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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

On the Counter‐intuitive Heterogeneous Electron Transfer Barrier Properties of Alkanethiolate Monolayers on Gold: Smooth versus Rough Surfaces

Abstract Alkanethiolate monolayers formed on rough gold surfaces can, somewhat surprisingly, act as stronger barriers to heterogeneous electron transfer than those on smooth gold surfaces. This paper presents a possible explanation for this observation by constructing simple geometric models of a “rough” and “smooth” gold surface to examine how microscopic roughness differences can affect the nucleation/growth of the adlayer and size/density of structural defects. Expectedly, the number of defects predicted for adlayers formed on smooth gold is lower than any of those for rough gold. The counter‐intuitive result is that the sizes of a small portion of the defects in the adlayer on the smooth surface are larger than any of those found on the rough surface. The potential implications of these results are discussed.

Chemistry↗
DOE OSTI2022

Microstructure-Sensitive modeling of surface roughness and notch effects on extreme value fatigue response

Fatigue life knockdown due to surface roughness induces local stress concentrations. Physical fatigue experiments are crucial to qualify materials for use but are limited in their capability to examine the mechanisms underlying the fatigue crack formation driving force due to these stress concentrations. Microstructure-sensitive computational models can aid in this regard and are employed in this work to examine the effects of surface roughness in Al 7075-T6. Digital microstructure models are subjected to crystal plasticity finite element method (CPFEM) simulations to examine the combined effects of microstructure and grain scale asperities on the driving force for fatigue crack formation. Following elastic–plastic shakedown, mesoscale volume-averaged fatigue indicator parameters (FIPs) are computed within fatigue damage process zones of grains. An increase in the intensity of realistic surface roughness profiles corresponds accordingly to larger FIPs but it is difficult to precisely interpret the mechanisms and effects of this intensification. We thus parametrically investigate surface asperities that couple with microstructure and lack of constraint on slip at the free surface to describe microstructure-sensitive surface roughness knockdown effects on fatigue resistance. The depth of a single valley (i.e., notch) due to surface roughness is found to be more detrimental to fatigue resistance than the radius (i.e., notch width, not to be confused with notch acuity). Finally, we also find that different crystallographic textures, grain morphologies, and number of sampled grains have a limited effect on the depth of influence of these notches.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Planarization of Rough (100) GaAs Substrates via Growth by Hydride Vapor Phase Epitaxy

Wafer reuse techniques help offset the cost of III-V growth substrates by using a single wafer for multiple growths, but costly re-polishing after device removal limits the end benefit. In this work, we present planarization growth by hydride vapor-phase epitaxy (HVPE), a potentially low-cost growth technique, as a method of smoothing rough substrates for subsequent high-quality device growth without the need for polishing. First, we show there is a threshold for allowable substrate roughness without device degradation by comparing devices grown by organometallic vapor-phase epitaxy (OMVPE) on epi-ready polished and pre-polished substrates that did not have the final epi-ready polish. We then demonstrate successful smoothing with HVPE growth on substrates with different surface morphologies, with features ranging from general roughness to large facets. Initial devices grown by HVPE on a pre-polished substate showed no degradation compared to a control wafer, indicating that planarizing rough substrates through HVPE growth is a promising path toward being able to use rough substrates directly for growth, without costly polishing steps.

GaAs↗
DOE OSTI2020

Tailoring Surface Roughness Using Additive Manufacturing to Improve Internal Cooling

Abstract Surface roughness present on internal cooling channels produced with additive manufacturing has been previously shown to augment heat transfer and pressure loss to levels similar to traditionally cast turbulators. Given the ability of the surface roughness to improve the cooling performance of small cooling channels, the question arises on whether there is an optimal combination of random roughness features to maximize internal cooling performance. To investigate this question, test coupons with different surface roughness morphologies and magnitudes were manufactured by manipulating the parameters in the laser powder bed fusion additive manufacturing process. The coupons were tested to characterize the friction factor and Nusselt number of the cooling channels over a range of Reynolds numbers. Results showed that certain roughness combinations outperformed others, increasing the internal cooling performance of the channels. Additionally, manipulation of the performance using the process parameters allowed for reductions in build time, which could be useful for controlling component cost.

