Metal additive manufacturing surface topographies are complex and challenging to characterise due to e.g. steep local slopes, re-entrant features, varying reflectivity and features of interest in vastly different scale ranges. Nevertheless, average height parameters such as Ra or Sa are commonly used as sole parameters for characterisation. In this paper, a novel method for selecting relevant parameters for evaluation is proposed and demonstrated using a case study where the smoothing effects after three processing steps of the electro chemical post-process Hirtisation of a metal AM surface are quantified. The method uses a combination of conventional areal texture parameters, multiscale analysis and statistics and can be used to efficiently achieve a detailed and more relevant surface topography characterisation. It was found that the three process steps have different effects on the surface topography regarding the types and sizes of features that were affected. In total, Sdq was reduced by 97 %, S5v was reduced by 81 % and Sa was reduced by 78 %. A surface texture with much lower average roughness, less deep pits and less steep slopes was produced, which is expected to be beneficial for improved fatigue properties.

In the field of tissue engineering, synthetic and degradable polyesters like poly(ε-caprolactone) (PCL) and poly(ε-caprolactone-co-p-dioxanone) (PCLDX) are widely used as scaffolds. Our previous research revealed that thermal storage conditions could alter the surface texture of PCL and PCLDX scaffolds, which might influence cell-scaffold interactions in tissue engineering applications. These findings highlighted the importance of multi-scale characterization techniques to identify the scales most sensitive to external changes and the need for personalized surface texture analysis. Sterilization techniques, such as ethylene oxide and gamma radiation, are essential for ensuring the sterility of polymeric medical devices. However, these processes can significantly impact the bulk polymer properties and/or surface texture of the scaffolds, potentially affecting their biocompatibility, safety, and overall performance. Therefore, the influence of sterilization processes on the surface texture of PCLDX films and electrospun nanofibers and to correlate these findings with the thermal and physical properties of the polymer are essential and have been assessed. Our results demonstrated that ethylene oxide maintained the structural integrity and surface texture of PCLDX scaffolds, while gamma irradiation caused a significant reduction in molar mass and increased the number of hills (Shn) and dales (Sdn) on PCLDX samples. Despite these changes, both sterilization methods showed minimal effects on the thermal properties, such as melting temperature and degree of crystallinity, and surface wettability of the scaffolds. This comprehensive surface texture analysis highlights the importance of evaluating feature parameters such as Shn and Sdn for optimizing the performance and biocompatibility of polymeric scaffolds in tissue engineering. 

Layer removal with electropolishing is a well-established method when measuring residual stress profiles with lab-XRD. This is done to measure the depth impact from processes such as shot peening, heat treatment, or machining. Electropolishing is used to minimize the influence on the inherent residual stresses of the material during layer removal, performed successively in incremental steps to specific depths followed by measurement. Great control of the material removal is critical for the measured stresses at each depth. Therefore, the selection of size of the measurement spot and electropolishing parameters is essential. The main objective in this work is to investigate how different electrolytes and electropolishing equipment affect the resulting surface roughness, geometry, microstructure, and consequently the measured residual stress. A second objective has been to establish a methodology of assessing the acquired electropolished depth. The aim has been to get a better understanding of the influence of the layer removal method on the accuracy of the acquired depth. Evaluation has been done by electropolishing one ground and one shot peened sample of a low-alloy carbon steel, grade 1.1730, with different methods. The results showed a difference in stresses depending on the electrolyte used where the perchloric acid had better ability to retain the stresses compared to the saturated salt. Electropolishing with saturated salt is fast and results in evenly distributed material removal but has high surface roughness, which is due to a difference in electropolishing of the two phases, ferrite, and pearlite. Perchloric acid electropolishing is slower but generates a smooth surface as both ferrite and pearlite have the same material removal rates but may cause an increased material removal for the center of the electropolished area. In this work, it is suggested to use perchloric acid electropolishing for the final layer removal step. © 2023, The Author(s).

