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Knife-edge interferogram analysis for corrosive wear propagation at sharp edges.

Zhikun Wang, ChaBum Lee

|March 10, 2021

Summary

This study introduces a noncontact method using knife-edge interferometry (KEI) to monitor corrosive wear on sharp edges. KEI quantifies edge loss and roughness, enabling precise tracking of material degradation.

Area of Science:

Materials Science
Optical Metrology
Corrosion Engineering

Background:

Corrosive wear on sharp edges poses challenges for material integrity and performance.
Accurate, noncontact monitoring of wear propagation is crucial for predictive maintenance and material lifespan assessment.
Existing methods may lack precision or require physical contact, limiting their applicability.

Purpose of the Study:

To develop and validate a novel noncontact measurement and inspection method for monitoring corrosive wear propagation on sharp edges.
To quantitatively assess edge loss and edge roughness using knife-edge interferometry (KEI).
To establish a reliable method for in-process tracing of corrosion degree.

Main Methods:

Utilized knife-edge diffraction theory and knife-edge interferometry (KEI) for noncontact measurement.

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Employed a system comprising a laser diode, avalanche photodiode, and linear stage for scanning.

Analyzed interferometric fringes using a cross-correlation algorithm to quantify lag (edge loss) and similarity (edge roughness).

Validated computational models with experimental data from razor blade samples.

Main Results:

KEI system demonstrated a sensor noise level of 0.03% full scale.
Computational approach showed less than 1% error, validated experimentally.
Increased lag correlated with edge loss (1.007/µm), and decreased similarity indicated edge roughness change (5.4×10^-4/µm).
Experimental results closely matched computational predictions.

Conclusions:

The developed KEI method provides a precise, noncontact solution for monitoring corrosive wear propagation on sharp edges.
Quantitative metrics (lag and similarity) effectively characterize edge loss and roughness changes due to corrosion.
The validated method offers a promising tool for material inspection and degradation analysis in various industrial applications.