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Lab-made biosilica (SiO2) nanoparticles were obtained from waste biomass (rice husks) and used as eco-friendly fillers in the production of nickel matrix composite films via the co-electrodeposition technique. The produced biosilica nanoparticles were characterized using XRD, FTIR, and FE-SEM/EDS. Amorphous nano-sized biosilica particles with a high SiO2 content were obtained. Various current regimes of electrodeposition, such as direct current (DC), pulsating current (PC), and reversing current (RC) regimes, were applied for the fabrication of Ni and Ni/SiO2 films from a sulfamate electrolyte. Ni films electrodeposited with or without 1.0 wt.% biosilica nanoparticles in the electrolyte were characterized using FE-SEM/EDS (morphology/elemental analyses, roundness), AFM (roughness), Vickers microindentation (microhardness), and sheet resistance. Due to the incorporation of SiO2 nanoparticles, the Ni/SiO2 films were coarser than those obtained from the pure sulfamate electrolyte. The addition of SiO2 to the sulfamate electrolyte also caused an increase in the roughness and electrical conductivity of the Ni films. The surface roughness values of the Ni/SiO2 films were approximately 44.0%, 48.8%, and 68.3% larger than those obtained for the pure Ni films produced using the DC, PC, and RC regimes, respectively. The microhardness of the Ni and Ni/SiO2 films was assessed using the Chen-Gao (C-G) composite hardness model, and it was shown that the obtained Ni/SiO2 films had a higher hardness than the pure Ni films. Depending on the applied electrodeposition regime, the hardness of the Ni films increased from 29.1% for the Ni/SiO2 films obtained using the PC regime to 95.5% for those obtained using the RC regime, reaching the maximal value of 6.880 GPa for the Ni/SiO2 films produced using the RC regime. [ABSTRACT FROM AUTHOR]

In this paper, the morphological, micromechanical and tribological characteristics of the Ti-6Al-4V ELI alloy after thermal oxidation (TO) were identified. TO was carried out at temperatures of 848 K, 898 K and 948 K over a period of 50 h. Microscopic examination revealed that an increase in temperature resulted in an improved uniformity of coverage and an increased oxide grain size. Micromechanical tests showed that TO of the Ti-6Al-4V ELI alloy led to an increase in hardness and deformation resistance. Following oxidation, a decrease (by approximately 10–22%) was observed in the total mechanical work of indentation, Wtotal, compared to the as-received material. The formation of protective oxide films on the Ti-6Al-4V ELI alloy also led to the improvement of tribological characteristics, both when tested under dry friction conditions and in Ringer's solution. The sliding wear resistance increased with an increase in the oxidation temperature. However, a greater degree of wear reduction (by approximately 30–50%) was found for the lubricated contact in comparison with the dry friction tests. Surface roughness also increased with the increase in temperature. [ABSTRACT FROM AUTHOR]

Carburized steel shafts are commonly used in industry due to their good wear resistance and fatigue life. If the surface of carburized shafts exhibits an undesired tensile stress, shot peening treatment may be required to alter the stress condition on the surface. In the present study, the effects of shot peening pressure (3–5 kg/cm2), time (32–64 s), and material (stainless steel, carbon steel, and glass) on the residual stress, retained austenite, microhardness, and surface roughness of the carburized shafts were investigated. The experimental results showed that the surface residual tensile stress was changed into compressive stress after the shot peening treatment. The shot peening effects increased with the increasing peening pressure and time. In addition, a significant decrease in the amount of retained austenite in the subsurface region was observed. Peening with different materials can affect the peening effect. Using glass pellets exhibited the best shot peening effect but suffered massive pellet fracture during processing. In overall consideration, the optimal peening parameters for carburized steel shafts for practical industrial applications involved using the stainless-steel pellets with a peening pressure of 5 kg/cm2 and a peening time of 64 s. The maximum residual stress was −779 MPa at a depth of 0.02 mm, while the highest surface microhardness was 827 HV0.1. [ABSTRACT FROM AUTHOR]

Flux calibrations in multi-source thermal co-evaporation of thin films have been developed based on real-time spectroscopic ellipsometry (RTSE) measurements. This methodology has been applied to fabricate CuInSe2 (CIS) thin film photovoltaic (PV) absorbers, as an illustrative example, and their properties as functions of deposition rate have been studied. In this example, multiple Cu layers are deposited step-wise onto the same Si wafer substrate at different Cu evaporation source temperatures (TCu). Multiple In2Se3 layers are deposited similarly at different In source temperatures (TIn). Using RTSE, the Cu and In2Se3 deposition rates are determined as functions of TCu and TIn. These rates, denoted Reff, are measured in terms of effective thickness which is the volume per planar substrate area and accounts for surface roughness variations with deposition time. By assuming that all incident metal atoms are incorporated into the films and that the atomic concentrations in the deposited material components are the same as in single crystals, initial estimates of the Cu and In atom fluxes can be made versus TCu and TIn. Applying these estimates to the co-evaporation of a set of CIS films from individual Cu, In, and Se sources, atomic concentration corrections can be assigned to the Cu and In2Se3 calibration films. The corrections enable generation of a novel calibration diagram predicting the atomic ratio y = [Cu]/[In] and rate Reff within the TCu-TIn plane. Using this diagram, optimization of the CIS properties as a PV absorber can be achieved versus both y and Reff. [ABSTRACT FROM AUTHOR]

The common machining technologies for difficult-to-machine materials do not remarkably ensure acceptable efficiency and precision in bulk materials cutting. High-energy abrasive water injection jet (AWIJ) treatment can cut diverse materials, even multi-layer composites characterized by divergent properties, accurately cutting complex profiles and carrying them out in special circumstances, such as underwater locations or explosion hazard areas. This work reports research on the AWIJ machining quality performance of X22CrMoV12-1 high-alloy steel. The response surface method (RSM) was utilized in modeling. The most influencing process control parameters on cut kerf surface roughness—abrasive flow rate, pressure, and traverse speed—were tested. The result is a mathematical model of the process in the form of a three-variable polynomial. The key control parameter affecting the cut slot roughness turned out to be the traverse speed. In contrast, pressure has a less significant effect, and the abrasive mass flow rate has the slightest impact on the cut slot roughness. Under the optimal conditions determined as a result of the tests, the roughness of the intersection surface Sq does not exceed 2.3 μm. Based on the ANOVA, we confirmed that the model fits over 96% appropriately with the research outcomes. This method reduces the computations and sharply determines the optimum set of control parameters. [ABSTRACT FROM AUTHOR]

This study assessed the surface topography and plastic deformation (PD) of new and used contemporary reciprocating instruments. Twenty-six WaveOne Gold (WOG) and EdgeOne Fire (EO) instruments were photographed under magnification. The instruments were randomly assigned to a control group of new instruments preserved for surface roughness analysis (n = 6 each), or to an experimental group to shape the root canal system of a single molar (n = 20 each), making a total of four groups (WOGnew, EOnew, WOGused, EOused). Used instruments were also photographed after instrumentation. The presence of fractures was registered. Preoperative and postoperative images were randomly ordered for evaluation. Two blinded calibrated examiners evaluated the presence of PD. Inter-observer agreement was calculated with the Kappa coefficient (K = 0.89). 3D profilometry was also used for the surface roughness analysis of six randomly selected instruments from the WOGused and EOused groups. Chi-square and two-way ANOVA tests were used to, respectively, compare PD and changes in surface roughness among the groups. No instruments fractured; however, a significantly greater percentage of EO instruments suffered plastic deformation than WOG instruments (p < 0.001), (OR = 11.09 (CI 95% 2.6–56.3)). The overall surface roughness was higher for most parameters in the EO instruments (p < 0.05). Single uses of EO instruments produced significantly higher chances of PD and increased surface roughness values compared to WOG. [ABSTRACT FROM AUTHOR]

