abrasive water jet machining research paper

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Water Jet and Abrasive Water Jet Machining: A Survey of Capability of a Machine in the Field

• Conference: National Conference on Mechanical Engineering Emerging Trends
• At: Vardhman College of Engineering , Hyderabad 501 218 India

• The Maharaja Sayajirao University of Baroda

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Computational fluid dynamics analysis of erosion in active components of abrasive water jet machine.

1. Introduction

2. materials and methods, 2.1. granulometry of abrasive material, 2.2. determination of sand particles shape factor, 2.3. determination of abrasive flow rate, 2.4. abrasive fluid modeling by active elements of awj machine, 3. results and discussion, 3.1. results regardint the granulometry of abrasive material, 3.2. determination of sand particles shape factor, 3.3. results regarding the abrasive flow rate, 3.4. results of cfd simulation, 3.4.1. evaluation of the erosion rate (er) produced by particles with 0.19 mm diameter, 3.4.2. evaluation of the er produced by particles with 0.285 mm diameter, 3.4.3. evaluation of the er produced by particles with a diameter of 0.38 mm, 4. conclusions, author contributions, data availability statement, conflicts of interest.

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Pătîrnac, I.; Ripeanu, R.G.; Tănase, M. Computational Fluid Dynamics Analysis of Erosion in Active Components of Abrasive Water Jet Machine. Processes 2024 , 12 , 1860. https://doi.org/10.3390/pr12091860

Pătîrnac I, Ripeanu RG, Tănase M. Computational Fluid Dynamics Analysis of Erosion in Active Components of Abrasive Water Jet Machine. Processes . 2024; 12(9):1860. https://doi.org/10.3390/pr12091860

Pătîrnac, Iulian, Razvan George Ripeanu, and Maria Tănase. 2024. "Computational Fluid Dynamics Analysis of Erosion in Active Components of Abrasive Water Jet Machine" Processes 12, no. 9: 1860. https://doi.org/10.3390/pr12091860

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Topography of textured surfaces using an abrasive-water jet technology

• Original Article
• Open access
• Published: 04 September 2024
• Volume 24 , article number  226 , ( 2024 )

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• Monika Szada-Borzyszkowska   ORCID: orcid.org/0000-0003-0504-2149 1 ,
• Wojciech Kacalak 1 ,
• Wiesław Szada-Borzyszkowski 2 ,
• Przemysław J. Borkowski 3 ,
• Dorota Laskowska 1 &
• Filip Szafraniec 1  

Surface texturing is a technique that allows for the shaping of surface topography to meet various mechanical and tribological requirements. Abrasive-water jet (AWJ) technology is a promising approach to surface texturing, offering minimal heat impact, flexibility, and compatibility with complex surface geometries. High-pressure abrasive-water jet (AWJ) technology, as an innovative and versatile approach, significantly expands the possibilities of surface texturing for materials. Its advantages, such as precision, minimal thermal impact, sustainability, and a wide range of industrial applications, make it an attractive solution across various sectors. With continuous development and integration with modern digital technologies, AWJ is becoming an increasingly practical and cutting-edge tool in surface processing. The abrasive-water jet texturing process also affects surface geometry during the mating of components, which may be significant in reducing wear. The aim of the research was to determine the feasibility of obtaining specific structures on the surface of 304/1.4301 steel using abrasive-water jet technology. Results show that the highest load-bearing ratio of Smrk1 peaks, approximately 25%, was achieved at a texturing speed of 0.803 m/min. Conversely, the lowest load-bearing ratio of Smrk1 peaks, below 10%, was achieved at a texturing speed of 1.948 m/min. Grinding the surface after texturing increases its load-bearing capacity, leading to a twofold increase in the ability to maintain an oil layer. The obtained results may find application in various fields where controlling surface geometry is essential for improving material functionality and efficiency.

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1 Introduction

Texturing is a technique of shaping the topography of engineering surfaces to achieve desired mechanical and tribological properties [ 1 ]. It is a process in which patterns or structures are applied to the surfaces of products, aiming to enhance their functionality, durability, or appearance. As a result of surface texturing, it is possible to improve the tribological properties of interacting surfaces, which leads to a reduction in their wear rate [ 2 ]. Surface texture also has a significant impact on the load-bearing capacity, wear resistance, and friction coefficient of tribological components. It is used in the field of engineering due to its advantages in oil lubrication, thermodynamics, hydrodynamics, and aerodynamics [ 3 ].