The fast-progressing landscape of the bioprocessing industry emphasizes innovation and efficiency enhancement, propelled by the integration of advanced solutions. Additive manufacturing technologies, particularly laser-based powder bed fusion with polypropylene, are pivotal in this industrial metamorphosis. However, despite the substantial scientific effort in the field, a significant gap exists in comprehending the surface characteristics of new surfaces and their implications for bacterial attachment and biofilm formation. This arises, in part, due to the absence of comprehensive and universally applicable topographical characterization analysis specifically designed for additively manufactured-fabricated surfaces. Typically, researchers tend to rely on the commonly used roughness parameter, Sa, that primarily quantifies the average height variation across a surface. Addressing this limitation is crucial for understanding the connection between surface characteristics and bacterial attachment dynamics. Here, we propose an innovative approach using surface analysis including confocal microscopy, advanced roughness measurements, and multivariate statistical analysis to uncover the connections between bacterial attachment for Gram negative Escherichia coli and Gram positive Staphylococcus aureus in early biofilm formation with surfaces produced by standardized and additively manufactured techniques. Finally, we advocate for the adoption of a set of roughness parameters that specifically describe the dale region of the surfaces. By doing so, we intend to establish direct links between surface texture and bacterial adhesion, thus contributing significantly to the advancement of both bioprocessing and additive manufacturing research domains. 

Milling is traditionally the most used machining method when manufacturing complex gas turbine components. In particular those made from nickel-based superalloys. However, for larger free form surfaces, grinding may be an efficient alternative that could be used throughout the complete manufacturing route, from roughing to finishing. Hence, in this work the two processing methods has been compared in regard to surface integrity and productivity. Machining tests have been performed on case plates of heat-treated Alloy 718 using best practise setting for roughing and finishing with grinding and milling. The surface integrity of the work pieces was evaluated regarding surface topography, residual stresses, and deformation. This comparison showed that the main advantage with grinding is the ability to switch between roughing and finishing by just altering the depth of cut. Further, grinding offers lower surface roughness, compressive residual stresses, and significantly lower degree of deformation. From a productivity perspective, deep grinding may offer high material removal rates and ability to machine several work pieces in the same setup. However, grinding is limited to simpler free form geometries and may result in minor surface damages and abrasive surface residue. For selection of machining strategy, advantages and drawbacks shown in this work need to be considered for the application at hand in respect to productivity, surface integrity and requirements on fatigue life. 

Milling is traditionally the most used machining method when manufacturing complex gas turbine components. In particular those made from nickel-based superalloys. However, for larger free form surfaces, grinding may be an efficient alternative that could be used throughout the complete manufacturing route, from roughing to finishing. Hence, in this work the two processing methods has been compared in regard to surface integrity and productivity. Machining tests have been performed on case plates of heat-treated Alloy 718 using best practise setting for roughing and finishing with grinding and milling. The surface integrity of the work pieces was evaluated regarding surface topography, residual stresses, and deformation. This comparison showed that the main advantage with grinding is the ability to switch between roughing and finishing by just altering the depth of cut. Further, grinding offers lower surface roughness, compressive residual stresses, and significantly lower degree of deformation. From a productivity perspective, deep grinding may offer high material removal rates and ability to machine several work pieces in the same setup. However, grinding is limited to simpler free form geometries and may result in minor surface damages and abrasive surface residue. For selection of machining strategy, advantages and drawbacks shown in this work need to be considered for the application at hand in respect to productivity, surface integrity and requirements on fatigue life.

To address the essential problem in surface metrology of establishing functional correlations spatial, frequencies in topographic measurements are progressively decomposed into a large number of narrow bands. Bandpass filters and commercially available software are used. These bands can be analyzed with conventional surface texture parameters, like average roughness, Sa, or other parameters, for detailed, multiscale topographic characterizations. Earlier kinds of multiscale characterization, like relative area, required specialized software performing multiple triangular tiling exercises. Multiscale regression analyses can test strengths of functional correlations over a range of scales. Here, friction coefficients are regressed against standard surface texture parameters over the range of scales available in a measurement. Correlation strengths trend with the scales of the bandpass filters. Using bandpass frequency, i.e., wavelength or scale, decompositions, the R2 at 25 μm, exceeds 0.9 for Sa compared with an R2 of only 0.2 using the broader band of conventional roughness filtering. These improved, scale-specific functional correlations can facilitate scientific understandings and specifications of topographies in product and process design and in designs of quality assurance systems.

