Search Results (133)

This study presents new results on the practical adhesion behavior of a boride layer formed on Monel 400 alloy, developed using the powder-pack boriding (PPBP) at 1223 K for 2, 4, and 6 h of exposure times, obtaining layer thicknesses from approximately 7.9 to 23.8 µm. The nickel boride layers were characterized using optical microscopy, Berkovich nanoindentation, X-ray diffraction (XRD), and scanning electron microscopy (SEM) to determine microstructure, hardness distribution, and failure mechanisms over the worn tracks. Scratch tests were conducted on the borided Monel 400 alloy according to the ASTM C-1624 standard, applying a progressively increasing normal load from 1 to 85 N using a Rockwell-C diamond indenter, revealing that critical loads (L_C1, L_C2, and L_C3) increased with layer thickness. The tests monitored the coefficient of friction and residual stress in real time. Critical loads were determined based on the correlation between the normal force and visual inspection of the worn surface, identifying cracks (cohesive failure) or detachment (adhesive failure). The results exposed those cohesive failures that appeared as Hertzian cracks, while adhesive failures were chipping and delamination, with critical loads reaching up to 49.0 N for the 6 h borided samples. Also, the results indicated that critical loads increased with greater layer thickness. The boride layer hardness was approximately 12 ± 0.3 GPa, ~4.0 times greater than the substrate, and Young’s modulus reached 268 ± 15 GPa. These findings underscore that PPBP significantly enhances surface mechanical properties, demonstrating the potential for applications demanding high wear resistance and strong layer adhesion. Full article

Two series of non-hydrogenated diamond-like carbon (DLC) films and molybdenum doped diamond-like carbon (Mo-DLC) films were grown on the silicon substrate using direct current magnetron sputtering. The influence of molybdenum doping (between 6.3 and 11.9 at.% of Mo), as well as the deposited temperature (between 185 and 235 °C) on the surface morphology, elemental composition, bonding microstructure, friction force, and nanohardness of the films, were characterized by atomic force microscopy (AFM), energy dispersive X-ray spectroscopy (EDX), Raman spectroscopy, and a nanoindenter. It was found that the increase in the metal dopant concentration led to a higher metallicity and graphitization of the DLC films. The surface roughness and sp³/sp² ratio were obtained as a function of the Mo concentration and formation temperature. The nanohardness of DLC films was improved by up to 75% with the addition of Mo. Meanwhile, the reduction in the deposition temperature decreased the nanohardness of the DLC films. The friction coefficient of the DLC films was slightly reduced with addition of the molybdenum. Full article

In this experiment, plasma-enhanced chemical vapor deposition technology was used to deposit diamond-like carbon thin films on the surface of a 2024 aluminum alloy. The effects of deposition temperature on the microstructure, carbon, silicon, and aluminum element distribution, and film substrate adhesion of diamond-like carbon thin films were studied using field emission scanning electron microscopy, energy-dispersive spectroscopy, XRD, scratch gauge, and ultra-depth-of-field microscopy. The results showed that with the increase in deposition temperature, the thickness of DLC film decreased from 8.72 μm to 5.37 μm, and the film bonded well with the substrate. There is a clear transition layer containing silicon elements between the DLC film and the aluminum alloy substrate. The transition layer is a solid solution formed by aluminum and silicon elements, which increases the bonding strength between the film and substrate. C-Si and C-C exist in the form of covalent bonds and undergo orbital hybridization, making the DLC film more stable. When the deposition temperature exceeds the aging temperature of a 2024 aluminum alloy, it will affect the properties of the aluminum alloy substrate. Therefore, the deposition temperature should be below the aging temperature of the 2024 aluminum alloy for coating. At a deposition temperature of 100 °C, the maximum membrane substrate bonding force is 14.45 N. When a continuous sound signal appears and the friction coefficient is the same as that of the substrate, the film is completely damaged. From the super-depth map of the scratch morphology, it can be seen that, at a deposition temperature of 100 °C, a small amount of thin film detachment appears around the scratch. Full article

