Materials

Research

27 pages, 10819 KiB

Open AccessArticle

Bio-Based Poly(3-hydroxybutyrate) and Polyurethane Blends: Preparation, Properties Evaluation and Structure Analysis

by Beata Krzykowska, Anna Fajdek-Bieda, Aneta Jakubus, Joanna Kostrzewa, Anita Białkowska, Maciej Kisiel, Štěpánka Dvořáčková, Wiesław Frącz and Iwona Zarzyka

Materials 2025, 18(9), 1914; https://doi.org/10.3390/ma18091914 - 23 Apr 2025

Viewed by 310

Abstract

The present work deals with polymer blends produced from poly(3-hydroxybutyrate), P3HB and polyurethane. Linear polyurethane (PU) was here synthesized by reacting polypropylene glycol with 4,4′-diphenylmethane diisocyanate, and was used in amounts of 5, 10 and 15 wt. %. The polymers were melt-mixed using [...] Read more.

The present work deals with polymer blends produced from poly(3-hydroxybutyrate), P3HB and polyurethane. Linear polyurethane (PU) was here synthesized by reacting polypropylene glycol with 4,4′-diphenylmethane diisocyanate, and was used in amounts of 5, 10 and 15 wt. %. The polymers were melt-mixed using a twin-screw extruder after prior premixing. The obtained blends were tested by differential scanning calorimetry analysis (DSC), Fourier transformation infrared spectroscopy (FTIR), and scanning electron microscopy (SEM) with energy dispersive X-ray analysis (EDX). Their thermal and mechanical properties, including impact resistance, hardness, tensile and flexural properties, were also determined, and the surface topography and roughness were analyzed. FTIR analysis of the prepared blends confirmed the interactions of PU with the P3HB matrix via hydrogen bonding. Analysis of the surface topography of the samples showed that the higher the PU content, the greater the regularity and homogeneity of the surface structure. The roughness of the P3HB blend containing 5 wt. % PU was the greatest. SEM images of the fracture surfaces of the blend samples explain the mechanism of the improvement of their mechanical properties. The obtained polymer blends were characterized by significantly lower hardness, and better impact strength and relative elongation at break compared to native P3HB. The DSC results confirm a decrease in the glass transition, melting and crystallization temperatures with increasing amounts of PU in the blends. The lower melting temperature and the higher degradation temperature of the resulted blends than native P3HB make the processing conditions easier, and prevent the degradation of the material. The best mechanical and thermal properties were shown by blends containing 10 wt. % of PU. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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20 pages, 8670 KiB

Open AccessArticle

Advances in Enhancing the Wear Performance of Ti-6Al-4V Biomedical Alloy Through Nb₂O₅ Coating

by Murilo Oliveira Alves Ferreira, Witor Wolf, Rogério Valentim Gelamo, Natália Bueno Leite Slade, Rodrigo Galo, Renato Goulart Jasinevicius, Carlos Alberto Fortulan and Jéferson Aparecido Moreto

Materials 2025, 18(7), 1593; https://doi.org/10.3390/ma18071593 - 1 Apr 2025

Viewed by 377

Abstract

The Ti-6Al-4V alloy is widely used in orthopedic and dental implants due to its excellent mechanical, corrosion, and biological properties. However, it exhibits several limitations that can compromise its performance in clinical applications. Notably, the alloy suffers from a high coefficient of friction, [...] Read more.

The Ti-6Al-4V alloy is widely used in orthopedic and dental implants due to its excellent mechanical, corrosion, and biological properties. However, it exhibits several limitations that can compromise its performance in clinical applications. Notably, the alloy suffers from a high coefficient of friction, which can lead to increased wear and reduced longevity of implants under relative movement conditions. Additionally, Ti-6Al-4V shows susceptibility to localized corrosion in physiological environments, particularly in the presence of bodily fluids that may result in the formation of pitting. These challenges underscore the need for surface modifications that can enhance the alloy’s tribological performance, thereby improving its overall efficacy and durability as a biomaterial in medical settings. In this context, the manuscript presents applied and innovative research that assesses the impact of implementing nanostructured Nb₂O₅ coatings through the reactive sputtering technique on the wear performance of Ti-6Al-4V alloy under both air and artificial saliva (AS) solution conditions using a Pin-on-Disk apparatus. The nanostructured Nb₂O₅ coating demonstrated the ability to reduce the wear rate and volume by up to 88% without inducing any modifications to the R_a and R_t of Ti-6Al-4V, a feature that is desirable for applications in implantable devices. The reduction in wear can be attributed to the shift from adhesive wear mechanisms on uncoated surfaces to abrasive mechanisms on coated surfaces. This research highlights the strategic advantage of utilizing Brazil’s abundant niobium resources to advance biomaterial technology and facilitate applications that benefit public health. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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20 pages, 27712 KiB

