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Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: 10 April 2026 | Viewed by 4731

Special Issue Editors

Dr. Kamil Leksycki

E-Mail Website
Guest Editor
Institute of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland
Interests: machining of hard-to-cut materials, e.g., stainless steel, titanium and its alloys; physical phenomena of the cutting process; shaping the geometric structure of the materials surface; friction and wear behavior of materials; cooling and lubrication conditions during machining
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Eugene Feldshtein

E-Mail Website
Guest Editor
Institute of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana street, 65-516 Zielona Gora, Poland
Interests: machining of hard-to-cut and unconventional materials, e.g., stainless steels, titanium alloys, powder metallurgy materials; physical phenomena of the cutting process; shaping the material surface texture; wear behavior of cutting tools; friction and wear behavior of the aforementioned materials and coatings; cooling and lubrication conditions during machining; plasma and laser processing conditions
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

High-strength materials are now widespread, from medical implants to products used in aerospace, the automotive industry or marine environments. Such a wide range of applications entails the use of both steels and non-ferrous alloys, as well as unconventional materials, including ceramics, composites, multilayer alloys, etc. The main advantages of these groups of materials are their attractive structural, mechanical, thermal properties, which, in its turn, means the use of such technologies such as high-temperature thermo-mechanical processing, powder metallurgy processing, plasma or laser coating, additive manufacturing technologies, and so on. On the other hand, it is necessary to ensure the high efficiency and quality of production processes, which is not an easy task because these materials are considered to be hard to cut.

The main aims and scopes of this Special Issue are to explore the latest advancements in the following field:

  • Details of chip shaping under machining of high-strength and unconventional materials;
  • Physical phenomenon of cutting and abrasive processing;
  • Modern designs of cutting and abrasive tools;
  • The use of effective technological environments, such as near-dry cutting, minimum cooling and lubrication, high-pressure cooling, etc.;
  • The impact of cutting and abrasive processing on the machined surface texture and the surface layer integrity;
  • Development of high-performance and high-speed cutting;
  • Friction and wear behavior of the surface machined.

Dr. Kamil Leksycki
Prof. Dr. Eugene Feldshtein
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • high-strength and unconventional materials
  • work-piece and tool coatings
  • cutting and abrasive processes
  • surface texture
  • surface layer integrity
  • friction and wear behavior
  • high-performance and high-speed cutting

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Published Papers (5 papers)