Surface texturing can also lead to increased corrosion resistance and reduced surface wettability [ 4 ]. In the work by Riveiro et al. [ 5 ], laser texturing is described as a method that changes the surface properties of various materials to control their wettability. It was found that different laser parameters allow for the creation of desired surface structures, which affect the interaction of materials with liquids.

In another study by Shaikh et al. [ 6 ], surface texturing using a femtosecond laser was utilized to treat the surface of 45S5 bioactive glass. Through the application of texturing, a significant reduction in bacterial attachment and biofilm formation was demonstrated, while maintaining biocompatibility with human cells. The results suggest that laser surface modification of 45S5 bioactive glass can effectively impart desired properties to bioimplants and medical devices. In the article by Ijaola et al. [ 7 ], various surface texturing methods were evaluated using techniques such as chemical modification, low-temperature annealing, organic air contaminants, and plasma treatment, necessary to achieve hydrophobicity or superhydrophobicity. The significant potential of laser-textured surfaces was demonstrated for applications such as self-healing surfaces, corrosion resistance, microfluidics, prevention of biological organism settlement, controlling heat flow in systems or materials to maintain proper temperature conditions, and preventing ice formation on the surfaces of various materials or devices.

Moreover, for additional visual effect and increased corrosion protection of metal surfaces, additional coatings are applied [ 8 ]. Surface texturing enhances the adhesion of the coating by increasing the contact surface [ 9 ]. Scientists from France [ 10 ] conducted the application of thermal coatings on textured surfaces. The applied surface texturing increases the adhesion area and the efficiency of particle deposition by appropriately matching the depressions to the particle sizes. The adhesion strength of the coatings significantly increased due to the specific shapes of the patterns, which direct cracks into the interior of the coating, enhancing its adhesion strength. Another group of applications includes adhesive (mechanical) connections in metal–polymer and metal–ceramic composites [ 11 ]. Surface texturing can effectively control bacterial adhesion on biomaterials without antimicrobial agents [ 12 ] or influence cell adhesion [ 13 ], thereby increasing the osseointegration potential of implant surfaces [ 14 ].Textured surfaces find their application in various industries: aerospace, space, civil engineering, renewable energy sector, medical and biotechnology.

Depending on the material and the desired effect, there are several methods for surface texturing. One of the most commonly used methods of surface texturing is laser texturing described earlier [ 15 ], which involves the removal of material through rapid melting or vaporization [ 1 ]. This process has its drawbacks, including the formation of a heat-affected zone and residual stresses in the machined material [ 16 ], which can lead to changes in the metallographic structure, burn marks, microcracks, or delamination [ 17 ]. Another promising method of surface treatment is the utilization of pulsating jet flows [ 18 ]. In the work by Stolárik G. et al., pulsating water jet was employed for roughening surfaces, yielding promising results on titanium samples [ 19 ]. These studies achieved a reduction in surface roughness (Sa and Sz) and a 25.30% increase in subsurface microhardness under specific conditions of linear trajectory and 40 kHz frequency. Moreover, cross trajectory ensures more uniform surfaces, and cross-sectional images revealed potential cell growth sites in the form of microtunnels [ 19 ]. A promising alternative to overcome these limitations while meeting high requirements is texturing using abrasive-water jet (AWJ) technology.

In article [ 20 ], research on creating free-standing structures with high aspect ratios using abrasive-water jet micro-machining is presented. The study employed higher water jet pressures, lower nozzle traverse speeds, and higher abrasive flow rates to minimize structure leveling, resulting in high-quality free-standing structures suitable for radiators. By controlling the depth of micro-abrasive water jet milling, intersecting free-standing microstructures were formed [ 21 ]. The research demonstrated the ability to create deeper intersecting free-standing structures up to 435 μm in height, while maintaining acceptable surface roughness (1.51 μm Ra and 2.47 μm Wa), undercutting (25 μm), and undesirable erosion (3%).