Open AccessArticle

Identification of Dynamic Recrystallization Model Parameters for 40CrMnMoA Alloy Steel Using the Inverse Optimization Method

by Xuewen Chen, Qiang Li, Bingqi Liu, Shiqi Zhao, Lei Sun and Hao Yi

Materials 2025, 18(3), 718; https://doi.org/10.3390/ma18030718 - 6 Feb 2025

Viewed by 603

Abstract

The microstructure of 40CrMnMoA during hot forging determines its macroscopic mechanical properties. Dynamic recrystallization (DRX) behavior is commonly used to refine grains and improve the microstructure of materials; therefore, it is important to be able to predict mechanical behavior during hot forging and [...] Read more.

The microstructure of 40CrMnMoA during hot forging determines its macroscopic mechanical properties. Dynamic recrystallization (DRX) behavior is commonly used to refine grains and improve the microstructure of materials; therefore, it is important to be able to predict mechanical behavior during hot forging and the microstructure evolution during dynamic recrystallization. In order to accurately determine the DRX model parameters of 40CrMnMoA steel, an inverse optimization method is proposed in this work. The uniaxial isothermal compression experiment of 40CrMnMoA steel was carried out on a Gleeble-1500D thermal simulation tester (Dynamic Systems Inc. (DSI), Poestenkill, NY, USA) under the temperature range of 900~1200 °C and the strain rate range of 0.005 to 5 s⁻¹. Based on the true stress–strain data obtained by a compression test, the DRX model of 40CrMnMoA was initially established using the traditional averaging method. Subsequently, the DRX model parameters calculated by the conventional averaging method were used as the initial values, the mean-square error between the experimental and calculated values of the DRX volume fraction was set as the objective function, and the DRX model parameters were optimized by the adaptive simulated annealing (ASA) algorithm. By comparing the correlation coefficient R, average absolute relative error (AARE), and the root mean square error (RMSE) of the predicted DRX percentage with the experimental values before and after optimization, it was found that the optimized model achieved an R-value of 0.992, with AARE and RMSE decreased by 34% and 2%, respectively, which verified the accuracy of the optimized DRX model. Through the program’s secondary development, the optimized DRX model of 40CrMnMoA was integrated into finite element software Forge^® 3.2 to simulate the isothermal compression process. The comparison between grain size from the central region of simulation results and actual samples revealed that the relative error is less than 3%. This result demonstrated that the inverse optimization method can accurately identify the DRX model parameters of 40CrMnMoA alloy steel. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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22 pages, 21801 KiB

Open AccessArticle

Modeling and Simulation of Dynamic Recrystallization Microstructure Evolution for GCr15 Steel Using the Level Set Method

by Xuewen Chen, Mingyang Liu, Yisi Yang, Yahui Si, Zheng Zhou, Xudong Zhou and Dongwon Jung

Materials 2025, 18(2), 342; https://doi.org/10.3390/ma18020342 - 14 Jan 2025

Cited by 1 | Viewed by 770

Abstract

The microstructure of metallic materials plays a crucial role in determining their performance. In order to accurately predict the dynamic recrystallization (DRX) behavior and microstructural evolution during the hot deformation process of GCr15 bearing steel, a microstructural evolution model for the DRX process [...] Read more.

