Three-dimensional Surface Topography Research Articles

Effect of different surface roughening treatment on polyether ether ketone and acrylic resin bonding: A pilot study.

As polyether ether ketone (PEEK) is a relatively new material in dentistry, its bonding properties with regard to dental acrylic base materials are not fully known. To ensure the long-term success of removable dentures with a PEEK framework, the base materials must be well bonded to each other. The study aimed to investigate the effects of different kinds of surface roughening treatment on PEEK and acrylic resin bonding. Eighty PEEK specimens (N = 80) were randomly divided into 5 groups (n = 16 per group) and subjected to various surface roughening treatment (control, grinding, sandblasting, tribochemical silica coating (CoJet), and sulfuric acid etching). Heat-polymerized acrylic resin was applied to the treated surfaces of the PEEK specimens. The shear bond strength (SBS) test, environmental scanning electron microscopy (ESEM) analysis and three-dimensional (3D) surface topography analysis were performed. The statistical analysis of the data was conducted using the analysis of variance (ANOVA) and Tukey's multiple comparison test. The one-way ANOVA showed significant differences in the SBS values between the groups (p = 0.001). Sandblasting, tribochemical silica coating and sulfuric acid etching resulted in high SBS values (p = 0.001). The highest SBS values were observed in the sulfuric acid etching group (8.83 ±3.63 MPa), while the lowest SBS values were observed in the control group (3.33 ±2.50 MPa). The additional roughening treatment applied to the PEEK surface increases the bond strength with heat-polymerized acrylic resin.

Extraction of structured light stripes center from Non-uniform scattering surfaces fused with deep learning

The non-uniform strongly scattering surface enormously influences the measurement accuracy of high-precision structured light Three-dimensional (3D) surface topography. Accurately extracting the central profile of non-uniform highly scattering surfaces is the basis for 3D measurement using point cloud data. In this paper, based on the analysis of the properties of structured light stripes on non-uniform scattering surfaces, a high-precision subpixel laser stripes center robust detection method is proposed. This method first used the Stripe-Segmentor network to accurately segment the Region of Interest (ROI) of the linear structured light stripes, then used the gradient descent method to determine the normal direction of the center of the ROI area light stripes, and finally used the gray-scale centroid method to realize the sub-pixel in the center of the linear structured light stripes precision extraction. Through validation, it is obtained that the laser stripes center extraction algorithm proposed in this study has good accuracy and real-time performance, and has certain engineering value.

A methodology for the 3D characterization of surfaces using X-ray computed tomography: Application to additively manufactured parts

Many studies highlight the significance of three-dimensional surface topography characterization in assessing its effect on the mechanical or functional properties of materials. This is especially obvious for parts made by additive manufacturing (AM), known for their complex shape and surface topographies. However, a vast majority of 3D characterizations have constraints regarding the macroscopic geometry of the parts they can probe. At the microscale, they are also unable to account for hidden surface features, e.g. notches hidden by unmelted powder particles. Even with the use of X-ray Computed Tomography (XCT) - a tool with the potential to circumvent these issues -data is often reduced to 2D or 2.5D formats for easier analysis, but this leads to a loss of information. This underscores the need for XCT data post-treatment tools to perform thorough 3D surface characterizations. Herein, we introduce a methodology for local roughness and curvature characterization of surfaces of complex shapes using XCT. This method has been designed to be user-friendly, especially for those without extensive data analysis expertise. It provides a comprehensive 3D characterization and efficiently tackles the issues caused by hidden features. After a detailed description of our methodology, we give a first illustrative example based on architected structures fabricated by Electron Powder Bed Fusion (E-PBF). By integrating roughness and curvature metrics, we also derive a parameter indicative of the stress concentrations caused by surface irregularities.

Effect of phosphate post-treatment on corrosion behavior of cerium-based conversion coated Mg-4.0Y-4.0Zn-0.5Zr-0.2Ca (wt.%) alloys

