Generating micro/nanostructures on magnesium alloy surface using ultraprecision diamond surface texturing process

The lightness and high strength-to-weight ratio of the magnesium alloy have attracted more interest in various applications.However,micro/nanostructure generation on their surfaces remains a challenge due to the flammability and ignition.Motivated by this,this study proposed a machining process,named the ultraprecision diamond surface texturing process,to machine the micro/nanostructures on magnesium alloy surfaces.Experimental results showed the various microstructures and sawtooth-shaped nanostructures were successfully generated on the AZ31B magnesium alloy surfaces,demonstrating the effectiveness of this proposed machining process.Furthermore,sawtooth-shaped nanostructures had the function of inducing the optical effect and generating different colors on workpiece surfaces.The colorful letter and colorful flower image were clearly viewed on magnesium alloy surfaces.The corresponding cutting force,chip morphology,and tool wear were systematically investigated to understand the machining mechanism of micro/nanostructures on magnesium alloy surfaces.The proposed machining process can further improve the performances of the magnesium alloy and extend its functions to other fields,such as optics.

Surface texturing for adaptive Ag/MoS_2 solid lubricant plating

The objective of this research is to prepare specially designed surface texture on hard steel surface by electrochemical micromachining (EM) and to incorporate electroless plated Ag/MoS2 solid lubricant coating into the dimples of EM textured steel surface to effectively reduce friction and wear of steel-steel contacts. The friction and wear behavior of the Ag/MoS2 solid lubricant coating on EM textured steel surface was evaluated in relation to the size and spacing of the dimples thereon. The microstructure of as-plated Ag/MoS2 solid lubricant coating and the morphology and elemental composition of the worn coating surface and counterface steel surface were analyzed by means of optical microscopy, scanning electron microscopy, and energy dispersive spectrometry. It is found that electroless plated Ag/MoS2 coating is able to greatly reduce the friction and wear of the EM textured steel disc coupled with GCr15 steel ring, mainly because of the formation of solid self-lubricating layer on the EM textured steel surface and of transferred lubricating film on counterface steel surface. The diameter and spacing of the dimples are suggested as 500 μm for acquiring the best wear resistance of the hard steel discs after electrochemical micromachining treatment and electroless plating of Ag/MoS2 solid lubricating coating.

Surface Texturing of TiO_2 Film by Mist Deposition of TiO_2 Nanoparticles

Unique and various microstructures of titanium oxide(TiO_2 ) film including macroporous structure, chromatic veins and rings, have been easily fabricated by mist deposition method on silicon substrate with mild preparation conditions. Rutile phase TiO_2 nanoparticles were directly used as starting material to prepare film and led to a simple preparation process. It was found that several different microstructures existed in the sample and changed with the varied positions from the center to the edge of the film when the concentration of the TiO_2 suspension is 0.06 mol/l, the deposition time is 30 min, the flow rate is 1 l/min and the temperature is150. The surface texturing shows apparent distinction as the concentration of the TiO_2 suspension decreased to 0.03 mol/l and 0.01 mol/l.

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.

Laser Surface Texturing of Co–Cr–Mo Alloy for Biomedical Applications:A Case Study for the Effects of Process Parameters on Surface Properties

This study presents a comprehensive approach to applying texturing processes created by engraving on the surface of CoCr28Mo alloy workpieces using a 20 W pulsed nanosecond fiber laser.The hatch strategy and distance,frequency,and scan speed were control parameters for texturing applications.The effectiveness of the parameters in terms of roughness and contact angle of the texturized surface was investigated.Surface roughness and contact angle were analyzed using variance analysis to identify each variable's influence.It has been determined that the roughness of the texture defined by the hatch strategy plays a decisive role in the wettability behavior of the surface;however,the scan speed,frequency,and hatch distance which are among the laser surface texturing conditions are influential in the roughness and contact angle.Increasing scan speed and hatch distance while decreasing frequency resulted in smoother surfaces,increasing the contact angle.Textures having rough surfaces produced with different processing conditions exhibit a super hydrophilic behavior.The contact angle is most sensitive to the hatch distance;however,the frequency has the least influence on the contact angle.The most and least efficient surface roughness parameters are revealed to be scan speed and hatch distance,respectively.