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Research

15 pages, 3078 KiB  
Article
In Situ Al3BC/Al Composite Fabricated via Solid-Solid Reaction: An Investigation on Microstructure and Mechanical Behavior
by Tapabrata Maity, Aditya Prakash, Debdas Roy and Konda Gokuldoss Prashanth
Appl. Sci. 2025, 15(9), 5189; https://doi.org/10.3390/app15095189 - 7 May 2025
Viewed by 164
Abstract
Al3BC, with its remarkably high modulus of elasticity (326 GPa) and hardness (14 GPa), coupled with a low density (2.83 g/cc), stands out as a promising reinforcement material for Al matrix composite. To study feasibility of solid-solid reaction (SSR) by forming [...] Read more.
Al3BC, with its remarkably high modulus of elasticity (326 GPa) and hardness (14 GPa), coupled with a low density (2.83 g/cc), stands out as a promising reinforcement material for Al matrix composite. To study feasibility of solid-solid reaction (SSR) by forming an in situ Al3BC reinforcing phase within the matrix, this study developed an Al3BC/Al composite via mechanical alloying, followed by sintering at 1000 °C/1 h, and subsequent hot pressing at 400 °C/40 MPa. The reaction kinetics and corresponding electron microscopy images suggest that the aluminum (Al)-boron (B) reacts with graphene nanoplates (GNPs) to form both clusters and a heterogeneous multi-structured Al3BC reinforcements network dispersed within the fine-grain (FG) Al matrix. The heterostructure contributes to a good balance between strength (~284 MPa) and ductility (~17%) and stiffness (~212 GPa). Superior strain hardening ability (n = 0.3515) endorses remarkable load-bearing capacity (σc = 1.63) and thereby promotes excellent strength-ductility synergy in the composite. The fracture morphology reveals that reasonable ductility primarily relies on the crack deflection by the FG-Al matrix, playing a critical role in delaying fracture. The potential importance of the matrix microstructure in the overall fracture resistance of the composite has been highlighted. Full article
(This article belongs to the Special Issue Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties)
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27 pages, 10971 KiB  
Article
Fracture Prediction in Weldox 700E Steel Subjected to High Velocity Impact Using LS-DYNA
by Nikesh Kumar Ojha, Ravindra K. Saxena, Govind Vashishtha and Sumika Chauhan
Appl. Sci. 2025, 15(7), 3677; https://doi.org/10.3390/app15073677 - 27 Mar 2025
Viewed by 238
Abstract
Analyzing fracture behaviour during high-velocity impacts is critical for designing and developing structures in various scientific and technological fields. This study investigates the fracture behaviour of Weldox 700E steel plates with varying values of fracture parameters and fracture strain criteria using LS-DYNA/explicit. It [...] Read more.
Analyzing fracture behaviour during high-velocity impacts is critical for designing and developing structures in various scientific and technological fields. This study investigates the fracture behaviour of Weldox 700E steel plates with varying values of fracture parameters and fracture strain criteria using LS-DYNA/explicit. It also discusses the effect of varying plate thicknesses (2 to 6 mm) when impacted by a blunt-nosed projectile with varying masses and varying velocities. The fracture behaviour of flat steel target plates is analyzed with a focus on fracture variables across the top, mid, and bottom elements of the plate thickness. It is observed that the higher value of the fracture parameter results in a smooth fracture surface with Johnson–Cook (JC) fracture strain criteria. For thicker plates, both strain rate and temperature significantly affect the process, while for thinner plates, strain rate predominantly determines element deletion. The results reveal that for the top elements, equivalent plastic strain is the dominant factor causing failure at higher velocities, while temperature plays a significant role at lower velocities. For the mid elements, both plastic strain rate and temperature are critical, whereas for the bottom elements, equivalent plastic strain, plastic strain rate, and temperature are the primary factors. In all cases, shear-type fracture is consistently observed along the mid element of the target plate. Full article
(This article belongs to the Special Issue Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties)
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15 pages, 3008 KiB  
Article
Stress Concentration Modelling in Internal Stiffeners of Ship-to-Shore Quay Cranes Legs Due to Structural Heightening
by José Roberto Castillo Rivera, María Inmaculada Rodríguez-García, María Gema Carrasco-García and Ignacio J. Turias
Appl. Sci. 2024, 14(22), 10269; https://doi.org/10.3390/app142210269 - 8 Nov 2024
Viewed by 905
Abstract
This paper presents a study on the modelling and estimation of stress concentration at the tips of leg stiffeners in ship-to-shore (STS) quay cranes, which is intensified in those on the sea-side leg extensions, which are more prone to crack formation, notably following [...] Read more.