The present study aims to investigate the effect of cerium-based conversion coating and phosphate post-treatment on the corrosion behavior of Mg-4.0Y-4.0Zn-0.5Zr-0.2Ca (wt.%) alloy (WZ44) in chlorinated solution. In this regard, as-cast and forged WZ44 alloy was subjected to cerium salt bath treatment at ambient followed by NaH2PO4 solution at 85 °C. The morphological evolution and chemical composition of the composite coating were examined using field emission scanning electron microscopy (FESEM), energy-dispersive X-ray spectroscopy (EDX), two and three-dimensional surface topography, and X-ray photoelectron spectroscopy (XPS) reveal the formation of complex phase mixture of CeO2, Ce2O3, CePO4, Mg(OH)2, and unknown hydrated compounds. The as-prepared cerium conversion coating possesses nodular CeO2 precipitates with abundant mud-cracks features originating due to hydrogen evolution and film dehydration-induced tensile stress. However, phosphate treatment develops a relatively smoother and compact coating with minimum surface roughness and conversion of nodular CeO2 precipitates into CePO4, albeit with few fine cracks. The tape adhesion and scratch test disclose that coating delamination predominant in cerium conversion coated specimens was reduced drastically by phosphate treatment with ∼16–23 % improvement in scratch hardness. Corrosion in terms of mass loss and potentiodynamic polarization (PDP) highlights that phosphate treatment improves the corrosion rate by ∼25–65 % compared to blank. Electrochemical impedance spectroscopy (EIS) demonstrates that coating (Rcoat) and polarization resistance (RP) at the film-metal interface was substantially increased to ∼953 Ω cm2 and ∼729 Ω cm2 for phosphate-treated specimens with a progressive increase in semicircular capacitive loop diameter indicating surface passivation. Overall, a duplex coating strategy with cerium salt bath followed by phosphate treatment can essentially develop a compact double-layer that effectively minimizes severe corrosion of WZ44 alloy in a 0.1 M NaCl electrolyte.

Investigation on tensional membrane force of the fluoropolymer dust covers in semiconductors

The photomask dust cover used in semiconductor manufacturing comprises a thin fluoropolymer membrane stretched tightly over an aluminum frame. The dust cover plays a vital role in protecting the photomask from dust pollution, thereby ensuring the purity of the exposed patterns and enhancing the wafer yield. However, the membrane is extremely thin and easily damaged during the manufacturing process. Therefore, this research proposes an analytical model for predicting the tensional force induced in the membrane under different distributed loads. The reflective fringe method, combined with a four-step phase-shifting technique, is used to measure the three-dimensional surface topography of the membrane under various distributed loads. A trial-and-error fitting method based on a simulation model of the dust cover is then employed to estimate the tensional force which yields the maximum vertical displacement closest to the experimental observations under different values of the distributed load. The analytical results confirm that a greater distributed load results in a higher membrane tensional force. However, the predicted tensional force reduces as the service life of the membrane increases due to the effects of plastic deformation. Overall, this study presents a simple approach of predicting the tensional force induced in the pellicle membrane under different loads. Thus, by taking the yield strength of the membrane as a threshold value, it serves as a useful tool for assessing the quality of the membrane and excluding its use from the production process if appropriate.

Measurement of Three-Dimensional Back Shape of Normal Adults Using a Novel Three-Dimensional Imaging Mobile Surface Topography System (MSTS): An Intra- and Inter-Rater Reliability Study

Postural and spinal deformities are major contributing factors to musculoskeletal (MSK) disorders. Posture screening and assessment can help to identify early morphological deformities, thereby preventing progression and reducing or correcting them with effective treatments. The study evaluates both intra- and inter-repeatability of using a mobile structured light sensor with a structured light pattern for building an accurate 3D human model and its use in postural screening. 16 young males (age: 25 ± 5.6 years, height: 172 ± 5.3 cm, mass: 69 ± 8.6 kg) participated without any musculoskeletal pain or pre-existing leg or spinal abnormalities. An iPad-based 3D mobile scanning tool, Structure SensorTM (2018 version), was used to capture the participants’ back and whole-body shape. The collected data (3D model) were realigned and processed in the open-source software, Netfabb BasicTM (7.2 version). For each participant, five trained raters individually measured three trials of standing back and body posture on two separate occasions to calculate both intra- and inter-rater reliability. With the use of this software, nine postural variables and angular displacements were individually measured by the raters. The results indicated good to excellent intra-rater and good to moderate inter-rater reliability for measuring 78% (7 out of 9) of postural variables with an ICC ranging from 0.70 to 0.98. The remaining 22% of variables (2 out of 9; lateral pelvic tilt and right frontal knee angle) showed moderate to low inter- and intra-rater reliability, with ICCs ranging from 0.26 to 0.79.

