Surface Roughness Research Articles

STYLUS BASED EVALUATION OF THE SURFACE ROUGHNESS

This paper deals with problems in determining surface roughness values. The process of determining surface roughness values is a relatively difficult task. In this process, it is necessary to set the measurement conditions, which have a huge impact on the measurement uncertainty, and neglecting this process can cause a complete degradation of the measurement and evaluation result. Certain changes in this process are defined by new standards that have been approved to guide this process. The development of the methodology is very necessary in this area in order to obtain reliable data on surface roughness values.

Mechanical and surface characterisation of additively manufactured polyetheretherketone for the tribo test

Purpose The additive manufacturing process, such as fused filament fabrication based on material extrusion, fabricates the samples layer-by-layer. The various parameters in the process significantly affect the dimensions, structure and mechanical properties of the fabricated parts. The purpose of this paper is to investigate the surface and mechanical properties that can affect the contact characteristics with other materials during tribological tests. Design/methodology/approach The investigation of 3D-printed Polyetheretherketone (PEEK) includes the measurement of dimensions, microhardness, surface roughness, surface energy and tensile strength to define material characteristics. The crystallinity is measured using an X-ray diffractometer to understand the hardness behaviour. Findings The printing parameters affect its surface roughness, hardness and crystallinity. This change in parameters such as layer thickness and infill density impacts mechanical properties such as hardness and surface roughness, which will influence the contact mechanism with the counter body during any tribological test. The change in a single parameter during the sample fabrication and the change in the surface and mechanical properties are observed. Research limitations/implications The material cost plays an important role in conducting numerous destructive tests, which is a major limitation to conducting parameter optimisation by varying more parameters. The study is limited to the as-fabricated samples rather than finished samples and without any heat treatment. Achieving optimal parameters is integral to the success of additive manufacturing, ensuring the production of components with consistent performance. Practical implications The study aims at the application of 3D-printed PEEK for bush or journal bearings that can be directly used in practice. The mechanical properties discussed in this paper can fill the gap between theory and practice. Social implications The research provides all fundamental properties, including the printing parameters and their effect on the dimensions and surface structure, which are required to understand the material and its use. The results are consistent as at least four samples were tested for tribological behaviour. The conclusion is updated as per suggestions. Originality/value The study outlines the relationship between the change in layer thickness and infill density with changes in surface energy, surface roughness, hardness and tensile strength. The deformation and adhesion during the friction test depend on these properties.

Tribological properties of dual-freedom sliding roller pairs with a loss of lubrication

Purpose This paper aims to design a novel test device and study the wear properties and the thermal mechanisms of roller pairs in dual-freedom sliding contacts. Design/methodology/approach On the transition process of lubrication regimes, experiments were conducted with various values of running speed and slip ratio obtained by two motorized spindles. Temperature and surviving time would be obtained of GCr15/GCr15 and DLC/GCr15 friction pairs. Micro photography was obtained with a PGI 3D stylus profiler and a confocal microscopy OLS4000-3D. An empirical mode decomposition method was used to eliminate measure errors. Findings Results showed that, even with little initial lubricant, rolling/sliding pairs still rotated for a certain time. With the synthetic actions of the dual-freedom sliding, the loss of lubrication and the tilt, interesting helical grooves appeared. Sliding speeds had remarkable effects on survive time, temperatures and surface topographies. In addition, the equilibrium values of the temperature and the surface roughness were obtained in sufficient oil supply. Extreme wear-out conditions were obtained with starved lubrication. Diamond-like carbon coatings showed better heat resistance and better wear resistance. Originality/value This work would be critical for the life design and the heat treatment of rolling bearings in the full flood lubrication and the starved lubrication. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0164/

An evaluation and comparison of frictional resistance, surface roughness, and microbial colonization of silver-coated and uncoated stainless steel archwires – An in vivo study