AWJ allows for the elimination of heat influence [ 22 ] or surface oxidation [ 23 ], but it is necessary to provide corrosion protection for the machined surface, especially for materials prone to erosion [ 24 ]. This technology is widely used for cutting various materials, including electrochemical sheet metals used in the construction of transformer cores or parts of electric motor stators and rotors [ 25 ], milling (micronization) [ 26 ], and cleaning surfaces of a wide range of materials [ 27 ].

In abrasive-water jet texturing, material is removed due to the interaction of abrasive particles suspended in a high-pressure water jet expelled from a nozzle. The undeniable advantages of AWJ include the ability to process a wide range of materials, absence of thermal stress generation in the interaction zone, flexibility of the texturing process through changing process parameters, and the ability to process surfaces with complex geometry and precise control of nozzle displacement [ 28 ]. This method, which sustainably utilizes natural resources, is environmentally friendly compared to chemical texturing technology. Textured surfaces can also undergo post-processing, including grinding using grinding wheels [ 29 ] or abrasive films [ 30 ].

While the application of AWJ in surface texturing is gaining increasing interest, this issue is not widely cited in the global literature. In one of the early works, Artaza et al. [ 11 ] described the possibility of using AWJ to ensure a rigid mechanical connection between a textured stainless steel substrate and a glass fiber–epoxy composite. Experimental studies indicated that the parameter with the greatest influence on the roughness of the textured surface was the jet pressure. Banon et al. [ 31 ] utilized AWJ technology for texturing the surface of thin aluminum alloy UNS A92024, analyzing the relationships between process parameters and the roughness of the textured surface. They demonstrated, among other findings, that reducing the displacement velocity results in increased exposure of the abrasive water jet, thereby minimizing kinetic energy losses and reducing the scale of erosion on the textured surface. Continuing their work on texturing thin aluminum alloys, Banon et al. [ 32 ] highlighted that the mass flow rate was a parameter having the greatest influence on surface roughness parameters such as Sa and Sk, as well as surface wettability. Meanwhile, the Sz parameter was mainly defined by the velocity of jet displacement. Special attention should also be paid to the work of Sourd et al. [ 33 ], in which AWJ texturing was used as a surface preparation technique for increasing the adhesive bonding of 3D woven Carbon Fiber Reinforced Polymer (CFRP) substrates. As the research has shown, such an operation led to a change in the mechanical performance of 3D woven CFRP composites. It was found that a higher crater volume correlated with decreased tensile and fatigue performance.

The analysis of surface texturing has shown that this process is significant in many industries, giving materials a unique appearance and texture. Surface texturing enhances the functional properties of materials [ 34 ], such as roughness for better adhesion or wear resistance [ 35 ]. The surface texturing process is crucial in manufacturing, both from aesthetic and functional perspectives. It is a key process that influences the final appearance, functional properties, and value of products [ 36 ].

Filling the gap regarding the application of high-pressure abrasive-water jet surface texturing technology using algorithms to create sophisticated surface structures can bring many benefits and innovations. Utilizing high water pressure and abrasives allows for precise and controlled surface texturing processes [ 37 ]. Complex patterns and textures can be achieved. The ability to control the type of abrasive and the velocity of the jet provides flexibility in achieving various effects [ 38 ]. The process can be tailored to specific needs and requirements for the textured surface. Compared to traditional texturing methods, using abrasive-water jet generates less waste and is more environmentally friendly. The speed and efficiency of the high-pressure abrasive-water jet surface texturing process can contribute to reducing production time and costs. Introducing texturing methods can improve quality, efficiency, and innovation in manufacturing processes.

The work focused on examining the potential use of AWJ jet in the process of developing the surface field structure of processed material using a texture pattern generated by an algorithm.

The aim of the conducted experimental research was to determine the feasibility of obtaining specific structures on the surface of 304/1.4301 steel using abrasive-water jet technology. The conducted studies enabled the determination of the influence of process parameters on the geometry of the produced micro-indentations. The research results form the basis for determining the possibilities of modifying the surface structure using abrasive-water jet technology, allowing for surface adaptation to operate under specific operating conditions.

2 Materials and methods

The high-pressure abrasive-water jet is a versatile tool with various applications. One of these possibilities is its use in surface shaping processes. Its remarkable characteristics minimize the influence of structural changes in the processed material. The basis for selecting the appropriate AWJ texturing parameters was the ability to control the type and amount of abrasive supplied, as well as the jet velocity, providing great flexibility in achieving various effects. This capability was utilized in laboratory studies to achieve diverse surface structures on the processed material.

