Surface Metrology and the National Science Foundation An Interactive Qualifying Project Submitted to the faculty of WORCESTER POLYTECHNIC INSTITUTE in partial fulfilment of the requirements for the degree of Bachelor of Science by Maereg Tafesse Date: May 30, 2015 Report Submitted to: Professor Christopher Brown This report represents work of WPI undergraduate students submitted to the faculty as evidence of a degree requirement. WPI routinely publishes these reports on its website without editorial or peer review. For more information about the projects program at WPI, see http://www.wpi.edu/Academics/Projects. Table of Contents Abstract ......................................................................................................................................................... 5 1. Introduction .......................................................................................................................................... 6 1.1. Objective ....................................................................................................................................... 6 1.2. Rationale ....................................................................................................................................... 6 1.3. State-of-the-art ............................................................................................................................. 7 1.4. Approach ....................................................................................................................................... 8 2. Background ........................................................................................................................................... 9 2.1. National Science Foundation ........................................................................................................ 9 2.2. Stylus Profilometry ...................................................................................................................... 10 2.2.1. Atomic Force Microscopy ....................................................................................................... 11 2.3. Optical Profilometry .................................................................................................................... 13 2.3.1. Confocal Microscopy ........................................................................................................... 13 2.3.2. Scale-Based Analysis ........................................................................................................... 15 2.4. Computer Simulation .................................................................................................................. 19 3. Methods .............................................................................................................................................. 20 3.1. Research Phase ........................................................................................................................... 21 3.2. Analysis Phase ............................................................................................................................. 22 4. Results ................................................................................................................................................. 23 4.1. NSF Project 1 ............................................................................................................................... 24 4.1.1. Research Summary ............................................................................................................. 24 4.1.2. Use of Surface Metrology ................................................................................................... 25 4.2. NSF Project 2 ............................................................................................................................... 27 4.2.1. Research Summary ............................................................................................................. 27 4.2.2. Use of Surface Metrology ................................................................................................... 28 4.3. NSF Project 3 ............................................................................................................................... 29 4.3.1. Research Summary ............................................................................................................. 29 4.3.2. Use of Surface Metrology ................................................................................................... 31 4.4. NSF Project 4 ............................................................................................................................... 34 4.4.1. Research Summary ............................................................................................................. 34 4.4.2. Use of Surface Metrology ................................................................................................... 35 4.5. NSF Project 5 ............................................................................................................................... 36 4.5.1. Research Summary ............................................................................................................. 36 1 4.5.2. Use of Surface Metrology ................................................................................................... 37 5. Discussion ............................................................................................................................................ 39 6. Conclusions ......................................................................................................................................... 40 Acknowledgments ....................................................................................................................................... 40 Bibliography ................................................................................................................................................ 41 Appendix A .................................................................................................................................................. 43 2D Stylus Parameters .............................................................................................................................. 43 3D (S-Parameters) ................................................................................................................................... 46 2 List of Figures Figure 1: Sources of Science and Engineering funding for public and private academic institutions (NSF, 2013) ........................................................................................................................................................... 10 Figure 2: Average Roughness (Ra) .............................................................................................................. 11 Figure 3: Simplified Schematic of AFM ....................................................................................................... 12 Figure 5: Surface Texture (with 3D ISO parameters) .................................................................................. 14 Figure 6: Peruvian Currency 3D surface Profile .......................................................................................... 15 Figure 7: Magnification on security thread on banknote ........................................................................... 15 Figure 8: Relative Area illustration (Brown et al., 2003) ............................................................................. 16 Figure 9: Relative-Area vs Scale graph (Metal foil sample 1 vs 2) .............................................................. 18 Figure 10: F-test Illustration ........................................................................................................................ 19 Figure 11: Project Methods flow-chart ....................................................................................................... 23 Figure 12: Roughness Values of tribofilms: Red depicts the ranges of error (Kar et al., 2008) .................. 25 Figure 13: SEM images of Tribofil with mineral oil (left) and castor oil (right) (Kar et al., 2008) ............... 26 Figure 14: Missing data points in stylus profilometry ................................................................................. 27 Figure 15: Ra value limitation in distinguishing two surfaces ..................................................................... 29 Figure 16: Arc Discharge a) Surface before treatment b) surface after treatment (Asgharifar et al., 2012) .................................................................................................................................................................... 31 Figure 17: Correlation of Relative Area with Adhesive Strength (Brown et al., 2001) ............................... 32 Figure 18: OLS4000 microscope: Field of View vs Objective Lens .............................................................. 33 Figure 19: Surface roughness obtained with the aid of four different acids (Li et al., 2015) ..................... 35 Figure 20: Surface roughness (Sa), Material Removal Rate and PH value (Li et al., 2015) ......................... 36 Figure 21: Surface frame showing individual grains (left) and full surface with a combination of certain orientations (right) (Zamiri et al., 2008) ....................................................................................................