Pure titanium is a preferred material for medical applications due to its outstanding properties, and the fabrication of its surface microtexture proves to be an effective method for further improving its surface-related functional properties, albeit imposing high demands on the processing accuracy of surface microtexture. Currently, we investigate the fabrication of precise microtextures on pure titanium surfaces with different grid depths using precision-cutting methods, as well as assess its impact on surface wettability through a combination of experiments and finite element simulations. Specifically, a finite element model is established for pure titanium precision cutting, which can predict the surface formation behavior during the cutting process and further reveal its dependence on cutting parameters. Based on this, precision-cutting experiments were performed to explore the effect of cutting parameters on the morphology of microtextured pure titanium with which optimized cutting parameters for high-precision microtextures and uniform feature size were obtained. Subsequent surface wettability measurement experiments demonstrated from a macroscopic perspective that the increase in the grid depth of the microtexture increases the surface roughness, thereby enhancing the hydrophilicity. Corresponding fluid–solid coupling finite-element simulation is carried out to demonstrate from a microscopic perspective that the increase in the grid depth of the microtexture decreases the cohesive force inside the droplet, thereby enhancing the hydrophilicity. [ABSTRACT FROM AUTHOR]

This study aimed to evaluate the effect of airborne particle abrasion with different particles on the surface free energy, roughness, and biaxial flexural strength of a feldspathic ceramic by comparing it with hydrofluoric acid etching, the standard surface treatment, and polishing. Square-shaped feldspathic ceramic specimens (12 mm × 12 mm × 1.2 mm) were divided into subgroups as airborne particles abraded with alumina (AO3a, AO3b, AO25, AO50a, AO50b, AO90, AO110a, AO110b, AO120a, and AO120b), silica (SO50a, SO50b, SO100, and SO100/200), or nutshell granule (NS100/200), hydrofluoric acid etched, and polished (n = 12). Surface free energy (n = 5), roughness (n = 5), biaxial flexural strength (n = 12), and Weibull moduli (n = 12) were investigated. Data were evaluated with 1-way ANOVA and Tukey HSD tests, and possible correlations were investigated with Pearson's correlation (α = 0.05). SO100/200 mostly had lower surface free energy (p ≤ 0.011), and polishing and etching led to higher surface free energy than AO3a, AO3b, and AO120a (p ≤ 0.031). Polished, SO100, and SO50b specimens mostly had lower roughness and AO125 had the highest roughness (p ≤ 0.029). SO100/200 mostly had lower biaxial flexural strength (p ≤ 0.041), and etched specimens had higher biaxial flexural strength than AO120a, AO120b, and SO50b (p ≤ 0.043). AO3b had the highest (33.56) and AO120b had the lowest (11.8) Weibull modulus. There was a weak positive correlation between the surface free energy and the biaxial flexural strength (r = 0.267, p = 0.011). A larger particle size mostly resulted in higher roughness, which was also affected by the particle shape. Most of the test groups had similar biaxial flexural strength to that of the hydrofluoric acid-etched group. Therefore, for tested feldspathic ceramic, airborne particle abrasion with tested parameters may be a suitable alternative without causing any further damage. [ABSTRACT FROM AUTHOR]

The Ti-5Al-5V-5Mo-3Cr (Ti-5553) alloy is a relatively novel difficult-to-cut material with limited machinability and tool life analysis available in the literature, and hence requires further investigation. This study focuses on the machining and tribological performance of Ti-5553 under high-speed finish turning (150 m/min, 175 m/min, and 200 m/min) via novel mono/bi-layered PVD-coated WC tools. A base AlTiN coating is used as the reference monolayer coating, with AlCrN, diamond-like ta-C, and TiAlSiN coatings each deposited on top of a base AlTiN coating, totaling four separate coated tools (one monolayer and three bi-layer). Tool life, cutting forces, workpiece surface quality, and tribological chip analysis are among the subjects of investigation in this study. Overall, the AlTiN/AlCrN coated tool outperformed all the other combinations: an improvement of ~19% in terms of tool life in reference to the base AlTiN coating when averaging across the three speeds; lowest surface roughness values: ~0.30, 0.33, and 0.64 µm; as well as the lowest chip back surface roughness values: ~0.80, 0.68, and 0.81 µm at 150, 175, and 200 m/min, respectively. These results indicate that the AlTiN/AlCrN coating is an excellent candidate for industrial applications involving high-speed machining of Ti-5553. [ABSTRACT FROM AUTHOR]

Friction and wear are the main failure sources of face seals. When the surfaces of sealing rings exhibit greater roughness, the level of friction might increase and lead to sealing failure. Therefore, in this paper, based on the elastic contact hypothesis of rough and wavy surfaces and the influence of temperature on the elastic modulus of materials, a thermoelastic contact lubrication model of a gas-lubricated end seal is established. The novelty and advantage of this study is that it takes the effect of surface roughness into consideration during thermoelastic analysis of gas-lubricated seals. The film pressure, temperature, contact force and deformation of a gas spiral groove-faced seal are numerically determined. The influence of surface roughness on the contact distribution, deformation and temperature of the end-face seal at different speeds and pressures is analyzed. The film thickness increases as the rotational speed increases from 1 rpm to 2000 rpm, while the contact pressure sharply decreases from 0.25 kPa to 0. The analysis shows that the roughness contact mainly happens on the inner side of the rings due to convergent distortion of the seal faces, which easily causes partial wear of the seal faces. Moreover, it can also be found that the spiral grooves on the sealing surface can produce obvious hydrodynamic pressure effect due to the function of shear speed when the speed increases to 2000 rpm, while the film temperature increases from 293.3 K to about 306 K. The greater surface roughness results in a larger temperature rise under low-rotational-speed and lower-seal-pressure conditions, which further increases the risk of severe wear or even failure of the seal faces. [ABSTRACT FROM AUTHOR]

The paper investigates various methods of microfinishing and arrives at the best technique to produce a very smooth surface. Various setups, with and without oscillation, were developed, together with a microfinishing attachment used on conventional lathes and milling machines. The workpiece material used was an amorphous nickel–phosphorus Ni–P alloy. The surface roughness parameters, such as Sa, Sv, and Sp, were measured with the TalySurf CCI6000 instrument. For the measurement of the surface protrusions, an "analysis of islands" technique was used at various levels of cut-off. The 2BA method—machining below the workpiece axis with oscillation—turned out to be the most effective method applied because it had the highest density of protrusions while having the smallest value of surface roughness. Non-oscillation with the machining zone below the axis also becomes effective, indicating that repositioning can compensate for a lack of oscillation. Already, the very compact surface structure achieved with minimized depths in the valleys by the 2BA method supported the improvement in tribological performance and increase in load-carrying capacity, together with lubricant retention enhancement. These results show that the microfinishing process can be optimized by parameter tuning, and also, non-oscillating methods could come to be a practical alternative, probably reducing the complexity of equipment and cutting costs. Further studies need to be aimed at the scalability of these methods and their application to other materials and fields. [ABSTRACT FROM AUTHOR]

