Search Results (61)

Protective coatings are essential for extending the service life of components exposed to harsh conditions, such as pipes used in industrial systems, where wear and corrosion remain constant challenges. This study explores the development of a nano-sized TiO₂-reinforced electroless nickel-based ternary (Ni-W-P) alloy and composite coating on API X60 steel, a high-strength carbon steel pipe grade widely used in oil and gas pipelines, using an alkaline hypophosphite-reduced bath. The surface morphology, microstructure, elemental composition, structure, phase evolution, adhesion, and roughness of the coatings were analyzed using optical microscopy, FESEM, EDS, XRD, AFM, cross-cut tape test, and 3D profilometry. The tribological performance was evaluated via Vickers microhardness measurements and reciprocating wear tests conducted under dry conditions at a 5 N load. The TiO₂ nanoparticle-reinforced composite coating achieved a consistent thickness of approximately 24 µm and exhibited enhanced microhardness and reduced coefficient of friction (COF), although the addition of nanoparticles increased surface roughness (S_a). Annealing the electroless composites at 400 °C led to a significant improvement in their tribological properties, primarily owing to the grain growth, phase transformation, and Ni₃P crystallization. XRD analysis revealed phase evolution from an amorphous state to crystalline Ni₃P upon annealing. Both the alloy and composite coatings exhibited excellent adhesion performances. The combined effect of TiO₂ nanoparticles, tungsten, and Ni₃P crystallization greatly improved the wear resistance, with abrasive and adhesive wear identified as the dominant mechanisms, making these coatings well suited for high-wear applications. Full article

While acetic acid has proven effective as a mild acidic treatment for removing adhered mortar from recycled concrete aggregate (RCA) surfaces, its potential for dissolving damage to the surface of the original natural coarse aggregate (NCA) within the RCA and its impact on the resultant concrete properties require careful consideration. This investigation systematically evaluates the effects of varying concentrations of dilute acetic acid solutions, commonly used in RCA treatment protocols, through a multi-methodological approach that includes comprehensive physical characterization, stylus and 3D optical profilometry, scanning electron microscopy (SEM), and nanoindentation analysis. The results show that even dilute acid solutions have an upper concentration limit, as excessive acid concentration, specifically 0.4 M, induces significant textural dislocations on NCA surfaces, creating millimeter-scale erosion pits that increase aggregate water absorption by 18.5%. These morphological changes significantly impair concrete workability and reduce compressive strength performance. Furthermore, microstructural analysis reveals a 45.24% expansion in interfacial transition zone (ITZ) thickness, accompanied by notable reductions in elastic modulus and microhardness characteristics. In practical RCA treatment applications, for RCA containing limestone-based NCA, it is recommended to use acetic acid concentrations between 0.1 and 0.3 M to avoid substantial physical and microstructural degradation of aggregates and concrete. Full article

Background: This study investigated a new multi-acid-etching formulation for zirconia ceramics, containing hydrochloric, hydrofluoric, nitric, orthophosphoric, and sulfuric acids. The solution was tested on polycrystalline (5Y-TZP zirconia), lithium disilicate, hybrid ceramic, and feldspathic porcelain to assess compatibility, etching selectivity, and surface conditioning. Methods: Two-hundred-and-forty CAD/CAM specimens were etched for 20 s, 60 s, 30 min, or 1 h, and their surface roughness and etching patterns ware evaluated using 3D optical profilometry and scanning electron microscopy (SEM). Results: A positive correlation was observed between etching time and surface roughness (Ra values). The most pronounced changes were observed in lithium disilicate and feldspathic porcelain, with Ra values increasing from 0.733 ± 0.082 µm (Group 5) to 1.295 ± 0.123 µm (Group 8), and from 0.902 ± 0.102 µm (Group 13) to 1.480 ± 0.096 µm (Group 16), respectively. Zirconia increased from 0.181 ± 0.043 µm (Group 1) to 0.371 ± 0.074 µm (Group 4), and the hybrid ceramic from 0.053 ± 0.008 µm (Group 9) to 0.099 ± 0.016 µm (Group 12). Two-way ANOVA revealed significant effects of material and etching time, as well as a significant interaction between the two factors (p < 0.001). SEM observation revealed non-selective etching pattern for the lithium disilicate groups, indicating a risk of over-etching. Conclusions: The tested etching solution increased surface roughness, especially for the lithium disilicate and feldspathic porcelain specimens. In zirconia, one-hour etching improved surface characteristics with minimal observable damage. However, additional studies are necessary to validate the mechanical stability and bond effectives of this approach. Full article

