This work was carried out to study the effect of shot-peening on the fatigue behaviour of carbon steels. Differently heat treated medium and high carbon steel specimens were selected. Medium carbon steels, AISI 1141 and AISI 1151, were respectively air cooled and quenched-tempered. A high carbon steel, C70S6 (AISI 1070), was air cooled. The other material was a powder metal (0.5% C) steel. Each group of steels was divided into two. One was shot-peened. The other half remained in their original conditions. All were fatigue tested under fully reversed (R=-1) tension-compression loading conditions. Microhardness tests were carried out on both the grip and gage sections of selected non shot-peened and shot-peened specimens to determine the hardness profile and effect of cycling. Shot-peening was found to be deeper on one side of each specimen. Compressive residual stress profiles and surface roughness measurements were provided. Shot-peening increased the surface roughness from 0.26±0.03µm to 3.60±0.44µm. Compressive residual stresses induced by shot-peening reached a maximum of -463.9MPa at a depth of 0.1mm.The fatigue limit (N≈106 cycles) and microhardness profiles of the non shot-peened and shot-peened specimens were compared to determine the material behaviour changes after shot-peening and cycling. Also their fatigue properties were related to the manufacturing process including heat and surface treatments. Comparing the grip and gage microhardness profiles of each steel showed that neither cyclic softening nor hardening occurred in the non shot-peened condition. Cyclic softening was apparent in the shot-peened regions of all steels except powder metal (PM) steel. The amount of softening in the shot-peened region was 55.0% on the left side and 73.0% on the right in the AISI 1141 steel , 46.0% on the left side and 55.0% on the right in the C70S6AC steel and 31.0% on the right side in AISI 1151QT steel. Softening was accompanied by a decrease in the depth of surface hardness. It is suggested that although the beneficial effects of shot peening, compressive residual stresses and work hardening, were offset by surface roughness, crack initiation was more likely to occur below the surface. Surface roughness was not a significant factor in controlling the fatigue lives of AISI 1141AC and C70S6 steels, since they were essentially the same for the non shot-peened and shot-peened conditions. Shot-peening had very little effect on the push-pull fatigue limit of C70S6 steel (-2.1%), and its effect on AISI 1141AC steel was relatively small (6.0%). However, the influence of shot-peening on the AISI 1151QT and PM steels was more apparent. The fatigue limit of the PM steel increased 14.0% whereas the fatigue limit of the AISI 1151QT steel decreased 11.0% on shot peening.

This thesis examines the qualitative and quantitative variation in local plastic deformation and surface roughening due to crystallographic texture in body-centered cubic materials, specifically interstitial-free steel sheet and molybdenum foil and sheet. Complex forming operations currently used in industrial manufacturing lead to high material failure rates, due in part to the severity of the applied strain path. A multi-scale model was developed to examine the contribution of mesoscopic and local microscopic behaviour to the macroscopic constitutive response of bcc metals during deformation. The model integrated a dislocation-based hardening scheme and a Taylor-based crystal-plasticity formulation into the subroutine of an explicit dynamic FEM code, LS-DYNA. Numerical analyses using this model were able to predict not only correct grain rotation during deformation, but variations in plastic anisotropy due to initial crystallographic orientation. Simulations of molybdenum foil under uniaxial tension supported the existence of bending due to local variations in plastic anisotropy, confirmed with good quantitative agreement by experimental measurements of surface roughening. A series of two-stage strain-path tests were performed, revealing a prestrain-dependent softening of both the steel and molybdenum samples when an orthogonal secondary strain path is applied. Numerical analyses of these tests overestimate macroscopic hardening during complex loading, due in part to the dynamic nature of the FEM code used. / Thesis (Ph.D, Mechanical and Materials Engineering) -- Queen's University, 2009-04-15 11:51:04.518

An experimental research was performed to study the effects of surface roughness on the characteristics of separated and reattached turbulent flows in an open channel. A backward facing step was used to induce flow separation. The rough surfaces comprised wire mesh grit-80 and sand grains of average diameter 1.5 mm. In each experiment, the Reynolds number based on the step height and freestream velocity of approach flow was fixed at 3240 and the Reynolds number based on the approach flow depth and freestream velocity was kept constant at 25130. Particle image velocimetry (PIV) technique was used to measure the flow velocity. The results showed that roughness effects on the mean and turbulent quantities are evident only in the recovery region. Moreover, roughness effects on the flow dynamics are dependent on the specific roughness element.