The microstructure of metallic materials plays a crucial role in determining their performance. In order to accurately predict the dynamic recrystallization (DRX) behavior and microstructural evolution during the hot deformation process of GCr15 bearing steel, a microstructural evolution model for the DRX process of GCr15 steel was established by combining the level set (LS) method with the Yoshie–Laasraoui–Jonas dislocation dynamics model. Firstly, hot compression tests were conducted on GCr15 steel using the Gleeble-1500D thermal simulator, and the hardening coefficient k₁ and dynamic recovery coefficient k₂ of the Yoshie–Laasraoui–Jonas model were derived from the experimental flow stress data. The effects of temperature, strain, and strain rate on DRX behavior and grain size during the hot working process of GCr15 steel were investigated. Through secondary development of the software, the established microstructural evolution model was integrated into the DIGIMU^® software. Metallographic images were imported in situ to reconstruct its initial microstructure, enabling GCr15 steel DRX microstructure finite element simulation of the hot compression process. The predicted mean grain size and flow stress demonstrated a strong correlation and excellent agreement with the experimental results. The results demonstrate that the established DRX model effectively predicts the evolution of the DRX fraction and average grain size during the hot forging process and reliably forecasts DRX behavior. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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14 pages, 3629 KiB

Open AccessArticle

Correlation of Solidification Thermal Variables with Microstructure and Hardness in CuMn11Al8Fe3Ni3 Manganese–Aluminum–Bronze Alloy

by Ricardo de Luca, Paulo Henrique Tedardi do Nascimento, Vinicius Torres dos Santos, Marcio Rodrigues da Silva, Flavia Gonçalves Lobo, Rogerio Teram, Mauricio Silva Nascimento, Antonio Augusto Couto, Anibal de Andrade Mendes Filho and Givanildo Alves dos Santos

Materials 2025, 18(2), 234; https://doi.org/10.3390/ma18020234 - 8 Jan 2025

Viewed by 785

Abstract

The mechanical properties of a final product are directly influenced by the solidification process, chemical composition heterogeneity, and the thermal variables during solidification. This study aims to analyze the influence of solidification thermal variables on the microstructure, hardness, and phase distribution of the [...] Read more.

The mechanical properties of a final product are directly influenced by the solidification process, chemical composition heterogeneity, and the thermal variables during solidification. This study aims to analyze the influence of solidification thermal variables on the microstructure, hardness, and phase distribution of the CuMn11Al8Fe3Ni3. The alloy was directionally and upward solidified from a temperature of 1250 °C. Heat extraction occurred through a water-cooled AISI 1020 steel interface. The thermal variables were recorded using a data acquisition system, with temperature monitored at seven different positions, where cooling rates varied from 13.03 °C/s at the closest position to 0.23 °C/s at the farthest. The Brinell hardness decreased from 199 HB at the highest cooling rate position to 184 HB at the slowest cooling rate position. This indicates that higher cooling rates increase the hardness of the alloy, which can be attributed to the stabilization of the metastable β phase with refined and equiaxial grains due to iron addition. Vickers microhardness was observed in regions subjected to slower cooling (244 HV) compared to faster cooling regions (222 HV). Therefore, the correlation between solidification thermal variables and alloy properties provides valuable insights into the relationship between microstructure and the properties of the CuMn11Al8Fe3Ni3 alloy. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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14 pages, 5225 KiB

Open AccessArticle

Slip-Resistant Connections with Hot-Dip Galvanized Faying Surface Under Freeze-Thaw Cycles and/or Low Temperature

by Alfonso Fuente García, Miguel Serrano López, Carlos López-Colina Pérez and Fernando López Gayarre

Materials 2025, 18(1), 84; https://doi.org/10.3390/ma18010084 - 28 Dec 2024

Viewed by 608

Abstract

In some occasions, outdoor steel structures like wind towers, bridges, winter sports facilities, and so on are subjected to extreme environmental conditions with the presence of ice and/or with below-zero temperatures. Sometimes in these situations, surface protection of the steel structure is usually [...] Read more.

In some occasions, outdoor steel structures like wind towers, bridges, winter sports facilities, and so on are subjected to extreme environmental conditions with the presence of ice and/or with below-zero temperatures. Sometimes in these situations, surface protection of the steel structure is usually designed using hot-dip galvanizing to improve its durability. In these special circumstances, the structure’s connections are also exposed to adverse climatic agents. International standards and codes such as Eurocode 3 or EN1090-2 do not provide indications for these cases. In this experimental research, 24 specimens of non-slip joints with hot-dip galvanized faying surfaces and HV M16 and M20 bolts have been studied. Twelve specimens were subjected to fourteen twelve-hour freeze-thaw cycles, with temperature oscillation and periodic immersion in water. Next, six of the connections were subjected to a slip test under monotonic load at a temperature of −20 ± 0.5 °C and the other six at room temperature. The results were compared with joints kept at room temperature and not subjected to freeze-thaw cycles for the same period of time. The main conclusion of this piece of research is that the short-term slip resistance behavior of joints with hot-dip galvanized surfaces is not reduced for the cases studied. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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17 pages, 3372 KiB