Objectives: When undergoing fixed orthodontic treatment, white spot lesions and caries are frequently observed. The silver coating on brackets, archwires, and bands can help prevent these conditions. However, this might have an impact on friction and the oral environment, which would then impact the movement of the teeth. Thus, this study was taken up to evaluate and compare the frictional resistance, surface roughness, and microbial colonization of silver-coated and uncoated stainless steel archwire. Material and Methods: The investigation contained sixty samples, with 30 samples in each sub-group. Group 1 included 30 samples of 0.019 × 0.025” stainless steel wires coated in silver nanoparticles and Group 2 included 30 uncoated 0.019 × 0.025” stainless steel wires. A thermal vacuum evaporation technique was used to coat the wire with a 10 nm layer of coating. After placing the wire for 6 weeks in the oral cavity, it was retrieved and evaluated for frictional resistance, surface roughness, and microbial colonization. Results: After comparing the friction across the groups, the results did not show statistically significant differences. Scanning electron microscopy revealed that the surface roughness of wires coated in silver was lesser compared to the wire’s uncoated segment. As for the microbial colonization, Streptococcus mutans and Lactobacillus acidophilus showed reduced growth in the silver-coated portion. Conclusion: It can be concluded that silver coating does not alter the frictional properties of the wire. In the archwire’s silver-coated part, the surface roughness was lower. The silver coating showed significant anti-bacterial activity.

Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy

The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a “turning point temperature” in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C.

Evaluation of the Influence of Surface Roughness Parameters on Ultrasonic Rayleigh Waveforms

Ultrasonic nondestructive testing is widely used not only in the laboratory, but also in industry. The tests use various types of ultrasonic waves, diverse measurement techniques and different apparatus. One of the problems encountered is the high susceptibility of the surface wave to interference. Some of the interference is random in nature and can be minimized (e.g., contamination of the surface or resting a finger on the surface under study). Some of the interference is permanent in nature, such as variable surface roughness. The aim of the conducted research was to evaluate the influence of roughness on ultrasonic wave propagation. The study used samples with surface roughness Sa from 0.28 to 219 µm, and ultrasonic surface wave probes with frequencies from 1.41 to 8.02 MHz. It was observed that roughness significantly affects the attenuation of the ultrasonic wave, and the differences in signal amplification reached more than 15 dB. Similarly, the effect of the ultrasonic wave’s transit time through surfaces of different roughness was noted. It was found that the difference in the ultrasonic wave transition time was more than 50 µs. The results of the study can be helpful for the ultrasonic testing of materials with different surface conditions.

Morphological and Optical Profiling of Melanocytes and SK‐MEL‐28 Melanoma Cells Via Digital Holographic Microscopy and Quantitative Phase Imaging

AbstractMelanoma, which originates from pigment‐producing melanocytes, is an aggressive and deadly skin cancer. Despite extensive research, its mechanisms of progression and metastasis remain unclear. This study uses quantitative phase imaging via digital holographic microscopy, Principal Component Analysis (PCA), and t‐distributed Stochastic Neighbor Embedding (t‐SNE) to identify the morphological, optical, and behavioral differences between normal melanocytes and SK‐MEL‐28 melanoma cells. Our findings reveal significant differences in cell shape, size, and internal organization, with SK‐MEL‐28 cells displaying greater size variability, more polygonal shapes, and higher optical thickness. Phase shift parameters and surface roughness analyses underscore melanoma cells' uniform and predictable textures. Violin plots highlight the dynamic and varied migration of SK‐MEL‐28 cells, contrasting with the localized movement of melanocytes. Hierarchical clustering of correlation matrices provides further insights into complex morphological and optical relationships. Integrating label‐free imaging with robust analytical methods enhances understanding of melanoma's aggressive behavior, supporting targeted therapies and highlighting potential biomarkers for precise melanoma diagnostics and treatment.

