Surface Texture Design Research Articles

Bionic Strategies for Pump Anti-Cavitation: A Comprehensive Review

The cavitation phenomenon presents a significant challenge in pump operation since the losses incurred by cavitation adversely impact pump performance. The many constraints of conventional anti-cavitation techniques have compelled researchers to explore biological processes for innovative alternatives. Consequently, the use of bionanotechnology for anti-cavitation pumping has emerged as a prominent study domain. Despite the extensive publication of publications on biomimetic technology, research concerning the use of anti-cavitation in pumps remains scarce. This review comprehensively summarizes, for the first time, the advancements and applications of bionic structures, bionic surface texture design, and bionic materials in pump anti-cavitation, addressing critical aspects such as blade leading-edge bionic structures, bionic worm shells, microscopic bionic textures, and innovative bionic coatings. Bionic technology may significantly reduce cavitation erosion and improve pump performance by emulating natural biological structures. This research elucidates the creative contributions of biomimetic designs and their anti-cavitation effects, hence boosting the anti-cavitation performance of pumps. This work integrates practical requirements and anticipates future applications of bionic technology in pump anti-cavitation, offering a significant research direction and reference for scholars in this domain.

Improvement of superhydrophobic properties of soft materials based on surface texture design

Superhydrophobic surfaces of rigid materials have been widely studied, which usually have excellent physical properties. However, the soft materials are rarely investigated. In order to explore ways to improve the superhydrophobic properties of soft materials, different textured structures were fabricated by the inverted molding method on three materials, including food-grade silica gel, industrial-grade mold silica gel, and Polydimethylsiloxane (PDMS). Further, a series of experiments were carried out, including water contact angle measurement, self-cleaning test, and drop-bounce test. The results show that hydrophobicity is highly related to both material and texture characteristics. For the same material, the contact angle can be greatly improved by surface micro-texture, and the contact angle of PDMS can be increased to 159.3°. Moreover, texture features and parameters are introduced to quantitatively analyze the contact angle of textured soft materials. It can be predicted that the soft materials with textured superhydrophobic properties will have greater applications in biomedicine, bionic sensors, flexible solar cells, and other fields.

Effects of double-sided textures matching on friction and wear performance in reciprocating contact interface

With increasing demands for friction reduction and wear resistance in heavy-duty diesel engines, the design of surface textures in reciprocating contact zone of the cylinder liner and piston ring (CLPR) has been a major concern. Through designed orthogonal tests for optimizing the double-sided textured CLPR, a maximum reduction in the friction coefficient of 12.63 % was achieved for the superior double-sided textured CLPR compared to the untextured surface, with corresponding reductions in the wear depth of the cylinder liner and piston ring of 16.73 % and 18.25 %, respectively. The relative position variation between the CLPR microtextures at the sliding contact area caused different stress values and stress distribution. Compared to the inferior double-sided textured CLPR, superior double-sided textured CLPR with lower stress concentration and symmetrical distribution within the contact area generated smoother and flatter worn platforms and non-spalling dimple edges with less abrasive wear. It can provide some insight into the matching design of double-sided CLPR surfaces under heavy load conditions.

Anisotropic Icephobic Mechanisms of Textured Surface: Barrier or Accelerator?

Icing has been seen as an economic and safety hazard due to its threats to aviation, power generation, offshore platforms, etc., where passive icephobic surfaces with a surface texturing design have the potential to address this problem. However, the intrinsic icephobic principles associated with the surface textures, energy, elasticity, and hybrid effects are still unclear. To explore the anisotropic wettability, ice nucleation, and ice detaching behaviors, a series of textured poly(dimethylsiloxane) (PDMS)-based coatings with various texture orientations were proposed through a simple stamping method with surface functionalization. The anisotropic hydrophobic/icephobic phenomena and mechanisms were discovered from wettability evaluation, experimentally studied by icing/deicing experiments, and finally verified by microscopic numerical simulations. One-way analysis of variance (one-way ANOVA analysis) was used to analyze the effect of surface textures on hydrophobic/icephobic properties, which assisted in understanding anisotropic phenomena. Typical anisotropic ice nucleation and growth on the textured coatings were clarified using in situ environmental scanning electron microscope (ESEM) characterization. The ice/coating interfacial stress responses were studied by numerical stimulation at the microscopic level, further verifying the localized, amplified, and propagated stress at the ice/coating interface. The theoretical anisotropic responses, barrier effect, and accelerating effect were verified to interpret the anisotropic wettability and icephobicity, depending on the specific surface conditions. This study revealed the basics of the anisotropic icephobic mechanisms of textured icephobic surfaces, further facilitating the R&D of passive icephobic surfaces.

