.7 in the case of the setup using a laser pointer (2 out of 2 correlations for illumination angle of 30°, and 4 out of 19 correlations for an illumination angle of 45°). Roughness parameters Sa and Sq had more correlations with R2 ≥ 0.7 for an illumination angle of 30° (1 out of 2 correlations each), and Sp and Sz had more correlations with R2 ≥ 0.7 for an illumination angle of 45° (4 out of 19 correlations each) in the case of the setup using a laser pointer. The novelty of this work is (1) being a correlation study between 3D surface roughness and speckle pattern using a He-Ne laser and spatial filter, and (2) being a comparison study between two experimental setups on the correlation between 3D surface roughness and speckle pattern.

Effect of surface roughness characteristics on the uplift capacity of piles: A physical modelling study

Pile surface roughness is one of the significant variables affecting the load-bearing capacity of piles. Especially for piles subjected to uplift loads, this parameter can be considered as the main factor that affects the uplift capacity since there is no contribution originating from the pile tip. According to limited previous research, a pile surface can be evaluated as smooth if pile surface roughness parameter (Rn) is less than 0.02, whereas the pile surface is considered completely rough when Rn value is greater than 0.10. This paper, therefore, is aimed to investigate the validity and effectiveness of the numerical limits previously suggested for Rn and intends to determine the relationship between Rn and soil-pile friction angle. For this purpose, laboratory model tests were performed on 12 small-scale pile models embedded in cohesionless soils having varying densities (Dr=25%, 50%, and 75%). Pile surfaces were specially textured to produce different surface roughness values from 0 to 2. Test results indicated that increasing the relative density of cohesionless soil and the pile surface roughness had a considerable contribution to the uplift capacity and soil-pile friction angle. Furthermore, some typical values of Rn like 0, 0.04, and 0.10 were found to be critical for pile uplift behaviour and capacity, and Rn value should be accepted as zero to consider the pile surface as completely smooth.

Dynamic grinding force model for face gear based on the wheel-gear contact geometry

The non-uniform grinding conditions due to the wheel-gear contact geometry lead to the changeable of grinding force in face gear grinding. As a result, the classical grinding force models for other gears are not applicable to the grinding process of face gear. In this work, a dynamic grinding force model for face gear was developed based on the wheel-face gear contact geometry. In this process, surface of a virtual pinion engaged with the face gear was divided into many micro-elements to calculate the undeformed chip thickness and number of effective abrasive grains. Considering the mechanical properties of the tool and workpiece materials, equations for the total normal and tangential force components were derived by using the grinding force model of single abrasive grain. For verifying the model, the measurement coordinate system was established to convert the spatial components of experimental grinding force into the normal grinding force and tangential grinding force. Experimental results show reasonable consistency with simulation results that validate the proposed model. Besides, main reason for the changeable of grinding forces from top to root of tooth surface can be summarized by the change of material removal rate caused by the interference grinding width of adjacent grinding trajectories. Characteristics of surface morphologies and surface roughness prove this reason as well. This work provides a method to obtain a uniform grinding force during the process of grinding face gear and can be utilized to optimize the grinding process for higher tooth surface integrity.

Surface Morphology, Roughness, and Structural Characteristics of Al1−xMgxSb (x = 0 and 0.1) Thin Films Deposited by Chemical Bath Deposition Technique

Aluminum antimonide (AlSb), a semiconductor compound, finds its applications in optoelectronics because of its tunable bandgap and promising properties achieved by tailoring suitable dopants. To explore the effects of doping, thin films of pure AlSb and 10% magnesium (Mg)-doped aluminum antimonide (MgAlSb) were synthesized through compound solution deposition on a glass substrate using a low-cost chemical bath deposition (CBD) technique at varying bath temperatures with deposition time intervals ranging from 60 to 180 min. Optical microscopy was used to evaluate the surface roughness and morphology of the synthesized films, revealing the surface roughness and thin film uniformity at different deposition times. The structural characteristics of AlSb and Mg-doped AlSb thin films were further examined using the X-ray diffraction technique, which validated the formation of AlSb and Mg-doped AlSb thin films. This research enables large-scale low-temperature deposition for a variety of conceivable applications in the coatings, materials penetration, energy, and photonic sectors due to the novel properties of this material.

AMS-Net: Attention mechanism based multi-size dual light source network for surface roughness prediction

Real-time and efficient surface roughness measurement is very essential for machining. Previously proposed non-contact roughness prediction methods usually use surface roughness images taken by a single light source. However, different light sources have a different reflection feature on the same roughness surface. A novel surface roughness prediction method of deep learning network model is proposed in this paper which is based on channel and spatial attention mechanisms, and embedded into the multi-size parallel framework (AMS-Net) for dual light sources. The network uses two branches which extract the features of surface roughness implied in images taken under different light sources. In each branch, the multi-size parallel convolution module (MSP) is constructed to extract parallel imagery pertaining to multi-size feature information of images with different roughness. In order to better fuse the surface roughness images taken by the dual light sources, the dual light source spatial attention module (DSA) and dual light source channel attention module (DCA) are proposed to project the space and channel respectively, while interacting with the roughness feature map from the MSP module. The dual light source roughness data set is built by white light and red laser for microimaging in this paper. Comparison experiments are implemented with other popular classification deep learning models. The results of experiment show the proposed novel AMS-Net network that achieves the best classification accuracy.

