Electrolyte jet tomography: Three-dimensional microstructure mapping with an electrochemical machine tool and an optical microscope
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Bibliographic record
Abstract
There is a general separation between the manufacturing processes that add value to materials on the factory floor and the techniques engineers use in the laboratory to evaluate the microstructures and the surface integrity that results. These techniques are often destructive or require a vacuum and are incompatible with production lines. However, this information has intrinsic value and could be exploited to inform production decisions during manufacture. In this study, a novel approach to acquire this information is presented that is underpinned by electrolyte jet machine tool coupled with optical microscopy, which can allow the extraction of both grain-wise partial orientation and morphological information, and crystallographic macro textures in three dimensions. Here, iterative sections are precisely machined into the near surface of a commercially pure titanium alloy using an electrochemical jet and subsequently imaged, allowing the reconstruction of high-fidelity microstructure models rapidly and under ambient conditions. In doing so, new insights into the specific orientation-dependent dissolution mechanisms are offered, and the acquisition of appropriate conditions that result in nanoscale roughness surfaces (avoiding the dominance of pitting and preferential grain removal) is firstly explored. Building on prior work, a piecewise approach is presented to analyse the acquired image stacks to map partial crystal orientations, while different approaches are proposed to account for jet-specific surface artefacts and waviness. This is repeated over 20 layers in an individual specimen and layer-wise orientation maps are used to construct volumetric models of the specimen. These data sets are then explored from the perspective of materials/manufacturing engineers, who may use to this information to effect advancements to materials processing technologies. • An electrolyte jet can be used as a rapid, ambient, and low-cost serial sectioning tool to map microstructures in 3D. • Surface generation mechanisms explored in Ti CP 1, allowing insight into stable process parameters for surface imaging. • Process stability was demonstrated by 20 repeated sections at a layer resolution of 1.8 μm allowing grain reconstruction. • Partial orientations were extracted from polarized light images, allowing observation of grain interfaces from 3D datasets.
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Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.001 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.001 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.001 | 0.001 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from it