On the fluid drag reduction in scallop surface.

In the field of biomimetics, the tiny riblet structures inspired by shark skin have been extensively studied for their drag reduction properties in turbulent flows. Here, we show that the ridged surface texture of another swimming creature in the ocean, i.e., the scallops, also has some friction drag reduction effect. In this study, we investigated the potential drag reduction effects of scallop shell textures using computational fluid dynamics simulations. Specifically, we constructed a conceptual model featuring an undulating surface pattern on a conical shell geometry that mimics scallop. Simulations modeled turbulent fluid flows over the model inserted at different orientations relative to the flow direction. The results demonstrate appreciable friction drag reduction generated by the ribbed hierarchical structures encasing the scallop, while partial pressure drag reduction exhibits dependence on alignment of scallop to the predominant flow direction. Theoretical mechanisms based on classic drag reduction theory in turbulence was established to explain the drag reduction phenomena. Given the analogous working environments of scallops and seafaring vessels, these findings may shed light on the biomimetic design of surface textures to enhance maritime engineering applications. Besides, this work elucidates an additional evolutionary example of fluid drag reduction, expanding the biological repertoire of swimming species.

Numerical simulation of the lubrication characteristics of bionic surface textures on mechanical sealing rings

Inspired by the shark scale surface in natural world, five different bionic surface textures were designed. Through numerical simulation, the influence mechanism of the geometrical parameters on the lubrication characteristics of the bionic surface textures on the mechanical sealing rings under refrigerant conditions was investigated. The results revealed that the lubrication characteristics of the bionic surface textures is jointly influenced by the texture shape, arrangement, vortex phenomenon, and hydrodynamic pressure effect. The lubrication characteristics of all five bionic surfaces designed in this study was superior to those of the smooth surface. The effects of density and texture depth on the lubrication characteristics of the surface textures exhibits criticality. The results provide valuable insights into the effective design of bionic surface textures on mechanical seal rings, especially in improving their lubrication characteristics under refrigerant conditions. The effectiveness of numerical simulation techniques in evaluating and optimizing the performance of bionic texture design in various micro- and nanofabrication processes is further validated.

Study on the subsurface characteristics of textured surfaces under EHL condition

PurposeThe purpose of this study is to investigate the influence of surface texture on the subsurface characteristics of contact interfaces under elastohydrodynamic lubrication condition. As a typical contact form of gears and bearings, the optimization of friction characteristics at the elastohydrodynamic lubrication (EHL) interface has attracted the attention of scholars. Laser surface texturing is a feasible optimization solution, but there have been concerns about whether the surface texture of high-pair parts will affect their fatigue life.Design/methodology/approachTo examine the impact of texture preparation on the subsurface characteristics of high-pair interfaces under EHL conditions, a point contact EHL model is developed that takes into account the effect of textured surface topography. The pressure and thickness of the oil film are calculated as input parameters under different loads and entrainment velocities. The finite element method is used to simulate the impact of textures with varying diameters, densities and depths on the subsurface characteristics of the elastohydrodynamic interface. According to ISO 25178, analyze the relationship between 3D topography parameters and subsurface characteristics and study the trend of friction characteristics and subsurface characteristics based on the results of the ball on disc friction tests.FindingsThe outcomes suggest that under different rotational velocity and load conditions, the textured surfaces exhibit improved friction reduction effects; however, the creation of textures can result in significant subsurface plastic deformation and local peeling. The existence of texture makes the larger stress zone in the subsurface layer closer to the surface, leading to fatigue failure near the surface. Reasonable design parameters can help enhance the attributes of the subsurface. A smaller Sa and a Str greater than 0.5 can achieve ideal subsurface properties on the textured surface.Originality/valueThis paper investigates the influence of surface texture on the friction and subsurface characteristics of EHL interfaces and analyzes the impact of surface texture on interface contact performance while achieving lubrication improvement functional characteristics. The results provide theoretical support for the optimization design and functional regulation of surface texture in EHL interfaces.Peer reviewThe peer review history for this article is https://publons.com/publon/10.1108/ILT-10-2023-0324/

Rayleigh-Taylor Instability in Soft Viscoelastic Solids.