Flame Retardation of Polyamide 6 by Electro-Sprayed Phosphorus–Copper Complex Supported by Layered Silicate

Abstract The primary objective of this study was to demonstrate the effect of a phosphorus–copper complex on the flammability of polyamide 6 (PA6) materials, including organoclay-reinforced nanocomposites. The secondary objective was to compare the effectiveness of the deposition methods of the three-layer copper complex. Our previous work successfully revealed the effectiveness of reducing the flammability of polyamide composites by depositing phosphorus and copper compounds using a Layer-by-Layer technique. In the current work, we turned our attention to modifying the PA6 surface by electro-spray (ES) using the same flame retardants as before, and we investigated the effectiveness of the resulting surface protection against high temperatures during combustion. Surface roughness analysis revealed that the use of the ES method favors the formation of surface unevenness. The UL-94 test results showed that composite materials having 5-15 triple layers were among the best flammability classes compared to the others. Both types of materials tested also showed a tendency to reduce the heat release rate (HRR) by increasing the degree of surface coverage when using the electro-spray technique. Remarkably, deposition of 15 triple layers on the surface of the nanocomposite reduced the maximum HRR point by 20%. Graphical abstract

Wear and Corrosion Resistance of ZrN Coatings Deposited on Ti6Al4V Alloy for Biomedical Applications

Zirconium nitrides films were synthesized on Ti6Al4V substrates at a bias voltage of −50 V, −80 V, −110 V and −150 V by the direct current (DC) reactive magnetron sputtering technique. The as-deposited coatings were characterized by X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM) and atomic force microscopy (AFM). The wear and corrosion resistance of the obtained ZrN coatings were evaluated to determine the possibility for their implementation in modern biomedical applications. It was found that the intensity of the diffraction peak of the Zr-N phase corresponding to the (1 1 1) crystallographic plane rose as the bias voltage increased, while the ZrN coatings’ thickness reduced from 1.21 µm to 250 nm. The ZrN films’ surface roughness rose up to 75 nm at −150 V. Wear tests showed an increase in the wear rate and wear intensity as the bias voltage increased. Corrosion studies of the ZrN coatings were carried out by three electrochemical methods: open circuit potential (OCP), cyclic voltammetry (polarization measurements) and electrochemical impedance spectroscopy (EIS). All electrochemical measurements confirmed that the highest protection to corrosion is the ZrN coating, which was deposited on the Ti6Al4V substrate at a bias voltage of −150 V.

Design and Optimization of PEDOT/Graphene Oxide and PEDOT/Reduced Graphene Oxide Electrodes to Improve the Performance of Microbial Fuel Cells, Accompanied by Comprehensive Electrochemical Analysis

A comprehensive investigation into the design and electrochemical optimization of composite electrodes consisting of poly(3,4-ethylenedioxythiophene) (PEDOT)/graphene oxide (GO)/Methanococcus deltae and reduced graphene oxide (rGO)/Methanococcus deltae hybrids, anchored onto stainless-steel (SS) substrates, has been conducted. The GO and rGO materials were synthesized using a modified Hummer method. The resulting SS/PEDOT/GO and SS/PEDOT/rGO composite electrodes were subjected to systematic electrochemical characterization, focusing on the PEDOT p-type and n-type doping/undoping processes within diverse solvent environments (CH3CN and H2O) and electrolyte compositions (LiClO4 and KCl). Raman spectroscopy analysis confirmed the successful integration of graphene derivatives into the electrode structures, while field-emission scanning electron microscopy (FESEM) and atomic force microscopy (AFM) revealed increased surface roughness upon GO and rGO incorporation. This increase in surface roughness is believed to enhance the adhesion of Methanococcus deltae microorganisms and facilitate efficient electron transport. Electrochemical measurements showed that the resulting SS/PEDOT/GO and SS/PEDOT/rGO anodes exhibit remarkable electrocatalytic activity. The SS/PEDOT/GO electrode achieved a maximum power density of 1014.420 mW/cm2, while the SS/PEDOT/rGO electrode reached 632.019 mW/cm2.

