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2024 | Buch

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Component Surfaces

Manufacturing-Morphology-Property Relationships

herausgegeben von: Jan C. Aurich, Hans Hasse

Verlag: Springer International Publishing

Buchreihe : Springer Series in Advanced Manufacturing

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

This book sheds new light on component surfaces and the scientific fundamentals of their creation, characterization, and application. The book also provides a new interdisciplinary perspective on the topic, studying component surfaces with a multiscale approach and linking fundamental and applied research. The book builds on the success of the coordinated research project funded by Deutsche Forschungsgemeinschaft (DFG) from 2011 – 2023: the CollaborativeResearch Center CRC 926 “Microscale Morphology of Component Surfaces (MI-COS)”, in which, over the years, 100+ researchers have co-operated at the University of Kaiserslautern, Germany, and affiliated institutes, yielding 500+ scientific papers in journals from different fields of science and engineering.

Divided into 2 main parts, the book starts with an introduction to the concept of Manufacturing-Morphology-Property (MMP) Relationships and dives into the fundamentals and technologies, including topics such as the geometrical, microstructural, and chemical characterization, indentation, and scratching on the nanoscale, micro milling and micro grinding, cryogenic machining, cold spraying, and additive manufacturing. In the first part, readers discover more about the interactions between particles and surfaces, the interrelationship of manufacturing, surface morphology and properties of titanium, the influence of manufacturing and load conditions on the phase transformation and fatigue of austenitic stainless steels, and the influence of surface morphology on fatigue and tribological behavior of Transformation-Induced-Plasticity (TRIP)/Twinning-Induced Plasticity (TWIP) Steels. The second part of this book is devoted to the applications of component surfaces, covering topics like the manufacturing of areal material measures, MMP relationships for rotating shaft sealing systems, the influence of the surface morphology on rolling bearing life under mixed lubrication, MMP relationships for chain joints, and MMP for biofilms.

Scientists and engineers who deal with the influence of surfaces on macroscopic properties of components and who are interested in designing and manufacturing these surfaces to obtain desired component properties will understand the appeal of this work. Given its interdisciplinary breadth, the book also appeals to scholars and professionals in the fields of mechanical engineering, process engineering, and physics.

Inhaltsverzeichnis

Frontmatter

Manufacturing–Morphology–Property (MMP) Relationships: Concept and Application to Component Surfaces

Abstract

Manufacturing–Morphology–Property Relationships (MMP) is a broadly applicable concept that has been pioneered, applied, and successfully validated in the research carried out in CRC 926. MMPs combine the complex relationships between the component manufacturing, the component’s morphology, and the component’s behavior into a single coherent concept. Hereby, they address two fundamental problems of mechanical engineering: How can a component with desired properties be designed, and how can it be manufactured?

Jan C. Aurich, Hans Hasse

Fundamentals and Technologies

Frontmatter

Geometrical, Microstructural, and Chemical Characterization

Abstract

The chapter presents work on the geometric, structural, and chemical analysis of microscale surface structures. In the first part, the focus is on the technical and methodological developments themselves. Techniques as well as technical and methodological developments for the geometric characterization of surfaces, including the associated measuring instruments, data evaluation, and the characterization methods, are discussed. Furthermore, some special methods for the microstructural analysis of surface morphologies, in particular, with optical methods and by means of X-ray diffraction, are presented. The second part of this chapter deals with the application of microscopic, spectroscopic, and mass spectrometric techniques to characterize surfaces subjected to friction and wear. It is shown which information can be obtained with the methods mentioned and it is shown exemplarily how, on the one hand, technologies that have been developed for analysis can be used to generate defined surface structures. On the other hand, special microscopic surface structures have been developed that can also be used beneficially for the investigation of tribological processes.

