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Abstract Electrical discharge erosion in liquid media is a simple, effective technique to generate multi-scale metallic particles. An experimental investigation was conducted to determine the main machining parameters which contribute to particle size (PS) and size distribution (SD) in WEDM of bronze. Five factors, including three-level built-in processing patterns, wire speed and dielectric medium, are selected as control parameters using an orthogonal array L16(45) Taguchi method, PS and SD of produced powders are the measure of quality. The goal is to obtain micron-scale spherical metal powder with uniform particle size. Results show that cutting-section pattern is the most significant factor, and the electrolyte is the least. The PS and SD performance of the optimized powders is significantly improved by using Taguchi method. Spherical bronze powder with particle size of d10 11.05 μm, d50 31.13 μm and d90 67.48 μm are prepared using the optimized WEDM process parameter, which is A3–B4–C3–D1–E1 including dielectric medium water, cutting class 4, cutting division 3, cutting Sect. 1 and wire speed 200 μm/s. The research confirms that WEDM can be used to produce micron-scale metallic powders, providing cheap and high-quality metallic powders for the metal additive manufacturing industry.

The development of innovative methods to prepare graphene-based polymer composites with remarkable properties has become a priority due to the many practical applications of these microstructures. Herein, a new technology was used to fabricate composites by combining graphene materials and polymer microspheres. Polyamide 6 (PA6) microspheres were synthesised by reaction-induced phase separation method, and they were wrapped with few-layer graphene (FLG) or graphene oxide (GO) by exfoliated adsorption method, which allows FLG and GO sheets to form a three-dimensional network structure in the PA6 matrix. Electrical and mechanical characterisation led to a distinct improvement in the properties of PA6 composites, which were superior to traditional graphene/polymer composites. Moreover, the process proposed in this work proved to be an effective method to prepare graphene/polymer composites, suitable for industrial production, and can be extended to other kinds of composites with nanofillers.

For purpose of developing damping materials with increased damping capacity over a wide band, NiTi–PU composites were fabricated by vacuum molding polyether polyurethane melt with NiTi alloy chips additive. The composites were tested using three-point bending at various testing temperatures. Appreciable improvements were observed in bending modulus and load-deflection hysteresis loops of PU matrix. The bending modulus and hysteresis loop area of a composite with 70% NiTi volume content reach a maximum, which are 5.4 times and 5.6 times higher than those of PU matrix, respectively. The mechanism of bending modulus enhancement of NiTi additive was discussed. Keywords: Nitinol, Polyurethane, Composites, Bending modulus, Hysteresis loop