The aim of this study is to investigate how two different polishing techniques affect the color stability, surface roughness, and changes in surface morphology of aged and coffee-stained bulk-fill resin composites. A total of 112 disc-shaped samples were prepared using Omnichroma Flow Bulk (OB), Charisma Bulk Flow One (CB), Estelite Bulk Fill Flow (EB), and Estelite Sigma Quick (control). Samples were divided into two subgroups (n = 16) and aged using thermocycling. A profilometer was used to measure the surface roughness (Ra) and a spectrophotometer was used for color stability (ΔE00). The EB group had the highest Ra values both before aging (disc: 0.23 ± 0.05, twist: 0.42 ± 0.05) and after aging (discs: 0.28 ± 0.04, twist: 0.46 ± 0.05). The OB group had the highest ΔE00 values before and after aging (discs: 3.06 ± 0.54, twist 3.05 ± 0.41) and the highest after coffee-staining (discs: 3.75 ± 0.70, twist: 3.91 ± 0.57). Re-polishing reduced the ΔE00 values in all materials but did not restore all to clinically acceptable levels. According to the results of this study, it can be concluded that the surface roughness and color stability of resin composites are notably influenced by the polishing technique, aging process, and coffee staining. Specimens that were polished using the multi-stage Super-Snap discs consistently exhibited smoother surfaces across all bulk-fill resin composites compared to those polished with the two-stage Diacomp plus Twist. [ABSTRACT FROM AUTHOR]

This study investigates the effects of a water-guided laser on the cutting performance of AISI 1020 steel sheets of various thicknesses by comparing the results with respect to a conventional laser. For this purpose, a novel nozzle design has been devised enabling the delivery of laser beams to the workpiece conventionally as well as through water guidance. Diverging from prior literature, a fiber laser is used with a high wavelength and a laser power output of 1 kW. Experiments are conducted on steel sheets with thicknesses ranging from 1.5 mm to 3 mm using three different cutting speeds and laser power levels. Analysis focuses on assessing surface roughness, burr formation and heat effects on the cut surfaces for both conventional and waterjet-guided cutting. Surface roughness is evaluated by using a 3D profilometer and cut surfaces are examined through SEM imaging. The results showed that the waterjet-guided laser system greatly reduced surface roughness and minimized problems associated with traditional laser cutting such as kerf, dross adherence and thermal damage. The study revealed that cutting speed had a greater effect on surface roughness reduction than laser power, with the most noticeable differences occurring in thinner sheets. Furthermore, the investigation suggests that the waterjet-guided laser cutting system demonstrates superior performance relative to conventional methods, particularly in surface quality. [ABSTRACT FROM AUTHOR]

This study presents research into the unique method of depositing carbon layers onto processed surfaces, during finishing with abrasive films, on a global basis. The authors of this article are holders of the patent for this method. What makes this technology outstanding is that it integrates processes, whereby micro-finishing and the deposition of a carbon layer onto freshly exposed surface fragments is achieved simultaneously, in a single process. Among the main advantages accruable from this process is the reduction of surface irregularities, while the deposition of a carbon layer is achieved simultaneously. Ultrathin graphite layers can be widely used in conditions where other methods of reducing the coefficient of friction are not possible, such as in regard to micromechanisms. This article illustrates the application of carbon coating, end on, on a surface processed with abrasive film, containing intergranular spaces, saturated with graphite. Thin carbon layers were obtained on two substrates that did not contain carbon in their initial composition: soda–lime glass and a tin–bronze alloy. It was performed through microscopic examinations of the produced surface, roughness analyses of these surfaces, and analysis of the chemical compositions determined by two methods, namely EDS and GDOES, proving the existence of the coatings. The aim of this paper is to prove the possibility and efficiency of using graphite-impregnated lapping films in the deposition process of carbon films, with improved surface smoothness, durability, and wear resistance. The produced coatings will be tested in regard to their operational properties in further research. The authors underline the potential of this method to revolutionize surface treatment processes, due to the significant advantages it offers across various industries. [ABSTRACT FROM AUTHOR]

Dental composites are gaining great popularity in restorative dentistry because of their aesthetic appeal and capacity to replicate the natural color of teeth. Nevertheless, their lifespan and durability rely on various factors, such as the polishing technique and the environmental conditions they are exposed to. The study aimed to assess the influence of the method of final polishing of dental composite on the surface roughness and microhardness of materials also considering the environment of different pHs. Disc-shaped samples (5 mm diameter and 2 mm thickness) have been prepared for microhardness and roughness tests from two dental composites: A2 Clearfil Majesty ES 2 Classic and A2D Clearfil Majesty Premium. One-third of samples were polished with polishing discs, OptiDisc, another one-third of samples were polished with Eve Diacomp Twist rubbers and polishing brush with diamond particles, and rest of the samples were stored without any polishing (the control group). Tested materials were incubated in distilled water or acidic buffer (pH = 2) for 3 weeks at a temperature of 37 °C. No statistically significant differences were found for roughness for the two materials tested after incubation in liquids. A decrease in Vicker microhardness was found for Clearfil Majesty ES 2 Classic after soaking in a low pH liquid, and no such relationship was found for Clearfil Majesty Premium. The improved resistance of these materials to the negative oral environment may result in the longer survival of composite restorations in patients with poor diet or diseases, causing a decrease in oral pH. [ABSTRACT FROM AUTHOR]

Surface micro-texture has been shown to enhance wettability and reduce wear on cutting tools. However, there is limited research on how laser parameters impact the dimensional accuracy of surface texture and its wettability. This study focuses on producing arrayed groove textures on WC/Co cemented carbide surfaces using Nd: YAG laser, evaluating the effect of the laser parameters on surface topography and texture accuracy through microscopic observation and simulation. The results indicate that, with laser parameters such as a number of passes less than 5, approximately 16 W power, scanning speed of 100–150 mm/s, and pulse frequency of 30 kHz, the error between the groove width and laser spot diameter was 4.7%. Additionally, the study explores the impact of the groove texture on surface wettability using the solid droplet method and XPS analysis. Comparative experiments reveal that increased surface roughness enhanced oleophobicity, with surfaces exhibiting high texture accuracy and integrity showing improved oleophobic and spreading properties. Thus, the precise regulation of laser processes is crucial for maintaining surface texture integrity and enhancing surface wettability. [ABSTRACT FROM AUTHOR]

Metal products for the metallurgical and machinery industries must meet high requirements in terms of their performance, including reliability, accuracy, durability and fatigue strength. It is also important that materials commonly used to manufacture such products must meet specific requirements. Therefore, various techniques and technologies for modifying the surface layer are becoming more and more widely used. These include burnishing, which may be dynamic or static. This article studies the process of slide burnishing of surfaces of cylindrical objects. The burnishing was performed using a slide burnisher with a rigid diamond-tipped clamp on a general-purpose lathe. The tests were performed for corrosion-resistant steel X2CrNiMo17-12-2. The aim of the research was to determine the impact of changes in burnishing conditions and parameters—feed rate, burnisher depth and burnishing force at a constant burnishing speed—on the surface roughness and hardness. Additionally, the microstructure was assessed in the critical areas: the surface and the core. Another phenomenon observed was surface cracking, which would be destructive due to the occurrence of indentation. In the paper, it was stated that the microstructure, or rather the grains, in the area of the surface layer was oriented in the direction of deformation. It was also observed that in the area of the surface layer, no cracks or other flaws were revealed. Therefore, slide burnishing not only reduces the surface roughness but hardens the surface layer of the burnished material. [ABSTRACT FROM AUTHOR]

Casimir force densities, i.e., force per area, become very large if two solid material surfaces come closer together to each other than 10 nm. In most cases, the forces are attractive. In some cases, they can be repulsive depending on the solid materials and the fluid medium in between. This review provides an overview of experimental and theoretical studies that have been performed and focuses on four main aspects: (i) the combinations of different materials, (ii) the considered geometries, (iii) the applied experimental measurement methodologies and (iv) a novel self-assembly methodology based on Casimir forces. Briefly reviewed is also the influence of additional parameters such as temperature, conductivity, and surface roughness. The Casimir effect opens many application possibilities in microelectromechanical systems (MEMS) and nanoelectromechanical systems (NEMS), where an overview is also provided. The knowledge generation in this fascinating field requires interdisciplinary approaches to generate synergetic effects between technological fabrication metrology, theoretical simulations, the establishment of adequate models, artificial intelligence, and machine learning. Finally, multiple applications are addressed as a research roadmap. [ABSTRACT FROM AUTHOR]