We present an experimental characterization of the gravity-driven Rayleigh-Taylor instability in viscoelastic solids. The instability creates periodic patterns on the free surface of the soft solids that are distinct from the previously studied elastic Rayleigh-Taylor instability. The experimental results are supported by the linear stability analysis reported here. We identify the dependence of the steady-state pattern of deformations on the gel's geometry, complex shear modulus, and surface tension. This study provides quantitative measures applicable to the design of tunable surface textures, soft machines, and 3D structures.

Reconstruction and analysis of surface topography of micro-indented surface texture by chi-square function

During surface texture micro-indentation processing, the texture around the contact area will form protrusions. The morphology of these protrusions can change the actual contact area of the contact surface and affect the functional surface. To accurately describe the morphology of surface texture protrusions during the micro-indentation process, scaled chi-square functions are proposed to fit and further analyze their morphology. By simulation, the surface protrusion curve is generated by the micro-indenter head in different materials and depths. The scaled chi-square function is used to fit the extracted curves, and the fitted n value is used as an important characteristic parameter of the protrusion morphology. The study shows that the morphology of the protrusions is related to the material’s elastic modulus, yield strength, power law hardening exponent, and forming depth. Based on our results, it is convenient to judge the highest position and maximum height of the protrusions. The research findings will aid in the holistic design of micro-indentation surface textures, predicting their morphology, and selecting appropriate processes, while also being relevant for evaluating material performance post-micro-indentation with broad application prospects.

Rapid surface texturing to achieve robust superhydrophobicity, controllable droplet impact, and anti-frosting performances

Robust superhydrophobic surfaces with excellent capacities of repelling water and anti-frosting are of importance for many mechanical components. In this work, wear-resistant superhydrophobic surfaces were fabricated by curing a mixture of polyurethane acrylate (PUA) coating and 1H,1H,2H,2H-Perfluorodecyltrichlorosilane (HFTCS) on titanium alloy (TC4) surfaces decorated with micropillars pattern, thus, composite functional surfaces with PUA coating in the valleys around the micropillars pattern of TC4 were achieved. Apparent contact angle on fabricated surfaces could reach 167°. Influences of the geometric parameters of micropillars pattern on the apparent contact angle were investigated, and the corresponding wear-resistant property was compared. Droplet impact and anti-frosting performances on the prepared surfaces were highlighted. An optimized design of surface texture with robust superhydrophobicity, controllable droplet impact, and anti-frosting performances was proposed. This design principle is of promising prospects for fabricating superhydrophobic surfaces in traditional mechanical systems.

Bubble Management for Electrolytic Water Splitting by Surface Engineering: A Review.

During electrocatalytic water splitting, the management of bubbles possesses great importance to reduce the overpotential and improve the stability of the electrode. Bubble evolution is accomplished by nucleation, growth, and detachment. The expanding nucleation sites, decreasing bubble size, and timely detachment of bubbles from the electrode surface are key factors in bubble management. Recently, the surface engineering of electrodes has emerged as a promising strategy for bubble management in practical water splitting due to its reliability and efficiency. In this review, we start with a discussion of the bubble behavior on the electrodes during water splitting. Then we summarize recent progress in the management of bubbles from the perspective of surface physical (electrocatalytic surface morphology) and surface chemical (surface composition) considerations, focusing on the surface texture design, three-dimensional construction, wettability coating technology, and functional group modification. Finally, we present the principles of bubble management, followed by an insightful perspective and critical challenges for further development.

Surrogate-based optimization design for surface texture of helical pair in helical hydraulic rotary actuator

A good surface texture design can effectively improve the tribological performance of the helical pair within a helical hydraulic rotary actuator(HHRA). However, the optimization design process can be time-consuming due to the multiple design variables involved and the complexity of the mathematical model. This paper proposes a modified efficient global optimization (MEGO) method for solving such demanding surface texture design challenges. The MEGO utilizes a Kriging model with the optimized Latin hypercube sampling (OLHS) for initial sampling and the proposed modified expected improvement (MEI) function for sequential sampling. A comparative study of several global optimization algorithms with the MEGO on the surface texture design is performed. Subsequently, surrogate-based optimization and parameter analysis are carried out, resulting in the identification of an optimal set of texture parameters. The findings reveal the superiority of the MEGO in both model prediction accuracy and refinement of minima. Moreover, compared to the base design, the friction coefficient can be reduced by up to 45.2%.

Surface Texture Designs to Improve the Core-Veneer Bond Strength of Zirconia Restorations Using Digital Light Processing.