Open AccessArticle

An Electrical Method to Detect Both Crack Creation and Propagation in Solid Electrical Insulators

by Tara Niakan, Zarel Valdez-Nava and David Malec

Materials 2025, 18(1), 24; https://doi.org/10.3390/ma18010024 - 25 Dec 2024

Viewed by 541

Abstract

Fracto-emission is the ejection of electrons and positive ions from matter undergoing a mechanical fracture. The creation and propagation of fractures in insulating material can generate an electrical signal that can be detected using a sufficiently fast signal recorder. The theoretical equations related [...] Read more.

Fracto-emission is the ejection of electrons and positive ions from matter undergoing a mechanical fracture. The creation and propagation of fractures in insulating material can generate an electrical signal that can be detected using a sufficiently fast signal recorder. The theoretical equations related to crack creation/propagation that induce an externally electric signal are detailed for two conditions: with and without an external applied electric voltage. Results from an experiment with no externally applied voltage are presented for fibreglass-reinforced epoxy laminate samples, in which current signals ranging from 50 mA to 100 mA are measured in a time frame of 200 ns. The signal-to-noise ratio is high enough to consider that the signal that was recorded is not a measurement artifact. This method may help to identify and track a crack propagating inside dielectric materials. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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21 pages, 10026 KiB

Open AccessArticle

A Modified Multiaxial Fatigue Model and Its Application for the Fatigue Life Prediction of Aircraft Hydraulic Pipes

by Yantian Wang, Yuanying Qiu, Jing Li, Jin Bai and Yan Wang

Materials 2024, 17(24), 6154; https://doi.org/10.3390/ma17246154 - 17 Dec 2024

Viewed by 865

Abstract

The fatigue failure of a structure may occur under a multiaxial vibration environment; it is necessary to establish a better multiaxial fatigue life prediction model to predict the fatigue life of the structure. This study proposes a new model (MWYT) by introducing the [...] Read more.

The fatigue failure of a structure may occur under a multiaxial vibration environment; it is necessary to establish a better multiaxial fatigue life prediction model to predict the fatigue life of the structure. This study proposes a new model (MWYT) by introducing the maximum absolute shear stress into the WYT model. The feasibility of the MWYT model is verified by using the multiaxial fatigue experimental data of 304 stainless steel, Q235B steel, 7075-T651 aluminum alloy and S355J0 steel. Further, finite element vibration simulations are performed on a typical parallel hydraulic pipe structure, and the vibration simulation results of the pipe structure are verified through the vibration experiment. Finally, the MWYT model is used to predict the fatigue lives of the pipe structure under random excitation and pulsation excitation, respectively, and the fatigue life of the pipe structure under the combined loading from random excitation and pulsation excitation is predicted based on Miner’s rule. By comparing with the design life of the aircraft, the predicted life of the pipe structure meets the service requirements for it. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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19 pages, 2199 KiB

Open AccessArticle

Assessment of the Effect of Multiple Processing of PHBV–Ground Buckwheat Hull Biocomposite on Its Functional and Mechanical Properties

by Grzegorz Janowski, Marta Wójcik, Wiesław Frącz, Łukasz Bąk and Grażyna Ryzińska

Materials 2024, 17(24), 6136; https://doi.org/10.3390/ma17246136 - 15 Dec 2024

Cited by 1 | Viewed by 851

Abstract

The influence of the addition of ground buckwheat hulls on the properties of biocomposite on the basis of 3-hydroxybutyrate-co-3-hydroxyvalerate (PHBV) is presented here. The changes in the material after repeated reprocessing—up to five recycling cycles—are written in the paper. Analysis of the shrinkage, [...] Read more.