Regulation and control of wet friction of soft materials using surface texturing:A review

Surface texturing is a smart strategy that is commonly used in nature or industry to improve the tribological properties of sliding surfaces.Herein,we focus on the recent research progress pertaining to the wet friction modification of soft elastomers via texturing.To consider the pertinent physical mechanisms,we present and discuss the fundamentals of wet sliding on soft surfaces(including dewetting and wetting transitions in compliant contacts).Subsequently,we consider the methods in which the characteristic textures regulate and control wet sliding behaviors on soft surfaces;these textures range from conventional patterns of dimples to bioinspired architectures and can either positively or adversely impact the interfacial friction force.Furthermore,we briefly address the perspectives,potential applications,and challenges of texture design for modifying the friction characteristics of soft materials.

Texturing and evaluation of concrete pavement surface:A state-of-the-art review

Concrete pavement is accompanied by two major functional properties,namely noise emission and friction,which are closely related to pavement surface texture.While several technologies have been developed to mitigate tirepavement noise and improve driving friction by surface texturization,limited information is available to compare the advantages and disadvantages of different surface textures.In this study,a state-of-the-art and state-of-thepractice review is conducted to investigate the noise reduction and friction improvement technologies for concrete pavement surfaces.The commonly used tests for characterizing the surface texture,skid resistance,and noise emission of concrete pavement were first summarized.Then,the texturing methods for both fresh and hardened concrete pavement surfaces were discussed,and the friction,noise emission and durability performances of various surface textures were compared.It is found that the next generation concrete surface(NGCS)texture generally provides the best noise emission performance and excellent friction properties.The exposed aggregate concrete(EAC)and optimized diamond grinding textures are also promising alternatives.Lastly,the technical parameters for the application of both diamond grinding and diamond grinding&grooving textures were recommended based on the authors'research and practical experience in Germany and the US.This study offers a convenient reference to the pavement researchers and engineers who seek to quickly understand relevant knowledge and choose the most appropriate surface textures for concrete pavements.

Modeling of surface texturing in hydrodynamic lubrication

Theoretical modeling of surface texturing in hydrodynamic lubrication is a necessary first step to obtain favorable effect of the texturing.This invited review presents a comprehensive summary of the modeling of several basic applications that was done mostly by the author’s group at Technion and published in the relevant literature.

Sliding wear characteristics of solid lubricant coating on titanium alloy surface modified by laser texturing and ternary hard coatings

Titanium alloys are poor in wear resistance and it is not suitable under sliding conditions even with lubrication because ofits severe adhesive wear tendency.The surface modifications through texturing and surface coating were used to enhance the surfaceproperties of the titanium alloy substrate.Hard and wear resistant coatings such as TiAlN and AlCrN were applied over texturedtitanium alloy surfaces with chromium as interlayer.To improve the friction and wear resisting performance of hard coatings further,solid lubricant,molybdenum disulphide(MoS2),was deposited on dimples made over hard coatings.Unidirectional sliding weartests were performed with pin on disc contact geometry,to evaluate the tribological performance of coated substrates.The tests wereperformed under three different normal loads for a period of40min at sliding velocity of2m/s.The tribological behaviours ofmulti-layer coatings such as coating structure,friction coefficient and specific wear rate were investigated and analyzed.The lowerfriction coefficient of approximately0.1was found at the early sliding stage,which reduces the material transfer and increases thewear life.Although,the friction coefficient increased to high values after MoS2coating was partially removed,substrate was stillprotected against wear by underlying hard composite layer.

A synergetic strategy based on laser surface texturing and lubricating grease for improving the tribological and electrical properties of Ag coating under current-carrying friction

Herein,a series of Ag coatings with different micro‐dimples were fabricated on copper surfaces by laser surface texturing(LST)and magnetron sputtering.Multilayer graphene lubricating grease(MGLG)was prepared using multilayer graphene as an additive.The textured Ag coatings and MGLG were characterized.Moreover,the tribological and electrical performances of the textured Ag coatings under MGLG lubrication were investigated in detail.Results demonstrated that the textured Ag coating with an appropriate dimple diameter could exhibit improved tribological and electrical properties when compared to the non‐textured Ag coating under MGLG lubrication.The characterization and analysis of the worn surfaces suggest that the synergetic effect of LST and MGLG contributes to these excellent tribological and electrical properties.