Veneered zirconia ceramics are widely used for dental restorations. However, the relatively poor bonding strength between the ceramic core and veneer porcelain remains a common problem in clinical applications. To address this issue, this study focused on enhancing the core-veneer bond strength of zirconia restorations through the implementation of surface textures using digital light processing (DLP) technology. The light intensity was precisely tuned to optimize mechanical strength and minimize light scattering. Subsequently, hexagonal or square grids were printed on the surface of the zirconia ceramic core. Following veneering procedures, the shear bond strength (SBS) test was conducted using a universal testing machine. Dates were compared using analysis of variance (ANOVA) and the least significant difference (LSD) test. Furthermore, optical microscopy and scanning electron microscopy (SEM) were used to examine the failure modes and observe the cross-sectional structures, respectively. The results indicated that the presence of a 0.09 mm high hexagon grid led to a significant 21% increase in the SBS value. However, grids with heights of 0.2 and 0.3 mm showed less improvement, owing to the formation of large defects at the interface during the fusion process. This study demonstrated the potential of DLP technology in preparing zirconia ceramics with complex structures and high mechanical strength, thereby offering promising solutions for overcoming challenges associated with dental applications.

Numerical study on the lubrication performance of oil films in textured piston/cylinder pairs

The piston/cylinder pair is one of the most important friction pairs in the axial piston pump; reducing the friction of it can improve the axial piston pump efficiency. In this paper, the Reynolds equation coupled with the Half–Sommerfeld boundary condition is applied to predict the dynamics of the textured piston/cylinder pairs, and the characteristic function is used to predict the optimal geometry parameters. The analysis results show that the combination of the shearing coefficient and the characteristic function can predict the cavitation region and the critical inclination angle. The results of this paper provide theoretical guidance for the surface texture design on piston/cylinder pairs.

EMBEDDING PERCEPTION: HOW CHANGES IN MANUFACTURING APPROACH INFLUENCE INTERACTION-DESIGN PREFERENCES

AbstractThis paper explores how small-but–detectable changes in manufacturing protocol can alter interaction-design preferences for users. Building on a number of previous studies by the authors, this paper focuses on the manufacture of a set of emotionally attuned pattern-based surface texture designs by means of computer-numerically controlled (CNC) machining. An experiment is subsequently reported that explores how the variations in toolpath rastering approach can affect the visual and tactile qualities of the textures in relation to interaction-design preferences, with a focus on psychological experience. The implications with respect to user-centred design (UX) and manufacturing protocol more broadly are subsequently discussed, with recommendations for a reconfiguration of computer-aided manufacturing (CAM) approaches to better encode the diverse preferences that users may have when considering how products are manufactured.

The Effect of Initial Texture on the Plastic Deformation of Gradient Aluminum.

The effect of specific processing-induced surface textures in gradient aluminum has not yet been investigated. A dislocation-based multi-scale framework is employed to explore the influence of various initial shearing textures and the depth from the surface of the region featuring each texture on the macroscopic behavior of gradient aluminum. By assigning different textures to the same grain size gradient aluminum sample, the initial texture was found to significantly affect the plastic deformation and macroscopic behavior of gradient aluminum. Specifically, the {111} texture can enhance the strength-ductility synergy, and this effect is dependent on the depth from the surface where the texture is located. This texture can lead to a slow stress/strain gradient in the assigned texture region and a sharp stress/strain gradient in the grain size gradient region connecting this region with the coarse grain region. Particularly, the sharp stress/strain gradient can result in extra strengthening by adjusting the stress/strain localization. These findings provide valuable insights for the design and optimization of surface textures in gradient aluminum.

Fingerprint-inspired surface texture for the enhanced tip pinch performance of a soft robotic hand in lubricated conditions

The core capabilities of soft grippers/soft robotic hands are grasping and manipulation. At present, most related research often improves the grasping and manipulation performance by structural design. When soft grippers rely on compressive force and friction to achieve grasping, the influence of the surface microstructure is also significant. Three types of fingerprint-inspired textures with relatively regular patterns were prepared on a silicone rubber surface via mold casting by imitating the three basic shapes of fingerprint patterns (i.e., whorls, loops, and arches). Tribological experiments and tip pinch tests were performed using fingerprint-like silicone rubber films rubbing against glass in dry and lubricated conditions to examine their performance. In addition to the textured surface, a smooth silicone rubber surface was used as a control. The results indicated that the coefficient of friction (COF) of the smooth surface was much higher than that of films with fingerprint-like textures in dry and water-lubricated conditions. The surface with fingerprint-inspired textures achieved a higher COF in oil-lubricated conditions. Adding the fingerprint-like films to the soft robotic fingers improved the tip pinch gripping performance of the soft robotic hand in lubricated conditions. This study demonstrated that the surface texture design provided an effective method for regulating the grasping capability of humanoid robotic hands.