2.1 Abrasive-water jet surface-texturing equipment

Achieving the appropriate surface structure is an extremely important process from the perspective of its application in subsequent processing stages or usage. Figure  1 shows examples of texture patterns manufactured using high-pressure abrasive-water jet and their topography maps obtained using the confocal microscope LEXT OLS4000 (Olympus, Shinjuku, Tokyo, Japan).

Examples of texture patterns manufactured using high-pressure abrasive-water jet: a texture 1; b texture 2; c texture 3

The structures obtained using AWJ confirmed findings by Ibrahim et al. [ 21 ], demonstrating the capability to produce diverse structures with depths exceeding 400 µm. On the textured surfaces (Fig.  1 ), a clearly directional structure is visible. Depending on the desired results, different depths (Fig.  1 a and b) and shapes (Fig.  1 c) of texturing can be achieved. These properties were utilized in an experimental study of spatially shaping the material surface using AWJ, conducted with an OMAX Jet Machining Center 55,100/4055 (OMAX Corporation, Kent, WA, USA, Fig.  2 ).

High-pressure abrasive-water jet surface texturing equipment

The OMAX Jet Machining Center is equipped with technical solutions in the form of a high-pressure pump rated at 30 kW. It features a unique Tilt-A-Jet head that dynamically adjusts its angular position relative to the cutting edge. These solutions enable the generation of a high-pressure jet with a maximum pressure of pmax = 385 MPa and a volumetric flow rate of Qmax = 0.065 dm 3 /s. The machine’s cantilever construction ensures high dimensional and shape accuracy, with a deviation value of approximately ± 0.05 mm. The worktable dimensions are 2540 mm by 1400 mm. Surface texturing was carried out under constant parameters as presented in Table  1 .

2.2 Process parameters

OMAX Intelli-ETECH software ((OMAX Corporation, Kent, WA, USA) was used for precising controlling of the AWJ surface texturing process.

In the first stage, the displacement speeds of the working head were determined. The maximum achievable texturing speed is 2.54 m/min. Table 2 presents selected working head speeds for texturing. The textured surfaces had dimensions of 25 mm × 25 mm (chosen for convenient microscopic observations during analysis).

The method involved controlling the displacement speeds of the abrasive-water jet relative to the surface of the textured material, ensuring that the jet interacts with specific areas of the surface at variable time intervals. The result of such variable interaction is varied indentations along the path of the jet's erosion. The general concept is presented in Fig.  3 .

The general concept of AWJ surface texturing process

For the successful implementation of the process, it is necessary to establish the starting and ending points, as well as the orientation of the abrasive-water jet passage. The process was carried out at a pressure of 128 MPa. As a result of subsequent passes of the stream, moved in increments proportional to the diameter of the mixing nozzle opening on the processed material, appropriate cavities were obtained.

For the AWJ surface texturing process, garnet with a granulation of 80 mesh was used as the abrasive. Figure  4 shows the morphology and particle size distribution of the abrasive. Particle size analysis was conducted using a laser particle size analyzer of the Analysette 22 MicroTec Plus type (Fritsch GmbH, Amberg, Germany).

Garnet abrasive used during AWJ surface texturing: a morphology, b particle size distribution of the abrasive used for the texturing process

2.3 Substrate material

The textured substrate was a stainless steel sheet of grade 304/1.4301. The sheet supplier provided relevant certificates. Its basic parameters and chemical composition are presented in Table  3 .

Stainless steel 304/1.4301 is a popular type of material that contains about 18% chromium and 8% nickel. This steel is one of the most commonly used grades of stainless steel due to its good corrosion resistance properties. It is resistant to high temperatures and easy to machine. Stainless steel 304 is used in many fields, such as the food, chemical, and pharmaceutical industries, as well as in the production of kitchenware, fittings, and structural components.

2.4 Examples of surface patterns generated using mathematical algorithm

To generate texture patterns, MATLAB R2024a (Natick, MA, USA) software was used. The texture patterns were generated through operations on data matrices containing information about texture regulation. Examples of generated texture patterns are presented in Fig.  5 .