Novel Populations of Mycobacterium smegmatis Under Hypoxia and Starvation: Some Insights on Cell Viability and Morphological Changes

The general features of the shift to a dormant state in mycobacterial species include several phenotypic changes, reduced metabolic activities, and increased resistance to host and environmental stress conditions. In this study, we aimed to provide novel insights into the viability state and morphological changes in dormant M. smegmatis that contribute to its long-term survival under starvation or hypoxia. To this end, we conducted assays to evaluate cell viability, morphological changes and gene expression. During starvation, M. smegmatis exhibited a reduction in cell length, the presence of viable but non-culturable (VBNC) cells and the formation of anucleated small cells, potentially due to a phenomenon known as reductive cell division. Under hypoxia, a novel population of pleomorphic mycobacteria with a rough surface before the cells reached nonreplicating persistence 1 (NRP1) was identified. This population exhibited VBNC-like behaviour, with a loss of cell wall rigidity and the presence of lipid-body-like structures. Based on dosR and hspX expression, we suggest that M. smegmatis encounters reductive stress conditions during starvation, while lipid storage may induce oxidative stress during hypoxia. These insights into the heterogeneous populations presented here could offer valuable opportunities for developing new therapeutic strategies to control dormant mycobacterial populations.

Real-time in-situ ultrasound monitoring of soft hydrogel 3D printing with subwavelength resolution

3D bioprinting has excellent potential in tissue engineering, regenerative medicine, and drug delivery systems due to the ability to fabricate intricate structures that are challenging to make with conventional manufacturing methods. However, the complexity of parametric combinations and lack of product quality control have restricted soft hydrogel bioprinting from practical applications. Here we show an in-situ ultrasound monitoring system that reveals the alginate-gelatin hydrogel’s additive manufacturing process. We use this technique to understand the parameters that influenced transient printing behaviors and material properties in approximately real-time. This unique monitoring process can facilitate the detection of minor errors/flaws during the printing. By analyzing the ultrasonic reflected signals in both time and frequency domains, transient printing information can be obtained from 3D printed soft hydrogels during the processes with a depth subwavelength resolution approaching 0.78λ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\lambda$$\\end{document}. This in-situ technique monitors the printing behaviors regarding the constructed film, interlayer bonding, transient effective elastic constant, layer-wise surface roughness (elastic or plastic), nozzle indentation/scratching, and gravitational spreading. The simulation-verified experimental methods monitored fully infilled printing and gridded pattern printing conditions. Furthermore, the proposed ultrasound system also experimentally monitored the post-crosslinking process of alginate-gelatin hydrogel in CaCl2 solution. The results can optimize crosslinking time by balancing the hydrogel’s stiffness enhancement and geometrical distortion.

Optimization of process parameters for polishing aero-engine blade with abrasive cloth wheel considering spindle vibration and polished roughness

The vibration of machine tool spindle is very important for machining. Firstly, in order to explore the relationship between spindle vibration and process parameters, the spindle vibration acceleration when polishing aero-engine blade was measured, and the quadratic polynomial models between the spindle vibration acceleration in X, Y and Z direction and the process parameters were established. Secondly, a quadratic polynomial model for the influence of process parameters on polished surface roughness was also determined. Thirdly, through the Analysis of Variance (ANOVA) and main effect analysis, it can be seen that the spindle speed has the greatest impact on the vibration. Finally, a multi-objective optimization model was established with the optimization objective of minimizing spindle vibration acceleration and polished surface roughness, and the optimal process parameters were solved using genetic algorithm. The optimal process parameters were verified and the results show that the polished surface roughness with the optimal process parameters are all less than 0.4 μm, and the deviation rates between the theoretical optimization results of spindle vibration acceleration and the experimental results are all less than 10%, indicating that the optimization results are good.

Combined Identification of Vehicle Parameters and Road Surface Roughness Using Vehicle Responses

Highways, urban roads, and bridges are the important transportation infrastructures for the economic development of modern society. The evaluation of bridge and road quality is crucial to the maintenance and management of the bridge and road industry. Road roughness is a widely accepted indicator in the evaluation of road quality and safety, which is a major input source for vehicles. The vehicle responses-based method of identifying road roughness is efficient and convenient. However, the dynamic characteristics of the vehicle have an important impact on the interaction between the vehicle and the road. When the vehicle parameters are not yet clear, the coupling of unknown parameters and unknown road roughness results in the need for mutual iteration when the existing methods simultaneously identify vehicle parameters and road roughness. To address this issue, this study proposes an effective method for the combined identification of vehicle parameters and road roughness using vehicle responses. The test vehicle is modeled as a four-degree-of-freedom half-vehicle model. In view of the coupling effect between tire stiffness and road roughness, the unknown vehicle physical parameters, except for tire stiffness, are first included in the extended state vector. Based on the extended Kalman filter for unknown excitation (EKF-UI), unknown vehicle physical parameters and unknown forces on the axle are identified. Subsequently, based on the property that the front and rear axles of the vehicle pass through the same road roughness area at a fixed time lag, the tire stiffness is identified by combining the identified unknown forces on the axle. Finally, the road roughness is obtained using the identified vehicle parameters and unknown forces. Numerical studies with different levels of roughness, different noise levels, and different vehicle speeds have verified the accuracy of this method in identifying vehicle parameters and road roughness.

