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Surface Topography Description as a Determinant of Quality and Functionality

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 June 2023) | Viewed by 19747

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Dr. Wiesław A. Graboń

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The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, Rzeszow, Poland
Interests: metrology; lubrication; wear; friction; coatings; surface treatment
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Dr. Thomas G. Mathia

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Laboratoire de Tribologie et Dynamique des Systèmes, CNRS, École Centrale Lyon, 69134 Ecully, France
Interests: metrology; physical-chemical surface characterizations; surface topography; instrumentation design; surface technology; nano-technology; machining; tribology; rheology
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Dear Colleagues,

The surface is an integral part of all objects and its texture has a great impact on functional properties. According to these facts, the correct description of the surface is very important, both on the level of production, as well as during the period of operation. In the first case, it gives information about the quality of the products, in the second one, it gives information (received based on texture changes) that is valuable for the designer and researcher about processes taking place during a period of operation. Based on this information, the direction of improving the functionality of the surface topography of materials can be found.

Since new technological solutions in terms of shaping the functional features of surfaces are created, requiring the implementation of the new methods of measurement, as well as surface texture description and analysis, therefore, continuous research in this area is necessary.

This Special Issue will bring together the work of academic scientists and researchers to spread and share their experiences and research results on many aspects of Surface Topography Description as a Determinant of Quality and Functionality from all fields, including civil engineering, mechanical engineering, and others.

We kindly invite you to submit manuscripts for this Special Issue. Research papers, communications, and reviews dealing with the research in the area of surface texture measurement and assessment are all welcome.

Dr. Wiesław A. Graboń
Dr. Thomas G. Mathia
Guest Editors

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Keywords

surface texture
surface treatment
surface metrology
surface characterization
surface texture analysis
manufacturing processes
measurement science

Related Special Issue

Surface: A Key Factor for Quality and Functionality of Materials and Coatings in Materials

Published Papers (12 papers)

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Research

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19 pages, 11001 KiB

Open AccessArticle

Tomographic and Tension Analysis of Polypropylene Reinforced with Carbon Fiber Fabric by Injection Molding

by Michal Wieczorowski, Alejandro Pereira, Teresa Prado, Alberto Lopez-Blanco, Karol Grochalski, Wieslaw Grabon and M. Consuelo Perez

Materials 2023, 16(18), 6231; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16186231 - 15 Sep 2023

Viewed by 810

Abstract

The use of thermoplastic materials has had significant growth in recent years. However, with great mechanical requirements, thermoplastics have limitations to their use. To improve these restrictions, these materials are reinforced to obtain better properties. Polypropylene is one of the most versatile polymers and is used in almost all modern industries. Thus, the aim of this study is to create composite materials that offer performance for various industrial fields using carbon fiber fabric reinforcement, which is an inexpensive material widely used by the aerospace, automotive, and marine industries. The samples are produced by the over-injection molding of polypropylene. The investigation is focused on the impact of two critical control parameters in the injection molding process: temperature and pressure. Twelve experiments have therefore been considered, taking into account the combination of three factors: the presence or absence of carbon fiber fabric reinforcement, three levels of temperature (200 °C, 220 °C, and 240 °C), and two injection pressures (5000 kPa and 10,000 kPa). To evaluate the influence of these factors, three analyses were carried out: first, on the samples’ shrinkage using a portable metrology-grade 3D laser scanner; second, on the internal defects using computed tomography (CT); and third, on the mechanical properties with tensile tests. From the results obtained, it is observed that the mold shrinkage fell slightly when PP samples were reinforced with carbon fiber, with both materials (PP and carbon-fiber-reinforced PP) having linear behavior with temperature. It is also noticed that polypropylene behaves as a crystalline material when processed at higher temperatures and pressures. From tests on the mechanical properties, it is concluded that the mean yield strength of PP-CF for injection temperatures of 220 °C and 240 °C represents an increase of 43% compared to the non-reinforced material. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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20 pages, 6882 KiB

Open AccessArticle

Surface Modification of Ti6Al4V ELI Titanium Alloy by Poly(ethylene-alt-maleic anhydride) and Risedronate Sodium

by Joanna Szczuka, Mariusz Sandomierski, Adam Voelkel, Karol Grochalski and Tomasz Buchwald