Examples of texture patterns generated with arrangement of straight sections

The generation process involves interactive operations to determine the absolute values from a data vector with a negative harmonic component, followed by multiplying the horizontal and vertical vectors using a convolution operation filter and then smoothing filters. Next, a randomized component typical for abrasive-water jet technology is introduced, and in the final stage, surface elevation modifications are made by mapping the ground surface only on the elevations (Algorithm 1).

The described approach allows for comprehensive utilization of various techniques for generating and visualizing textures patterns. It can also be used to experiment with different types of textures patterns and their modifications in the context of image analysis or computer graphics.

Generate textured surface with arrangement of straight sections

Abrasive-water jet technology offers extensive capabilities for generating various textured structures on material surfaces. Its versatility and precision enable the creation of both microscopic and macroscopic patterns, such as grids, meshes, or hexagons, each with diverse functional properties. Integrated with advanced control systems and capable of combining with other technologies, AWJ becomes an indispensable tool across many industrial sectors.

Example textures generated based on an algorithm are presented in Fig.  6 .

Surface topography of experimentally fabricated structures

2.5 Geometric surface structure and shape deviations analysis

Geometric surface structure analysis for textured surfaces were conducted using the confocal microscope LEXT OLS4000. The basic parameters of microscope are presented in Table  4 .

Thanks to the two operating modes of the LEXT OLS4000 microscope, observations can be carried out non-destructively in both microscope mode and confocal mode. The motorized measurement stage allows for observation and movement in the x–y axes within the observation field, depending on the current magnification, ranging from 16 µm × 16 µm to 2560 µm × 2560 µm.

Measurements were conducted at 108 × magnification. Figure  7 shows the microscope alongside one of the tested samples and the selected area for measurements. The obtained data were analyzed using TalyMap Platinum software (Taylor Hobson, Leicester, UK).

Confocal microscope LEXT OLS4000 with one of the tested samples and the area selected to measurements

3 Results and discussion

3.1 experimental studies on surfaces textured with abrasive-water jet.

The process of shaping textured surfaces with abrasive water jet allowed us to determine the influence of the feed rate of the cutting head on the depths of the indentations (Fig.  8 ).

Depth of indentation (y) of the textured surface as a function of the feed rate of the cutting head (x)

To calculate the valley depth of a textured surface as a function of the head displacement speed, a general equation was formulated:

The research results clearly indicate that with an increase in the head displacement speed, the depth of valleys in the textured surface decreases. The valley depth varied depending on the variable displacement speed of the working head, affecting the duration of interaction time between the AWJ and the material. At the lowest investigated speed of 0.803 m/min, the valley depth measured 204 µm. However, at the highest investigated speed of 1.948 m/min, the valley depth decreased to approximately 87 µm (Fig.  8 ).

Based on these results, it was found that increasing the displacement speed of the working head led to a reduction in valley width and an increase in peak width on the tested textured surfaces (Fig.  9 ).

Topography of tested surfaces textured with different displacement speeds of the working head (designations P1–P7 according to Table  2 )

The width of the valleys decreases with increasing displacement speeds of the working head. For the lowest speed of 0.803 m/min, the width of the valleys was 0.47 mm, while for the highest speed of 1.948 m/min, it measured 0.395 mm. Meanwhile, the width of the peaks increases with increasing displacement speeds of the working head, ranging from 0.3 mm at a speed of 0.803 m/min to 0.365 mm at a speed of 1.948 m/min.

In summary, the analysis of the obtained widths of the peaks and valleys revealed a significant dependence on the abrasive water jet processing speed. This property can be utilized to optimize the shaping of the geometric structure of cooperating surfaces, which are exposed to wear or characterized by an increased ability to maintain an oil film.

Friction processes on material surfaces lead to damage or wear, primarily affecting the surface layer of the material. Therefore, the surface formed as a result of texturing with different displacement speeds using abrasive-water jet determines the intensity and course of wear during use. The surface condition, particularly the geometric structure of the surface, is best described by parameters such as surface roughness or structural directionality. The arrangement of peaks and valleys can be described by a bearing curve. The bearing capacity of the analyzed surfaces is presented using Abbott–Firestone curves, as shown in Fig.  10 .