The objective of this study is to understand the effect of surface roughness of the Cu substrate on the wetting of molten solder alloys. Eutectic Sn-Pb, pure Sn and eutectic Sn-Cu solder alloys and Cu substrates with different surface finish viz., highly polished surface, polished surface and unpolished surface were used in this work. Highly polished surface was prepared in Metallography lab, University of Kentucky while other two substrates were obtained from a vendor. Surface roughness properties of each substrate were measured using an optical profilometer. Highly polished surface was found to be of least surface roughness, while unpolished surface was the roughest. Hot-stage microscopy experiments were conducted to promote the wetting behavior of each solder on different Cu substrates. Still digital images extracted from the movies of spreading recorded during hot-stage experiments were analyzed and data was used to generate the plots of relative area of spread of solder versus time. The study of plots showed that surface roughness of the Cu substrate had major influence on spreading characteristics of eutectic Sn-Pb solder alloy. Solder showed better spreading on the Cu substrate with least surface roughness than the substrates with more roughness. No significant influence of surface roughness was observed on the wetting behavior of lead free solders (pure Sn and eutectic Sn-Cu).

A turbulent channel flow was used to study the scaling of the combined effects of roughness and flow injection on the mean flow and turbulence statistics of turbulent plane Poiseuille flow. It was found that the additional momentum injected through the rough surface acted primarily to enhance the roughness effects and, with respect to the mean flow, blowing produced similar mean flow effects as increasing the roughness height. This was not found to hold for the turbulence statistics, as a departure from Townsend’s hypothesis was seen. Instead, the resulting outer-scaled streamwise Reynolds stress for cases with roughness and blowing deviated significantly from the roughness only condition well throughout the inner and outer layers. Investigation into this phenomena indicated that suppression of the large-scale motions due to blowing may have been contributing to this deviation.

This thesis provides insight into techniques for the detection and classification of various marginal ice zone roughnesses in the southern Beaufort Sea using in situ and satellite-based microwave remote sensing. A proposed model of surface roughness shows the dependence of circular coherence, a discriminator of roughness, on the roughness and dielectrics. A relationship between ice slopes in azimuth and range direction is derived. Microwave brightness temperature of open water is significantly correlated with wave height but not with the wind speed, having the strongest correlations for the H-polarization at both 37 and 89 GHz. A modified formula for the relationship between non-dimensional form of energy and wave age at wind speeds 0−10 m/s is obtained. The brightness temperature (April−June) of sea ice at H-polarization of 89 GHz is found to decrease with increasing roughness, and is attributed to the dominant contributions from rapidly varying thermodynamic properties of snow-covered sea ice.

An experimental research was performed to study the effects of surface roughness on the characteristics of separated and reattached turbulent flows in an open channel. A backward facing step was used to induce flow separation. The rough surfaces comprised wire mesh grit-80 and sand grains of average diameter 1.5 mm. In each experiment, the Reynolds number based on the step height and freestream velocity of approach flow was fixed at 3240 and the Reynolds number based on the approach flow depth and freestream velocity was kept constant at 25130. Particle image velocimetry (PIV) technique was used to measure the flow velocity. The results showed that roughness effects on the mean and turbulent quantities are evident only in the recovery region. Moreover, roughness effects on the flow dynamics are dependent on the specific roughness element.

This thesis presents a study on the applicability of common roughness parameterization guidelines in determining values of the surface roughness length (z0). These guidelines are often used for vertical extrapolation of wind speeds in the renewable energy industry. The specific goal of this thesis is to determine whether these guidelines (most notably the Davenport roughness classification system) can provide a quality estimate of the roughness length for wind resource assessment purposes. To test this hypothesis, empirical relationships between calculated values of z0 derived from logarithmic profile fitting and those estimated from subjective terrain analyses guidelines are compared at two prospective wind farm locations in Southern Ontario. The results suggest that the use of roughness parameterization guidelines for extrapolating wind speeds can cause serious underestimation of the local wind resources, especially at locations where local topographic challenges exist. Their use in energy assessments should be avoided if possible through on-site measurements of the wind profile.

