Surface Roughness Values Research Articles

Effects of abrasive grain size of flexible body-armor-like abrasive tool (BAAT) on high-shear and low-pressure grinding for zirconia ceramics

Zirconia ceramics exhibit remarkable performance. However, the high hardness and brittleness poses enormous challenges for machining. This study is integrally focused on preparing a flexible body-armor-like abrasive tool (BAAT) with enhanced tangential-to-normal force ratio. The rheological characteristics of the BAAT abrasive system with different abrasive grain were investigated. A series of grinding tests were conducted on a precision grinding machine. The grinding performance of the BAAT with different abrasive grain sizes was examined. Surface roughness (Ra) variation and tangential-to-normal force ratio were analyzed, together with the investigation of the three-dimensional surface morphology and surface hydrophilicity. It was found that smaller abrasive grain sizes ultimately generated lower surface roughness values after grinding. Under the optimal grinding conditions, the surface roughness (Ra) of zirconia ceramics decreased from 102 nm to 1.7 nm after 5 grinding strokes (∼1 min). Meanwhile, uniform grinding textures were obtained.

Enhancement of bone mineral formation on Ti6Al4V surface by PM-EDCLT combined with acid etching

For Bone-anchored limb prostheses, osseointegration plays a significant role in the mechanically stable interface between bone and implants. Titanium alloy is the most usable alloy for hard tissue replacement. The drawbacks of the titanium implant are corrosion, leaching and poor osseointegration. In this research, powder mixed (hydroxyapatite) - electric discharge-assisted centreless turning (PM-EDCLT) (Impulse current- 5amp, duty factor- 57%, hydroxyapatite concentration 18 g/l, and rpm-360) and acid etching (solution – HF: HNO3: H2O = 1:2:50) were used for the surface modification of screw-fit implants. Average surface roughness value maximum in PM-EDCLT machined surface (1.249 µm) followed by PM-EDCLT machined + 5 min. Acid etching (1.055 µm), PM-EDCLT machined + 10 min. Acid etching (0.9829 µm), PM-EDCLT machined + 15 min. acid etching (0.8223 µm), bare surface with 10 min. Acid etching (0.2866 µm), 15 min. acid etching (0.2714 µm) and 5 min. Acid etching (0.1896 µm). Investigations using Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), and Fourier Transform Infrared Spectroscopy (FTIR) proved that the deposited layer on the powder-mixed EDCLT machined sample was hydroxyapatite. After sinking samples in the Simulated Body Fluid (SBF) solution, it was concluded that the percentage of bone minerals like oxide, Ca, and P deposition increases after increasing the acid etching time on the PM-EDCLT machined surfaces. Little effect was found on the deposition of bone minerals on the surface of acid etching only by increasing the etching time. There is a clear trend of decreasing the contact angle with increasing the acid etching time on the PM-EDCLT surfaces.

The effect of high values of relative surface roughness on heat transfer and pressure drop characteristics in the laminar, transitional, quasi-turbulent and turbulent flow regimes

This study investigated the effect of large values of relative surface roughness on the heat transfer and pressure drop characteristics using simultaneously measured heat transfer and pressure drop data. Experiments were conducted using a horizontal circular tube with a base inner diameter of 5 mm and length of 4 m. One smooth and two rough tubes, with relative roughnesses of 0.04 and 0.11, were tested at different constant heat fluxes between Reynolds numbers of 100 and 8 500. Water was used as the test fluid and the Prandtl number varied between 3 and 7. Contrary to the trend in the Moody Chart, a significant increase in laminar friction factors with increasing surface roughness was observed. Both the friction factors and Nusselt numbers as functions of Reynolds number showed a clear upward and leftward shift with increasing surface roughness across the different flow regimes. Furthermore, the boundaries between the flow regimes were the same for the pressure drop and heat transfer results. The width of the transitional flow regime was narrower for rough tubes and had a differing trend. The quasi-turbulent and turbulent flow regimes occurred at lower Reynolds numbers for increasing roughness. When investigating the relationship between heat transfer and pressure drop, it was found that an increase in surface roughness favoured heat transfer in the quasi-turbulent flow regime. This is useful for rough tubes as the quasi-turbulent flow regime onsets early with regards to the Reynolds number in tubes with large roughnesses.