Michael Kopnarski, Tilmann Beck, Stella Diederichs, Eberhard Kerscher, Jörg Seewig, Marek Smaga

Indentation and Scratching on the Nanoscale

Abstract

Indentation and scratching of Fe, as a model of ferritic steels, are studied by atomistic simulation and experiment. The modeling allows to include the effect of lubrication. Selected experiments reveal the relevance of the nanoscopic simulation results to real surface scratching. We study the evolution of plasticity under indentation and scratching, the dependence of scratching on surface orientation and scratch direction, the influence of tip geometry on scratching, the effect of lubrication during scratching, and friction and wear on micro- and nanoscales.

Herbert M. Urbassek, Iyad Alabd Alhafez, Hans Hasse, Michael Kopnarski, Simon Stephan

Creating Surface Morphologies by Micro Milling and Micro Grinding

Abstract

Micro cutting and micro abrasive processes are promising techniques to produce microstructured surfaces in a wide range of materials in a short time and in an economic way. However, due to occurring size effects, simply downscaling of known and mastered macro-scaled processes is not readily possible. At the same time, material removal at small scales holds challenges in observing and characterizing the process itself as well as the process results. Our investigations focused on developing methods and implementing measurement techniques to close the knowledge gap in micro milling and micro grinding. This article presents the development of customized machine tools, tools, processes as well as measurement equipment for micro milling with micro end mills with typical diameters of 50 \(\upmu \)m. It will be shown how and with which methods the process and its results can be optimized. Regarding micro grinding, special emphasis is on the manufacturing and application of micro pencil grinding tools via electroless plating, a process customized to produces tools with diameters down to 5 \(\upmu \)m.

Jan C. Aurich, Nicolas Altherr, Sonja Kieren-Ehses, Benjamin Kirsch, Tobias Mayer

Creating Surface Morphologies by Cryogenic Machining

Abstract

Cryogenic machining offers the potential to improve the surface morphology within a single process step by substituting the surface hardening into the form-shaping process. To realize a sufficient surface hardening, low temperatures and high mechanical loads have to be provided by the cryogenic machining process. Within this chapter, facilities and processes are presented aiming to optimize the surface morphology via cryogenic turning and milling. Cryogenic cooling strategies aim to achieve the necessary low thermal loads. The thermal loads are characterized via cutting experiments and temperature field simulations. The machining operations are designed in terms of cutting parameters and tool properties to provide favorable thermo-mechanical loads and consequently an optimized surface morphology. For both a metastable austenitic steel and a difficult-to-cut titanium alloy, an optimization of the surface morphology is realized. In addition, a novel, sub-zero cooling approach is presented and compared with the application of cryogenic coolants and conventional cooling approaches.

Benjamin Kirsch, Jan C. Aurich, Kevin Gutzeit, Erik von Harbou, Hans Hasse, Ralf Müller

Creating Surface Morphologies by Cold Spraying

Abstract

This chapter presents the method for the microstructuring of component surfaces by the cold spray process with fine particles. Depending on the process parameters the collision phenomena of particles with the substrate surface by this method can lead to different surface morphologies. The focus of this work is on the investigation of the manufacturing–morphology–property relationship. The mechanisms of cold spraying are explained and the investigated surfaces are discussed in detail. From CFD simulations, the velocities and temperatures of the particle before collision were obtained from the overall velocity and temperature of the gas stream. The impact phenomena were studied by FEM simulations. The microstructured surfaces were used for applications like biofilm growth or friction improvements.

Sergiy Antonyuk, Mustafa Bozoglu, Siegfried Ripperger

Creating Surface Morphologies by Additive Manufacturing

Abstract

Additive manufacturing on the micron-scale allows for unprecedented control of surface morphologies. With the smallest feature sizes in the range of 50 nm, surface roughness in the order of 10 nm, and with no observable damage to the underlying substrate material, additive manufacturing is an ideal choice if the influence of surface topography as part of the morphology is to be studied. While the highest surface definition is achieved with polymer-based materials, first, promising steps towards additive manufacturing of metals on the micron-scale have been recently made. To reach as small as possible deviations between the designed structure and the manufactured one, dimensional accuracy is crucial. To reach high dimensional accuracy, the fabrication processes for polymeric as well as metallic materials are to be understood in detail via numerical simulations. In this chapter, we review the underlying physical principles, discuss the numerical models employed, and provide an overview over common materials.