Metrological Comparison between Heterogeneous Surfaces and their Imprints

This article seeks to compare roughness characteristics of surfaces created through unconventional machining technologies, specifically utilizing plasma and laser. Cuts of different thickness of material were taken for this purpose. Furthermore, the article presents an evaluation of surfaces obtained from an impression material SILOFLEX&#174;, followed by the determination of similarities between these impressions and original surfaces. In this work, we mainly aimed to statistically find and determine the differences inbetween the evaluation of surfaces in concert with ISO 4287, ISO 4288, and ISO 25 178. Next, investigation analysis of the machined and replicated surfaces was done utilizing the contactless profilometer and the follow-up statistical evaluation of measured data from compared surface groups.

Comparative steam bending characteristics of some planted forest wood species in Malaysia

The bending performance of wood is important for its application in furniture, and it is one of the criteria used to assess the suitability of a particular wood species for furniture. In this context, the steam-bending and surface roughness characteristics of four forest plantation wood species were evaluated. One batch of wood specimens were subjected to both surface roughness experiments using the stylus and toluene spread methods, while another batch of the wood specimens were subjected to steaming, clamped, and bent using a circular shape mold. The instantaneous spring-back was measured after 10 days, while the spring-back over time was measured from days 15 to 65. The surface roughness experiments showed that the Hevea brasiliensis had the lowest surface roughness, followed by the Eucalyptus pellita, Acacia mangium, and finally Revotropix paulownia. In terms of the bending performance, it was found that only the H. brasiliensis achieved the threshold 95% satisfactory level based on visual ranking. Furthermore, the wood species also recorded the lowest spring-back, both instantaneous and over-time, to register the best bending performance. On the other hand, R. paulownia had the worst bending performance, primarily due to its low density.

Research on Elastic-Plastic Contact Behavior of Hemisphere Flattened by a Rigid Flat.

The contact behavior of a hemisphere pressed by a rigid plane is of great significance to the study of friction, wear, and conduction between two rough surfaces. A flattening contact behavior of an elastic–perfectly plastic hemisphere pressed by a rigid flat is researched by using the finite element method in this paper. This behavior, influenced by different elastic moduli, Poisson’s ratios, and yield strengths, is compared and analyzed in a large range of interference values, which have not been considered by previous models. The boundaries of purely elastic, elastic–plastic, and fully plastic deformation regions are given according to the interference, maximum mean contact pressure, Poisson’s ratio, and elastic modulus to yield strength ratio. Then, a new elastic–plastic constitutive model is proposed to predict the contact area and load in the elastic–plastic range. Compared with previous models and experiments, the rationality of the present model is verified. The study can be applied directly to the contact between a single sphere and a plane. In addition, the sphere contact can also be used to simulate the contact of single asperity on rough surfaces, so the present proposed model can be used to further study the contact characteristics of rough surfaces.

Influence of plasma spray WCCrCNi coating and shot peening on surface properties and corrosion behavior of AZ31 Mg alloy

In the present research work, an attempt has been made to improve the mechanical properties and corrosion resistance of AZ31 Mg alloy by shot peening and Plasma spray coating processes. Samples such as coated metal (CM), Post-shot peening coated (PSC), Pre-coated shot peening (PCS) were prepared. The following parameters were maintained to perform plasma spray coating: current density 30–4 A/dm2, deposition speed 25 μm/h and focus distance 40 mm. Double side Plasma spray coating and shot peening processes were implemented in the 5 mm thickness sheet of AZ31 Mg alloy. Results showed that Mg grain boundaries were converted into α-Mg grain boundaries and α′dynamic recrystallization growth were noted in AZ31 Mg alloy owing to the heat input. In case of PSC and PCS samples, 28% and 22% highest elongation was noted respectively, compared to coated metal. Plasma spray coating was implemented on the outer and inner surfaces; hence, high heat inputs directly affected the Mg crystallographic and MgO phase structures. Microstructure studies revealed that large Mg bulk structures were rehabilitated into the secondary phases and CrCo structures due to the high heat inputs of coating process. Further, MgCNi3-xCrC oxides were formed on the outer layers. Hardness results indicated that PSC and PCS samples showed 13% higher average hardness values compared to base materials. The surface roughness characteristics of all the samples were investigated using atomic force microscope. Corrosion resistance of all the samples was analyzed by electrochemical study using potential dynamic polarization. PSC and CM exhibited better corrosion resistance and surface properties.