Evaluation of plasma parameters’ impact on MRR and surface roughness in plasma polishing of fused silica: An investigation of surface characterization

Advanced fabrication methods with high efficiency are needed to meet the rising demand for precision optical components. This study proposes a plasma-based isotropic polishing method to remove fused silica's surface defects and subsurface damaged layers. Hence, a medium-pressure plasma process is developed to serve this purpose. The qualitative analysis of the plasma and atom emission spectrum explores the plasma generation and scattering of the activated fluorine (F*) radicals inside the plasma chamber. Material removal rate (MRR) and surface roughness variations with different total pressures of 5–30 mbar and substrate dimensions (i.e., varying length between 5 and 45 mm with fixed width and thickness of 5 and 2 mm) at fixed process parameters, i.e., radio-frequency power of 80 W, pressure ratio of 1:1, gas composition of 90:10, have been investigated. The highest and lowest MRR, i.e., 0.039 mm3/min and 0.0061 mm3/min, are achieved at 5 and 30 mbar total pressures on substrates having lengths 45 and 5 mm, respectively. The highest and lowest percentage change in surface roughness observed are 86.4 % and 17.1 % at 5 mbar and 30 mbar for substrates with 5 and 45 mm lengths, respectively. Surface morphology analysis shows the micro-cracks are reduced after plasma processing. The presence of elements, i.e., F and C, through EDX analysis, confirms the reactions on the plasma processed surface. Moreover, The XPS findings demonstrated that minimal radicals could be incorporated onto the fused silica surface during He/O2/SF6 plasma processing. At lower pressure, the surface roughness value increases due to the increased excitation and ionization rate caused by more interaction between the fluorine and surface atoms. The MRR increases with substrate dimension with constant pressure. Larger substrate dimensions result in increased MRR at lower pressure.

Fused filament fabrication using stainless steel 316L‐polymer blend: Analysis and optimization for green density and surface roughness

AbstractThis study is centered on the analysis of composite component additive manufacturing, via fused filament fabrication (FFF), comprising of 316L stainless steel particles in a polymer matrix. It examines the impact of several process factors of FFF, including extrusion speed, layer height, and extrusion temperature, on the density and surface roughness with the goal to minimize porosity. The independent and interaction impacts of these parameters were investigated using a central composite design technique. The technique of analysis of variance was utilized to determine the influence of relevant factors. Regression analysis was used to establish statistical models linking the parameters to green density and surface roughness. The green density was enhanced by reducing the layer height from 0.2 to 0.1 μm and decreasing the nozzle speed from 100 to 20 mm min−1. The surface roughness was improved by using a slow printing speed and minimum layer height. The ideal temperature range for producing favorable results in terms of green density and surface roughness during extrusion was found to be between 235 and 240°C. Significant correlations were found between the parameters and the green density and surface roughness. A genetic algorithm was used as an optimisation tool to determine the thresholds that would provide the highest green density and the lowest surface roughness values. The porosity of the samples generated with the optimized settings was evaluated using microtomography scans. The methodology presented here can be applied to composite and standard polymeric filament printing to determine optimal printing parameters.Highlights Blend of stainless steel 316L and polymer was used for fused filament fabrication. Printing speed and layer height were the dominating for density and roughness. Height 0.2 mm, speed 20 mm s−1, and temperature 239°C resulted 4.73 g cm−3 density and 21.09 μm roughness Microtomography revealed porosity of 1.7% in the optimized sample.

Design and Analysis of Composite Biomaterial Bone Graft Plate

The mixing technique was applied in this study to enhance the strength performance of the cement. The addition of 3% by weight of hydroxyapatite (HA) nanoparticles were mixed with 97% polymethyl methacrylate (PMMA) acrylic polymer, which has a nano size to serve as the matrix material. The surface roughness and continuous porosity of the bone cement were found to be slightly increased by the incorporation of nanoparticles, which enhanced bone-implant osseointegration and ingrowth. Atomic force microscopy (AFM) analysis revealed that the addition of hydroxyapatite (HAp) nanoparticles resulted in a surface roughness value (Sa) of 16.25 nm, which is similar to that of natural bone. The energy-dispersive X-ray spectroscopy (EDS) mapping results discover precentor material and uniform distribution. The Sample exhibited promising results in the antibacterial test, showing efficacy against bacteria both with and without sterilization, confirming its antibacterial properties. The mechanical tests conducted on the sample, including tensile, compression, bending and Vickers hardness tests, yielded favorable results and indicated that the sample is suitable for its intended application. In the theoretical works the design of the bone, screw, and bone plate was conducted using SolidWorks, followed by an analysis using ANSYS under both axial and bending load conditions. The theoretical analysis revealed that the safety factor was less than 1 when an axial load of 13 N was applied and a bending load of 2 N was applied, indicating that the structure may not be able to withstand these loads safely. Under both ambient and physiologically relevant conditions in the human body, HA and PMMA have demonstrated to be excellent choices for enhancing the clinical performance of bone cement. This, in turn, can lead to increased longevity of implants, decreased patient risk, and lower healthcare costs