Calcareous sand has been widely used as a construction material for offshore projects; however, the problem of foundation settlement caused by particle crushing cannot be ignored. Although many methods for reinforcing calcareous sands have been proposed, they are difficult to apply on-site. In this study, a permeable polyurethane polymer adhesive (PPA) was used to reinforce calcareous sands, and its mechanical properties after reinforcement were investigated through compression creep, direct shear, and triaxial shear tests. The reinforcement mechanism was analyzed using optical microscopy, CT tomography, and mercury intrusion porosimetry. The experimental results indicate that there is a critical time during the compression creep process. Once the critical time is surpassed, creep accelerates again, causing failure of the traditional Burgers and Murayama models. The direct shear strength of the fiber- and geogrid-reinforced calcareous sand reinforced by PPA was approximately nine times greater than that without PPA. The influence of normal stress was not significant when the moisture content was less than 10%, but when the moisture content was more than 10%, the shear strength increased with an increase in vertical normal stress. Strain-softening features can be observed in triaxial shear tests under conditions of low confining pressure, and the relationship between the deviatoric stress and strain can be described using the Duncan–Chang model before softening occurs. The moisture content also has a significant influence on the peak strength and cohesive force but has little influence on the internal friction angle and Poisson’s ratio. This influence is caused by the different PPA structures among the particles. The higher the moisture content, the greater the number of pores left after grouting PPA. Full article

The Ni-GQDs composite plating was created using direct current (DC), single-pulse, and double-pulse power supplies, with GQDs serving as additives under supercritical CO₂ conditions. A comparative analysis was conducted to evaluate the effects of different electrodeposition power sources on the microstructure and properties of the Ni-GQDs composite plating. High-Resolution Transmission Electron Microscopy (HRTEM) was employed to investigate the distribution of GQDs within the composite plating as well as to analyze d-spacing and diffraction patterns. Scanning Electron Microscopy (SEM) was utilized to illustrate the surface morphology of the plating and assess its surface quality. The grain size and preferred orientation of the plated layer were examined using X-ray Diffraction (XRD), while Atomic Force Microscopy (AFM) was used to evaluate the roughness of the surface. To compare the abrasion resistance of the various plating types, wear amounts and friction coefficients were measured through friction and wear tests. Additionally, corrosion resistance tests were performed to assess the corrosion resistance of each plating variant. The results indicate that the Ni-GQDs-III composite layers produced via double-pulse electrodeposition exhibit superior surface quality, characterized by smaller grain sizes, enhanced surface flatness, reduced surface roughness, and improved resistance to wear and corrosion. Full article

In view of the current problems of slow crystallization rate, varying grain sizes, complex process conditions, and low safety in the preparation of CL−20/TNT cocrystal explosives in the laboratory, an opposite spray crystallization method is provided to quickly prepare ultrafine explosive cocrystal particles. CL−20/TNT cocrystal explosive was prepared using this method, and the obtained cocrystal samples were characterized by electron microscopy morphology, differential thermal analysis, infrared spectroscopy, and X-ray diffraction analysis. The effects of spray temperature, feed ratio, and preparation method on the formation of explosive cocrystal were studied, and the process conditions of the pneumatic atomization spray crystallization method were optimized. The crystal plane binding energy and molecular interaction forces between CL−20 and TNT were obtained through molecular dynamic simulation, and the optimal binding crystal plane and cocrystal mechanism were analyzed. The theoretical calculation temperature of the binding energy was preliminarily explored in relation to the preparation process temperature of cocrystal explosives. The mechanical sensitivity of ultrafine CL−20/TNT cocrystal samples was tested. The results showed that choosing acetone as the cosolvent, a spraying temperature of 30 °C, and a feeding ratio of 1:1 was beneficial for the formation and growth of cocrystal. The prepared CL−20/TNT cocrystal has a particle size of approximately 10 μm. The grain size is small, and the crystallization rate is fast. The impact and friction sensitivity of ultrafine CL−20/TNT cocrystal samples were significantly reduced. The experimental process conditions are simple and easy to control, and the safety of the preparation process is high, providing certain technical support for the preparation of high-quality cocrystal explosives. Full article