Influence of particle density on turbulence characteristics over a rough surface

The objective of the study is to use a 3D Acoustic Doppler Velocimeter (ADV) to gauge the typical flow and turbulence characteristics within a non-uniform open channel. The findings of experimental examinations of the subcritical flow along the channel are presented in this work. The behavior of sand grains in turbulent open channel flow across porous and rough bed surfaces was examined in laboratory research, and the results were obtained. The properties of turbulent flow, i.e., turbulence intensity, turbulent kinetic energy, and Reynolds shear stresses, are determined from ADV data. The continuity equation and the Reynolds equation of open-channel flow have been used to build theoretical formulations for the velocity distribution and Reynolds stress distribution in the vertical direction. Measured profiles of vertical velocity and Reynolds stress are compared to the derived expressions. The impact of the size of particles on the distribution of mean flow characteristics is discussed. This work provides a novel origin for the profile and analyzes the behavior of the vertical velocity distribution in the region where fully formed turbulence is dominating in open channels using the Navier–Stokes equations. In comparison to other sand roughness, Chopan sand bed (with greater density) exhibits the strongest turbulence intensities in both vertical and streamwise direction just next to the bed when away from the channel boundary. In contrast to flow across a rough surface, the variance ranges between 150 and 250% concerning the channel bed’s roughness type, impacting the velocity triple products that signifies transfer of turbulent kinetic energy.

Optimisation of laser surface ablation of alumina/GO coating on AZ31D magnesium alloy using Cuckoo Search Algorithm method

ABSTRACT Graphene oxide (GO) and alumina (Al2O3) work in concert to give magnesium alloys advantageous surface qualities and protection from adverse environments. This paper aims to investigate the effect of laser surface treatment on plasma sprayed alumina-graphene oxide (GO) coating on AZ31D magnesium alloy. Key ablation quality responses; HAZ width, surface roughness and ablation rate were correlated with laser parameters using the Response Surface Methodology and optimised using the metaheuristic Cuckoo Search Algorithm Method. Laser power significantly influenced all ablation characteristics of the composite coating. The addition of 1.5 wt% GO in the alumina coating caused a significant reduction in HAZ width (43.32%), surface roughness (25.11%) and ablation rate (76.58%) when treated with optimal combinations of laser power (8 W), scanning speed (950 mm/s) and frequency (78.2 kHz). The surface quality was characterised by smooth textures, and resolidified splats along with deep pits when ablated with lower and intermediate power whereas surfaces ablated with higher power showed debonded splats with peripheral surface destruction. While a prominent 2D peak at 16 W confirmed the presence of GO layers during high-power laser contacts, the ID/IG ratio below unity across all specimens indicated minimal defect concentrations.

Understanding Electric Current Effects on Tribological Behaviors of Instantaneous Current-Carrying Pair With Recurrence Plot