Materials 2023, 16(15), 5404; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16155404 - 01 Aug 2023

Viewed by 963

Abstract

With the simultaneous increase in the number of endoprostheses being performed, advances in the field of biomaterials are becoming apparent—whereby the materials and technologies used to construct implants clearly improve the implants’ quality and, ultimately, the life of the patient after surgery. The aim of this study was to modify the titanium alloy Ti6Al4V ELI used in the construction of hip joint endoprostheses. This is why the continuous development of biomaterials is so important. This paper presents the results of research for a new application of polymer poly(ethylene-alt-maleic anhydride) as a drug release layer, placed on the surface of a titanium alloy. The obtained layers were analyzed using Raman spectroscopy (spectra and maps), Fourier transform infrared spectroscopy (spectra and maps), contact angle measurements as well as scanning electron microscopy and energy dispersive spectroscopy imaging and topography analysis. The results confirmed that the polymer layer obtained on the plate surface after the alkali heat treatment process is much better—it binds much more polymer and thus the applied drug. In addition, a longer and more gradual release of the drug was observed for the alkali heat treatment modification than for H₂O₂ solution. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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21 pages, 24831 KiB

Open AccessArticle

Influence of Inorganic Additives on the Surface Characteristics, Hardness, Friction and Wear Behavior of Polyethylene Matrix Composites

by Natalia Wierzbicka, Rafał Talar, Karol Grochalski, Adam Piasecki, Wiesław Graboń, Miłosz Węgorzewski and Adam Reiter

Materials 2023, 16(14), 4960; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16144960 - 12 Jul 2023

Cited by 2 | Viewed by 713

Abstract

The aim of this research was to analyze the effect of inorganic additives on the tribological properties of the high-density polyethylene (HDPE) matrix composite surface. Titanium (Ti) and hexagonal boron nitride (hBN) were added in different mass fractions. The samples were produced by pressing a pre-prepared mixture of granules. The composite samples with the following mass fractions of additives were fabricated: 5% hBN, 10% hBN, 28% Ti–2% hBN, 23% Ti–7% hBN, and 20% Ti–10% hBN. An even distribution of individual additives’ concentrations was confirmed. Observations of morphology, surface topography, hardness, and tribological measurements were conducted using reciprocating motion tests with the “pin-on-flat” and rotational tests with the “pin-on-disc” configuration. Subsequently, microscopic observations and measurements of the wear track profile were carried out. Additionally, geometry parameters of the contacting elastic body were calculated for various counter-samples. It was found that the Shore D hardness of samples containing Ti and hBN increased with the Ti content, while the coefficient of friction (COF) value decreased. The addition of hBN alone did not significantly affect the hardness, regardless of the ratio, while the COF increased with the increasing hBN content. The COF value doubled with the addition of 10% hBN (COF = 0.22), whereas the addition of 90% Ti–10% hBN resulted in a decrease in the COF value, to COF = 0.83. The highest hardness value was obtained for the sample containing 28% Ti–2% hBN (66.5), while the lowest was for the sample containing 10% hBN (63.2). The wear track analysis, including its height and width caused by deformation, was detected using a focal differentiation microscope and scanning electron microscopy. Additionally, EDS maps were generated to determine the wear characteristics of the composite. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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13 pages, 9095 KiB

Open AccessArticle

Multiscale Data Treatment in Additive Manufacturing

by Damian Gogolewski

Materials 2023, 16(8), 3168; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16083168 - 17 Apr 2023

Cited by 1 | Viewed by 932

Abstract

The article assesses the impact of data treatment on the possibility of assessing the morphological features of additively manufactured spherical surfaces. Tests were carried out on specimens manufactured by PBF-LB/M additive technology, using titanium-powder-based material (Ti6Al4V). The surface topography was assessed using one of the multiscale methods—wavelet transformation. The tests carried out on a wide spectrum of mother wavelet forms emphasized the occurrence of characteristic morphological features on the surface of the tested specimens. Moreover, the significance of the impact of specific metrology operations, measurement data processing and its parameters on the filtration result were noted. Comprehensive assessment of additively manufactured spherical surfaces with simultaneous analysis of the impact of measurement data processing is a novelty and fills a research gap relating to comprehensive surface diagnostics. The research contributes to the development of modern diagnostic systems allowing for a fast and comprehensive assessment of surface topography, taking into account the various stages of data analysis. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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16 pages, 6656 KiB

