Knife-edge interferogram analysis for corrosive wear propagation at sharp edges
Zhikun Wang, ChaBum Lee
Abstract
This paper presents a novel noncontact measurement and inspection method based on knife-edge diffraction theory for corrosive wear propagation monitoring at a sharp edge. The degree of corrosion on the sharp edge was quantitatively traced in process by knife-edge interferometry (KEI). The measurement system consists of a laser diode, an avalanche photodiode, and a linear stage for scanning. KEI utilizes the interferometric fringes projected on the measurement plane when the light is incident on a sharp edge. The corrosion propagation on sharp edges was characterized by analyzing the difference in the two interferometric fringes obtained from the control and measurement groups. By using the cross-correlation algorithm, the corrosion conditions on sharp edges were quantitatively quantified into two factors: lag and similarity for edge loss and edge roughness, respectively. The KEI sensor noise level was estimated at 0.03% in full scale. The computational approach to knife-edge diffraction was validated by experimental validation, and the computational error was evaluated at less than 1%. Two sets of razor blades for measurement and control groups were used. As a result, the lag will be increased at an edge loss ratio of 1.007/µm due to the corrosive wear, while the similarity will be decreased at a ratio of <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline"> <mml:mn>5.4</mml:mn> <mml:mo>×</mml:mo> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:msup> <mml:mn>10</mml:mn> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mo>−</mml:mo> <mml:mn>4</mml:mn> </mml:mrow> </mml:msup> </mml:mrow> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mo>/</mml:mo> </mml:mrow> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mtext>µ</mml:mtext> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mi mathvariant="normal">m</mml:mi> </mml:mrow> </mml:mrow> </mml:mrow> </mml:math> with respect to edge roughness change. Experimental results showed a good agreement with computational results.