Georg von Freymann, Julian Hering-Stratemeier, Kristin E. J. Kühl, Thomas Palmer, Erik H. Waller

Interactions Between Particles and Surfaces

Abstract

Interactions between particles and surfaces play a significant role in many technical systems. To better understand the impact of particles on the overall behavior, the interactions between particles and surfaces are investigated experimentally and numerically for three generalized systems. The systems are chosen such that they differ in the number, mechanical properties, and kinematics of the particles, in the applied surrounding fluid, and in the spacial and temporal scales. In system one, the topography resulting from the interaction of abrasive particles being in contact with surfaces is analyzed. Depending on particle size and wetting conditions, the resulting topography varies from uniformly scattered to single local indentations. System two represents impacting particles on surfaces. The rebounce behavior varies strongly depending on the local structure of the surface and the wetting conditions, which can cause additional adhesive forces. System three investigates particles moving in a liquid close to a surface. Though not being in direct contact with the surface, the liquid mediates interactions between the particles and the surface. The particle’s trajectory depends strongly on its elastic modulus. These three systems are used to analyze special particle surface interactions independently. However, the results can also be used to characterize real applications, in which these interactions may occur in combination.

Kristin M. de Payrebrune, Clarissa Schönecker, Sergiy Antonyuk, Raphael Bilz, Fabian Krull, Isabell Noichl, Siegfried Ripperger, David Strohner

Adsorption and Wetting of Component Surfaces

Abstract

The wetting properties of component surfaces are important in many technical applications. They depend on the wetting liquid and the morphology of the component surface, including the adsorption layer, which is always present on technical surfaces. Both wetting and adsorption are governed by the same molecular interactions, and it is highly interesting to study the influence of these interactions on macroscopic wetting and adsorption behavior. This was done here in a scale-bridging approach by coupling molecular dynamics simulations with phase field simulations in a consistent way by a molecular-based equation of state. Systematic studies of wetting and adsorption in dispersive model systems were carried out, which, however, exhibit basically all phenomena observed in real systems. These simulation studies were complemented by experiments, in which contact angle measurements were combined with X-ray photoelectron spectroscopy (XPS) surface analytics. The results demonstrate that the wetting of technical surfaces is dominated by the adsorption layer. The substrate’s role is only indirect: It influences the morphology of the surface layer.

Hans Hasse, Martin T. Horsch, Michael Kopnarski, Kai Langenbach, Ralf Müller, Simon Stephan, Herbert M. Urbassek

Interrelationship of Manufacturing, Surface Morphology, and Properties of Titanium

Abstract

Manufacturing of titanium parts modifies the surface morphology mostly with the goal of a functionalization like grooves to change the wettability or to act as reservoirs for lubricants, for instance. While the function of the surface is adapted to special efforts, it must be considered how the new surface morphology acts on mechanical properties like the fatigue limit. Therefore, it is necessary to know which hardening mechanisms are activated during the change of the morphology. To do so, we analyzed the processes during manufacturing and measured the modified morphology of the surface with classical and new methods. The main influence on the fatigue limit is given by the changed roughness or newly introduced notches at the surface. These imperfections must be taken into account when calculating the consequences on the fatigue limit. Thereby, it is of high relevance to be aware of the interaction between the size of the imperfection and the governing microstructural dimensions, i.e., the grain size in titanium because the same imperfection can reduce the fatigue limit in a fine-grained metal while it has no influence on the fatigue limit in a coarse-grained metal.