The aim of this study was to identify the areal surface parameters that correlated with lowering of sliding friction. Different ground surfaces were created on stainless steel and the lubricated sliding friction generated at the contact interface with a flat-faced aluminum pin was studied. The frictional force encountered is an order of magnitude lower for a P1200-finished surface than the other ground surfaces. Using 3D surface profilometry, a unique surface parameter ratio “Spk/Sk” was found to predict the frictional performance of these surfaces. When this surface parameter ratio was less than 1, average sliding friction was close to 0.1. When this ratio was greater than 1, the coefficient was an order of magnitude lower. Using energy dispersive spectrometry, such surfaces after wear showed the presence of a uniform dispersed layer of iron oxide on the surface of the pin. This was absent on the surfaces having high friction, indicating the role of the steel counter surface in building this beneficial transfer layer. Scanning electron microscopy provided topography images to visualize the surface wear. The motivation for the authors was to use a commercially scaled process like precision grinding for the surface modifications on stainless steel. Full article

Tailor-made materials used for advanced applications are nowadays of great research interest in various industrial and technological fields, ranging from aerospace and automotive applications to consumer goods and biomedical components. In the present research, Inconel 718 superalloy specimens were fabricated by the selective laser melting (SLM) technique. Structural characterization of the 3D-printed samples showed that they consisted of γ solid solution along with spherical carbide particles. To explore the applicability of these materials in abrasive tribological applications, reciprocating sliding tests were performed under dry conditions versus an Al₂O₃ counter-body. A 3D representation (triboscopy) of the tangential force during each sliding cycle was carried out in order to obtain better insight on the evolution of friction and to visualize localized tribological phenomena. Quantification of wear was performed with confocal microscopy and the wear mechanisms were analyzed with SEM and EDS techniques. Furthermore, the effect of surface finishing (as-printed and polished) on friction and wear were also investigated, and a comparison with other industrial materials is also included to evaluate the applicability of these alloys. The results indicated that surface finishing had an effect on friction during the run-in stage, whereas in steady-state conditions, no significant differences were observed between the as-printed and polished specimens. In all cases, the main wear mechanisms observed were a mixture of two-body and three-body abrasion, along with oxidative wear (indicated by the formation of an oxide-based tribo-layer). Full article

Superhydrophobic surfaces have garnered significant attention in various industrial applications, such as photovoltaic power generation, anti-icing, and corrosion resistance, due to their exceptional water-repellent properties. However, the poor durability of conventional superhydrophobic coatings has severely impeded their practical implementation. To achieve the dual self-recovery of microscale and nanoscale surface structures and maintain low surface energy after damage to superhydrophobic coatings, thereby enhancing their durability, a rapidly self-healing superhydrophobic coating was developed using polydimethylsiloxane (PDMS) and n-nonadecane in this study. The coating surface demonstrated exceptional hydrophobic characteristics, as evidenced by a water contact angle (WCA) of 157.5° and a sliding angle (SA) of 4.2° achieved at optimized proportions. Through scanning electron microscopy, it was observed that the coating surface exhibited a rough structure at both the microscale and nanoscale. The stability test results showed that the WCA only decreases by 5.7° and the SA only increases by 3.6° after 100 instances of external friction. The stability test results demonstrated that the superhydrophobic coating maintains excellent hydrophobicity under mechanical external forces and in acidic and alkaline environments. The results of the self-healing capability test showed that the WCA rebounded to 151.5° and 149.5° after we subjected the samples to 20 MPa of vertical pressure damage and chloroform exposure for 4 h, respectively. The coating regained a robust hydrophobic state even after experiencing repeated mechanical and chemical damage. The above results indicate that the resulting coating demonstrates outstanding durability, including high resistance to friction, stability against acids and alkalis, and the ability to self-recover hydrophobicity after repeated damage. Full article