Optical fringe projection is an outstanding technology that significantly enhances three-dimensional (3D) metrology in numerous applications in science and engineering. Although the complexity of fringe projection systems may be overwhelming, current scientific advances bring improved models and methods that simplify the design and calibration of these systems, making 3D metrology less complicated. This paper provides an overview of the fundamentals of fringe projection profilometry, including imaging, stereo systems, phase demodulation, triangulation, and calibration. Some applications are described to highlight the usefulness and accuracy of modern optical fringe projection profilometers, impacting 3D metrology in different fields of science and engineering. Full article

The current investigation evaluated a novel acid-etching solution containing hydrochloric acid (HCl), hydrofluoric acid (HF), nitric acid (HNO₃), orthophosphoric acid (H₃PO₄), and sulfuric acid (H₂SO₄) designed for etching zirconia ceramics. Achieving reliable bonding to zirconia is challenging due to its chemical inertia, unlike lithium disilicate, which can be effectively conditioned with HF etching. One hundred and twenty specimens of zirconia and lithium disilicate underwent etching with the experimental solution for six different durations: control, 20 s, 60 s, 5 min, 30 min, and 1 h. Surface roughness was assessed using 3D optical profilometry and scanning electron microscopy (SEM). The roughness of both materials increased with etching time; however, lithium disilicate demonstrated a significantly greater response, with Ra values rising from 0.18 µm (control) to 1.26 µm (1 h), while zirconia increased from 0.21 µm to 0.60 µm. ANOVA revealed significant effects depending on the ceramic type, time, and their interaction (p < 0.001). SEM images revealed non-selective etching of lithium disilicate, suggesting potential over-etching. The novel acid-etching solution improved surface roughness, especially in lithium disilicate ceramics. An application duration of one hour appears optimal for zirconia, improving surface characteristics while reducing damage; however, further research is required to assess its clinical safety and long-term effects on the mechanical properties of this dental ceramic. Full article

Objectives: To examine the effects of surface treatments on the color stability, surface roughness, surface gloss, and wettability of monolithic polychromatic material jetting (MJT) 3D-printed denture material. Material and Methods: Twenty-one color variants of the same denture material (TrueDent; Stratasys, Eden, MN, USA) underwent two surface treatments (polishing only or polishing and glazing), creating 42 study groups with a total of 420 samples (n = 10 per group). The samples were manufactured using a PolyJet 3D printer (J5 DentaJet; Stratasys, Eden, MN, USA), a type of MJT 3D printer. Color measurements were taken with a digital spectrophotometer before and after the surface treatments, and quantitative color differences (ΔE₀₀ and ΔC*) were calculated using the CIE2000 system. Comparisons of ΔE₀₀ were made against the 50%:50% acceptability threshold (AT) of 1.8 and the 50%:50% perceptibility threshold (PT) of 0.8 for tooth shade, as well as the 50%:50% PT of 1.72 and the 50%:50% AT of 4.08 for gingival (pink) shade. After surface treatment, the gloss was measured using a glossmeter, surface roughness was measured with optical profilometry, and wettability was measured by contact angle measurements using an optical tensiometer. The significance of surface treatment on color changes for each color variant was evaluated using one-sided, one-sample t-tests against the AT and PT. The effects of surface treatment on surface gloss, surface roughness, contact angle, and ΔC* were analyzed using t-tests for each color variant. Pairwise comparisons between groups were made using Fisher’s Protected Least Significant Differences (α = 0.05). Results: In most cases, glazing caused the color change (ΔE₀₀) to exceed the AT and PT, with a few exceptions. Most materials exhibited a more vibrant (more saturated) appearance and statistically higher chroma, with glazed surface treatments compared to polished ones, though there were some exceptions. For all materials, the glazed samples had significantly higher gloss units than the polished ones (p < 0.0001). Additionally, all materials showed significantly higher surface roughness in glazed samples compared to polished ones (p < 0.0001 for most). The polished samples had significantly higher contact angles (p < 0.0001 for most). Conclusions: Surface treatments significantly influenced the color, surface gloss, surface roughness, and wettability of MJT 3D-printed denture materials. Glazing led to increased chroma and gloss and produced more hydrophilic surfaces, although it also increased surface roughness. These results highlight the importance of surface treatment selection in optimizing the clinical performance of MJT-fabricated dentures. Full article