Surface roughness and gloss retention of bioactive resin composite after simulated toothbrush abrasion

Background. Newly introduced bioactive resin composites are being used more often. Few studies have evaluated the influence of toothbrush abrasion on their surface characteristics. Methods. This study aims to assess the surface roughness (Ra) and gloss values (GU) of 3 bioactive composites and a conventional nanohybrid composite before and after simulated toothbrush abrasion. Five samples each of Filtek Z250 XT, Beautifil Flow Plus, Activa Presto and Predicta Bioactive Bulk were subjected to 10,000 cycles of simulated toothbrush abrasion. Ra and GU values were evaluated at baseline and after each 2,500 cycles. Results. Significant difference was found in both Ra and GU (P < 0.001). For each material, GU gradually decreased as the brushing cycles increased. GU values of Beautifil Flow Plus were significantly higher at the baseline, 2,500- and 5,000-cycles stages (P < 0.05). The GU values were 78.20 (7.20), 69.67 (6.17) and 63.30 (5.52) respectively. Activa Presto showed the lowest mean GU after 10,000 cycles. A significant increase in Ra at each of the measuring stages was observed in all materials compared to the baseline measurement (P < 0.001). No significant difference in Ra values of all four materials at the baseline and up to 5,000-cycles (P > 0.05). After 7,500 cycles, the mean Ra value of Activa Presto at 0.64 (0.14) was significantly higher than that of Z250 XT at 0.49 (0.03) (P < 0.001). At 10,000 cycles, Activa Presto had significantly higher Ra at 0.70 (0.10) when compared to Z250 XT at 0.52 (0.08), Beautifil Flow Plus at 0.56 (0.07) and Predicta Bioactive Bulk at 0.59 (0.10) (P < 0.001). Conclusion. All materials showed an increase in Ra and decrease in GU after simulated toothbrushing.

Effect of process parameters on the mechanical behavior of Ti6Al4V alloys fabricated by laser powder bed fusion method

The parameters used in the production process in laser powder bed fusion (L-PBF) technology, one of the additive manufacturing methods, have a critical effect on the mechanical behavior and density properties of the product and can change the properties of the product. Therefore, this study examined the influence of laser power, scanning speed, hatch spacing and beam rotation angle on the tensile strength, impact energy, surface roughness, and porosity levels of Ti–6Al–4V produced through the L-PBF method. It was observed that the tensile strength changes directly proportional to the laser power. In addition, the tensile strength decreases significantly with a value of 645 MPa obtained at lowest 0.07 mm hatch spacing, 190 W laser power and 900 mm scanning speed. The lowest value of impact energy, with a value of 8.7 J, was reached at a rotation angle of 180°. It has been determined that surface roughness decreases significantly with increasing laser power, while it demonstrates an increase with higher scanning speeds. Surface roughness values of 8.9 μm parallel and 8.35 μm perpendicular to the building direction were achieved at a laser power level of 220 W. Laser power was identified as the most influential factor in determining the porosity ratio, with a high porosity rate 0.48% occurring at 160 W laser power. Furthermore, an increase in scanning speed resulted in a corresponding increase in the porosity rate.