Cooperative effect of surface alloying and laser texturing on tribological performance of lubricated surfaces

The cooperative effect of laser surface texturing(LST) and double glow plasma surface alloying on tribological performance of lubricated sliding contacts was investigated.A Nd:YAG laser was used to generate microdimples on steel surfaces. Dimples with the diameter of 150μm and the depth of 30-35μm distributed circumferentially on the disc surface.The alloying element Cr was sputtered to the laser texturing steel surface by double glow plasma technique.A deep diffusion layer with a thickness of 30μm and a high hardness of HV900 was formed in this alloy.Tribological experiments of three types of samples(smooth,texturing and texturing+alloying) were conducted with a ring-on-disc tribometer to simulate the face seal.It is found that,in comparison with smooth steel surfaces,the laser texturing samples significantly reduce the friction coefficient.Moreover,the lower wear rate of the sample treated with the two surface techniques is observed.

Does laser surface texturing really have a negative impact on the fatigue lifetime of mechanical components?

Laser surface texturing(LST)has been proven to improve the tribological performance of machine elements.The micro-scale patterns manufactured by LST may act as lubricant reservoirs,thus supplying oil when encountering insufficient lubrication.However,not many studies have investigated the use of LST in the boundary lubrication regime,likely due to concerns of higher contact stresses that can occur with the increasing surface roughness.This study aims to examine the influence of LST on the fatigue lifetime of thrust rolling bearings under boundary lubrication.A series of periodic patterns were produced on the thrust rolling bearings,using two geometrically different designs,namely cross and dimple patterns.Base oil ISO VG 100 mixed with 0.05 wt%P of zinc dialkyldithiophosphate(ZDDP)was supplied.The bearings with cross patterns reduce the wear loss by two orders of magnitude.The patterns not only retain lubricant in the textured pockets but also enhance the formation of an anti-wear tribofilm.The tribofilm generation may be improved by the higher contact stresses that occur when using the textured surface.Therefore,in contrast to the negative concerns,the ball bearings with cross patterns were instead found to increase the fatigue life by a factor of three.

Theoretical and experimental study of surface texturing with laser machining

To explore the forming process and mechanism of the surface texture of laser micropits,this paper presents the thermal model of laser machining based on the Neumann boundary conditions and an investigation on the effects of various parameters on the processing.The surface profile and quality of the formed micropits were analyzed using NanoFocus 3D equipment through a design of experiment(DOE).The results showed that more intense melting and splashing occurred with higher power density and narrower pulse widths.Moreover,the compressive stress is an important indicator of the damage effects,and the circumferential thermal stress is the primary factor influencing the diameter expansion.During the process of laser machining,not only did oxides such as CuO and ZnO generate,the energy distribution also tended to decrease gradually from region#1 to region#3 based on an energy dispersive spectrometer(EDS)analysis.The factors significantly affecting the surface quality of the micropit surface texture are the energy and pulse width.The relationship between taper angle and energy is appropriately linear.Research on the formation process and mechanism of the surface texture of laser micropits provides important guidance for precision machining.

Enhancement of wear resistance of Ti–6Al–4V alloy by picosecond laser surface micro texturing process

A pulsed,picosecond Nd:YAG laser with a wavelength of 532 nm is used to texture the surface of grade 5 titanium alloy(Ti–6Al–4V)for minimizing its wear rate.The wear properties of the base samples and laser surface textured samples are analyzed by conducting wear tests under a sliding condition using pin-on-disk equipment.The wear tests are conducted based on the Box–Benhken design,and the interaction of the process parameters is analyzed using response surface methodology.The wear analysis is conducted by varying the load,rotating speed of the disc,and track diameter at room temperature with a sliding distance of 1500 m.The results demonstrate that the laser textured surfaces exhibited a lower coefficient of friction and good anti-wear properties as compared with the non-textured surfaces.A regression model is developed for the wear analysis of titanium alloy using the analysis of variance technique.It is also observed from the analysis that the applied load and sliding distance are the parameters that have the greatest effect on the wear behavior followed by the wear track diameter.The optimum operating conditions have been suggested based on the results obtained from the numerical optimization approach.