This article is used to reconstruct mechanical parts with highly reflective surfaces. Three-dimensional reconstruction based on Phase Measuring Profilometry (PMP) is a key technology in non-contact optical measurement and is widely applied in the intelligent inspection of mechanical components. Due to the high reflectivity of metallic parts, direct utilization of the captured high-dynamic-range images often results in significant information loss in the oversaturated areas and excessive noise in the dark regions, leading to geometric defects and reduced accuracy in the reconstructed point clouds. Many image-fusion-based solutions have been proposed to solve these problems. However, unknown geometric structures and reflection characteristics of mechanical parts lead to the lack of effective guidance for the design of important imaging parameters. Therefore, an adaptive high-precision 3D reconstruction method of highly reflective mechanical parts based on optimization of exposure time and projection intensity is proposed in this article. The projection intensity is optimized to adapt the captured images to the linear dynamic range of the hardware. Image sequence under the obtained optimal intensities is fused using an integration of Genetic Algorithm and Stochastic Adam optimizer to maximize the image information entropy. Then, histogram-based analysis is employed to segment regions with similar reflective properties and determine the optimal exposure time. Experimental validation was carried out on three sets of typical mechanical components with diverse geometric characteristics and varying complexity. Compared with both non-saturated single-exposure techniques and conventional image fusion methods employing fixed attenuation steps, the proposed method reduced the average whisker range of reconstruction error by 51.18% and 25.09%, and decreased the median error by 42.48% and 25.42%, respectively. These experimental results verified the effectiveness and precision performance of the proposed method. Full article

Objectives: Potential adverse effects and pH-related effectiveness of bleaching agents have raised some concerns. The aim of this study was to compare three bleaching agents containing hydrogen peroxide (HP) and carbamide peroxide (CP) in terms of whitening effectiveness, pH variation, and changes in enamel surface roughness. Methods: After controlled staining with a black tea solution, 42 human enamel specimens underwent bleaching treatment using the following agents: HP 40%; HP 35%; CP 16%. Color changes were evaluated according to the CIEDE2000 system. Gel pH was measured before and after each application. Surface roughness (Sa) was assessed through optical 3D profilometry before and after bleaching treatment. Results: The whitening effectiveness was similar for HP 40% and HP 35% while CP 16% had significantly lower results. HP 40% showed a remarkable pH acidification (−0.41), while HP 35% and CP 16% showed a mild increase in pH values (+0.26 and +0.03, respectively), and the differences between HP 40% and HP 35% and between HP 35% and CP 16% were statistically significant. Sa slightly decreased in all groups after bleaching, with no significant differences among them and a significant difference in HP 40% before and after treatment. Conclusions: Similar bleaching results were achieved regardless of pH and HP concentration for HP-based agents, while a lower bleaching effect was observed for the less concentrated CP-based agent, as anticipated. Higher HP and greater tendency to pH instability induced more pronounced modifications of surface roughness. This in vitro study suggests that bleaching gels with neutral and stable pH ensure good bleaching effectiveness and are less likely to cause enamel surface changes. Full article

This paper presents an effective three-dimensional (3D) surface reconstruction technique aimed at profiling composite surfaces with both specular and diffuse reflectance. Three-dimensional measurements based on fringe projection techniques perform well on diffuse reflective surfaces; however, when the measurement targets contain both specular and diffuse components, the efficiency of fringe projection decreases. To address this issue, the proposed technique integrates digital holography into the fringe projection setup, enabling the simultaneous capture of both specular and diffuse reflected light in the same optical path for full-field surface profilometry. Experimental results demonstrate that this technique effectively detects and accurately reconstructs the 3D profiles of specular and diffuse reflectance, with fringe analysis providing the absolute phase of composite surfaces. The experiments validate the effectiveness of this technique in the 3D surface measurement of integrated circuit carrier boards with chips exhibiting composite surfaces. Full article

Fringe projection profilometry (FPP) is extensively utilized for the 3D measurement of various specimens. However, traditional FPP typically requires at least three phase-shifted fringe patterns to achieve a high-quality phase map. In this study, we introduce a single-shot FPP method based on common path polarization interferometry. In our method, the projected fringe pattern is created through the interference of two orthogonal circularly polarized light beams modulated by a liquid crystal spatial light modulator (LC-SLM). A polarization camera is employed to capture the reflected fringe pattern, enabling the simultaneous acquisition of four-step phase-shifting fringe patterns. The system benefits from advanced anti-vibration capabilities attributable to the common path self-interference optical path design. Furthermore, the utilization of a low-coherence LED light source results in reduced noise levels compared to a laser light source. The experimental results demonstrate that our proposed method can yield 3D measurement outcomes with high accuracy and efficiency. Full article

A highly robust dual-frequency hierarchical temporal phase unwrapping (DHTPU) based on the novel spatial computer-generated Moiré profilometry (SCGMP) is proposed. The method requires only three patterns: a high-frequency fringe to provide robust surface information, a multi-period low-frequency fringe to eliminate the 2π-phase ambiguities, and a flat pattern to remove the average intensity of the two fringes. In decoding, different from traditional Moiré profilometries that rely on spectrum filters, SCGMP only employs spatial-domain calculations to extract the wrapped phase, thereby preserving more detailed information. Furthermore, we fully explore SCGMP’s capability to significantly alleviate phase ambiguity and provide an algorithm to determine the maximum measurable height range for a fixed system, enabling the direct extraction of the continuous basic phase from the multi-period low-frequency fringe. Consequently, the proposed basic phase exhibits an enhanced signal-to-noise ratio, compared to the traditional basic phase derived from the single-period fringes, effectively releasing the high-frequency restriction in the traditional DHTPU. The experimental results verify that the proposed DHTPU method has considerable accuracy and great potential for high-speed measurements, due to there being only three shots required. Full article

