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DOE OSTI2025

Tailoring copper current collector roughness and crystallographic orientation to improve lithium plating

Secondary lithium metal batteries are of great interest due to a high theoretical energy density, but rechargeability is limited by the formation of lithium dendrites that lead to internal short circuits and catastrophic cell failure. Mitigating dendrites through uniform current distribution at the current collector is a promising solution to enabling long cycle life of lithium metal electrodes. Here, the impact of copper crystal orientation and roughness on electrochemically deposited lithium morphology is studied. For 50 cycles, the capacity retention from greatest to least followed polycrystalline copper 95 ± 1 % (MC-PC) ≥ 94.55 ± 0.01 % Cu (110) > 93.0 ± 0.4 % Cu(111) > 75.8 ± 0.1 % Cu(100). Cu(100) performed the worst in all cases with shorts occurring frequently before reaching 50 cycles. Cryo-scanning electron microscopy images showed that after 50 cycles, MC-PC Cu had the best lithium morphology, but at early cycles, Cu(111) formed the densest lithium layer. MC-PC Cu had the most uniform lithium nucleation which may have been caused by increased roughness relative to the single crystal samples. When polycrystalline Cu (F-PC) roughness was systematically controlled, the cumulative Coulombic efficiency increased from about 0.3–0.5 with increasing roughness from an Ra of about 10–40 nm. Lastly, plating rates were studied. Slower rates of 0.25 mA/cm 2 exhibited denser lithium morphology in all cases as compared to 0.5 and 1.0 mA/cm 2 , but the relative porosity of Li deposited on the different current collectors depended on the rate applied.

Copper↗

DOE OSTI2024

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Purpose Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel. Design/methodology/approach A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy. Findings The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm 3 ) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation. Originality/value This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

Engineering↗

DOE OSTI2024

Optimizing Aluminum Bonding: Exploring Surface Roughness and Contact Angle Effects through Plasma and Acid Etching Contrasts

The use of adhesives to replace traditional techniques like welding and riveting has been on the rise in various industries as increasingly complex geometries and situations for bonding is required. It’s well known in the scientific community that an adhesive bond is only as efficient as the surface preparation used beforehand. Plasma treatments have been shown to gently clean the surface by only removing the top-most layer from the adherend and “charging” the surface instead of berating it. Whereas chemical treatments “etch” the surface in hopes of increasing surface area by increasing surface roughness. This method can be difficult to control quantitatively and can generate waste leading to serious environmental concerns. This study aims to address the encountered differences between plasma treatments and acid etching on aluminum substrates for adhesive bonding. Treating the surface of adherends plays a crucial role in promoting a good bond between adhesive and adherend. In this study, the effects of plasma and acid treatments are categorized using surface roughness measurements as well as contact angle which have been shown to correlate to mechanical strength. When evaluating different surface treatments, it is notable to mention that not only surface roughness and contact angle play a role in determining which method is most effective but also the consequences of the treatment itself. It was found that although chemical etching was the most effective in increasing roughness and decreasing contact angle, it generates a large amount of waste and is not sustainable compared to plasma work which uses a renewable process. The results from this work provide a deeper understanding of the relationship between surface treatments and surface roughness/contact angle and how this relates to a stronger adhesive bond.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Optimizing Aluminum Bonding: Exploring Surface Roughness and Contact Angle Effects through Plasma and Acid Etching Contrasts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Characterizing Stress Roughness at Utah FORGE Through Simulation of Hydraulic Fracture Growth During 16A Stage 3 Stimulation