This study reports the synthesis of Ni-Co-SiC coatings onto Q235A steel substrates through magnetic-field-induced electrodeposition to improve the surface performances of the machine parts. The microstructure, topology, roughness, corrosion, and wear resistances of the coatings were investigated through X-ray diffraction (XRD), transmission electron microscopy (TEM), scanning electron microscopy (SEM), atomic force microscopy (AFM), hardness testing, electrochemical analysis, and friction wear testing, respectively. The Ni-Co-SiC coating deposited at 0.4 T (MS1) with a perpendicular magnetic direction showed the maximum SiC content and NiCo grain size (86.5 nm). The surface topology was also fine, dense, and smooth. In addition to that, the images obtained from the AFM characterization showed that the surface roughness of the MS1 coating was 76 nm, which was significantly lower compared to the roughness observed in Ni-Co-SiC coatings fabricated under the magnetic induction of 0 T (MS0) and magnetic field applied in a parallel direction to 0.4 T (MS2). The XRD results revealed that the preferential growth direction of the NiCo grains was changed from the (200) crystal plane to the (111) plane with the introduction of a perpendicular magnetic field. Moreover, MS2, MS1, and MS0 had thickness values of 25.3, 26.7, and 26.3 μm, respectively. Among all the coatings, MS1 showed the lowest friction coefficient and the highest hardness value (914.8 HV), suggesting enhanced wear resistance. Moreover, the MS1 coating revealed a maximum corrosion potential of −257 mV, and the lowest corrosion current of 0.487 μA/cm², suggesting its improved corrosion resistance. Full article

Insects optimize friction in their joints by combining microstructures with a—so far unknown—lubricant. To develop environmentally friendly lubricants, we research the sophisticated tribological system found in the joints of beetles. We characterize the lubricant as well as the microstructure of the joints to gain inspiration for the development of a degradable and—hopefully—superior alternative to mineral-oil-based lubricants. However, restrained by the tiny quantities of beetle lubricant and the compactness of their joints, this tribological analysis is challenging. Therefore, we apply atomic force microscopy (AFM) to record the joints' microstructures and the lubricant's frictional properties. Furthermore, we research the inner structure of the bearing surface in beetle joints by focused ion beam (FIB) tomography. With this approach, we discover a network of channels supplying the lubricant to pores which represent the inlets of the hinged joint system. As a subsequent step, we analyze different types of presently available plant mucilage using AFM friction measurements to compare the suitability of plant mucilage as an alternative lubricant to the tiny quantities of beetle lubricant. Finally, we develop an artificial surface mimicking the microstructure of beetle joints. We determine its frictional properties utilizing colloidal AFM probes in the dry state as well as the lubricated state with plant mucilage as the lubricant. Full article

The conventional cutting tools used for machining titanium alloys normally experience rapid tool wear, and it is generally difficult to achieve a cutting speed over 60 m/min. In this paper, a comprehensive study on improving the machining of Ti-6Al-4V alloy is presented, focusing on high-speed end milling at 100 m/min. Three different AlCrN PVD-coated cemented carbide tools were employed over cemented solid carbide endmills. The study aimed to understand the factors influencing tool performance and, particularly, the uncommon tool wear behavior characterized by chipping on the rake face. The research methodology involves a detailed investigation of coating properties, mechanical characteristics, surface defects, and tool edge geometries. Mechanical properties were measured to assess the resistance to plastic deformation and impact fatigue fracture resistance. Surface defects were meticulously observed, and tool edge geometries were evaluated through optical microscopies. These analyses uncover the key factors contributing to the best tool performance, notably the resistance to plastic deformation (H³/E² ratio), impact fatigue fracture resistance, and maintaining uniform tool edge geometries. The results of this study reveal that the moderate stress C3 coating outperformed the other two coatings, exhibiting a 1.5-times-longer tool life, a relatively stable cutting force curve, and favorable friction conditions in the cutting zone. Full article

