Lateral scale calibration for focus variation microscopy

Areal surface texture measuring instruments can be calibrated by determining a set of metrological characteristics currently in the final stages of standardisation. In this paper, amplification, linearity and perpendicularity characteristics have been determined to calibrate the lateral performance of a focus variation microscope. The paper presents a novel and low-cost material measure and procedures that are used to determine the characteristics. The material measure is made of stainless steel with a cross-grating grid of hemispherical grooves. The design, manufacturing and calibration of the material measure are discussed. The (20 × 20) mm grid is measured with and without image stitching. The results show that the proposed material measure and procedures can be used to determine the error of the amplification, linearity and perpendicularity characteristics. In addition, the lateral stage error can be significantly reduced by measurement with image stitching

Noise evaluation of a point autofocus surface topography measuring instrument

In this work, the measurement noise of a point autofocus surface topography measuring instrument is evaluated, as the first step towards establishing a route to traceability for this type of instrument. The evaluation is based on the determination of the metrological characteristics for noise as outlined in draft ISO specification standards by using a calibrated optical flat. The static noise and repeatability of the autofocus sensor are evaluated. The influence of environmental disturbances on the measured surface topography and the built-in software to compensate for such influences are also investigated. The instrument was found to have a measurement noise of approximately 2 nm or, when expressed with the measurement bandwidth, 0.4 nm/√Hz for a single-point measurement

Aerial wetting contact angle measurement using confocal microscopy

A method is presented in which the wetting contact angle of a sessile drop is acquired aerially using confocal techniques to measure the radius and the height of a droplet deposited on a planar surface. The repeatability of this method is typically less than 0.25°, and often less than 0.1°, for droplet diameters less than 1 mm. To evaluate accuracy of this method, an instrument uncertainty budget is developed, which predicts a combined uncertainty of 0.91° for a 1 mm diameter water droplet with a contact angle of 110°. For droplets having diameters less than 1 mm and contact angles between 15° and 160°, these droplets approach spherical shape and their contact angles can be computed analytically with less than 1% error. For larger droplets, gravitational deformation needs to be considered

Characterisation of the topography of metal additive surface features with different measurement technologies

The challenges of measuring the surface topography of metallic surfaces produced by additive manufacturing are investigated. The differences between measurements made using various optical and non-optical technologies, including confocal and focus-variation microscopy, coherence scanning interferometry and x-ray computed tomography, are examined. As opposed to concentrating on differences which may arise through computing surface texture parameters from measured topography datasets, a comparative analysis is performed focussing on investigation of the quality of the topographic reconstruction of a series of surface features. The investigation is carried out by considering the typical surface features of a metal powder-bed fusion process: weld tracks, weld ripples, attached particles and surface recesses. Results show that no single measurement technology provides a completely reliable rendition of the topographic features that characterise the metal powder-bed fusion process. However, through analysis of measurement discrepancies, light can be shed on where instruments are more susceptible to error, and why differences between measurements occur. The results presented in this work increase the understanding of the behaviour and performance of areal topography measurement, and thus promote the development of improved surface characterisation pipelines

Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V

Use of an alpha-beta (multiphase HCP-BCC) titanium alloy, Ti6Al4V, is ubiquitous in a wide range of engineering applications. The previous decade of finite element analysis research on various titanium alloys for numerous biomedical applications especially in the field of orthopedics has led to the development of more than half a dozen material constitutive models, with no comparison available between them. Part of this problem stems from the complexity of developing a vectorised user-defined material subroutine (VUMAT) and the different conditions (strain rate, temperature and composition of material) in which these models are experimentally informed. This paper examines the extant literature to review these models and provides quantitative benchmarking against the tabulated material model and a power law model of Ti6Al4V taking the test case of a uniaxial tensile and cutting simulation