Eberhard Kerscher, Stella Diederichs, Nafiseh Ghavidel, Andrej Keksel, Charlotte Kuhn, Ralf Müller, Jörg Seewig, Fábio J. P. Sousa

Influence of Manufacturing and Load Conditions on the Phase Transformation and Fatigue of Austenitic Stainless Steels

Abstract

The passivity and, hence, “stainlessness” as well as a very good combination of material strength and ductility was the main scope in the development of high alloyed chromium–nickel austenitic stainless steels. However, the chemical composition strongly influences not only the chemical passivity, but also the microstructural metastability, since deformation-induced martensite transformation takes place in a huge number of austenitic stainless steels. In this work, the phase transformation behavior was investigated under different loading conditions, using molecular dynamics simulation on the atomistic scale as well as phase field modeling on the microscale. To comprehensively assess the metastability of the investigated materials, a new method was developed and compared with the conventional metastability parameters in the literature. Furthermore, experimental work focusing on the detailed characterization of the surface morphology after different manufacturing processes, i.e., cryogenic turning, conventional milling, ultrasonic surface modification as well as micro-shot peening, is shown. The resulting surface morphologies and their influences on the fatigue properties were investigated from the low cycle fatigue, over the high cycle fatigue to the very high cycle fatigue regime, under uniaxial fully reversed tension–compression loading conditions. Additionally, the fatigue life of austenitic stainless steels with different metastabilities and surface morphologies was investigated in four-point bending fatigue tests.

Tilmann Beck, Marek Smaga, Sergiy Antonyuk, Dietmar Eifler, Ralf Müller, Herbert M. Urbassek, Tong Zhu

Influence of Surface Morphology on Fatigue and Tribological Behavior of TRIP/TWIP Steels

Abstract

Opposite to widely used austenitic stainless steels (see Chapter “Influence of Manufacturing and Load Conditions on the Phase Transformation and Fatigue of Austenitic Stainless Steels”), high manganese Transformation Induced Plasticity (TRIP)/TWinning Induced Plasticity (TWIP) steels are not corrosion resistant. However, these steels undergo intensive research work, because of their unique combination of high strength and high ductility. First fully austenitic TWIP steels are already industrially available. Parallel to research presented elsewhere on TRIP/TWIP steels as a bulk material, the surface morphology on the micro scale was investigated in this work. The possibility to manufacture different surface morphologies as well as the change in the topography, microstructure, and mechanical properties of near-surface regions up to 10 \(\upmu \)m depth after conventional milling, micro milling as well as lapping was investigated in detail. Based on that, the influence of different surface morphologies on the cyclic deformation behavior and fatigue life in LCF, HCF, and VHCF regime as well as tribological properties of austenitic TRIP/TWIP steels are analyzed.

Marek Smaga, Tilmann Beck, Michael Kopnarski, Rolf Merz, Kristin M. de Payrebrune, Stefan Wolke

Applications

Frontmatter

Manufacturing of Areal Material Measures

Abstract

Whereas the profile-based measurement and the calibration of the corresponding measuring instruments has been applied for a long time, the discipline of areal surface topography measuring instrument calibration still faces challenges. In the CRC 926, the design of corresponding material measures which can map the metrological characteristics to be considered in areal surface topography measurement just as well as the manufacturing of areal material measures using micro-milling and direct laser writing were examined. The results of different parameter studies for the design and manufacturing are presented in the following.

Jörg Seewig, Georg von Freymann, Jan C. Aurich, Matthias Eifler, Julian Hering-Stratemeier, Katja Klauer-Dobrowolski

Manufacturing-Morphology-Property Relationships for Rotating Shaft Sealing Systems

Abstract

In this chapter, results of the investigation of manufacturing-morphology-property (MMP) relationships for radial shaft seals, with a special focus on the shaft countersurface of the seal, are presented. This includes experimental investigations of alternative manufacturing and micro structuring processes such as turning, micro grinding, micro milling, shot- and micro peening and lapping. Furthermore, the influence of metastable austenitic shaft materials, of the rubber material and fillers and of lubricants on wear, friction and function of sealing systems with radial shaft seals was also investigated.