Open AccessArticle

Characterization of Magnesium and Zinc Forms of Sodalite Coatings on Ti6Al4V ELI for Potential Application in the Release of Drugs for Osteoporosis

by Mariusz Sandomierski, Wiktoria Stachowicz, Adam Patalas, Karol Grochalski, Wiesław Graboń and Adam Voelkel

Materials 2023, 16(4), 1710; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16041710 - 17 Feb 2023

Cited by 2 | Viewed by 1360

Abstract

Osteoporosis is the most common metabolic disease of the skeletal system and is characterized by impaired bone strength. This translates into an increased risk of low-energy fractures, which means fractures caused by disproportionate force. This disease is quite insidious, its presence is usually detected only at an advanced stage, where treatment with pharmaceuticals does not produce sufficient results. It is obligatory to replace the weakened bone with an implant. For this reason, it is necessary to look at the possibilities of surface modification used in tissue engineering, which, in combination with the drugs for osteoporosis, i.e., bisphosphonates, may constitute a new and effective method for preventing the deterioration of the osteoporotic state. To achieve this purpose, titanium implants coated with magnesium or zinc zeolite were prepared. Both the sorption and release profiles differed depending on the type of ion in the zeolite structure. The successful release of risedronate from the materials at a low level was proven. It can be concluded that the proposed solution will allow the preparation of endoprostheses for patients with bone diseases such as osteoporosis. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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20 pages, 11880 KiB

Open AccessArticle

A Multiscale Topographical Surface Analysis of High Entropy Alloys Coatings by Laser Melting

by Maxence Bigerelle, Anaïs Galliere, Yucelys Y. Santana, Hervé Morvan, Mirentxu Dubar, Jean-François Trelcat, Laurent Boilet and Emmanuel Paris

Materials 2023, 16(2), 629; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16020629 - 09 Jan 2023

Viewed by 1096

Abstract

High Entropy Alloys (HEAs) coatings obtained by laser melting (LM) technique were studied through a multiscale topographical surface analysis using a focus variation microscope. The laser melting creates a multiscale topography from under-powder size (incomplete or complete powder melting) to upper-powder size (process conditions). The surface topography must be optimized because of the significant influence on friction and material transfer during sliding wear. The analyses were shown that different pre-melting zone interactions were present. Statistical analysis based on covariance analyses is allowed to highlight the different process melting scales. The best LM parameter values to minimize Surface Heterogeneity were laser power (Pw) of 55 W, laser exposition time (te) of 1750 µs, and distance between two pulses (dp) of 100 µm. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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24 pages, 6873 KiB

Open AccessArticle

Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation

by Zhitao Chen, Caixu Yue, Xianli Liu, Steven Y. Liang, Xudong Wei and Yanjie Du

Materials 2021, 14(24), 7679; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14247679 - 13 Dec 2021

Cited by 5 | Viewed by 2328

Abstract

With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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28 pages, 25809 KiB

Open AccessArticle

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

by Anshan Zhang, Caixu Yue, Xianli Liu and Steven Y. Liang

Materials 2021, 14(23), 7143; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14237143 - 24 Nov 2021

Cited by 1 | Viewed by 1111

Abstract

Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q₂: β ∈ [0°, 90°]) or lower left (Q₃: β ∈ [90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q₁: β ∈ (−90°, 0°]) or upper left (Q₂: β ∈ [0°, 90°)). Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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13 pages, 6980 KiB

Open AccessArticle

Study of Lapping and Polishing Performance on Lithium Niobate Single Crystals

by Karim Ravilevich Muratov, Timur Rizovich Ablyaz, Evgeny Anatolevich Gashev, Sarabjeet Singh Sidhu and Evgeny Sergeevich Shlykov

Materials 2021, 14(17), 4968; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14174968 - 31 Aug 2021

Cited by 1 | Viewed by 1802

Abstract

Recently, the range of crystal materials used in industrial microelectronics has significantly increased. Lithium niobate single crystals are most often used in integrated optics, due to the high values of optical and electro-optical coefficients. An integral-optical circuit based on a lithium niobate single crystal is a key element in the production of local high-precision fiber-optic gyroscopic devices used in civil and military aviation and marine technologies. In the process of production of an integral-optical circuit, the most labor-intensive operations are mechanical processing, such as lapping and polishing. Technological problems that arise while performing these operations are due to the physical and mechanical properties of the material, as well as target surface finish. This work shows the possibility to achieve the required surface quality of lithium niobate single crystal plates by mechanization of lapping and polishing process in this article. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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28 pages, 8837 KiB