Powder deposition of even and homogeneous layers is a major aspect of every powder bed fusion process. Powder sieving is commonly performed to powder batches outside of the PBF machine, prior to the part manufacturing stage. In this work, sieving is examined as a method of powder deposition rather than a method to solely filter out agglomerates and oversized particles. Initially, a DEM powder model that has been validated experimentally is implemented, and the sieving process is modelled. The sieving process is optimized in order to maximize mass flow, duration of its linear stage and total mass sieved during linearity. For this, a Taguchi design of experiments with subsequent analysis of variance is deployed, proving that the larger the initial powder loaded in the sieve, the larger the sieve stimulation necessary, both in terms of oscillating frequency and amplitude. The sieve's aperture shape is also evaluated, proving that the more sides the canonical polygon has, the less the mass flow per aperture for the same maximum passing particle size. Then, the quality of the layer produced via controlled sieving is examined via certain layer quality criteria, such as the surface roughness, layer thickness deviation, surface coverage ratio and packing density. The findings prove that controlled sieving can outperform powder deposition via a non-vibrated doctor blade recoater, both in terms of layer surface quality and duration of layer deposition, as proven by surface skewness and kurtosis evaluation. [ABSTRACT FROM AUTHOR]

This study investigates the effects of process parameters in the powder bed fusion–laser beam (PBF-LB) process on IN939 samples. The parameters examined include laser power (160, 180, and 200 W), laser scanning speed (400, 800, and 1200 mm/s), and hatch distance (50, 80, and 110 μm). The study focuses on how these parameters affect surface roughness, relative density, defect formation, and the microstructure of the samples. Surface roughness analysis revealed that the average surface roughness (Sa) values of the sample ranged from 4.6 μm to 9.5 μm, while the average height difference (Sz) varied from 78.7 μm to 176.7 μm. Furthermore, increasing the hatch distance from 50 μm to 110 μm while maintaining constant laser power and scanning speed led to a decrease in surface roughness. Relative density analysis indicated that the highest relative density was 99.35%, and the lowest was 93.56%. Additionally, the average porosity values were calculated, with the lowest being 0.06% and the highest reaching 9.18%. Although some samples had identical average porosity values, they differed in porosity/mm2 and average Feret size. Variations in relative density and average porosity were noted in samples with the same volumetric energy density (VED) due to different process parameters. High VED led to large, irregular pores in several samples. Microcracks, less than 50 μm in length, were present, indicating solidification cracks. The microstructural analysis of the XZ planes revealed arc-shaped melt pools, columnar elongated grains aligned with the build direction, and cellular structures with columnar dendrites. This study provides insights for optimizing PBF-LB process parameters to enhance the quality of IN939 components. [ABSTRACT FROM AUTHOR]

Sn-doped Ga2O3 thin films and metal–semiconductor–metal (MSM) ultraviolet detectors were prepared using the co-sputtering method to enhance their photoelectric performance. The results revealed that Sn doping can effectively change the optical and electrical properties of thin films, greatly improving the photoelectric responsiveness of the devices. Through microstructure testing results, all of the thin film structures were determined to be monoclinic beta phase gallium oxide. At a DC power of 30 W, the thickness of the Sn-doped thin film was 430 nm, the surface roughness of the thin film was 4.94 nm, and the carrier concentration, resistivity, and mobility reached 9.72 × 1018 cm−3, 1.60 × 10−4 Ω·cm, and 45.05 cm3/Vs, respectively. The optical results show that Sn doping clearly decreases the transmission of thin films and that the bandgap can decrease to 3.91 eV. Under 30 W DC power, the photo dark current ratio of the detector can reach 101, time responses of tr = 31 s and tf = 22.83 s were obtained, and the spectral responsivity reached 19.25 A/W. [ABSTRACT FROM AUTHOR]

High-volume fraction silicon carbide particle-reinforced aluminum (SiCp/Al) has a promising application for its high specific strength, wear resistance, and thermal conductivity. However, SiCp/Al components with a high-volume fraction are prone to poor surface quality and defects such as fractures, cracks, and micro-pits. It has been reported that ultrasonic-assisted grinding machining (UAG) helps to improve the quality of SiCp/Al machined surfaces. However, the differences between SiCp/Al with different volume fractions obtained by UAG machining are not clear. Therefore, a comparative study of surface roughness, morphology, and cutting force was carried out by UAG machining on SiCp/Al samples with volume fractions of 45% and 60%. Compared to the 45% volume fraction SiCp/Al, the 60% volume fraction SiCp/Al has a higher cutting force and roughness under the same machining parameters. In addition, experiments have shown that cutting forces and surface roughness can be reduced by increasing the tool speed or decreasing the feed rate. UAG machining with an ultrasonic amplitude within 4 μm can also reduce cutting forces and surface roughness. However, more than 6 μm ultrasonic amplitude may lead to an increase in roughness. This study contributes to reasonable parameter settings in ultrasonically-assisted grinding of SiCp/Al with different volume fractions. [ABSTRACT FROM AUTHOR]

Nanocrystalline diamond (NCD) films are attractive for many applications due to their smooth surfaces while holding the properties of diamond. However, their growth rate is generally low using common Ar/CH4 with or without H2 chemistry and strongly dependent on the overall growth conditions using microwave plasma chemical vapor deposition (MPCVD). In this work, incorporating a small amount of N2 and O2 additives into CH4/H2 chemistry offered a much higher growth rate of NCD films, which is promising for some applications. Several novel series of experiments were designed and conducted to tailor the growth features of NCD films by fine-tuning of the gas-phase compositions with different amounts of nitrogen and oxygen addition into CH4/H2 gas mixtures. The influence of growth parameters, such as the absolute amount and their relative ratios of O2 and N2 additives; substrate temperature, which was adjusted by two ways and inferred by simulation; and microwave power on NCD formation, was investigated. Short and long deposition runs were carried out to study surface structural evolution with time under identical growth conditions. The morphology, crystalline and optical quality, orientation, and texture of the NCD samples were characterized and analyzed. A variety of NCD films of high average growth rates ranging from 2.1 μm/h up to 6.7 μm/h were successfully achieved by slightly adjusting the O2/CH4 amounts from 6.25% to 18.75%, while that of N2 was kept constant. The results clearly show that the beneficial use of fine-tuning of gas-phase compositions offers a simple and effective way to tailor the growth characteristics and physical properties of NCD films for optimizing the growth conditions to envisage some specific applications. [ABSTRACT FROM AUTHOR]

Parts made using selective laser melting (SLM) often require improvements to the quality of side surfaces. Therefore, the analysis of the machinability of metallic printed material is new/innovative. The surface of printed parts requires improvement in quality—surface roughness. Hence, there is a need for effective manufacturing techniques that improve the quality of the side surfaces of printed parts. In our work, we try to fill this research gap. This work comparatively analyzed the surface quality (roughness parameter Ra) after milling and wire electrical discharge machining (WEDM). The processed material was AISI 316L stainless steel, which was produced using the casting and SLM method. In the case of printed material, the influence of the direction of the tool (perpendicular, parallel) on the arrangement of sintered layers was also analyzed. The analysis of the results showed that processing the cast material and processing the material perpendicular to the arrangement of the layers gives similar results—similar relationships between the processing parameters and surface roughness were observed. However, processing parallel to the arrangement of sintered layers showed ambiguity in the relationships. Moreover, the best results of the Ra parameter (0.1–0.2 µm) were obtained for feeds of 0.08 mm/rev and 0.12 mm/rev and a cutting speed of 90 m/min. In this work, the novelty is the comparison of the surfaces of materials manufactured using different techniques (SLM, casting) after milling and WEDM processing. [ABSTRACT FROM AUTHOR]