Improving high-temperature wear resistance of NiCr matrix self-lubricating composites by controlling oxidation and surface texturing

Self-lubricating composites(SLCs)are widely used in the fields of aerospace and marine,but the conventional NiCr matrix SLCs with sulfide as solid lubricant often suffer from low wear resistance at high temperatures.In view of its high affinity with oxygen and also the high oxidation rate,appropriate amount of nano Ti was added to NiCr-WS_(2)composites prepared by spark plasma sintering(SPS)to adjust the oxidation behavior and surface texture.When exposed to high temperature,Ti was preferentially oxidized in comparison to Ni and Cr,resulting in abundant TiO_(2)protrusions and microdimples on the surface,i.e.in situ surface texturing.Besides,TiO_(2)was of high chemical activity and readily to react with other oxide debris during high temperature sliding process to form compounds of NiTiO_(3)and CrTi_(2)O_(5).The high chemical activity of oxide debris that was conducive to sintering,combining with the special surface texture that stores as many wear debris as possible,promoted the rapid formation of a protective glaze layer on the sliding surface.The NiCr-WS_(2)-Ti composite exhibited low friction coefficient but high wear resistance at elevated temperatures.Especially at 800℃,it presented a wear rate of as low as(2.1±0.3)×10^(-5)mm^3N-1m^(-1),accounting for only 2.7%of that of NiCr-WS_(2)composite.

Metal surface wettability modification by nanosecond laser surface texturing:A review

Laser surface texturing(LST)is a non-contact manufacturing process for fabricating functional surfaces in a manner that improves the corresponding wettability,and is widely used in biomedicine and industry.Laser surface texturing is a facile approach that is compatible with various materials,can result in a hierarchical texture,and enables a high degree of surface wetting(i.e.,extreme wetting).In addition to surface structures,surface chemical modification is a primary factor in producing extreme wetting surfaces.This review discusses the effects of various surface textures and surface chemistries on wettability.Optimal laser parameters for the desired surface texture are based on the fundamental wettability and laser mechanism.In particular,bumps in the morphology are conducive to obtaining extreme wetting.Diverse surface chemical strategies result in extreme wetting by different mechanisms.This paper makes a rigorous evaluation of the laser parameters and optimal surface chemical modifications by elucidating the relationships between the surface structure,surface chemical modification,and wettability,and in so doing,determines the final wettability.The unresolved problems of LST are presented in the conclusion.This review provides guidance,development directions,and an integrated framework for LST,which will be useful for fabricating extreme wetting surfaces on various metals.

Targeting new ways for large-scale,high-speed surface functionalization using direct laser interference patterning in a roll-to-roll process

Direct Laser Interference Patterning(DLIP)is used to texture current collector foils in a roll-to-roll process using a high-power picosecond pulsed laser system operating at either fundamental wavelength of 1064 nm or 2nd harmonic of 532 nm.The raw beam having a diameter of 3 mm@1/e^(2) is shaped into an elongated top-hat intensity profile using a diffractive so-called FBS■-L element and cylindrical telescopes.The shaped beam is split into its diffraction orders,where the two first orders are parallelized and guided into a galvanometer scanner.The deflected beams inside the scan head are recombined with an F-theta objective on the working position generating the interference pattern.The DLIP spot has a line-like interference pattern with about 15μm spatial period.Laser fluences of up to 8 J cm^(-2) were achieved using a maximum pulse energy of 0.6 mJ.Furthermore,an in-house built roll-to-roll machine was developed.Using this setup,aluminum and copper foil of 20μm and 9μm thickness,respectively,could be processed.Subsequently to current collector structuring coating of composite electrode material took place.In case of lithium nickel manganese cobalt oxide(NMC 622)cathode deposited onto textured aluminum current collector,an increased specific discharge capacity could be achieved at a C-rate of 1℃.For the silicon/graphite anode material deposited onto textured copper current collector,an improved rate capability at all C-rates between C/10 and 5℃ was achieved.The rate capability was increased up to 100%compared to reference material.At C-rates between C/2 and 2℃,the specific discharge capacity was increased to 200 mAh g^(-1),while the reference electrodes with untextured current collector foils provided a specific discharge capacity of 100 m Ah g^(-1),showing the potential of the DLIP technology for cost-effective production of battery cells with increased cycle lifetime.