Wetting behavior of fluid/fluid/solid systems, largely influenced by surface properties and interactions between the three phases, plays a big role in nature and in industrial applications Traditionally, wetting studies have focused on liquid/vapor systems, especially the study of a sessile liquid droplet in air. Liquid/vapor systems can only probe the effects of surface properties and interactions between the solid and the wetting liquid. This type of characterization is inadequate for liquid/liquid systems, where surface wettability is additionally influenced by interactions between the two wetting liquids. The present study is the first to examine the effects of nanoscale roughness on wetting behavior in liquid/liquid systems and the modulation of roughness effects by fluid properties and the wetting order. This study examines both equilibrium and dynamic wetting behavior in liquid/liquid systems using well characterized substrates. Rough substrates were fabricated by coating glass substrates with nanometer sized polymer particles. Partial dissolution of the particles and molecular de-deposition of the polymer allowed for tuning of substrate roughness while retaining the original surface chemistry. The effectiveness of this fabrication technique was verified using electron microscopy and electrokinetic analysis. We examined the wetting behavior in three fluid/fluid systems: an air/water system, a decane/water system, and an octanol/water system. The oils were chosen based on their different polarities. Equilibrium wetting behavior was determined using contact angle measurements. Results indicate that for all systems where the primary wetting fluid was a liquid, an increase of the surface roughness resulted in Cassie-Baxter wetting. How hydrophilic a surface appears with regard to a water/fluid interface depended on the polarity of that fluid. The octanol/water system provided the strongest evidence regarding the effect of wetting order: a transition from Wenzel to Cassie-Baxter wetting was only observed when water was the primary wetting liquid. The observed transition was confirmed using a modified Wenzel/Cassie-Baxter model. The kinetics of droplet spreading was measured using high speed optical microscopy. After a droplet was placed on a solid surface, the motion of the contact line was imaged at a rate of 1000 fps. The wetted area was then extracted using custom Matlab® scripts. The spreading kinetics underwent a transition between two regimes: a visco-inertial regime and a slower spreading regime. Results indicated that surface roughness influenced spreading kinetics in both regimes. The overall spreading rate was always slower for rough surfaces than for smoother surfaces. In liquid/liquid systems, the duration of visco-inertial regime was dependent on the surface roughness as well; in general, it was shorter for smooth substrates compared to rough substrates. Increasing the viscosity of the non-aqueous fluid significantly increased the duration of the visco-inertial regime and decreased the overall spreading rate. This study provides insight into the competitive wetting of solid surfaces relevant in many industrial applications such as oil recovery or inkjet printing, and may guide the development of improved wetting models in an area that currently lacks an adequate theoretical description.

This study investigates the effect of front surface roughness on ultrasonic echo amplitude. Experiments were carried out on specimens whose front surfaces are machined by milling machine. Machining parameters were changed in milling process in order to obtain desired roughness values and milling head was tilted to a very small angle to obtain periodic rough surfaces. Experiments were performed with these specimens having roughness value of 0.5, 4.5, 11, 26.5 &micro / m. Ra. The back surface roughness of all specimens was kept constant at 1.5 &micro / m Ra by grinding operation. 1.5, 2, 3, 4 mm. holes were drilled at constant depth and to same side of each specimen to represent reference discontinuities. Ultrasonic tests, using pulse echo technique were carried out to monitor echo amplitudes corresponding to different roughness values. The tests were also repeated by using different ultrasonic probes having different frequencies. For additional comparison, different couplants were used through the tests. The results showed that there was a significant increase in the reduction of the sound pressure level with the increase in the surface roughness. Although there was no uncertainty observed about not being able to detect discontinuity because of roughness but correct couplant and frequency selection has a positive effect on correctly sizing the discontinuity and at attenuation measurements. The results obtained with this work can be used as a guide for testing rough surfaces, predicting the effect on ultrasonic examination before testing and discontinuity detecting capability under rough surface conditions.