This paper presents a study on the modelling and estimation of stress concentration at the tips of leg stiffeners in ship-to-shore (STS) quay cranes, which is intensified in those on the sea-side leg extensions, which are more prone to crack formation, notably following structural heightening of the cranes. A computer-simulated database was generated, incorporating mechanical parameters and geometric features that impact stress concentration. These variables can then be integrated as inputs into a multiple linear regression model (MLR). This methodology offers an alternative to the finite element method (FEM) for the computation of stress concentration and deformations. At the same time, the statistical significance of the parameters influencing this scenario is determined, ensuring a comprehensive assessment of their impact on the studied phenomenon. The research underscores the importance of incorporating stress concentration and structural geometry considerations into crane design or modification, given their crucial role in preserving the remaining lifecycle of the structure. Crack initiation is significantly intensified in regions characterised by high stress concentrations, particularly in areas where there are geometric changes at the tips of the stiffeners, where local stiffness is altered. All of this is in combination with work cycles under the supported loads. Full article
(This article belongs to the Special Issue Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties)
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15 pages, 4102 KiB  
Article
Sliding Layer Formation during Tribological Contact between Expanded Graphite and Stainless Steel—A Pilot Study
by Aleksandra Rewolińska, Kamil Leksycki, Karolina Perz and Grzegorz Kinal
Appl. Sci. 2024, 14(11), 4497; https://doi.org/10.3390/app14114497 - 24 May 2024
Cited by 1 | Viewed by 987
Abstract
The sliding layer created during operation of the expanded graphite–steel combination has had a huge impact on the effectiveness of the friction process, and thus on the sustainable development of society. Knowledge of the factors determining the properties of the sliding layer will [...] Read more.
The sliding layer created during operation of the expanded graphite–steel combination has had a huge impact on the effectiveness of the friction process, and thus on the sustainable development of society. Knowledge of the factors determining the properties of the sliding layer will make it possible to reduce friction resistance in the future through the proper design and selection of sliding pairs for given applications. This paper studies the effect of the moisture content of expanded graphite on the formation of a sliding layer on a stainless steel surface. The tests were carried out in static contact for 30 s and dynamic contact for 15 and 30 min, for loads of 10, 20, and 30 N and speeds of 25 and 50 mm/s. To determine the changes in surface geometry due to material transfer, the Ra roughness value of the surface of stainless steel samples was measured. In order to realize the purpose of the work and evaluate the effect of moist rings on the resulting sliding layer, the results of the surface roughness of stainless steel samples working with dry and moist graphite rings were compiled. The obtained results show that the presence of water in the stainless steel-expanded graphite friction node affects the formation of a sliding layer. The resulting layer reduces the surface roughness of the cooperating materials and prevents their accelerated wear. After 5 min of work with the water-soaked graphite counter-sample, depending on the applied friction conditions, a reduction in the surface roughness of the stainless steel sample was achieved in the range of 11–18% compared to the initial value. After 30 min of operation, the surface roughness decreased by 3 to 25%. Pilot studies have shown that operating conditions influence the formation of a sliding layer in the stainless steel-expanded graphite tribological contact. This confirms the validity of conducting further research in this area. Full article
(This article belongs to the Special Issue Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties)
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13 pages, 10340 KiB  
Article
High-Temperature Oxidation of the 304/6061 Welding–Brazing Joint and Its Effects on Corrosion Characteristics
by Ruilin Liu, Yunqi Liu, Hongming Liu, Yuanxing Li, Hui Chen and Zongtao Zhu
Appl. Sci. 2024, 14(7), 3131; https://doi.org/10.3390/app14073131 - 8 Apr 2024
Viewed by 1465
Abstract
Laser–MIG hybrid welding–brazing was used to weld 304 stainless steel and 6061-T6 aluminum alloy with a thickness of 2 mm. The microstructure, morphology, chemical composition and corrosion behavior of the samples after high-temperature oxidation were investigated. The results reveal that the 304/6061 dissimilar [...] Read more.
Laser–MIG hybrid welding–brazing was used to weld 304 stainless steel and 6061-T6 aluminum alloy with a thickness of 2 mm. The microstructure, morphology, chemical composition and corrosion behavior of the samples after high-temperature oxidation were investigated. The results reveal that the 304/6061 dissimilar joint had a thicker intermetallic compound layer (7–8 μm) during high-temperature oxidation (HTO) treatment than the sample without HTO treatment (2–3 μm). The oxide film thickness of the 6061 side of the weld joint treated by HTO (2401 nm) increased compared to the samples (181.1 nm) without HTO treatment. Unlike other metals treated by high-temperature oxidation, the high-temperature treatment process in this paper can reduce the corrosion resistance of the base metal and dissimilar joints, and the sequence of the corrosion current density was weld (HTO) >weld>6061 (HTO) >6061>304 (HTO) >304. Full article
(This article belongs to the Special Issue Advances in High-Strength Materials Processing: Machining, Surface Integrity Management, and Operational Properties)
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