Abstract Armature–rail instantaneous current-carrying friction in electromagnetic launchers refers to a sliding electric-mechanical impact friction and transition-induced arc erosion on a millisecond time scale. To reveal the electric current (50–300 A) effects on friction behavior and wear mechanism, the instantaneous current-carrying friction tests were performed with Al 1060 and Brass H62. Given the short nonlinear friction-induced signals, the friction behavior, including the time-domain information and system state, was comprehensively analyzed via frictional sound pressure (FSP), recurrence plot (RP), and recurrence quantification analysis (RQA). The wear topography was observed and characterized by the multifractal spectrum. Recurrence analyses demonstrate that as the current increases, the nonstationarity of the system state weakens, and the complexity and unpredictability enhance. Higher currents reduce the FSP amplitude, i.e., enhance the interfacial lubrication effect, but intensify electrical wear and surface roughness. This signifies a wear mechanism transition from abrasive wear and slight adhesive wear to arc ablation, fatigue wear, and severe adhesive wear. The widening spectrum width implies that the irregularity and fluctuation of the topography are enhanced with the current. RP patterns and RQA quantifiers correlate with the wear damage state. The results provide a reference for antiwear design and online degradation tracking of the rail.

Turbulence statistics estimation across a step change in roughness via interpretable network-based modelling

Abstract This study proposes a data-driven methodology to complement existing time-series measurement tools for turbulent flows. Specifically, a cluster-based transition network model is employed for the estimation of velocity time traces and their corresponding statistics. The method is tested on a laboratory-modelled turbulent boundary layer over a step change in surface roughness, where velocity time series are recorded for training and validation purposes via Laser Doppler Anemometry. Results show that our approach can estimate velocity and momentum flux statistics within experimental uncertainty over a rough surface through an unsupervised approach, and across the step change in roughness through a semi-supervised variant. The friction velocity across the domain is also estimated with 10\% relative error compared to the measured value. The proposed methodology is interpretable robust against the main methodological parameters. A reliable data-driven framework is hence provided that can be integrated within existing laboratory setups to supplement or partially replace measurement systems, as well as to reduce wind tunnel running times.

Comparison of the ablative performance of silicone rubber‐based composites by analyzing a large number of samples

AbstractSilicone rubber‐based materials are important thermal protection materials for high‐temperature applications. In this work, a holistic analysis of silicone rubber‐based materials was conducted with an aim to comparatively study the ablative performance of different rubber matrices using the oxyacetylene flame. Six types of silicone rubber‐based composites were prepared in large quantities using a customized device, and the relationship between the ablative properties and influencing factors was elucidated, which was useful in guiding the design and preparation of flexible ablative materials for thermal protection purpose. The expansion and ceramicization of char layer, which was realized by introducing expandable graphite and alumina was found helpful in reducing line ablation rate. The increase in the thickness of char layer and the decrease in surface roughness indicated a successful implementation of the above strategy, which led to a significant decrease in line ablation rate and an increase in thermal insulation performance of the studied system. Moreover, a thermal ablative composite with excellent moldability after ablation process was prepared which showed a promising application as a reusable thermal protection material. This work provided guidelines for developing flexible thermal ablative composites, which can be targeted for practical applications in aerospace and fire protection sectors.

Efficiency Improvement on Indium Tin Oxide Films for Dye-Sensitized Solar Cell Using Oxygen Plasma by Bias-Magnetron RF Sputtering Process

Dye-sensitized solar cells (DSSCs) are among the most widely studied thin-film solar cells because of their cost-effectiveness, low toxicity, and simple fabrication method. However, there is still much scope for replacing current DSSC materials due to their high cost, low volume, and lack of long-term stability. Accordingly, indium tin oxide (ITO)-nanorod films were fabricated by electron (E)-beam evaporation using the glancing angle deposition method in this study. Then, the ITO-nanorod was treated with oxygen plasma via a bias-magnetron radio-frequency (RF) sputtering process to improve the efficiency of DSSCs under a varying gas flow rate of 20, 40, 60, 80, and 100 sccm. The field emission scanning electron microscopy (FE-SEM) investigation of the ITO film structure revealed that the obtained nanorod structures have slightly different diameters. At the same time, an increase in the oxygen flow rate resulted in a rougher film surface structure. In this, the lower sheet resistance was received because of rougher morphology. When comparing the DSSCs efficiency (η) test results, we found that at a gas flow rate of 100 sccm, the highest efficiency value showed 9.5%. On the other hand, the ITO-nanorod without plasma treatment exhibited the lowest η. Hence, plasma technology can be practically applied to improve the η of DSSC devices. This study will be a prototype of a highly advanced solar cell manufacturing method for the solar cell industry.