Corrosion Behavior of Shot-Peened Ti6Al4V Alloy Produced via Pressure-Assisted Sintering

For the first time, the present study investigates the corrosion, surface, and subsurface properties of a shot-peened Ti6Al4V powder metallurgical alloy produced via pressure-assisted sintering. Shot peening yielded a fine-grained microstructure beneath the surface down to 100 microns, showing that it caused severe plastic deformation. XRD analysis revealed that the sizes of the crystallites in unpeened and shot-peened Ti6Al4V alloy samples were 48.59 nm and 27.26 nm, respectively, indicating a substantial reduction in crystallite size with shot peening. Cross-sectional hardness maps of shot-peened samples showed a work-hardened surface layer, indicating a ~17% increase in near-surface hardness relative to unpeened samples. Three-dimensional surface topographies showed that shot peening yielded uniform peaks and valleys, with a maximum peak height of 4.83 μm and depth of 6.56 μm. With shot peening, the corrosion potential shifted from −0.386 V to −0.175 V, showing that the passive layer developed faster and was more stable than the unpeened sample, improving corrosion resistance. As determined via XRD analysis, the increased grain refinement (i.e., the number of grain boundaries) and the subsequent accumulation of TiO2 and Al5Ti3V2 compounds through shot peening also suggested the effective formation of a protective passive layer. As demonstrated via electrochemical impedance spectroscopy, the formation of this passive film improved the corrosion resistance of the alloy. The findings will likely advance surface engineering and corrosion research, enabling safer and more productive shot peening in corrosion-critical applications.

Three-dimensional Element-by-element Surface Topography Reconstruction of Compound Samples Using Multisegment Silicon Drift Detectors.

Elemental surface topography information in microscopic material characterization contributes to a better understanding of surfaces, interfaces, substrates, and their applications. Here, a general approach based on microbeam proton-induced X-ray emission (micro-PIXE) to reconstruct the three-dimensional (3D) elemental surface topography using the annular multisegment silicon drift detector has been demonstrated. The proposed method includes four main steps: acquiring four two-dimensional elemental concentration maps using the multichannel spectrometer, reconstructing the local inclination angle from the atomic model of ion-matter interaction, calculating the two independent topography gradient components, and numerical surface topography integration. In this study, the general algorithm to obtain the gradient components has been successfully tested on a four-segment configuration to reconstruct the 3D surface topography of compound alloys with different microstructure scales. In synchrotron and accelerator facilities dealing with elemental X-ray mapping where the development of customized multisegment detectors is needed, the introduced method is applicable to elemental surface/interface roughness reconstruction in microscale for cultural heritage samples, fusion plasma-facing materials, and microelectronic devices.

Accurate measurement of high-reflective surface based on adaptive fringe projection technique

Fringe projection profilometry (FPP) is one of the most effective methods to obtain three-dimensional surface topography information about an object. However, for objects with large variations in surface reflectance, it is difficult to measure the saturated regions with conventional FPP. In this paper, a new adaptive fringe projection (AFP) method is proposed to solve this problem. Compared with existing methods, the proposed method can automatically generate low-intensity projected fringe patterns instead of requiring manual adjustment. First, we built a projection intensity model for the captured pixels and defined the surface reflection factor and environmental factor for saturated pixels. Then, a small number of uniform grayscale pattern sequences were projected to mark the saturated areas, while the surface reflection factor and the environment factor of individual pixels were calculated and a surface coefficient look-up table (SCLUT) was created. The low-intensity projected fringe patterns were automatically calculated and generated based on the captured uniform grayscale sequences of images to establish the mapping relationship between the camera image plane and the projector image plane. Finally, the optimal projection intensities of pixels in the saturated regions were calculated according to the SCLUT, and adaptive fringe patterns were generated. Experiments show that using the adaptive fringe patterns generated by the proposed method to measure objects can accurately adjust the projection intensity and substantially improve the measurement accuracy of high-reflective surface.

A novel simulation model of three-dimensional surface topography for five-axis CNC milling using bull-nose tool

A novel simulation model of three-dimensional surface topography for five-axis CNC milling using bull-nose tool

Comprehensive evaluation of surface parameter correlation in running-in wear process

The first wear process is running-in, which is a stage of each machine system must go through. The friction pair’s surface topography is an important feature of the running-in process. After running-in, the surface topography directly affects the performance in stable working state. The wear performance of the contact pair was focused on by mostly existing studies after a time; however, we should consider the correlation of the surface topography before and after running-in. In fact, exploration of this problem is significantly important to extend the service life of machine parts and improve the running performance. Based on the three-dimensional (3D) surface topography parameter evaluation method, in this study, experiments were designed to analyze the effect of the unworn surface topography on that after running-in, and investigated the correlation of 3D surface topography parameters. The results demonstrated that the topography characterization parameters, i.e., Sa, Sq, Sv, Sdc, Str, Sdq, and Sdr under different working conditions maintained a strong autocorrelation (the correlation coefficient of the same parameter). Moreover, the cross-correlation (the correlation coefficient between different parameters) among height parameters (Sq), hybrid parameters (Sdq, Sdr), and functional parameters (Sdc, Sk) was strong. The results of the surface roughness parameters found in this study can be used as input and output feature selection research based on working conditions and surface topography prediction after the modeling research of running-in surface topography.