In most geologic formations, the vertical gradient of the minimum horizontal stress (𝜎 h ) exceeds the hydrostatic gradient, often driving hydraulic fractures to propagate upward. However, observations indicate that the upward growth of real hydraulic fractures is less pronounced than theoretical predictions based on smoothly varying 𝜎 h fields. In fact, the layered structure of sedimentary rocks hinders fracture propagation across layers, partially explaining the limited height growth observed in practice (Zoback et al., 2022). While crystalline rocks lack the pervasive layered fabric of sedimentary formations, they still possess structural fabric formed over their geologic history, resulting in inherently "rough" in situ stress fields. Recent studies have identified another key factor: the "roughness" of in situ stress, characterized by temporal, relatively short-wavelength fluctuations superimposed on the overall stress gradient. This stress roughness leads to apparent toughness anisotropy, where the vertical toughness appears significantly larger than the horizontal toughness (P. Fu et al., 2019; Dontsov & Suarez-Rivera, 2021). Neglecting the effects of rock fabric and stress roughness can yield inaccurate predictions of hydraulic fracture geometry and growth rates at larger length scales.

58 GEOSCIENCES↗

NASA NTRS1970

Effect of wall roughness on liquid oscillations damping in rectangular tanks

Tests were conducted in two rectangular glass tanks using silicon carbide grit bonded to walls to determine effect of wall roughness for damping liquid oscillations. Tests included effects of roughness height, roughness location, roughness at various values, amplitude decay, Reynolds number, and boundary layer thickness.

Bugg, F. M.↗

NASA NTRS1972

Surface roughness effects on bidirectional reflectance

An experimental study of surface roughness effects on bidirectional reflectance of metallic surfaces is presented. A facility capable of irradiating a sample from normal to grazing incidence and recording plane of incidence bidirectional reflectance measurements was developed. Samples consisting of glass, aluminum alloy, and stainless steel materials were selected for examination. Samples were roughened using standard grinding techniques and coated with a radiatively opaque layer of pure aluminum. Mechanical surface roughness parameters, rms heights and rms slopes, evaluated from digitized surface profile measurements are less than 1.0 micrometers and 0.28, respectively. Rough surface specular, bidirectional, and directional reflectance measurements for selected values of polar angle of incidence and wavelength of incident energy within the spectral range of 1 to 14 micrometers are reported. The Beckmann bidirectional reflectance model is compared with reflectance measurements to establish its usefulness in describing the magnitude and spatial distribution of energy reflected from rough surfaces.

Smith, T. F.↗

NASA NTRS1973

Surface roughness effects on bidirectional reflectance.

An experimental study of surface roughness effects on bidirectional reflectance of metallic surfaces is presented. Samples consisting of glass, aluminum alloy, and stainless steel materials were roughened using standard grinding techniques and coated with a radiatively opaque layer of pure aluminum. Surface roughness parameters, rms height and rms slope, were evaluated from digitized surface profile measurements and are less than 1.0 micron, and 0.28, respectively. Rough-surface specular, bidirectional, and directional reflectance measurements for selected values of polar angle and wavelength of incident energy within the range from 10 to 80 deg and from 1 to 14 microns, respectively, are reported. The influence of surface roughness is discussed in terms of rms height and rms slope.

Smith, T. F.↗

NASA NTRS1981

Effect of Surface Roughness on Hydrodynamic Bearings

A theoretical analysis on the performance of hydrodynamic oil bearings is made considering surface roughness effect. The hydrodynamic as well as asperity contact load is found. The contact pressure was calculated with the assumption that the surface height distribution was Gaussian. The average Reynolds equation of partially lubricated surface was used to calculate hydrodynamic load. An analytical expression for average gap was found and was introduced to modify the average Reynolds equation. The resulting boundary value problem was then solved numerically by finite difference methods using the method of successive over relaxation. The pressure distribution and hydrodynamic load capacity of plane slider and journal bearings were calculated for various design data. The effects of attitude and roughness of surface on the bearing performance were shown. The results are compared with similar available solution of rough surface bearings. It is shown that: (1) the contribution of contact load is not significant; and (2) the hydrodynamic and contact load increase with surface roughness.