Comparing surface characteristics of Cu-Al-Fe alloys using thermal-based machining processes

The exceptional shape memory properties and load-handling capabilities of shape memory alloys makes them perfect for a spectrum of applications, such as actuators in robotics, control of aircraft wings and biomedical applications. Other than nickel-titanium shape memory alloy there are also various combinations of elements that show the same memory effect, namely Cu-Al-Fe, Cu-Al-Zn, and Cu-Al-Fe-Mn. However, a major problem often associated with shape memory alloys is the technical difficulty associated with machining them. Consequently, they do not tend to last longer when put to use. An optimal selection of input process parameters has a direct influence on the physical properties of these compounds. The traditional machining process, such as drilling, milling and grinding, pose a great threat to their properties. Hence, the research community has focused their study towards unconventional processes, such as (i) Wire Electric Discharge Machining, and (ii) Laser Beam Machining. In this research study, machining of the Cu-Al-Fe shape memory alloy was performed using three unconventional machining processes, namely (i) electric discharge machining (EDM), (ii) laser beam machining (LBM), (iii) powder-mixed electric discharge machining (PMEDM) and the effect of input process parameters were analysed. Various characterization tests provide useful information specific to changes in the microstructure and thermal behaviour of the alloy. The results show that the samples machined with PMEDM, EDM and LBM have surface roughness values of 2.377, 3.120 and 3.432 µm, respectively, which proves that PMEDM is best suited for machining the CuAlFe smart alloy.

The effect of cutting depth, feed rate, and cutting angle on surface roughness in the lathe process of aluminum 6061.

In the turning process, the machining parameters have a significant impact on the product quality. Consumers frequently request that certain industries adhere to product quality standards, especially regarding surface texture. Numerous product failures have resulted in dissatisfaction among the company's clientele because many lathe operators are fixated solely on product size drawings and are unaware of factors that can impact the surface roughness value. This investigation was conducted to ascertain how machining parameters affect surface irregularity. Variations in feed rates of 47.5 mm/min and 345.6 mm/min, cutting angles of 60° and 80°, and depths of cut of 1 mm and 3 mm were utilized to conduct the investigation on aluminum alloy 6061 specimens. The results of turning were evaluated for surface roughness using a surface roughness analyzer and a macro test to determine the structure of the surface roughness. Using the Minitab 2019 application, the obtained data was then analyzed to determine the influence of each trimming parameter working individually or simultaneously. Using the method of geometric factorial analysis, integrate the research parameters. The results indicated that the surface roughness increased as the feed rate increased; the lowest surface roughness was achieved with a depth of cut of 1 mm, a feeding rate of 47.5 mm/min, and a cut angle of 80°. In this study, the surface roughness value decreased as the cutting angle increased at lower levels of feeding rate, while the surface roughness value increased at higher levels of feeding rate.

Analisis Metode Anodizing Aluminium dengan Variasi Kuat Arus sebagai Material Velg Kendaraan

Aluminum Alloy 6061 is widely used in various engineering applications, including automotive vehicle wheels. The selection of aluminum alloy wheels involves aspects such as corrosion resistance. To enhance corrosion resistance, there are several methods, one of which is anodizing. Anodizing is a process that involves an electrolytic coating process that transforms the surface of aluminum into aluminum oxide (Al2O3), which the main process of aluminum anodizing requires a solution of sulfuric acid, chromic acid, or a mixture of sulfuric acid and oxalic acid. The sulfuric acid used must be concentrated acid, and acid is an oxidizing substance. The thickness of the oxide is approximately twice the thickness of the lost aluminum. The purpose of this research is to determine the characteristic such as surface roughness values, corrosion rates, and changes in morphology in Aluminum 6061 after undergoing anodizing. In this study, various current strengths were used, namely 0.75 Amperes, 1.5 Amperes, 2.25 Amperes, and 3 Amperes. The highest surface roughness value was obtained at 0.447 μm in the third specimen of the 0.75 Ampere variation, while the lowest was 0.075 μm in the first specimen of the 3 Ampere variation. The highest corrosion rate was observed in the 0.75 Ampere variation, with a rate of 17.724004 mpy, and the lowest was 0.0731653 mpy in the 3 Ampere variation. SEM results show that, in general, Aluminum 6061 tends to have a bright gray color, which is a surface that has been coated by cathode.