Dry lubricants used in highly loaded rolling bearings are in the focus of current research. In previous studies, graphene platelets applied as dry lubricants on the surfaces of angular contact ball bearings demonstrated superior properties. These specific bearings, experiencing both rolling and spinning motion, create more severe conditions for dry lubricants. To gain deeper insights into the lubrication effects, micro-tribological studies were carried out on the respective film formation and running behavior effects. In the tests, a fixed steel ball slid against an oscillating counterpart under a defined load. During the measurements, the applied load and tangential forces on the ball were recorded to calculate the friction. Comparative investigations included nano-graphite particles and fullerene as dry lubricants, in addition to graphene platelets of various staple thicknesses. To increase the adhesion of the films to the surfaces, a pre-rolling process was implemented. Afterwards, the friction on the compressed films was measured. The results indicate that the pre-rolling process effectively reduces the friction of the system. After testing, the surfaces underwent analysis using laser scanning microscopy to assess the formed films, wear, and material transfer. It has been demonstrated that the pre-rolling process leads to the formation of a very thin compacted film with surface protective properties. With the ball as a counterpart, the graphene platelets generate a transfer film on the contacting surface. Full article

When a severe plastic deformation (SPD) process is performed at high temperatures, it becomes more versatile. Designed originally for the bulk nanoconstruction of hard-to-deform alloys, high-speed high-pressure torsion (HSHPT) is an SPD method used in this research for assembling multiple layers of shape memory nanocomposites. Three hard-to-deform magnetic alloys in the cast state were used. Soft magnetic shape memory alloys, NiFeGa and FePdMn, and a potentially hard magnetic alloy, CoZr, were assembled in various composites. Both grain refinement and strong layer bonding were achieved in ZrCo/FePdMn and ZrCo/NiFeGa composites in seconds. The very short SPD time is specific to HSHPT because of the intense friction that occurs under high pressures, which generates huge amounts of heat. After SPD, the temperature rises in bulk material like a pulse, being dissipated mostly through heat conduction. The SPD parameters were carefully controlled with an advanced automation system using a programmable logic controller. Nevertheless, the major drawbacks of high-pressure torsion were overcome, and large SPD discs were obtained. Various investigation techniques (optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and atomic force microscopy) show well-defined interfaces as well as a fine and ultrafine structure. Full article

Aluminium matrix composites (AMCs) represent an important group of high-performance materials. Due to their specific strength and a high thermal conductivity, these composites have been considered for the large-scale production of brake discs. However, preconditioning the friction surfaces is necessary to avoid severe wear of both the brake discs and the brake linings. This can be achieved through controlled friction against commercially available brake-lining materials and the formation of transfer or reactive layers (tribosurfaces). Homogeneous tribosurfaces allow for nearly wear-free brake systems under moderate brake conditions. In this work, preconditioning was carried out with a pin-on-disc tester, aiming for the fast creation of homogeneously formed and stable tribosurfaces. The influence of surface microedges perpendicular to the direction of friction on the machined AMC surfaces on the build-up speed and homogeneity of the tribosurfaces was investigated. The microedges were generated using ultrasonic-vibration-superimposed face turning. Thereby, the vibration direction corresponded to the direction of the passive force. For research purposes, the distance of the microedges was changed by varying the cutting speed and feed. The experiments were carried out using AMC disc specimens with a reinforcement content of a 35% volume proportion of silicon carbide particles. Machining was realised with CVD-diamond-tipped indexable inserts. The evaluation of the generated surfaces before and after preconditioning was achieved using 3D laser scanning microscopy and scanning electron microscopy. It was demonstrated that ultrasonic-vibration-superimposed face turning effectively generated microedges on the AMC surfaces. The results show that larger distances between the microedges enhanced the formation of stable tribosurfaces. Thus, the tribosystem’s steady state was reached quickly. Therefore, the benefits of AMC-friction-surface microstructuring on the generation of tribosurfaces under laboratory conditions were proven. These findings contribute to the development of high-performance AMC brake systems. Full article