Open AccessArticle

The Effect of Surface Topography Feature Size Density and Distribution on the Results of a Data Processing and Parameters Calculation with a Comparison of Regular Methods

by Przemysław Podulka

Materials 2021, 14(15), 4077; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14154077 - 22 Jul 2021

Cited by 24 | Viewed by 2411

Abstract

In this paper, the influence of occurrence of surface texture features on the values of surface topography parameters calculated after the application of various data processing techniques was presented. Different types of surface topographies were considered, as follows: cylinder liners, some with additionally burnished dimples, turned, ground, milled, laser-textured, composite, ceramic, or isotropic in general. The effects of feature size on the areal form removal, noise suppressions, or end-effect reducing in surface texture measurements were studied. The variations of the ISO 25178 standard surface topography parameters were taken into consideration in detail. It was assumed that some of the feature sizes, distributions, and densities have a substantial impact on the values of surface topography parameters calculated after applications of regular (commonly used) algorithms and procedures, defined as basic operations, provided for raw surface texture data obtained directly from the measurement process. In the end, some of the practical applications for receiving the relevant values of surface topography parameters were proposed. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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21 pages, 48351 KiB

Open AccessArticle

Reduction of Influence of the High-Frequency Noise on the Results of Surface Topography Measurements

by Przemysław Podulka

Materials 2021, 14(2), 333; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14020333 - 11 Jan 2021

Cited by 21 | Viewed by 3281

Abstract

The influence of errors in the processes of detection and then reduction of surface topography measurement noise is of great importance; many research papers are concerned with the definition of this type of measurement error. This paper presents the influence of high-frequency measurement noise, defined for various types of surface textures, e.g., two-process plateau-honed, turned, ground, or isotropic. Procedures for the processing of raw measured data as a detection of the high-frequency errors from the results of surface topography measurements were proposed and verified (compared) according to the commonly used (available in the commercial software of the measuring equipment) algorithms. It was assumed that commonly used noise-separation algorithms did not always provide consistent results for two process textures with the valley-extraction analysis; as a result, some free-of-dimple (part of the analyzed detail where dimples do not exist) areas were not carefully considered. Moreover, the influence of measured data processing errors on surface topography parameter calculation was not comprehensively studied with high-frequency measurement noise assessments. It was assumed that the application of the Wavelet Noise Extraction Procedure (WNEP) might be exceedingly valuable when the reduction of a disparate range of measured frequencies (measurement noise) was carefully considered. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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Review

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19 pages, 4353 KiB

Open AccessReview

The Influence of Geometry, Surface Texture, and Cooling Method on the Efficiency of Heat Dissipation through the Heat Sink—A Review

by Karol Grochalski, Wojciech Rukat, Bartosz Jakubek, Michał Wieczorowski, Marcin Słowiński, Karolina Sarbinowska and Wiesław Graboń

Materials 2023, 16(15), 5348; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16155348 - 29 Jul 2023

Viewed by 1448

Abstract

The performance of a heat sink is significantly influenced by the type of cooling used: passive or active (forced), the shape of the heat sink, and the material from which it is made. This paper presents a review of the literature on the influence of geometry and surface parameters on effective heat transfer in heat sinks. The results of simulation studies for three different heat sink fin geometries and cooling types are presented. Furthermore, the influence of the surface texture of the heat sink fins on the heat transfer efficiency was determined. It was shown that the best performance in terms of geometries was that of a wave fin heat sink. When the surface texture was analyzed, it was found that an increase in the amplitude values of the texture decreases the heat dissipation efficiency in the case of active cooling, while for passive cooling, an increase in these parameters has a beneficial effect and increases the effective heat transfer to the surroundings. The cooling method was found to be the most important factor affecting heat dissipation efficiency. Forced airflow results in more efficient heat transfer from the heat sink fins to the surroundings. Full article

(This article belongs to the Special Issue Surface Topography Description as a Determinant of Quality and Functionality)

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