Fused filament fabrication (FFF) is a commonly used method for producing three-dimensional scaffolds using synthetic, degradable polymers. However, there are several variables that must be considered when fabricating devices for clinical use, one of which is storage conditions after printing. While the academic community has examined the impact of FFF on mechanical and thermal properties, there has been less focus on how storage conditions would affect the surface texture of scaffolds. Our hypothesis was that the surface, thermal and physical properties of FFF scaffolds are significantly influenced by the storage conditions. We evaluated the surfaces of FFF poly (ε-caprolactone) (PCL) and poly (ε-caprolactone-co-p-dioxanone) (PCLDX) strands that were stored at 4 °C, 20 °C, and 37 °C for 28 days. We monitored surface texture, physical and thermal changes to understand the effect of storage on the strands. The implementation of scale-sensitive fractal analysis and feature parameters revealed that storage conditions at 37 °C increased the number of hills and dales, as well as the density of peaks and pits compared to 20 °C and 4 °C, for both materials. The feature roughness parameters for PCL had up to 90% higher values than those of PCLDX, which correlated with the physical and thermal properties of the materials. These differences may impact further surface-cell interaction, highlighting the need for further evaluation for faster clinical translation. Our findings emphasize the importance of considering storage conditions in the design and manufacture of FFF scaffolds and suggest that the use of feature roughness parameters could facilitate the optimization and tailoring the surface properties for specific applications. © 2023 The Authors

Additive manufacturing (AM) using powder bed fusion is becoming a mature technology that offers great possibilities and design freedom for manufacturing of near net shape components. However, for many gas turbine and aerospace applications, machining is still required, which motivates further research on the machinability and work piece integrity of additive-manufactured superalloys. In this work, turning tests have been performed on components made with both Powder Bed Fusion for Laser Beam (PBF-LB) and Electron Beam (PBF-EB) in as-built and heat-treated conditions. The two AM processes and the respective heat-treatments have generated different microstructural features that have a great impact on both the tool wear and the work piece surface integrity. The results show that the PBF-EB components have relatively lower geometrical accuracy, a rough surface topography, a coarse microstructure with hard precipitates and low residual stresses after printing. Turning of the PBF-EB material results in high cutting tool wear, which induces moderate tensile surface stresses that are balanced by deep compressive stresses and a superficial deformed surface that is greater for the heat-treated material. In comparison, the PBF-LB components have a higher geometrical accuracy, a relatively smooth topography and a fine microstructure, but with high tensile stresses after printing. Machining of PBF-LB material resulted in higher tool wear for the heat-treated material, increase of 49%, and significantly higher tensile surface stresses followed by shallower compressive stresses below the surface compared to the PBF-EB materials, but with no superficially deformed surface. It is further observed an 87% higher tool wear for PBF-EB in as-built condition and 43% in the heat-treated condition compared to the PBF-LB material. These results show that the selection of cutting tools and cutting settings are critical, which requires the development of suitable machining parameters that are designed for the microstructure of the material.

In order to improve efficiency when manufacturing gas turbine components, alternative machining techniques need to be explored. In this work, abrasive water jet (AWJ) machining by milling has been investigated as an alternative to traditional milling. Various test campaigns have been conducted to show different aspects of using AWJ milling for the machining of superalloys, such as alloy 718. The test campaigns span from studies of individual AWJ-milled tracks, multi-pass tracks, and the machining of larger components and features with complex geometry. In regard to material removal rates, these studies show that AWJ milling is able to compete with traditional semi/finish milling but may not reach as high an MRR as rough milling when machining in alloy 718. However, AWJ milling requires post-processing which decreases the total MRR. It has been shown that a strong advantage with AWJ milling is to manufacture difficult geometries such as narrow radii, holes, or sharp transitions with kept material removal rates and low impact on the surface integrity of the cut surface. Additionally, abrasive water jet machining (AWJM) offers a range of machining possibilities as it can alter between cutting through and milling. The surface integrity of the AWJM surface is also advantageous as it introduces compressive residual stress but may require post-processing to meet similar surface roughness levels as traditional milling and to remove unwanted AWJM particles from the machined surface. © 2022 by the authors.