Digital holographic 3D surface topography measurement based on recording-plane rotation

In the present study, a three-dimensional (3D) surface topography measurement method based on digital holography is proposed that changes the observation vector by rotating a charge-coupled device(CCD) . Two digital holograms with different observation vectors were recorded by rotating the CCD at a small angle. In this paper, the 3D surface topographies of an irregular spheres with a radius of 16 mm and an surface relief denture with a dimensional of 10 mm ×10 mm were obtained. The results matches well with the real value of the hemisphere, which verifies the feasibility of the proposed method. At the same time, the surface topography measurement of the denture crown reflects its contour information well and can be used to guide dentists in the process of restorative teeth and denture making.

A two-phase density-based solver for simulating wet steam flows with non-equilibrium condensation. II. Effects of 3D surface topography through nozzles

In Paper I, we developed a new two-phase flow solver and assessed its reliability and effectiveness through a series of numerical simulations. In Paper II, we utilized this solver to study the steam flow through nozzles characterized by three-dimensional surface topography. To generate random rough surfaces, we employed a multivariate Weierstrass–Mandelbrot function. Our numerical simulation results exhibited good agreement with the reported experimental data for pressure distribution. Moreover, we examined the changes in pressure, temperature, humidity, Mach number, average Nusselt number, and thrust as the wall surface morphology varied. We observed that the pressure field was prone to fluctuations, the boundary layer structure thickened and changed, the degree of condensation decreased with reduced humidity, three-dimensional Mach waves occurred, and the averaged Nusselt number decreased while thrust deviation increased. These findings contribute to a better understanding of the effects of fractal dimensions and condensation on random roughness in steam flow through nozzles and highlight the significance of incorporating surface topography into numerical simulations to improve accuracy and predictability in engineering applications.

Plastic side flow and elastic recovery influences on optical diffraction effect of diamond turning: theoretical simulation and experimental verification.

Spherical/aspherical mirrors are widely used in optical systems and imaging systems, but their reflectivity is affected by the surface roughness. In this study, the effects of plastic side flow and elastic recovery on the diffraction phenomenon and reflectivity are analyzed systematically. The energy ratio of an ultra-precision turning surface is calculated by rigorous coupled-wave method, the influence of aberration on diffraction efficiency is considered in combination with the specific structural parameters of spherical/aspherical surface, and the appropriate measuring beam diameter is selected. Through predicted results and experimental observations, it can be found that with the increase of plastic side flow height, the energy ratio of zero-order diffracted light reduces, the brightness weakens, and the diffraction light spots become more obvious. This is because large plastic side flow height leads to more complex three-dimensional surface topography and great roughness P-V value. The influence of elastic recovery on the reflectivity is different from that of plastic side flow. As the elastic recovery increases, the roughness P-V value lessens. As a result, the energy ratio of zero-order diffracted light enlarges, and the brightness strengthens. This paper provides a theoretical basis for machining of spherical/aspheric mirrors with high reflectivity.

Application of Computer Image Processing Technology in Visual Communication System

ABSTRACT This research paper aims to enhance the operation of visual communication systems by incorporating computer image processing technology. The study investigates the potential applications of visual communication systems by utilizing imaging equipment to capture distorted fringe images of height-modulated objects from different angles. Phase information closely associated with the object is then extracted from the images and utilized to obtain the object’s three-dimensional surface topography following calibration. The paper applies multi-frequency phase-shift profilometry and Fourier transforms profilometry to construct further a visual communication system based on computer graphics processing technology. The article contributes to visual communication systems by proposing a novel approach that incorporates computer image processing technology. This approach enhances the performance of visual communication systems, resulting in a more effective means of communication. The study’s experimental analysis demonstrates computer image processing technology’s superiority and ability to enhance the visual communication system’s application. The study’s key findings indicate that computer image processing technology can effectively enhance the effectiveness of visual communication systems. The incorporation of imaging equipment and phase extraction methods leads to the production of accurate three-dimensional surface topography data. Furthermore, multi-frequency phase-shift profilometry and Fourier transform profilometry aid in constructing a visual communication system based on computer graphics processing technology, which leads to an overall enhancement of the visual communication system’s application.