Engineering↗
DOE OSTI2022

Impacts of the Additive Manufacturing Process on the Roughness of Engine Scale Vanes and Cooling Channels

Abstract By leveraging the additive manufacturing (AM) platform, development time and costs for turbine component testing can be reduced relative to traditional investment casting. Surface roughness is a key characteristic of the additive manufacturing process that can impact flow, heat transfer, and mechanical integrity of printed components. There are multiple design and build considerations that result in variability in surface roughness, especially when additively fabricating complicated three-dimensional vanes and internal cooling passages. This study characterizes the surface roughness of internal cooling passages, vanes, and flat external surface samples made using additive manufacturing, specifically the direct metal laser sintering process. The samples were manufactured with various wall thicknesses, layer thicknesses, build locations, build directions, and on different AM machines. A combination of computed tomography scanning and optical profilometry was used to evaluate surface roughness levels. The data indicate that the dominant factors in roughness for a given layer thickness are a function of wall thickness, build location, and build direction.

Engineering↗
DOE OSTI2020

The emergence of small-scale self-affine surface roughness from deformation

Most natural and man-made surfaces appear to be rough on many length scales. There is presently no unifying theory of the origin of roughness or the self-affine nature of surface topography. One likely contributor to the formation of roughness is deformation, which underlies many processes that shape surfaces such as machining, fracture, and wear. Using molecular dynamics, we simulate the biaxial compression of single-crystal Au, the high-entropy alloy Ni 36.67 Co 30 Fe 16.67 Ti 16.67 , and amorphous Cu 50 Zr 50 and show that even surfaces of homogeneous materials develop a self-affine structure. By characterizing subsurface deformation, we connect the self-affinity of the surface to the spatial correlation of deformation events occurring within the bulk and present scaling relations for the evolution of roughness with strain. These results open routes toward interpreting and engineering roughness profiles.

42 ENGINEERING↗
DOE OSTI2023

SURFACE ROUGHNESS REDUCTION AND PERFORMANCE OF Nb3Sn FILM FOR SRF APPLICATIONS

Nb3Sn offers better RF performance (Q and Eacc) than Nb at any given temperature because of its superior superconducting properties. The potential deployment of Nb3Sn-coated SRF cavities at 4 K, delivering similar performance to that of Nb cavities at 2 K, will be a transformational technology to enable new classes of SRF accelerator applications. A clean and smooth surface can enhance the performance of the Nb3Sn-coated cavity, typically, the attainable acceleration gradient. The reduction of surface roughness is often linked with a correlative reduction in average coating thickness and grain size. A new approach to enhance the nucleation centers using the pre-deposition of Sn on Nb is introduced for surface roughness reduction. Besides Sn supply's careful tuning, the temperature profiles were varied to engineer the coating surface with reduced roughness as low as ~40 nm in 20 µm × 20 µm AFM scans, one-third that of the typical coating. Electropolishing of coated sample shows surface a clear surface smoothening. A few sets of coating parameters were used to coat 1.3 GHz sin-gle-cell cavities to understand the effects of roughness variation on the RF performance. This presentation discusses ways to reduce surface roughness with results from a systematic analysis of the samples and Nb3Sn-coated single-cell cavities.

Pudasaini, Uttar↗
DOE OSTI2023

SURFACE ROUGHNESS REDUCTION AND PERFORMANCE OF Nb3Sn FILM FOR SRF APPLICATIONS

Nb3Sn offers better RF performance (Q and Eacc) than Nb at any given temperature because of its superior superconducting properties. The potential deployment of Nb3Sn-coated SRF cavities at 4 K, delivering similar performance to that of Nb cavities at 2 K, will be a transformational technology to enable new classes of SRF accelerator applications. A clean and smooth surface can enhance the performance of the Nb3Sn-coated cavity, typically, the attainable acceleration gradient. The reduction of surface roughness is often linked with a correlative reduction in average coating thickness and grain size. A new approach to enhance the nucleation centers using the pre-deposition of Sn on Nb is introduced for surface roughness reduction. Besides Sn supply's careful tuning, the temperature profiles were varied to engineer the coating surface with reduced roughness as low as ~40 nm in 20 µm × 20 µm AFM scans, one-third that of the typical coating. Electropolishing of coated sample shows surface a clear surface smoothening. A few sets of coating parameters were used to coat 1.3 GHz sin-gle-cell cavities to understand the effects of roughness variation on the RF performance. This presentation discusses ways to reduce surface roughness with results from a systematic analysis of the samples and Nb3Sn-coated single-cell cavities.