Investigation of the Effect of Denture Cleaning Solutions on Surface Hardness and Surface Roughness of Soft Lining Materials

Aim: The purpose of this study is to investigate the effects of commercial and non-commercial agents used to clean dentures on the surface roughness and hardness of two soft lining materials. Material and Methods: A total of 50 samples were used in this study. Samples were prepared from acrylic resin (Visco Gel) and silicone-based (Molloplast B) soft lining materials. The samples’ roughness and hardness values were measured. After the samples were kept in distilled water, white vinegar, denture cleanser tablet, 2% chlorhexidine gluconate, and 5% sodium hypochlorite for 15 minutes, 30 minutes, 45 minutes, 60 minutes, 2 hours, 8 hours, 24 hours, and 48 hours, roughness and hardness values were measured again. Statistical analysis was performed using the computer program SPSS Statistics 20.0 (SPSS Inc. Chicago, IL, USA) at a 95% confidence interval and p=0.05 significance level. Three-way ANOVA and Tukey’s multiple comparison tests were used for the statistical analysis of data. Results: The analysis of variance determined that the material type and time had a very significant effect (p&lt;.001) on surface roughness and hardness values, while the solutions in which samples were kept had an insignificant effect (p&gt;.05). Conclusion: The surface roughness and hardness of acrylic resin and silicone-based soft lining materials were affected by denture cleaning solutions to different extents.

Diamond machining of additively manufactured Ti6Al4V ELI: Newer mode of material removal challenging the current simulation tools

Single point diamond machining (SPDM) produces smooth machined surfaces that other production methods cannot match. While the mechanics of machining of cast alloys with SPDM is well-explored, the realm of SPDM for additively manufactured parts remains largely uncharted. This work reveals new insights into the surface generation process of an additively manufactured titanium alloy, specifically, a Ti6Al4V Extra Low Interstitials (ELI) alloy workpiece. Our examination of the chip morphology unveiled a distinct mode of chip removal, previously unrecorded in existing literature. During SPDM of additively made Ti6Al4V ELI workpiece, identification of numerous pores and discontinuities in the chips flowing on the tool rake face, indicating periodic intermittent cracking during the material's plastic flow was seen. To examine this phenomenon, a finite element analysis (FEA) model was developed. While the FEA model can well explain the machining mechanics and chip morphology of SPDM of cast Ti6Al4V ELI reported in the literature, it failed to describe the chip morphology that are obtained during machining of additively made workpiece in this work. This disparity underscores the need for innovative simulation approaches tailored for additively manufactured components. The experimental observations in this study highlight a unique form of chip formation in contrast to conventional Ti6Al4V alloy machining processes. At lower feeds, there was a presence of short, discontinuous chip formation with tearing at the outer periphery. Conversely, at higher feeds, a long, continuous ribbon-like chip formation was observed. In addition, some typical additive manufacturing defects appear on the machined surface and chips. Through optimisation of the SPDT parameters, a surface roughness (Ra) value of about 11.8 nm was achieved on additively manufactured Ti6Al4V ELI workpiece. This work provides a fresh perspective on the mechanics of SPDM for additively manufactured components, offering a stepping stone for subsequent studies.

Modelling Surface Roughness of 3/1 Twill Fabric Using Weft Yarn Count and Weft Thread Density

The surface roughness of fabric is one of the fabric properties that is used to evaluate the sensorial comfort of clothes. However, its objective evaluation requires sophisticated and expensive testing instruments and skilled testing expertise. Developing a predictive model is therefore an alternative approach to overcome such limitations. This study investigated a regression model to predict the surface roughness of 3/1 twill fabric using weft yarn count and weft thread density. Nine samples were produced by varying the weft yarn count and weft thread density at three different levels, while their surface roughness was determined using a Kawabata instrument (KES-FB4) under standard testing conditions. A two-factor predictive model equation was developed using design expert software. Based on the results and findings, the effects of count and density on the roughness of 3/1 twill fabric were found to be statistically significant for the developed model at a confidence interval of 95%. The model was tested by correlating the measured and predicted surface roughness values of 100% cotton 3/1 twill fabric. The results of the model test indicate a significant correlation (R2 = 0.9644) between the measured and predicted surface roughness values of 3/1 twill fabric, with a 95% confidence interval. Model validation was performed, and the study showed that the measured and predicted values of the surface roughness of 3/1 twill fabric have a 0.828 coefficient of determination (R2). This indicates that the surface roughness of 3/1 twill fabric can be predicted well by weft yarn count and weft thread density. This model can be thus used in textile industries and by research institutes for predicting the surface roughness of 3/1 twill fabrics in the new product development process.

The effect of different liquids on the surface roughness and color stability of single shade and nanohybrid resin composites: An AFM and SEM analysis.

