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Materials 2018, 11(5), 771; https://doi.org/10.3390/ma11050771

Evaluation of Surface Roughness by Image Processing of a Shot-Peened, TIG-Welded Aluminum 6061-T6 Alloy: An Experimental Case Study

1
Industrial Engineering Department, School of Applied Technical Sciences, German Jordanian University (GJU), Amman 11180, Jordan
2
Mechatronics Engineering Department, School of Applied Technical Sciences, German Jordanian University (GJU), Amman 11180, Jordan
3
Department of Physics & Astronomy, College of Science, King Saud University, Riyadh 11451, Saudi Arabia
4
King Abdullah Institute for Nanotechnology (KAIN), King Saud University, Riyadh 11451, Saudi Arabia
*
Author to whom correspondence should be addressed.
Received: 12 April 2018 / Revised: 3 May 2018 / Accepted: 4 May 2018 / Published: 10 May 2018
(This article belongs to the Special Issue Surface Modification to Improve Properties of Materials)
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Abstract

Visual inspection through image processing of welding and shot-peened surfaces is necessary to overcome equipment limitations, avoid measurement errors, and accelerate processing to gain certain surface properties such as surface roughness. Therefore, it is important to design an algorithm to quantify surface properties, which enables us to overcome the aforementioned limitations. In this study, a proposed systematic algorithm is utilized to generate and compare the surface roughness of Tungsten Inert Gas (TIG) welded aluminum 6061-T6 alloy treated by two levels of shot-peening, high-intensity and low-intensity. This project is industrial in nature, and the proposed solution was originally requested by local industry to overcome equipment capabilities and limitations. In particular, surface roughness measurements are usually only possible on flat surfaces but not on other areas treated by shot-peening after welding, as in the heat-affected zone and weld beads. Therefore, those critical areas are outside of the measurement limitations. Using the proposed technique, the surface roughness measurements were possible to obtain for weld beads, high-intensity and low-intensity shot-peened surfaces. In addition, a 3D surface topography was generated and dimple size distributions were calculated for the three tested scenarios: control sample (TIG-welded only), high-intensity shot-peened, and low-intensity shot-peened TIG-welded Al6065-T6 samples. Finally, cross-sectional hardness profiles were measured for the three scenarios; in all scenarios, lower hardness measurements were obtained compared to the base metal alloy in the heat-affected zone and in the weld beads even after shot-peening treatments. View Full-Text
Keywords: materials characterization; shot-peening; image processing; TIG welding; aluminum 6061-T6 materials characterization; shot-peening; image processing; TIG welding; aluminum 6061-T6
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Atieh, A.M.; Rawashdeh, N.A.; AlHazaa, A.N. Evaluation of Surface Roughness by Image Processing of a Shot-Peened, TIG-Welded Aluminum 6061-T6 Alloy: An Experimental Case Study. Materials 2018, 11, 771.

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