Reflectance Map Techniques for Analyzing Surface Defects in Metal Castings

This report explores the relation between image intensity and object shape. It is shown that image intensity is related to surface orientation and that a variation in image intensity is related to surface curvature. Computational methods are developed which use the measured intensity variation across surfaces of smooth objects to determine surface orientation. In general, surface orientation is not determined locally by the intensity value recorded at each image point. Tools are needed to explore the problem of determining surface orientation from image intensity. The notion of gradient space , popularized by Huffman and Mackworth, is used to represent surface orientation. The notion of a reflectance map, originated by Horn, is used to represent the relation between surface orientation image intensity. The image Hessian is defined and used to represent surface curvature. Properties of surface curvature are expressed as constraints on possible surface orientations corresponding to a given image point. Methods are presented which embed assumptions about surface curvature in algorithms for determining surface orientation from the intensities recorded in a single view. If additional images of the same object are obtained by varying the direction of incident illumination, then surface orientation is determined locally by the intensity values recorded at each image point. This fact is exploited in a new technique called photometric stereo. The visual inspection of surface defects in metal castings is considered. Two casting applications are discussed. The first is the precision investment casting of turbine blades and vanes for aircraft jet engines. In this application, grain size is an important process variable. The existing industry standard for estimating the average grain size of metals is implemented and demonstrated on a sample turbine vane. Grain size can be computed form the measurements obtained in an image, once the foreshortening effects of surface curvature are accounted for. The second is the green sand mold casting of shuttle eyes for textile looms. Here, physical constraints inherent to the casting process translate into these constraints, it is necessary to interpret features of intensity as features of object shape. Both applications demonstrate that successful visual inspection requires the ability to interpret observed changes in intensity in the context of surface topography. The theoretical tools developed in this report provide a framework for this interpretation.

Defects in Self Assembled Colloidal Crystals

Colloidal self assembly is an efficient method for making 3-D ordered nanostructures suitable for materials such as photonic crystals and macroscopic solids for catalysis and sensor applications. Colloidal crystals grown by convective methods exhibit defects on two different scales. Macro defects such as cracks and void bands originate from the dynamics of meniscus motion during colloidal crystal growth while micro defects like vacancies, dislocation and stacking faults are indigenous to the colloidal crystalline structure. This paper analyses the crystallography and energetics of the microscopic defects from the point of view of classical thermodynamics and discusses the strategy for the control of the macroscopic defects through optimization of the liquid-vapor interface.

Bubble Behavior in a Taylor Vortex

We present an experimental study on the behavior of bubbles captured in a Taylor vortex. The gap between a rotating inner cylinder and a stationary outer cylinder is filled with a Newtonian mineral oil. Beyond a critical rotation speed (ω[subscript c]), Taylor vortices appear in this system. Small air bubbles are introduced into the gap through a needle connected to a syringe pump. These are then captured in the cores of the vortices (core bubble) and in the outflow regions along the inner cylinder (wall bubble). The flow field is measured with a two-dimensional particle imaging velocimetry (PIV) system. The motion of the bubbles is monitored by using a high speed video camera. It has been found that, if the core bubbles are all of the same size, a bubble ring forms at the center of the vortex such that bubbles are azimuthally uniformly distributed. There is a saturation number (N[subscript s]) of bubbles in the ring, such that the addition of one more bubble leads eventually to a coalescence and a subsequent complicated evolution. Ns increases with increasing rotation speed and decreasing bubble size. For bubbles of non-uniform size, small bubbles and large bubbles in nearly the same orbit can be observed to cross due to their different circulating speeds. The wall bubbles, however, do not become uniformly distributed, but instead form short bubble-chains which might eventually evolve into large bubbles. The motion of droplets and particles in a Taylor vortex was also investigated. As with bubbles, droplets and particles align into a ring structure at low rotation speeds, but the saturation number is much smaller. Moreover, at high rotation speeds, droplets and particles exhibit a characteristic periodic oscillation in the axial, radial and tangential directions due to their inertia. In addition, experiments with non-spherical particles show that they behave rather similarly. This study provides a better understanding of particulate behavior in vortex flow structures.

Model Order Reduction for Determining Bubble Parameters to Attain a Desired Fluid Surface Shape

In this paper, a new methodology for predicting fluid free surface shape using Model Order Reduction (MOR) is presented. Proper Orthogonal Decomposition combined with a linear interpolation procedure for its coefficient is applied to a problem involving bubble dynamics near to a free surface. A model is developed to accurately and efficiently capture the variation of the free surface shape with different bubble parameters. In addition, a systematic approach is developed within the MOR framework to find the best initial locations and pressures for a set of bubbles beneath the quiescent free surface such that the resultant free surface attained is close to a desired shape. Predictions of the free surface in two-dimensions and three-dimensions are presented.