The aim of this study is to evaluate the surface roughness (SR) and color changes of single-shade and nanohybrid resin-based restorative materials (RBC) after immersion in liquids at different pH values. For RBCs, a total of 120 specimens, 30 for each material, were prepared using 10 mm diameter and 2 mm thick molds. For flowable bulk fill RBC, a total of 40 specimens, 10 for each material, were prepared using 10 mm diameter and 4 mm thick molds (n = 10). After initial color and SR measurements, samples were stored in the liquids for 14 days and all of the measurements were repeated on 14th days. Scanning electron microscopy and atomic force microscopy analyzes were performed in all groups. When SR results are examined; among all liquids, the highest SR value was observed in the Carisma Diamond One (CDO) group, while the lowest SR value was observed in the Omnichroma Flow Bulk (OMF) group (p < .05). When the color changes (ΔE) results are examined; it was observed that CDO group had highest color change and OMF group had the lowest values. It has been observed that among the liquids, the liquids that affect the ΔE values of the materials the most are coffee and cola. When the ΔE values of the subgroups of the materials were examined, there was a statistically significant difference in all subgroups of RBCs (p < .05). While acidic liquids increased the SR of RBCs, coffee more affected the color change of RBCs. RESEARCH HIGHLIGHTS: Clinicians should keep in mind that the RBCs tested may change their surface properties and colors when exposed to various liquids. People who have RBCs should pay attention to the consumption of acidic and highly pigmented liquids.

Protective effect of various toothpastes and mouthwashes against erosive and abrasive challenge on eroded dentin: an in vitro study

The study aimed to compare various toothpastes and mouthwashes on permanent tooth dentin after erosive and abrasive challenges. 130 sound premolars dentin were randomly submitted to an initial erosive challenge and a cycle of erosive and abrasive challenges for five days. The five experimental groups (n = 26) were: (1) Control group (artificial saliva), (2) Elmex erosion protection toothpaste and mouthwash, (3) Vitis anticaries biorepair toothpaste and mouthwash, (4) Oral B Pro-expert toothpaste and Oral B Fluorinse mouthwash, and (5) MI Paste ONE toothpaste and Caphosol mouthwash. Microhardness, surface roughness values, and the topographical characteristics of the dentin surface were assessed. The highest percentage of recovered dentin microhardness (%RDMH) value was observed in groups 2 and 4, followed by groups 5 and 3, respectively. The %RDMH values in groups 2 and 4 did not demonstrate a significant difference (p = 0.855). The highest percentage of improvement in surface roughness was recorded in groups 2 and 4, with no significant differences (p = 0.989). The atomic force microscopy (AFM) findings were consistent with the surface roughness data. The best recovery of dentin microhardness and roughness were measured with the Elmex and Oral B toothpaste and mouthwash, followed by MI Paste ONE toothpaste and Caphosol mouthwash and Vitis anticaries biorepair toothpaste and mouthwash.

Surface characteristics of additively manufactured γ-TiAl intermetallic alloys post-processed by electrochemical machining

Electron beam melting (EBM) process is the most preferable powder bed fusion process for high melting point alloys. γ-TiAl alloys are intermetallic chemical compounds, which are lightweight and resistant to oxidation and heat, and have low ductility as well. EBM is the best manufacturing process for such alloys to produce aerospace parts, but poor surface quality is the main drawback of this process. Thus, surface post-processing is needed after the EBM process. This study presents the surface characteristics of EBM γ-TiAl alloy surfaces post-processed by electrochemical machining (ECM). The surfaces were ECM and the surface roughness values (Sa, Sq and Sz) have been reduced significantly. The mean reduction values of the experiments are 98.6 %, 98.5 % and 95.3 % for Sa, Sq and Sz, respectively. Additionally, it is observed that the surface roughness is inversely proportional to the electrolyte conductivity up to a limit value (115 mS/cm), and after that the roughness increases via the stray current transition. Sq values decrease with the increased feed rate via the increased current density. However, an increase in feed rate negatively affects the Sku values, which statistically describe the sharpness or spread of surface roughness. Also, XRD results showed that Ti2AlN layer is formed on the surface via the HIP operation. This layer inhibits the electrochemical dissolution of γ-TiAl alloy and caused surface defects.