Stefan Thielen, Sergiy Antonyuk, Jan C. Aurich, Tilmann Beck, Hans Hasse, Michael Kopnarski, Balázs Magyar, Bernd Sauer, Marek Smaga

Influence of the Surface Morphology on Rolling Bearing Life Under Mixed Lubrication

Abstract

In the existing design guidelines for rolling bearings, there is no direct evaluation of the influence of the surface morphology on the achievable fatigue life under mixed lubrication conditions. This work focuses on the influence of different surface finishing processes, i.e., fine grinding, rough grinding, and hard turning, on the fatigue life of inner rings of radial cylindrical roller bearings. In addition to fatigue life experiments at a four-bearing test rig, detailed analyses of the finishing-induced surface morphology as well as calculations of the stress condition caused by the different surface topographies were conducted. To characterize the surface morphology, the local mechanical properties were determined using cyclic micro-indentation tests and the residual stresses were measured by X-ray diffraction. For the stress calculations, a multiscale simulation composed of a multi-body model at the macro-level and a half-space contact model at the micro-level was used. The results obtained in fatigue life experiments, surface morphology characterization, and stress calculations were combined. From this for the hard turning a high potential to increase the fatigue life of roller bearings under mixed lubrication conditions was examined.

Bernd Sauer, Tilmann Beck, Bastian Blinn, Flavien Foko Foko, Pascal Ostermayer, Lukas Rüth

Manufacturing-Morphology-Property Relationships for Chain Joints

Abstract

In this chapter, correlations between the surface morphology and the functional properties regarding friction and wear are investigated for the tribological contact between pin and bush in drive chains. Using a combination of experimental and simulative methods, influences such as surface topography, shape deviations of the components, lubricants and their contamination as well as boundary conditions with regard to load and relative velocity are determined. Friction and wear on individual chain joints are reliably determined with a single joint test rig. Essential findings are, for example, the strong dependence of wear on the inner contour of the bushings as well as the low influence of hydrodynamic effects on the friction behavior in the chain joint. Surface modifications such as micro-structuring do not bring any advantages in terms of tribological properties.

Manuel Oehler, Dominik Meffert, Bernd Sauer

Manufacturing-Morphology-Property Relationships for Biofilms

Abstract

Prokaryotic and eukaryotic biofilm-forming microorganisms offer a wide spectrum of various biotechnological interesting products, which makes them promising cultivation organisms for industry, as biotechnological processes can be made simpler and more efficient. The biggest challenge is the cultivation since standard bioreactors like airlift or stirred tank reactors are not suitable for the cultivation of biofilms. Here, special biofilm bioreactors have been developed in recent years that imitate the natural habitat of biofilms. The choice of the surface plays an important role in the initial adhesion of the cells that form the basis for the subsequent biofilm formation and productivity. To enhance initial adhesion different materials were microstructured and used as a surface for the cultivation of different biofilms. It could be shown, that initial adhesion can positively be influenced by designing flow-breaker structures. Furthermore, pH and ionic strength have an impact on initial adhesion. In summary, it can be said that microstructured surfaces have an impact on biofilm thickness and structure, biomass formation, and productivity of valuable products.

Roland Ulber, Sergiy Antonyuk, Jan C. Aurich, Tilmann Beck, Mustafa Bozoglu, Georg von Freymann, Sonja Kieren-Ehses, Christine Müller-Renno, Kai Muffler, Andrea Schmeckebier, Clarissa Schönecker, Jörg Seewig, Marek Smaga, Judith Stiefelmaier, Dorina Strieth, Ahmed Zayed, Christiane Ziegler, Sebastian Zimmermann

Titel: Component Surfaces
herausgegeben von: Jan C. Aurich
Hans Hasse
Verlag: Springer International Publishing
Electronic ISBN: 978-3-031-35575-2
Print ISBN: 978-3-031-35574-5
DOI: https://doi.org/10.1007/978-3-031-35575-2

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