Development and characterization of antioxidant composite films based on starch and gelatin incorporating resveratrol fabricated by extrusion compression moulding

Starch/gelatin (SG) films incorporated with resveratrol (RES) at various concentrations (0%–20%, w/w, on the weight of starch and gelatin) were developed via thermal extrusion followed by compression moulding. The SG based films were characterized using scanning electron microscopy (SEM) and Fourier transform infrared (FTIR) spectroscopy, together with the determination of optical, physical, thermal, and antioxidant properties of the films. SEM images showed the SG films containing RES had a higher surface roughness than that without RES, which was also confirmed by the three-dimensional surface topography images. The FTIR analysis revealed the existence of physical interactions among starch, gelatin, and RES through hydrogen bonding. The incorporation of RES significantly increased the thickness, opacity, and tensile strength of the films, while decreasing their transmittance, water solubility, water vapor and oxygen permeability. Furthermore, the elongation at break, surface hydrophobicity and thermal stability of the films also enhanced to some extent after addition of RES. More importantly, the composite films showed excellent antioxidant activity proportional to the RES concentration, and all films showed good anti-permeate property for oil without or with RES. Consequently, the SG film containing 20% RES with the highest oxygen barrier property and antioxidant activity could effectively reduce oxidative rancidity of soybean oil stored at 50 °C for 24 days when compared to SG film without RES and control sample (without film). To sum up, the thermoplastic processed SG films incorporating RES exhibited adequate properties for food packaging such as oil products which are highly susceptible to oxidation.

Advances of Confocal Microscopy in Three-Dimensional Surface Topography Measurement

Advances of Confocal Microscopy in Three-Dimensional Surface Topography Measurement

Three-dimensional surface topography measurement technology of color highly reflective objects

Three-dimensional surface topography measurement technology of color highly reflective objects

Three-dimensional topography modelling and grinding performance evaluating of micro-structured CVD diamond grinding wheel

Micro-structured chemical vapour deposition (CVD) diamond grinding tools are attracting increasing attention in precision grinding and micro-grinding because of their advantages in low grinding forces, high machining accuracy and good wear resistance. A well-developed wheel topography model for this kind of emerging grinding tool not only can facilitate the analysis and optimization the grinding process, but also is the essential basics for the intelligent machining. In this paper, a novel three-dimensional surface topography model of original CVD diamond grinding wheels was firstly established based on the multiple random data of the shape, size, posture and distribution of the CVD diamond grains. And the ground surface topography model was simulated depending on the established wheel model and grinding kinematics. Secondly, the models were verified by the results of grinding experiments in the means of topographical characteristics, surface roughness and PSD. Then, the influence of grinding parameters and wheel wear on the grinding performance of CVD diamond wheels was discussed. Finally, the micro-structured CVD grinding wheel models were presented by coupling different forms of micro-structures. And the effects of micro-structure parameters including widths, inclination angles, structuring ratios and types on the grinding performance of micro-structured CVD diamond wheels were investigated quantitatively. This study provides a quantitative and effective method for the design of CVD diamond grinding wheels and their surface structuring. Furthermore, the proposed micro-structured analysis method is also available for other structured grinding wheels.

Prediction Model of Three-Dimensional Machined Potassium Dihydrogen Phosphate Surfaces Based on a Dynamic Response Machining System.

To comprehensively obtain the effect of the machining process on the three-dimensional surface topography of machined potassium dihydrogen phosphate crystals, a dynamic response model of a machining system was built to calculate the dynamic displacement variables in the different processing directions. This model includes almost all processing factors, such as cutting parameters, environment vibration, radial and axial runout of the spindle, cutting tool parameters, material parameters, guide way error, fast tool servo and lubrication condition errors, etc. Compared with the experimental results, the three-dimensional topographies and two-dimensional profiles of the simulation surfaces were nearly consistent with those of experimental machined surfaces. As the simulation shows, the cutting parameters, axial runout of the spindle, and the output noise of the fast tool servo can respectively impact the main, low, and high frequencies of the machined surface topography. The main frequency of all the simulated and experimental surfaces in this study was 0.0138 μm-1. The low and high frequencies of the simulation surfaces had slight differences, about 0.003 μm-1 from those of the experimental surfaces. The simulation model, based on dynamic response, can accurately predict the entire machining process and three-dimensional topographies of machined potassium dihydrogen phosphate surfaces.