Deep-reactive ion etching of silicon nanowire arrays at cryogenic temperatures

The pursuit of sculpting materials at increasingly smaller and deeper scales remains a persistent subject in the field of micro- and nanofabrication. Anisotropic deep-reactive ion etching of silicon at cryogenic temperatures (cryo-DRIE) was investigated for fabricating arrays of vertically aligned Si nanowires (NWs) of a large range of dimensions from micrometers down to 30 nm in diameter, combined with commonly used wafer-scale lithography techniques based on optical, electron-beam, nanoimprint, and nanosphere/colloidal masking. Large selectivity of ∼100 to 120 and almost 700 was found with resists and chromium hard masks, respectively. This remarkable selectivity enables the successful transfer of patterned geometries while preserving spatial resolution to a significant extent. Depending on the requirements by applications, various shapes, profiles, and aspect ratios were achieved by varying process parameters synchronously or asynchronously. High aspect ratios of up to 100 comparable to the best result by metal-assisted wet-chemical etching and sub-μm trenches by DRIE were obtained with NW diameter of 200 nm, at an etch rate of ∼4 μm/min without being collapsed. At the same time, low surface roughness values were maintained on the NW top, sidewall, and bottom surface of ∼0.3, ∼13, and ∼2 nm, respectively, as well as high pattern fidelity and integrity, which were measured using angle-resolved Fourier microscopy, combined atomic force, and scanning electron microscopy on selected NWs. This work establishes the foundation in the controllable development of Si nanoarchitectures, especially at sub-100 nm structures, for energy-harvesting and storage, damage-free optoelectronics, quantum, photovoltaics, and biomedical devices.

The Impact of Temperature and Power Variation on the Optical, Wettability, and Anti-Icing Characteristics of AZO Coatings

The structural, wettability, and optical characteristics of aluminum-doped zinc oxide (AZO) thin films were studied with the objective of understanding the impact of deposition power and deposition temperature. Thin films were deposited using a radio frequency (RF) magnetron sputtering technique. The power output of the RF was augmented from 200 to 260 W, and the temperature was increased from 50 to 200 °C, which led to the development of a (002) peak for zinc oxide. The study of film thickness was carried out using the Swanepoel envelope method from data obtained through the UV-Vis spectrum. An increase in surface roughness value was shown to be connected with fluctuations in temperature as well as increases in deposition power. The findings revealed that as deposition power and temperature increased, the value of optical transmittance decreased, ranging from 70% to 90% based on the deposition parameters within the range of wavelengths that extend from 300 to 800 nm. The wettability properties of the samples were studied, and the maximum contact angle achieved was 110°. A Peltier apparatus was utilised in order to investigate the anti-icing capabilities, which revealed that the icing process was slowed down 3.38-fold. This work extends the understanding of the hydrophobicity and anti-icing capabilities of AZO thin films, specifically increasing both attributes which provide feasible options for purposes requiring resistance to ice.

Modelling the material removal obtained using a pneumatically configurable polishing tool subjected to a reciprocating linear feed

A nanofinishing technique - Pneumatically Configurable Polishing (PCP) process can be used for producing surface roughness of the order of a few nanometers on surfaces. It is a deterministic polishing process which employs pneumatic pressure for precise control of finishing forces across the polishing spot. The material removal rate is an important characteristic for determining the final surface generated after polishing. The material removal mechanism of PCP process typically exhibits multidisciplinary complexity due to simultaneous contribution of various process parameters. A mathematical model has been proposed in this study to achieve an in-depth understanding of the process physics. The model is developed using the fundamental tenets of contact behaviour between the tool and workpiece, and study of the microscopic material removal caused by a single abrasive particle. The polishing tool undergoes a reciprocating linear feed to polish a linear strip of the work surface. Various process parameters such as feed rate, tool rotational speed, working gap, mean diameter of abrasive particles, slurry concentration etc have been incorporated in the model as per the physics of the process. In order to validate the model, finishing experiments and MATLAB simulations have been conducted under similar polishing conditions to estimate the prediction error. The material depth removal rate in the PC polishing of die steel was found to range between 39 nm/min and 257 nm/min. The error between the experimental and predicted values of material removal rate was found within a range of 2.7 %–15.9 %. The repeatability of final surface roughness values and MRR obtained is ±0.007 μm and ±10 nm/min respectively. The developed model helps to make the PCP process more predictable and provides valuable insights into the various parameters which predominantly affect the material removal. The simulation of the gradual evolution of the surface profile has been obtained using the developed model.