Majumdar, B. C.↗

NASA NTRS1982

Microwave emissions from soils with rough surfaces

The effect of surface roughness on the thermal microwave emission of soils has been studied with the Kirchoff approach. A model is presented that includes both the coherent and incoherent reflectivities of the rough surface. It is demonstrated that both the coherent and incoherent terms must be included in order for theoretical computations to provide good agreement with the experimental data, especially for wet soil, where surface roughness causes a dramatic increase in brightness temperature. In addition, the model including both the coherent and incoherent terms allows one to use the physically measured surface height deviations of the rough surface in the model. Previous models have required that an effective height, not equal to the actual surface height measurements, be used in order for theoretical computations to match measurements.

Tsang, L.↗

NASA NTRS1983

Effects of a rough boundary surface on polarization of the scattered field from an inhomogeneous medium

A combination of the standard Kirchhoff method for rough surface scattering with the Rayleigh phase function radiative transfer method for volume scattering is employed in the present study of the effect of surface roughness on the polarization of the scattered field. It is found that for pure surface scattering, the polarization ratio between zero and 20 deg incidence angles is sensitive to surface roughness change. When both surface and volume scattering are present, however, copolarization nulls by colatitude or degree of polarization at zero to 15 deg incidence angle, and copolarization or crosspolarization nulls by longitude at large incidence angles, are better indicators of surface roughness changes. It is noted that degree of polarization and copolarization nulls by colatitude vary monotonously with incidence angle, while in combined surface and volume scattering these have, respectively, a minimum and a maximum. This characteristic allows the separation of combined surface and volume scattering from pure surface or volume scattering.

Fung, A. K.↗

NASA NTRS1984

Bidirectional reflectance spectroscopy. III - Correction for macroscopic roughness

A mathematically rigorous formalism is derived by which an arbitrary photometric function for the bidirectional reflectance of a smooth surface may be corrected to include effects of general macroscopic roughness. The correction involves only one arbitrary parameter, the mean slope angle, and is applicable to surfaces of any albedo. Using physically reasonable assumptions and mathematical approximations, the correction expressions are evaluated analytically to second order in the mean slope angle. The correction is applied to the bidirectional-reflectance function of Hapke (1981). Expressions for both the differential and integral brightnesses are obtained. Photometric profiles on hypothetical smooth and rough planets of low and high albedo are shown to illustrate the effects of macroscopic roughness. The theory is applied to observations of Mercury and predicts the integral phase function, the apparent polar darkening, and the lack of limb brightness surge on the planet. The roughness-corrected bidirectional-reflectance function is sufficiently simple that it can be conveniently evaluated on a programmable hand-held calculator.

Hapke, B.↗

NASA NTRS1983

Quantitative comparisons of radar image, scatterometer, and surface roughness data from Pisgah Crater, CA

The relationships between radar image brightness and backscatter coefficient, between the backscatter coefficient and surface roughness, and between surface roughness and geology, must be established in order to satisfy criteria for the quantitative use of radar images. Attention is presently given to the merits of calibrated radar images and scatterometers as sources of the backscatter coefficient, theories that yield the coefficient on the basis of known surface roughness (and vice versa), and the geologic interpretation of surface roughness and backscatter signatures. These considerations are discussed in the case of the Pisgah Crater and lava field in the Mojave Desert of California.

Farr, T. G.↗

NASA NTRS1985

The influence of surface roughness of deserts on the July circulation - A numerical study

The effect of the low surface roughness characteristics of deserts on atmospheric circulation in July is examined using numerical simulations with the GCM of the Goddard Laboratory for Atmospheric Science (GLAS). Identical sets of simulations were carried out with the model starting from the initial state of the atmosphere on June 15, for the years 1979 and 1980. The first simulation included a surface roughness factor of 45 cm, and the second set had a surface roughness factor of 0.02 cm for desert regions, and 45 cm for all other land. A comparative analysis of the numerical data was carried out in order to study the variations for the desert regions. It is shown that rainfall in the Sahara desert was reduced significantly in the data set with the nonuniform surface roughness factor in comparison with the other data set. The inter-tropical convergence zone (ITCZ) moved southward to about 15 degrees, which was close to its observed location at about 10 degrees N. In other deserts, the North American Great Plains, Rajputana in India, and the Central Asian desert, no similar changes were observed. Detailed contour maps of the weather conditions in the different desert regions are provided.