Abbott–Firestone curves for tested surfaces textured with different displacement speeds of the working head (designations P1–P7 according to Table  2 )

The material ratio curves provide reliable information about the shape of the analyzed profiles, including their peaks and valleys. Through appropriate analysis of Abbott-Firestone curves, information about the properties of the analyzed profiles regarding the functional performance of the geometric structure of the surface can be obtained. The observed decrease in the Sk parameter indicates surface smoothing at higher displacement speeds of the working head. Figure  11 presents a group of analyzed parameters upon which an assessment of the functional behavior of the surface after texturing can be based. It has been shown that parameters such as Sa or Sz, depend on the velocity of the AWJ jet, as confirmed by the study of Banon et al. [ 32 ].

Geometric structure surface parameters for tested AWJ textured surfaces: a Sa—arithmetic mean height, b Sz—maximum height of the surface, c S10z—ten-point height, d Sp—maximum peak height, e Sv—maximum valleys depth

The analysis of the obtained parameter values showed that both the arithmetic mean height of the surface Sa (Fig.  11 a) and its maximum height Sz, and the height of ten-point height S10z (Fig.  11 b and c), decrease with the increase in displacement speeds of working head. For the lowest analyzed displacement speeds, a parameter Sa twice as high was obtained, which is significant in terms of reduced wear resistance of the surface.

The smallest values of the peak height Sp (Fig.  11 d) were obtained for the surfaces textured with speeds of 1.948 m/min (P7), 1.841 m/min (P6) and 1.647 m/min (P5). Therefore, these surfaces have the highest bearing capacity among the analyzed surfaces. The height of the peaks above the core roughness profile Sp determines the behavior of the geometric surface structure during mating of components. Additionally, this is also evidenced by the decreasing load-bearing contribution of the peaks Smrk1 with increasing texturing speed. The highest load-bearing contribution, approximately 25%, of the peaks Smrk1 was obtained for a displacement speed of 0.803 m/min (Fig.  10 , P1). Meanwhile, the lowest load-bearing contribution of the peaks Smrk1, below 10%, was obtained for a texturing speed of 1.948 m/min (Fig.  10 , P7).

The analysis of the depth of the valleys Sv (Fig.  11 e), which is the depth of the valleys located below the core roughness profile, showed similar values for displacement speeds in their middle range and the smallest depths for the lowest and highest speeds. The largest values of the load-bearing contribution of the valleys Smrk2 (Fig.  10 ) were obtained for surfaces textured with moderate displacement speeds. A high value of this parameter indicates the ability to maintain a lubricating oil film held by the surface structure. Surfaces requiring good lubrication should be characterized by large values of Sv parameter.

Figure  12 shows the distribution of surface point frequencies after texturing.

The distribution of surface point heights for tested AWJ textured surfaces (designations P1–P7 according to Table  2 )

The range of frequency distribution decreases with increasing displacement speeds of the working head, indicating surface leveling. The parameter c2-c1 indicates the dispersion of surface point heights. More dispersed surface points can be observed at low displacement speeds of the head. For the lowest speed of 0.803 m/min, this dispersion is 192 µm, whereas for high speeds, it is around 100 µm. Parameters Sp and Sv represent the boundaries of surface point frequencies. The sum (Sp + Sv) of the maximum peak height Sp and the maximum valley depth Sv decreases with increasing displacement speed. Thus, the decrease in this parameter indicates surface smoothing of the textured surfaces at higher speeds.

Table 5 presents the maximum and average depth and density of the valleys for textured surfaces at various displacement speeds of the texturing head.

3.2 Experimental studies of surfaces textured with high-pressure abrasive-water jet after grinding process

Based on the conducted analysis of the textured surface, it was found that the least favorable values of the analyzed geometric surface structure parameters, in terms of the load-bearing contribution of peaks and valleys, were obtained for surfaces P2 and P3, corresponding to low displacement speeds of the working head. To achieve better parameters such as Sp, Sv, Smrk1, and Smrk2 for these surfaces, a grinding process using abrasive films with grit sizes ranging from 14 µm to 20 µm was conducted. Figure  13 shows the surface views of P2 and P3 before and after the grinding process.