Pudasaini, Uttar↗
NASA NTRS1976

Influence of surface roughness and waviness on film thickness and pressure distribution in elastohydrodynamic contacts

The Christensen theory of a stochastic model for hydrodynamic lubrication of rough surfaces was extended to elastohydrodynamic lubrication between two rollers. Solutions for the reduced pressure at the entrance as a function of the ratio of the average nominal film thickness to the rms surface roughness, were obtained numerically. Results were obtained for purely transverse as well as purely longitudinal surface roughness for cases with or without slip. The reduced pressure was shown to decrease slightly by considering longitudinal surface roughness. The same approach was used to study the effect of surface roughness on lubrication between rigid rollers and lubrication of an infinitely wide slider bearing. Using the flow balance concept, the perturbed Reynolds equation, was derived and solved for the perturbed pressure distribution. In addition, Cheng's numerical scheme was modified to incorporate a single two-dimensional elastic asperity on the stationary surface. The perturbed pressures obtained by these three different models were compared.

Chow, L. S. H.↗
NASA NTRS1978

Effect of surface roughness on the microwave emission from soils

The effect of surface roughness on the brightness temperature of a moist terrain was studied through the modification of Fresnel reflection coefficient and using the radiative transfer equation. The modification involves introduction of a single parameter to characterize the roughness. It is shown that this parameter depends on both the surface height variance and the horizontal scale of the roughness. Model calculations are in good quantitative agreement with the observed dependence of the brightness temperature on the moisture content in the surface layer. Data from truck mounted and airborne radiometers are presented for comparison. The results indicate that the roughness effects are greatest for wet soils where the difference between smooth and rough surfaces can be as great as 50K.

Choudhury, B. J.↗
NASA NTRS1979

Effect of surface roughness on the microwave emission from soils

The effect of surface roughness on the brightness temperature of a moist terrain has been studied through the modification of Fresnel reflection coefficient and using the radiative transfer equation. The modification involves introduction of a single parameter to characterize the roughness. It is shown that this parameter depends on both the surface height variance and the horizontal scale of the roughness. Model calculations are in good quantitative agreement with the observed dependence of the brightness temperature on the moisture content in the surface layer. Data from truck mounted and airborne radiometers are presented for comparison. The results indicate that the roughness effects are great for wet soils where the difference between smooth and rough surfaces can be as great as 50 K.

Choudhury, B. J.↗
NASA NTRS1982

Turbulent boundary layer over solid and porous surfaces with small roughness

Skin friction and profiles of mean velocity, axial and normal turbulence intensity, and Reynolds stress in the untripped boundary layer were measured directly on a large diameter, axisymmetric body with: (1) a smooth, solid surface; (2) a sandpaper-roughened, solid surface; (3) a sintered metal, porous surface; (4) a smooth, perforated titanium surface; (5) a rough solid surface made of fine, diffusion bonded screening, and (6) a rough, porous surface of the same screening. Results obtained for each of these surfaces are discussed. It is shown that a rough, porous wall simply does not influence the boundary layer in the same way as a rough solid wall. Therefore, turbulent transport models for boundary layers over porous surfaces either with or without injection or suction, must include both surface roughness and porosity effects.

Kong, F. Y.↗
NASA NTRS1981

Effect of surface roughness on elastohydrodynamic line contact

A numerical solution of an elastohydrodynamic lubrication (EHL) contact between two long rough surface cylinders is obtained. A simultaneous solution of an elasticity equation and the Reynolds equation for two partially lubricated rough surfaces is used to obtain a theoretical solution of pressure distribution, elastohydrodynamic load and film thicknesses for given speeds. A theoretical solution is also found for lubricants with pressure dependent viscosity, material properties of cylinders, and surface roughness parameters. Elastic deformation is found from hydrodynamic and contact pressure using plane strain analysis, and results indicate that for a constant central film thickness, increasing the surface roughness decreases the EHL load and there is little variation in minimum film thicknesses as the surface roughness is increased.

Majumdar, B. C.↗
NASA NTRS1985

Calculations of microwave brightness temperature of rough soil surfaces: Bare field

A model for simulating the brightness temperatures of soils with rough surfaces is developed. The surface emissivity of the soil media is obtained by the integration of the bistatic scattering coefficients for rough surfaces. The roughness of a soil surface is characterized by two parameters, the surface height standard deviation sigma and its horizontal correlation length l. The model calculations are compared to the measured angular variations of the polarized brightness temperatures at both 1.4 GHz and 5 GHz frequences. A nonlinear least-squares fitting method is used to obtain the values of delta and l that best characterize the surface roughness. The effect of shadowing is incorporated by introducing a function S(theta), which represents the probability that a point on a rough surface is not shadowed by other parts of the surface. The model results for the horizontal polarization are in excellent agreement with the data. However, for the vertical polarization, some discrepancies exist between the calculations and data, particularly at the 1.4 GHz frequency. Possible causes of the discrepancy are discussed.