Sud, Y. C.↗

NASA NTRS1986

The SIR-B observations of microwave backscatter dependence on soil moisture, surface roughness, and vegetation covers

An experiment was conducted from an L-band SAR aboard Space Shuttle Challenger in October 1984 to study the microwave backscatter dependence on soil moisture, surface roughness, and vegetation cover. The results based on the analyses of an image obtained at 21-deg incidence angle show a positive correlatlion between scattering coefficient and soil moisture content, with a sensitivity comparable to that derived from the ground radar measurements reported by Ulaby et al. (1978). The surface roughness strongly affects the microwave backscatter. A factor of two change in the standard deviation of surface roughness height gives a corresponding change of about 8 dB in the scattering coefficient. The microwave backscatter also depends on the vegetation types. Under the dry soil conditions, the scattering coefficient is observed to change from about -24 dB for an alfalfa or lettuce field to about -17 dB for a mature corn field. These results suggest that observations with a SAR system of multiple frequencies and polarizations are required to unravel the effects of soil moisture, surface roughness, and vegetation cover.

Wang, J. R.↗

NASA NTRS1988

Rotating disk transition due to isolated roughness with intense acoustic irradiation

The low transition Reynolds numbers associated with boundary-layers which exhibit crossflow instability have made them an important area of study in fluid mechanics. An excellent test bed for the study of this flow is a flat disk rotating in still fluid. An experimental investigation of stability and transition of a rotating disk boundary-layer has been conducted. The effects of isolated roughness elements and acoustic forcing, both alone and in combination, were considered. The flow showed no receptivity to intense monochromatic acoustic forcing except in the presence of sizable roughness. A case was investigated where the growth of the primary instability, seeded by an isolated roughness element, was positively altered in the presence of sound, leading to a downstream movement of transition. In agreement with the work of several investigators, the results of this study suggest that receptivity to long wavelength phenomena, such as traveling sound waves, is contingent upon the presence of strong localized pressure gradients (such as those introduced by roughness) to reduce the length scales of the disturbance to those which are consistent with unstable wavelengths in the flow field.

Waitz, Ian A.↗

NASA NTRS1989

Modeling of surface roughness effects on glaze ice accretion

The cause and effects of roughness on accreting glaze ice surfaces were studied with microvideo observations. Distinct zones of surface water behavior were observed, including a smooth wet zone in the stagnation region with a uniform water film, a rough zone where surface tension effects caused coalescence of surface water into stationary beads, and a zone where roughness elements grow into horn shapes. In addition, a zone where surface water ran back as rivulets and a dry zone where rime feathers formed were observed. The locations and behaviors of these zones are discussed. A simple multizone modification to the glaze ice accretion model is proposed to include spatial variability in surface roughness. Two test cases using the multizone model showed significant improvements for the prediction of glaze ice shapes.

Hansman, R. John, Jr.↗

NASA NTRS1990

The effect of small-scale roughness on the main flow profile of a laminar boundary layer

The profile distortion due to a single roughness element, to two such elements, and to many elements is investigated. Signal-averaging of the velocity difference due to the roughness being alternately present or absent is employed in order to improve accuracy. The primary objective of examining the distributed-roughness profiles for any evidence of instability-enhancing form is not met, but the results are reconsidered, and relevant hypotheses and suggestions are presented. It is noted that the reason for not meeting the objective of estimating Tollmien-Schlichting amplification from rough-wall profiles is that much of the distortion occurs close to the wall and below the element tops.

Kendall, James M., Jr.↗