In 3D optical metrology, single-shot deep learning-based structured light profilometry (SS-DL-SLP) has gained attention because of its measurement speed, simplicity of optical setup, and robustness to noise and motion artefacts. However, gathering a sufficiently large training dataset for these techniques remains challenging because of practical limitations. This paper presents a comprehensive DL-SLP dataset of over 10,000 physical data couples. The dataset was constructed by 3D-printing a calibration target featuring randomly varying surface profiles and storing the height profiles and the corresponding deformed fringe patterns. Our dataset aims to serve as a benchmark for evaluating and comparing different models and network architectures in DL-SLP. We performed an analysis of several established neural networks, demonstrating high accuracy in obtaining full-field height information from previously unseen fringe patterns. In addition, the network was validated on unique objects to test the overall robustness of the trained model. To facilitate further research and promote reproducibility, all code and the dataset are made publicly available. This dataset will enable researchers to explore, develop, and benchmark novel DL-based approaches for SS-DL-SLP. Full article

This study focuses on the influence of electrospray deposition parameters on the morphology, topography, optical and sensing properties of ZnO films deposited on gold electrodes of quartz crystal resonators. The substrate temperature, precursor feed rate and emitter’s voltage were varied. Zinc acetate dehydrate dissolved in a mixture of deionized water, ethanol and acetic acid was used as a precursor. The surface morphology and average roughness of the films were studied by scanning electron microscopy (SEM) and 3D optical profilometry, respectively, while the optical properties were investigated by diffuse reflectance and photoluminescence measurements. The sensing response toward ammonia was tested and verified by the quartz crystal microbalance (QCM) method. The studies demonstrated that electrospray deposition parameters strongly influence the surface morphology, roughness and gas sensing properties of the films. The deposition parameters were optimized in order for the highest sensitivity toward ammonia to be achieved. The successful implementation of the electrospray method as a simple, versatile and low-cost method for deposition of ammonia-sensitive and selective ZnO films used as a sensing medium in QCM sensors was demonstrated and discussed. Full article

The accurate depth imaging of piled products provides essential perception for the automated selection of individual objects that require itemized food processing, such as fish, crabs, or fruit. Traditional depth imaging techniques, such as Time-of-Flight and stereoscopy, lack the necessary depth resolution for imaging small items, such as food commodities. Although structured light methods such as laser triangulation have high depth resolution, they depend on conveyor motion for depth scanning. This manuscript introduces an active dual line-laser scanning system for depth imaging static piled items, such as a pile of crabs on a table, eliminating the need for conveyor motion to generate high-resolution 3D images. This advancement benefits robotic perception for loading individual items from a pile for itemized food processing. Leveraging a unique geometrical configuration and laser redundancy, the dual-laser strategy overcomes occlusions while reconstructing a large field of view (FOV) from a long working distance. We achieved a depth reconstruction MSE of 0.3 mm and an STD of 0.5 mm on a symmetrical pyramid stage. The proposed system demonstrates that laser scanners can produce depth maps of complex items, such as piled Chesapeake Blue Crab and White Button mushrooms. This technology enables 3D perception for automated processing lines and offers broad applicability for quality inspection, sorting, and handling of piled products. Full article

Fringe projection profilometry (FPP), with benefits such as high precision and a large depth of field, is a popular 3D optical measurement method widely used in precision reconstruction scenarios. However, the pixel brightness at reflective edges does not satisfy the conditions of the ideal pixel-wise phase-shifting model due to the influence of scene texture and system defocus, resulting in severe phase errors. To address this problem, we theoretically analyze the non-pixel-wise phase propagation model for texture edges and propose a reprojection strategy based on scene texture modulation. The strategy first obtains the reprojection weight mask by projecting typical FPP patterns and calculating the scene texture reflection ratio, then reprojects stripe patterns modulated by the weight mask to eliminate texture edge effects, and finally fuses coarse and refined phase maps to generate an accurate phase map. We validated the proposed method on various texture scenes, including a smooth plane, depth surface, and curved surface. Experimental results show that the root mean square error (RMSE) of the phase at the texture edge decreased by 53.32%, proving the effectiveness of the reprojection strategy in eliminating depth errors at texture edges. Full article