It is important to adapt the morphology of CeO2 to different applications. A novel flaky CeO2 with nanocrystals was successfully synthesized using the ordinal precipitation method and calcination. The size of the flaky CeO2 was about 10 μm, and the nanocrystals were about 100 nm. Under the action of the precipitant NH4HCO3, Ce3+ nucleated in large quantities. The nanosized crystals gathered into flakes driven by the surface energy. As the calcination temperature increased, the grains grew slowly by mass transfer due to the slow diffusion of reactants. By adding AlOOH to the starting material, the Al3+ doped into the CeO2 increased the content of Ce3+ in the CeO2, which improved the chemical activity of the CeO2. When the starting material's Al:Ce ratio was 5:1, the Ce3+ increased to 31.11% in the CeO2, which provided good application potential in the polishing field. After polishing by the slurry of flaky CeO2 for 1 h, the SiC surface roughness reduced from 464 nm to 11 nm. [ABSTRACT FROM AUTHOR]

This article presents the effect of the conditions of abrasive compounds on the wear of samples made by different methods. The 28MnB5 steel was used, which is intended for agricultural components, to which two arc and laser coatings were applied. The study included the analysis of microstructure, microhardness, roughness, and tribological experiments on a dedicated stand. The arc coating was found to significantly improve the tribological properties compared to the samples without the coating. Varied wear results were obtained for the laser coating depending on the parameters of the abrasive compound. Studies of the surface roughness of the samples showed that the concentration and pH of the abrasives have a significant effect on the changes in the surface parameters after the tribological tests. The results of the tribological experiments indicated that wear resistance for some of the abrasive mass conditions was improved by the application of heat-applied coatings. In addition, it was found that the power consumption on the stand was the highest for abrasive mass conditions of a 10% moisture content and a pH of 10. For these test conditions, the mass loss was four times higher than for the parameter with W0% and pH7. The energy consumption of the stand was 60 kWh lower for this variant than for the parameter with W10% and pH10. The results of the study have important practical applications that can help in the selection of materials for agricultural machinery components, depending on the abrasive mass conditions. [ABSTRACT FROM AUTHOR]

Aluminum–air (Al–air) batteries are considered one of the most promising next-generation energy storage devices. In this paper, we carry out an orthogonal experimental study on the SLM printing process parameters in 3D-printed Al–air battery anodes. The surface roughness, densification, and discharge performance of the electrodes under different process parameters are observed to reveal the effects of different process parameters on the forming quality and discharge performance of aluminum–air battery anodes. The results show that the laser power is the most important factor affecting the surface roughness of the porous aluminum anode, and the scanning spacing is the most important factor affecting the densification. The best printing parameters for the porous aluminum anode can be obtained when the laser power is 325 W, the scanning speed is 1000 mm/s, the scanning spacing is 0.12 mm, and the thickness of the powder spread is 0.03 mm. At this time, the surface roughness of the porous aluminum anode obtained by this process parameter is 15.01 μm, the densification is 94.97%, and the discharge is stable with a high value. In addition, we also carry out data validation to ensure that the data we obtain are optimal and valid. [ABSTRACT FROM AUTHOR]

This article presents Cu/diamond composite coatings produced by electrochemical reduction on steel substrates and a comparison of these coatings with a copper coating without diamond nanoparticles (<10 nm). Deposition was carried out using multicomponent electrolyte solutions at a current density of 3 A/dm2 and magnetic stirring speed of 100 rpm. Composite coatings were deposited from baths with different diamond concentrations (4, 6, 8, 10 g/dm3). This study presents the surface morphology and structure of the produced coatings. The surface roughness, coating thickness (XRF), mechanical properties (DSI), and adhesion of coatings to substrates (scratch tests) were also characterized. The coatings were also tested to assess their solderability, including their spreadability, wettability of the solder, durability of solder-coating bonds, and a microstructure study. [ABSTRACT FROM AUTHOR]

Fiber laser cutting machines are widely used in industry for cutting various sheet metals. Hardox steel is widely used in the construction of machinery and equipment that are subjected to wear and impact due to its anti-wear properties and good impact resistance. In this experimental study, the effect of input parameters including laser output power (LOP), laser-cutting speed (LCS), and focal point position (FPP) of fiber laser on the surface roughness and kerf width of Hardox 400 steel sheets are studied. In addition, the optimization of input parameters to achieve the desired surface roughness and kerf width are investigated and analyzed using the response surface methodology (RSM). The experiments are performed using a 4 kW fiber laser-cutting machine and the output results including surface roughness and kerf width are measured using roughness meters and optical microscope. The results of the analysis of variance (ANOVA) for surface roughness and kerf width show that the FPP and LCS are the most significant process parameters affecting the surface roughness and kerf width. With a positive focal point, the surface roughness decreases while the kerf width increases. With increasing the laser-cutting speed, both the surface roughness and kerf width decrease. [ABSTRACT FROM AUTHOR]

LaFeO3 thin films were successfully epitaxially grown on single-crystalline SrTiO3 substrates by the one-step hydrothermal method at a temperature of 320 °C in a 10 mol/L KOH aqueous solution using La(NO3)3 and Fe(NO3)3 as the raw materials. The growth of the films was consistent with the island growth mode. Scanning electronic microscopy, elemental mapping, and atomic force microscopy demonstrate that the LaFeO3 thin films cover the SrTiO3 substrate thoroughly. The film subjected to hydrothermal treatment for 4 h exhibits a relatively smooth surface, with an average surface roughness of 10.1 nm. X-ray diffraction in conventional Bragg–Brentano mode shows that the LaFeO3 thin films show the same out-of-plane orientation as that of the substrate (i.e., (001)LaFeO3||(001)SrTiO3). The in-plane orientation of the films was analyzed by φ-scanning, revealing that the orientational relationship is [001]LaFeO3||[001]SrTiO3. The ω-rocking curve indicates that the prepared LaFeO3 films are of high quality with no significant mosaic defects. [ABSTRACT FROM AUTHOR]

Ultrasonic rolling is an effective technique for enhancing surface integrity, and surface integrity is closely related to fatigue performance. The process parameters of ultrasonic rolling critically affect the improvement of surface integrity. This study proposes an optimization method for process parameters by combining machine learning (ML) with the NSGA-II. Five ML models were trained to establish relationships between process parameters and surface residual stress, hardness, and surface roughness by incorporating feature augmentation and physical information. The best-performing model was selected and integrated with NSGA-II for multi-objective optimization. Ultrasonic rolling tests based on a uniform design were performed, and a dataset was established. The objective was to maximize surface residual stress and hardness while minimizing surface roughness. For test specimens with an initial surface roughness of 0.54 µm, the optimized process parameters were a static pressure of 900 N, a spindle speed of 75 rpm, a feed rate of 0.19 mm/r, and rolling once. Using optimized parameters, the surface residual stress reached −920.60 MPa, surface hardness achieved 958.23 HV, surface roughness reduced to 0.32 µm, and contact fatigue life extended to 3.02 × 107 cycles, representing a 52.5% improvement compared to untreated specimens and an even more significant improvement over without parameter optimization. [ABSTRACT FROM AUTHOR]