Comparison of dimples and grooves based on friction and leakage properties of textured mechanical seals

PurposeThis study aims to obtain a design scheme of the surface texture on mechanical seal with lower friction and leakage by comparing two common texture types: dimples and grooves.Design/methodology/approachAn optimal free-form shape and an optimal circular shape were chosen by multi-objective optimization, and two types of grooves with different directions were chosen by a series of experiments. Then, the optimal free-form dimple, the optimal circular dimple, the groove perpendicular to the direction of movement (hereafter called groove-1) and the groove angled at 60° to the direction of movement (hereafter called groove-2) were compared by experiments under different loads.FindingsThe optimal free-form dimple shows a better performance in terms of a lower coefficient of friction (COF) and a lower leakage than the other shapes, especially for the high speed and low load conditions. The reduction rate of COF is up to 37.5%, and the leakage rate is reduced by about 12.5%. The dimples have a lower leakage than the grooves. The groove angled at 60° to the direction of movement is easier to pump the oil into the interface of the sealing face, leading to a lower friction but a higher leakage.Originality/valueThis study provides a feasible surface texture design scheme for improving the combination performance of mechanical seals.

Surface Texture Design of FBR-ALD Pt/C Catalyst to Enhance PEMFC Performance

Proton exchange membrane fuel cell (PEMFC) is an efficient electrochemical energy conversion device that directly generates electricity from the chemical energy of fuels without the emission of greenhouse gases. The most reliable catalyst in PEMFC is Platinum (Pt) metal nanoparticles (NPs) that exhibit excellent electrochemical activity and stability compared to other catalysts. However, using of Pt catalyst is limited due to its very high cost and low abundance on Earth. Therefore, it is important to use Pt catalyst efficiently for making the PEMFC economically viable. In this regard, several synthesis techniques have been developed to reduce the loading and uniform distribution of Pt NPs on carbon support with high electrochemically active surface area (ECSA). One of the most efficient techniques to uniformly deposit Pt NPs with a controllable size on carbon support is to use a fluidized bed reactor (FBR) atomic layer deposition (ALD). Our group recently demonstrated that FBR-ALD Pt/C catalysts can exhibit high fuel cell performance and high endurance even with low Pt NPs loading by optimizing the surface of carbon supports combined with proper ALD process parameters [1]. However, it is still challenging to further improve the fuel cell performance by rational designing the Pt NPs surfaces in order to make FBR-ALD into a viable commercial production.In this study, a unique way to improve the fuel cell performance was suggested to design and optimize atomic scale surface textures of Pt NPs. During the FBR-ALD of Pt NPs, in-situ surface modulation of Pt NPs was applied via a proper protective oxide deposition and etching. A careful surface studies was performed to analyze the surface morphology, distribution and uniformity of Pt NPs. Electrochemical performances were evaluated and optimized by measuring cyclic voltammetry (CV) and oxygen reduction reaction (ORR). Finally, a fuel cell performance was studied through membrane electrode assembly (MEA) characteristics.References W. J. Lee, S. Bera, H. C. Shin, W. P. Hong, S. J. Oh, Z. wan, S. H. Kwon, Adv. Mater. Interfaces 6, 1901210 (2019).

Effect of volcano-like textured tools on machining of Ti-6Al-4V alloy: a numerical and experimental analysis

Higher temperature and lower thermal conductivity between the tool-chip contact face easily result in adhesion and wear on the tool surface which negatively affects the tool life and the machining quality of the workpiece in the machining Ti-6Al-4V alloy process. To address these problems, the investigation, combining the simulation and experiment, introduced the volcano-like textures of different diameters with excellent anti-adhesion performance on the tool rake face. Deform-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using the Johnson-Cook material model to predict the cutting forces, cutting temperature and tool wear. In machining experiments, volcano-like textures (VT) with different diameters were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Experiments in machining Ti-6Al-4V alloy were carried out with the textured tools and non-textured tool under rough machining, semi-finishing and finishing conditions. Then, cutting force, cutting temperature and tool wear were investigated. The results showed that textured tools generally perform better than non-textured tool. The cutting force of VT1 was reduced by 31.2% and 50%, respectively, compared with the non-textured tool under semi-finishing and finishing conditions. With the refinement of machining, the cutting performance of the textured tools is improved, and the service life of the tool is extended. Therefore, the investigation can provide a basis for the surface texture design and optimization of the carbide tool.