Topography of tested textured surfaces before (P2, P3) and after (P2S, P3S) grinding process using abrasive films

Thanks to the grinding process, the height of the peaks was reduced by 134 µm for P2S and by 89.6 µm for P3S. Figure  14 shows a comparison of Abbott–Firestone curves for selected surfaces before and after smoothing.

Abbott–Firestone curves for selected surfaces before (P2, P3) and after (P2S, P3S) grinding process

Table 6 presents parameters for quantitative analysis of the load-bearing curve (Abbott–Firestone curves) of the textured surface before and after grinding process.

Based on the obtained load-bearing curve parameters for the textured surface before and after smoothing, a decrease in the Spk parameter was observed, indicating an increase in the load-bearing capacity of these surfaces after grinding by approximately 10% for surface P2S and about 1.5% for surface P3S. A decrease in the Svk parameter by approximately 50% for surfaces after grinding indicates poorer fluid retention by the surface. Figure  15 shows the distribution of surface point heights before and after grinding with abrasive film.

The distribution of surface point heights for selected surfaces before (P2, P3) and after grinding process (P2S, P3S)

The characterization of the elevation distribution of the analyzed surfaces after grinding takes on a bimodal character, indicating the presence of maximum elevation values in two zones. This phenomenon suggests a smoothing effect on the ridges of the textured surfaces.

4 Conclusions

Abrasive-water jet is a tool used in surface treatment processes, especially for metals. Its application for surface texturing can bring several benefits, such as improving coating adhesion, removing scratches, and imparting surface texture. Another aspect advocating for surface structure development is the ability to maintain an oil layer on the surface, which is extremely important in processes requiring surface lubrication. The conducted analysis of the use of AWJ in surface material structuring processes has demonstrated its effectiveness. Based on the conducted research, the following conclusions can be drawn:

The use of AWJ technology for texturing stainless steel surfaces is possible and justified. The results obtained by other researchers [ 32 ] regarding the impact of AWJ texturing speed on the parameters of the geometric surface structure have been confirmed. Increasing the texturing speed increases both surface load-bearing capacity and the ability to maintain an oil film.

The highest load-bearing contribution of peaks, Smrk1 (approximately 25%), was achieved at a texturing speed of 0.803 m/min, while the lowest (below 10%) was observed at a speed of 1.948 m/min.

The surface texturing process has a positive effect on maintaining the geometric structure of the surface during lapping of the elements, causing a decrease in the value of the height of the upper part of the surface Sp and a decrease in the load-bearing share of the Smrk1 vertices with an increase in the texturing speed.

As the texturing speed increases, the depth of the recesses located below the Sv roughness core profile increases and the load-bearing share of the Smrk2 recesses increases, thereby improving the lubricating properties of these surfaces.

The process of grinding the surface after texturing increases the load-bearing capacity of the surface, causing a several percent increase in the Spk parameter, thus doubling the ability of the surface to maintain an oil film.

The use of water abrasive jet in the process of texturing the surface of materials is an innovative technology that offers many advantages over traditional processing methods. Thanks to precise process control and the variety of abrasives used, this technology is not only effective but also sustainable and versatile. Its application in various industries contributes to improving the quality of products and enhancing their aesthetic and functional value. In the implemented surface texturing process, the development of the processed surface was achieved at selected process speeds. New possibilities of controlling the process of shaping the surface processed with an AWJ jet to obtain a surface with the desired functional and operational properties can also be used for other materials. Research on surface texturing of 304/1.4301 steel using abrasive blasting technology (AWJ) has shown that specific surface structures can be obtained, which can significantly improve the functionality and performance of materials in various engineering applications.

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Scientific work funded from the state budget under the program of the Minister of Science entitled “Polish Metrology II” (Poland), project number PM-II/SP/0038/2024/02, funding amount 999,530.40 PLN, total project value 999,530.40 PLN.

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Szada-Borzyszkowska, M., Kacalak, W., Szada-Borzyszkowski, W. et al. Topography of textured surfaces using an abrasive-water jet technology. Arch. Civ. Mech. Eng. 24 , 226 (2024). https://doi.org/10.1007/s43452-024-01035-z

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Received : 10 May 2024

Revised : 17 July 2024

Accepted : 17 August 2024

Published : 04 September 2024

DOI : https://doi.org/10.1007/s43452-024-01035-z

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