The present work is aimed at studying the effects of the magnetorheological finishing process, using a low-frequency alternating magnetic field, on the finishing performance of 6063 aluminum alloy. The study investigates the influence of key excitation parameters such as current, frequency, excitation gap, and iron powder diameter on the material removal and surface roughness (Ra) of the finished workpiece by experiments. This study employs a single-factor experimental method, and the finish surface is analyzed by a Zigo non-contact white light interferometer. The magnetic field strength in the processing area increases with the increase in the excitation current and decreases with the increase in the excitation gap. When the current frequency is set to 1 Hz, the circulation and renewal of abrasives in the magnetic cluster is most sufficient, resulting in the optimal surface roughness value for the workpiece. According to the experimental results of the excitation parameters, more suitable process parameters were selected for a two-stage finishing experiment. The surface roughness of 6063 aluminum alloy was improved from 285 nm to 3.54 nm. Experimental results highlighted that the magnetorheological finishing using a low-frequency alternating magnetic field is a potential technique for obtaining nano-scale finishing of the 6063 aluminum alloy. [ABSTRACT FROM AUTHOR]

Additively manufactured aluminum alloy parts attract extensive applications in various felids. To study the machinability of additively manufactured aluminum alloys, micro-milling experiments were conducted on the additively manufactured AlSi7Mg and AlSi10Mg. By comparing the machinability of Al-Si-Mg aluminum alloys with different Si content, the results show that due to the higher hardness of the AlSi10Mg, the cutting forces are higher than the AlSi7Mg by about 11.8% on average. Due to the increased Si content in additively manufactured Al-Si-Mg aluminum alloys, the surface roughness of AlSi10Mg is 26.9% higher than AlSi7Mg on average. The burr morphology of additively manufactured aluminum alloys in micro-milling can be divided into fence shape and branch shape, which are, respectively, formed by the plastic lateral flow and unseparated chips. The up-milling edge exhibits a greater burr width than the down-milling edge. Due to the better plasticity of AlSi7Mg, the burr width of the down-milling edge is 28.1% larger, and the burr width of the up-milling edge is 10.1% larger than the AlSi10Mg. This research can provide a guideline for the post-machining of additively manufactured aluminum alloys. [ABSTRACT FROM AUTHOR]

Among various metal additive manufacturing (AM) technologies, L-PBF is known for fabricating intricate components. However, due to step edges and powder particle attachments, attaining a good surface finish is challenging, especially on downskin surfaces. Contour scanning has potential to improve surface quality because such scanning may dominate the surface formation of sloped features. This study evaluates the effects of pre- and post-contouring strategies on the sloped downskin surfaces fabricated using a commercial L-PBF system with Ti6Al4V powder. L-PBF parts printed at inclination angles 30°, 45° and 60° were investigated. A double-contouring approach with varying processing conditions was employed and surface characteristics were analyzed using data acquired by white light interferometry. The average surface roughness, Sa, surface skewness, Ssk, and percentage area of powder particles attached onto surfaces were statistically evaluated. The lowest Sa obtained for pre- and post-contoured samples is 14.08 µm and 18.88 µm, respectively. For both strategies, the combination of a low laser power and a high scan speed on the interface of downskin surface and underneath powder results in smoother surfaces. However, while comparing both strategies, pre-contouring gives better surface finish for samples built at similar processing conditions, with a difference of nearly 5 µm in Sa. [ABSTRACT FROM AUTHOR]

Welded tuffs have a wide range of welding degrees and show significant variability in mechanical behavior. However, the detailed influence of welding degree on the meso-mechanical behavior of welded tuffs remains unclear. Based on petrographic and pore-structure analysis, we conducted a series of meso-mechanical experiments on weakly to strongly welded tuffs by utilizing a mesoscale real-time loading-observation-acquisition system. The results indicated that the strongly and weakly welded tuffs showed a small range in mineralogical composition and porosity, while the meso-mechanical behavior exhibited significant variability. Strongly welded tuffs showed lower uniaxial compression strength, weaker mechanical anisotropy, and smaller fracture surface roughness. In contrast, weakly welded tuffs exhibited higher uniaxial compression strength, stronger mechanical anisotropy, and rougher fracture surface roughness. Welded tuffs with strong packing and welding of glass shards tended to have fractures propagating along the maximum principal direction, while those with weak packing and welding of glass shards may have had failure along the alignment of glass shards. The influence of welding degree on the meso-mechanical behavior of welded tuffs probably originates from their diagenesis environments, mainly depending on the combined effect of the pyroclastic properties and pseudo-rhyolitic structure. The findings reveal the meso-mechanical differences of welded tuffs and shed light on improving tuffs for stable and durable construction. [ABSTRACT FROM AUTHOR]

Injection molding technology is widely utilized across various industries for its ability to fabricate complex-shaped components with exceptional dimensional accuracy. However, challenges related to injection quality often arise, necessitating innovative approaches for improvement. This study investigates the influence of surface roughness on the efficiency of conformal cooling channels produced using additive manufacturing technologies, specifically Direct Metal Laser Sintering (DMLS) and Atomic Diffusion Additive Manufacturing (ADAM). Through a combination of experimental measurements, including surface roughness analysis, scanning electron microscopy, and cooling system flow analysis, this study elucidates the impact of surface roughness on coolant flow dynamics and pressure distribution within the cooling channels. The results reveal significant differences in surface roughness between DMLS and ADAM technologies, with corresponding effects on coolant flow behavior. Following that fact, this study shows that when cooling channels' surface roughness is lowered up to 90%, the reduction in coolant media pressure is lowered by 0.033 MPa. Regression models are developed to quantitatively describe the relationship between surface roughness and key parameters, such as coolant pressure, Reynolds number, and flow velocity. Practical implications for the optimization of injection molding cooling systems are discussed, highlighting the importance of informed decision making in technology selection and post-processing techniques. Overall, this research contributes to a deeper understanding of the role of surface roughness in injection molding processes and provides valuable insights for enhancing cooling system efficiency and product quality. [ABSTRACT FROM AUTHOR]

The use of CNC equipment that integrates several machining operations eliminates downtime due to changes in setup and clamping of workpieces in more than one machining device. A review of CNC equipment and tools known from the literature and from manufacturers' offerings indicates that new technical solutions are being developed to integrate two or more technological operations. However, these examples have numerous limitations and are mostly not suitable for machining surfaces with complex shapes. An example of such solutions is the use of a dual-tool grinding head, which integrates the process of rough grinding with a ceramic grinding wheel and finish grinding with a flexible grinding wheel. Unfortunately, it has the disadvantage of being limited by the angular shape of the ceramic grinding wheel, making it unable to adapt to the complex geometries of the shaped surfaces being ground. The need to overcome this limitation became the motivation for the research work described in this article. By means of experimental research, it was verified what effect the radial outline on the periphery of a ceramic grinding wheel realized by rough grinding would have on the surface roughness parameters obtained in the process of grinding shaped surfaces. For this purpose, grinding processes using a ceramic wheel with a conical and radial outline were compared. The result of the study was a summary of the surface roughness parameters Sa, St, Sq, Spk, Str, and Sds obtained after two-stage machining (rough and finish grinding). The obtained analysis results showed that changing the axial outline of the ceramic grinding wheel makes it possible to significantly expand the range of applications of the dual-tool head without negatively affecting the quality of the machined surface. Thus, such an improvement will make it possible to increase the applicability of the head by grinding shaped surfaces with a radial profile of curvature. [ABSTRACT FROM AUTHOR]