Impressive strides in amelioration of corrosion behavior of Mg-based alloys through the PEO process combined with surface laser process: A review

The unsatisfactory corrosion properties of Mg-based alloys pose a significant obstacle to their widespread application. Plasma electrolytic oxidation(PEO) is a prevalent and effective coating method that produces a ceramic-like oxide coating on the surface of Mg-based alloys,enhancing their resistance to corrosion. Research has demonstrated that PEO treatment can substantially improve the corrosion performance of alloys based on magnesium in the short term. In an effort to enhance the corrosion resistance of PEO coatings over an extended period of time, researchers have turned their attention to the use of laser processes as both pre-and post-treatments in conjunction with the PEO process. Various laser processes, such as laser shock melting(LSM), laser shock adhesion(LSA), laser shock texturing(LST), and laser shock peening(LSP), have been investigated for their potential to improve PEO coatings on Mg substrates and their alloys. These laser melting processes can homogenize and alter the microstructure of Mg-based alloys while leaving the bulk material unchanged, thereby modifying the substrate surface. However, the porous and rough structure of PEO coatings, with their open and interconnected pore structure, can reduce their long-term corrosion resistance. As such, various laser processes are well-suited for surface modification of these coatings. This study will first examine the PEO process and the various types of laser processes used in this process, before investigating the corrosion behavior of PEO coatings in conjunction with laser pre-and post-treatment processes.

Fast laser surface texturing of spherical samples to improve the frictional performance of elasto-hydrodynamic lubricated contacts

Textured surfaces offer the potential to promote friction and wear reduction by increasing the hydrodynamic pressure,fluid uptake,or acting as oil or debris reservoirs.However,texturing techniques often require additional manufacturing steps and costs,thus frequently being not economically feasible for real engineering applications.This experimental study aims at applying a fast laser texturing technique on curved surfaces for obtaining superior tribological performances.A femtosecond pulsed laser(Ti:Sapphire)and direct laser interference patterning(with a solid‐state Nd:YAG laser)were used for manufacturing dimple and groove patterns on curved steel surfaces(ball samples).Tribological tests were carried out under elasto‐hydrodynamic lubricated contact conditions varying slide‐roll ratio using a ball‐on‐disk configuration.Furthermore,a specific interferometry technique for rough surfaces was used to measure the film thickness of smooth and textured surfaces.Smooth steel samples were used to obtain data for the reference surface.The results showed that dimples promoted friction reduction(up to 20%)compared to the reference smooth specimens,whereas grooves generally caused less beneficial or detrimental effects.In addition,dimples promoted the formation of full film lubrication conditions at lower speeds.This study demonstrates how fast texturing techniques could potentially be used for improving the tribological performance of bearings as well as other mechanical components utilised in several engineering applications.

Effects of surface texturing on microalgal cell attachment to solid carriers

The objective of this study was to understand the role of surface texturing in microalgal cell attachment to solid surfaces.Two microalgal species,Scenedesmus dimorphus and Nannochloropsis oculata,were studied on solid carriers made of nylon and polycarbonate.Ridge,pillar and groove at micro-scale were engineered on the solid carriers.Cell response to the textured surfaces was separately described by the Cassie and Wenzel models and the contact point theory.Comparison between measured and model-predicted contact angles indicated that the wetting behavior of the textured solid carriers fell into the Wenzel state,which implied that algal cells could fully penetrate into the designed textures,but the adhesion behavior would be dependent on the size and shape of the cell.Experimental results showed that the attachment was preferred when the feature size was close to the diameter of the cell attempting to settle.Larger or smaller feature dimensions had the potential to reduce cellular attachment.The observation was found to qualitatively comply with the contact point theory.