Mo, T.↗
NASA NTRS1986

Surface roughness studies for wind tunnel models used in high Reynolds number testing

This paper focuses on stylus and optical techniques for the measurement of surface roughness in wind tunnel models. The stylus instruments provide detailed information, such as surface profiles and area maps, that may then be used either to calculate statistical properties (i.e., the rms surface roughness) or to study individual surface peaks or other features. By contrast, certain optical techniques yield area-averaged statistical properties of the surface roughness directly. Two instruments that use the technique of optical angular scattering are compared. One is a research instrument that has been developed to study the basic scattering phenomena by testing the optical theories and surface models used in inverse calculations of statistical roughness parameters. The second instrument is more compact and is under development as a hand held, on-line device to be used during manufacture of wind tunnel models for the National Transonic Facility at NASA Langley Research Center. The scattering geometries for the two instruments are compared and results from these instruments and the stylus technique are shown for roughness specimens that are typical of the surface finish of wind tunnel models.

Vorburger, T. V.↗
NASA NTRS1985

Calculations of microwave brightness temperature of rough soil surfaces

A model for simulating the brightness temperatures of soils with rough surfaces is developed. The surface emissivity of the soil media is obtained by the integration of the bistatic scattering coefficients for rough surfaces. The roughness of a soil surface is characterized by two parameters, the surface height standard deviation sigma and its horizontal correlation length l. The model calculations are compared to the measured angular variations of the polarized brightness temperatures at both 1.4 GHz and 5 GHz frequencies. A nonlinear least-squares fitting method is used to obtain the values of delta and l that best characterize the surface roughness. The effect of shadowing is incorporated by introducing a function S(theta), which represents the probability that a point on a rough surface is not shadowed by other parts of the surface. The model results for the horizontal polarization are in excellent agreement with the data. However, for the vertical polarization, some discrepancies exist between the calculations and data, particularly at the 1.4 GHz frequency. Possible causes of the discrepancy are discussed.

Mo, T.↗
NASA NTRS1988

Structure of rough-wall turbulent boundary layers

Recent experiments have shown that, in rough-wall turbulent boundary layers, drag varies systematically with the spanwise aspect ratio lambda(z) (span/height) of roughness elements. In this paper, the effect of lambda(z) on turbulence structure has been examined. Based on lambda(z), the roughness in a transversely grooved surface with lambda(z) much greater than 1 is the opposite extreme of model plant canopies with lambda(z) much less than 1, studied in wind tunnels, whereas sandgrain is an intermediate type. Second-, third-, and fourth-order turbulence moments have been measured in turbulent boundary layers over transversely grooved and smooth surfaces and compared with available turbulence structure measurements over other types of surfaces. The near-wall turbulence structure is found to vary with lambda(z). The instantaneous motions involved in the flux of shear stress near the wall in smooth and transversely grooved surfaces are opposite in sign to those in three-dimensional roughness. The former is explained in terms of hairpin vortices alone, while the latter group is modeled to have an additional vortex (the so-called necklace vortex which straddles a three-dimensional roughness element near its base).

Bandyopadhyay, Promode R.↗
NASA NTRS1991

Two-dimensional Navier-Stokes heat transfer analysis for rough turbine blades

A quasi-three-dimensional thin-layer Navier-Stokes analysis was used to predict heat transfer to rough surfaces. Comparisons are made between predicted and experimental heat transfer for turbine blades and flat plates of known roughness. The effect of surface roughness on heat transfer was modeled using a mixing length approach. The effect of near-wall grid spacing and convergence criteria on the accuracy of the heat transfer predictions are examined. An eddy viscosity mixing length model having an inner and outer layer was used. A discussion of the appropriate model for the crossover between the inner and outer layers is included. The analytic results are compared with experimental data for both flat plates and turbine blade geometries. Comparisons between predicted and experimental heat transfer showed that a modeling roughness effects using a modified mixing length approach results in good predictions of the trends in heat transfer due to roughness.

Boyle, R. J.↗