Carbon fibre-reinforced plastic (CFRP) composites, prized for their exceptional properties, often encounter surface quality issues during slotting due to their inherent heterogeneity. This paper tackles CFRP slotting challenges by employing multi-tooth mills in experiments with various fibre orientations and tool feed rates. In-plane scratching tests are performed under linearly varying loads; then, slotting experiments are conducted at different parameters. The scratching test results indicate that the fibre orientation and cutting angles have significant influences on forces and fracture process. The slotting experiments demonstrate that cutting forces and surface roughness Sa of the bottom slotting surface are notably affected by the fibre orientation, with disparities between up-milling and down-milling sides. Reorganising Sa data by local fibre cutting angle θ highlights consistent Sa variations between up-milling and down-milling sides for 0° ≤ θ ≤ 90°, with lower Sa on the up-milling side. However, for 90° < θ ≤ 150°, Sa variations diverge, with lower Sa on the down-milling side. Unexpectedly, Sa on the down-milling side decreases with increasing θ in this range. Additionally, the tool feed rate exerts a more pronounced influence on Sa on the up-milling side. [ABSTRACT FROM AUTHOR]

The undoped and tungsten (W)-doped vanadium dioxide (VO2) thin films were prepared by electron beam evaporation associated with ion-beam-assisted deposition (IAD). The influence of different W-doped contents (3–5%) on the electrical, optical, structural, and thermo-mechanical properties of VO2 thin films was investigated experimentally. Spectral transmittance results showed that with the increase in W-doped contents, the transmittance in the visible light range (400–750 nm) decreases from 60.2% to 53.9%, and the transmittance in the infrared wavelength range (2.5 μm to 5.5 μm) drops from 55.8% to 15.4%. As the W-doped content increases, the residual stress in the VO2 thin film decreases from −0.276 GPa to −0.238 GPa, but the surface roughness increases. For temperature-dependent spectroscopic measurements, heating the VO2 thin films from 30 °C to 100 °C showed the most significant change in transmittance for the 5% W-doped VO2 thin film. When the heating temperature exceeds 55 °C, the optical transmittance drops significantly, and the visible light transmittance drops by about 11%. Finally, X-ray diffraction (XRD) and scanning electron microscope (SEM) were used to evaluate the microstructure characteristics of VO2 thin films. [ABSTRACT FROM AUTHOR]

In this paper, Cu thin films were deposited on Si (100) substrates by the high−power impulse magnetron sputtering (HiIPMS) technique, and the effects of different duty cycles (from 2.25% to 5.25%) on the plasma discharge characteristics, microstructure, and electrical properties of Cu thin films were investigated. The results of the target current test show that the peak target current remains stable under 2.25% and 3% duty cycle conditions. Under the conditions of a 4.5% and 5.25% duty cycle, the target peak current shows a decreasing trend. The average power of the target shows a rising trend with the increase in the duty cycle, while the peak power of the target shows a decreasing trend with the increase in the duty cycle. The results of OES show that with the increase in the duty cycle, the total peak intensity of copper and argon emissions shows an overall increasing trend. The duty cycle from 3% to 4.5% change in copper and argon emission peak total intensity change is not obvious. The deposition rate and surface morphology of the copper film were investigated by scanning electron microscopy, and the deposition rate of the copper film increased with the increase in the duty cycle, which was mainly due to the increase in the average power. The surface roughness of the copper film was evaluated by atomic force microscopy. X−ray diffraction (XRD) was used to analyze the grain size and texture of the Cu film, and the results showed that the average grain size of the Cu film increased from 38 nm to 59 nm on the (111) and (200) crystal planes. Four−probe square resistance test copper film resistivity in 2.25%, 3% low duty cycle conditions of the copper film resistivity is generally higher than 4.5%, 5.25% high duty cycle conditions, the copper film resistivity shows the trend of change is mainly affected by the copper film grain size and the (111) face of the double effect of the optimal orientation. The lowest resistivity of the copper film measured under the 4.5% duty cycle condition is 1.7005 μΩ·cm, which is close to the intrinsic resistivity of the copper film of 1.67 μΩ·cm. [ABSTRACT FROM AUTHOR]

Network microstructure titanium matrix composites (NMTMCs), featuring Ti6Al4V as the matrix and network-distributed TiB whiskers (TiBw) as reinforcement, exhibit remarkable potential for diverse applications due to their superior physical properties. Due to the difficulty in machining titanium matrix composites, electrical discharge machining (EDM) stands as one of the preferred machining techniques for NMTMCs. Nevertheless, the compromised surface quality and the recast layer significantly impact the performance of the workpiece machined by EDM. Therefore, for the purpose of enhancing the surface quality and restraining the defects of NMTMCs, this study conducted comparative EDM milling experiments between NMTMCs and Ti6Al4V to analyze the effects of discharge capacitance, charging current, and pulse interval on the surface roughness, recast layer thickness, recast layer uniformity, and surface microcrack density of both materials. The results indicated that machining energy significantly influences workpiece surface quality. Furthermore, comparative experiments exploring the influence of network reinforcement on EDM milling revealed that NMTMCs have a higher melting point, leading to an accumulation phenomenon in low-energy machining where the reinforcement could not be completely removed. The residual reinforcement in the recasting layer had an adsorption effect on molten metal affecting the thermal conductivity and uniformity within the recasting layer. Finally, specific guidelines are put forward for optimizing the material's surface roughness, recast layer thickness, and uniformity, along with minimizing microcrack density, which attain a processing effect that features a roughness of Ra 0.9 μm, an average recast layer thickness of 6 μm with a range of 8 μm, and a surface microcrack density of 0.08 μm−1. [ABSTRACT FROM AUTHOR]

Electrical discharge machining (EDM) is a rapidly evolving method in modern industry that manufactures highly complex components. The physical properties of a tool electrode material are significant factors in determining the effectiveness of the process, as well as the characteristics of the machined surfaces. The current trend of implementing graphite tool electrodes in manufacturing processes is observed. Innovative material engineering solutions enable graphite production with miniaturized grain size. However, the correlation between the graphite electrode grain size and the mechanism of the process removal in the EDM is a challenge for its widespread implementation in the industry. This research introduces a new method to evaluate the impact of the graphite electrode grain size and machining parameters on the material removal effectiveness, relative tool wear rate, and surface roughness (Ra) of Hastelloy C-22 following EDM with negative polarity. The study utilized new graphite materials with a grain size of 1 µm (POCO AF-5) and 10 µm (POCO EDM-180). An assessment of the impact of the EDM process parameters on the technological parameters and the development of the surface roughness was carried out. Electrical discharge machining with fine-grained graphite electrodes increases process efficiency and reduces tool wear. Graphite grains detached from the tool electrode affect the stability of electrical discharges and the efficiency of the process. Based on the experimental results, mathematical models were developed, enabling the prediction of machining effects to advance state-of-the-art manufacturing processes. The obtained mathematical models can be implemented in modern industrial EDM machines as guidelines for selecting adequate machining parameters depending on the desired process efficiency, tool wear rate, and surface roughness for advanced materials. [ABSTRACT FROM AUTHOR]

The authors present the results of laboratory tests analysing the impact of selected cutting data and tool geometry on surface quality, chip type and cutting forces in the process of orthogonal turning of sintered cobalt. The selected cutting data are cutting speed and feed rate. During the experiments, the cutting speed was varied in the range of vc = 50–200 m/min and the feed rate in the range of f = 0.077–0.173 mm/rev. In order to measure and acquire cutting force values, a measuring setup was assembled. It consisted of a Kistler 2825A-02 piezoelectric dynamometer with a single-position tool holder, a Kistler 5070 signal amplifier and a PC with DynoWare software (Version 2825A, Kistler Group, Winterthur, Switzerland)). The measured surface quality parameters were Ra and Rz. The components of the cutting forces obtained in the experiment varied depending on the feed rate and cutting speed. The obtained test results will make it possible to determine the optimal parameters for machining and tool geometry in order to reduce the machine operating time and increase the life of the cutting insert during the turning of sintered cobalt, which will contribute to sustainable technology. [ABSTRACT FROM AUTHOR]

The positive effects of deep rolling on fatigue strength—reduced surface roughness, work hardening and compressive residual stress—in the near-surface region are achieved by controlled high plasticisation of the treated material. However, excessive and/or repeated plasticising poses a risk of damage to the machined component. This paper investigates the damage caused by deep rolling of a railway axle. Two sections of the axle are experimentally deep rolled repeatedly at different feed rates until damage is detected. For comparative analysis, these experiments are numerically analysed and the damage is assessed using the strain-based damage calculation. The results are compared and a damage sum of ~120% is evaluated for both tests, thus developing a reliable and conservative assessment method. The single deep rolling treatment at a feed rate of 0.25 mm causes damage of 6.1%, and at a feed rate of 0.5 mm, damage of 4.7%. The developed and experimentally validated evaluation method allows for investigating the limits of applicability of different deep rolling parameters. The influence of the deep rolling force and feed rate and a proposed optimisation with multiple deep rolling with reduced deep rolling forces are investigated. [ABSTRACT FROM AUTHOR]

Cryogenic cooling has gathered significant attention in the manufacturing industry. There are inherent difficulties in machining materials that are difficult to machine because of high levels of hardness, abrasiveness, and heat conductivity. Increased tool wear, diminished surface finish, and reduced machining efficiency are the results of these problems, and traditional cooling solutions are insufficient to resolve them. The application of cryogenic cooling involves the use of extremely low temperatures, typically achieved by employing liquid nitrogen or other cryogenic fluids. This study reviews the current state of cryogenic cooling technology and its use in machining difficult-to-machine materials. In addition, this review encompasses a thorough examination of cryogenic cooling techniques, including their principles, mechanisms, and effects on machining performance. The recent literature was used to discuss difficult-to-machine materials and their machining properties. The role of cryogenic cooling in machining difficult materials was then discussed. Finally, the latest technologies and methods involved in cryogenic cooling condition were discussed in detail. The outcome demonstrated that the exploration of cryogenic cooling methods has gained prominence in the manufacturing industry due to their potential to address challenges associated with the machining of exotic alloys. [ABSTRACT FROM AUTHOR]

CeO2 is widely used in the field of chemical–mechanical polishing for integrated circuits. Morphology, particle size, crystallinity, and Ce3+ concentration are crucial factors that affect polishing performance. In this study, we successfully synthesized two novel triangular CeO2 abrasives with similar particle sizes (600 nm) but different morphologies and Ce3+ concentrations using a microwave-assisted hydrothermal method with high-concentration raw materials, and no surfactants or template agents were added. It is generally believed that CeO2 with a higher Ce3+ concentration leads to better polishing performance. However, the results of polishing indicate that CeO2 synthesized at 200 °C, despite its lower Ce3+ concentration, demonstrates outstanding polishing performance, achieving a polishing rate of 324 nm/min, and the Sa of Si wafers decreased by 3.6% after polishing. This suggests that, under similar particle size conditions, the morphology of CeO2 plays a dominant role in the mechanical effects during the polishing process. Additionally, compared to commercial polishing slurries, the synthesized samples demonstrated better polishing performance. This indicates that, in CMP, the pursuit of smaller spherical abrasives may not be necessary. Instead, the appropriate shape and particle size can better balance the material removal rate and surface roughness. [ABSTRACT FROM AUTHOR]

With the continuous integration of semiconductor devices, the requirements of the size accuracy and surface quality of etched lead frames are stricter. The etchant is a key factor in the etching process and etched surface quality, while the effects of the difference in etchants on the etched surface morphology of Cu alloy have not been directly studied. In this study, aqua regia, acidic FeCl3 and two CuCl2 solutions were used as etchants, and different CuCrSn specimens were etched and characterized. The results show that the etching rate in aqua regia is high, and the grain orientation, grain boundary (GB) and dislocations have significant influences on the local etching rate. The preferential etching of some atomic planes forms steps between the grains with different orientations, and preferential etching around the GB and dislocation group forms grooves, resulting in high surface roughness. For the surfaces etched by the FeCl3 and CuCl2 etchants, the steps and grooves are blurred; thus, they are less rough. The CuCrSn alloy surface etched by the aqua regia is clean, with little Cr-rich particles, while high-density Cr-rich particles remain on the surfaces etched by the FeCl3 and CuCl2 etchants. For the same kind of etchant, the ion concentration can affect the etching mechanism, rate and the etched surface morphology. [ABSTRACT FROM AUTHOR]

The aim of the work was to investigate the influence of the surface texture of composite based on PA6, intended for wet painting, on the stability of the colour and gloss parameters. The stability of the paint coating was required to be maintained despite exposure to mechanical stress resulting from attempts to manually remove graffiti stains. The study examined the influence of surface texture on the effectiveness of cleaning. In the case of painted surfaces from which graffiti stains were effectively removed, the roughness, colour parameters and gloss of the paint coating were measured. During the research, it was found that roughness after painting decreased to the value of Ra < 2.00 µm meets aesthetic expectations and at the same time ensures the effective removal of graffiti stains. For this surface, there were no negative effects of the mechanical impact on the textures or quality parameters of the coating as a result of manual graffiti removal. As a result of the conducted research, the recommended maximum values of roughness and textures of the surfaces to be painted were determined in order to ensure a sufficiently low amount of work necessary to effectively remove traces of graffiti. [ABSTRACT FROM AUTHOR]

An innovative in situ thermal approach in the domain of LPBF for Ti-6Al-4V fabrication has been carried out with results directing towards an improved fatigue life without the need for post-processing. The thermal process involves an additional laser scan with different process parameters to preheat the selected regions of each layer of the powder bed prior to their full melting. This preheating step influences the cooling rate, which in turn affects surface characteristics and subsurface microstructure, both of which are directly correlated with fatigue properties. A thorough analysis has been conducted by comparing the preheated samples with reference samples with no preheating. Without any additional thermal processing, the preheated samples showed a significant improvement over their reference counterparts. The optimized preheated sample showed an improved prior β-grain distribution with a circular morphology and thicker α laths within the even finer prior β-grain boundaries. Also, an overall increment of the c/a ratio of the HCP α has been observed, which yielded lattice strain relaxation in the localized grain structure. Furthermore, a less-profound surface roughness was observed in the preheated sample. The obtained microstructure with all these factors delivered a 10% improvement in its fatigue life with better mechanical strength overall. [ABSTRACT FROM AUTHOR]

The prerequisite of the weld bead finishing is intricately linked to the quality of the welded joint. It constitutes the final, yet pivotal, stage in its formation, significantly influencing the reliability of structural components and machines. This article delineates an innovative post-weld surface finishing method, distinguished by the movement of a specialized cutting tool along a butt weld. This method stands out due to its singular approach to machining allowance, wherein the weld bead height is considered and eradicated in a single pass of the cutting tool. Test samples were made of AISI 304L, AISI 316L stainless steels and EN AW-5058 H321, EN AW-7075 T651 aluminum alloys butt-welded with TIG methods. Following the welding process, the weld bead was finished in accordance with the innovative method to flush the bead and the base metal's surface. For the quality control of welded joints before and after the weld finishing, two non-destructive testing methods were chosen: Penetrant Testing (PT) and Radiographic Testing (RT). This article provides results from the examination of 2D profile parameters and 3D stereometric characteristics of surface roughness using the optical method. Additionally, metallographic results are presented to assess changes in the microstructure, the microhardness, and the degree of hardening within the surface layer induced by the application of the innovative post-weld finishing method. [ABSTRACT FROM AUTHOR]