The influence of the addition of ground buckwheat hulls on the properties of biocomposite on the basis of 3-hydroxybutyrate-co-3-hydroxyvalerate (PHBV) is presented here. The changes in the material after repeated reprocessing—up to five recycling cycles—are written in the paper. Analysis of the shrinkage, water adsorption, selected mechanical properties, tensile impact strength, hardness and the microstructure of the surface layer was performed. The results show that the application of the buckwheat hulls into the biopolymer decreases the material shrinkage. It improves the material dimensional stability, as well as increases the water adsorption in the wake of the hydrophobic properties of the filler. The addition of the natural filler also leads to an increase in composite stiffness. The decrease in the tensile impact strength and the elongation at break is also noted. The reprocessing of the biocomposite initially led to a decrease in its mechanical properties, but the results stabilized after further processing cycles. This indicates the improvement of the microstructure homogeneity. The microscopic analysis shows that buckwheat hull particles were better embedded in the matrix after recycling. The increase in hardness was also noted. The PHBV–ground buckwheat hull biocomposite is characterized by stable mechanical properties and by recycling resistance, which makes it a promising material in terms of the sustainable development. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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15 pages, 7203 KiB

Open AccessArticle

Rectangular Improvement Method for Plan View Pattern of Plates During the Angular Rolling Process

by Chunyu He, Junyi Luo, Zhipeng Xu, Zhiqiang Wang, Zhong Zhao, Zhiqiang Wu and Zhijie Jiao

Materials 2024, 17(23), 5964; https://doi.org/10.3390/ma17235964 - 5 Dec 2024

Cited by 1 | Viewed by 766

Abstract

The effect of the angular rolling process on the plan view pattern of a plate was studied, and the rectangular influencing factors and improvement methods for this process were proposed in this paper. DEFORM (v11.0) finite element software was used to simulate the [...] Read more.

The effect of the angular rolling process on the plan view pattern of a plate was studied, and the rectangular influencing factors and improvement methods for this process were proposed in this paper. DEFORM (v11.0) finite element software was used to simulate the processes of conventional rolling and angular rolling, and the degree of rectangularity of plates under different rolling process conditions was compared. A formula to characterize the degree of rectangularity of plates was established; the closer this value is to one, the better the degree of rectangularity. Considering the actual rolling process conditions, the range of theoretically calculated rectangular rotation angles was extended to obtain the optimum rectangular rotation angle using the finite element simulation method. In the two-pass angular rolling process, the optimal rectangular angle of the second pass was 14.275° when the first pass was 15°. The optimal rectangular angle of the plate was 19.008° when the first pass’ angle was 20°. Two-pass angular rolling is different to four-pass rolling, and the simulation results showed that

J_{15 °}^{4}

(1.0012) was less than

J_{15 °}^{2}

(1.0015) and

J_{20 °}^{4}

(1.0034) was less than

J_{20 °}^{2}

(1.0055). The rectangularity degree of the four-pass process was better than the two-pass process. Angular rolling experiments were carried out, and the actual data show that the characteristic rectangular value of the rolled piece was 1.003 during the four-pass process and 1.014 during the two-pass process. This verified that separating the one-group two-pass angular rolling process from the one-group four-pass angular rolling process can improve the rectangular degree of the rolled plate, thereby increasing the yield rate. This provides a theoretical basis for industrial applications. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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13 pages, 4786 KiB

Open AccessArticle

Influence of Temperature on the Damping Properties of Selected Viscoelastic Materials

by Lucjan Witek and Piotr Łabuński

Materials 2024, 17(23), 5832; https://doi.org/10.3390/ma17235832 - 28 Nov 2024

Viewed by 955

Abstract

The paper presents results of experimental investigations of the influence of temperature on the effectiveness of passive vibration isolation. Two types of viscoelastic materials (butyl rubber and bituminous material) were tested. In the performed vibration analysis, the Oberst beam made out of aluminum [...] Read more.

The paper presents results of experimental investigations of the influence of temperature on the effectiveness of passive vibration isolation. Two types of viscoelastic materials (butyl rubber and bituminous material) were tested. In the performed vibration analysis, the Oberst beam made out of aluminum alloy with a damping material in a Free Layer Damping (FLD) configuration was used. The experimental modal analysis was performed using the Unholtz-Dickie UDCO TA-250 vibration system. To investigate the influence of temperature on the effectiveness of passive vibration isolation, an isothermal cooling chamber (using Peltier cells) was designed and constructed. The tests were carried out in a wide frequency range from 40 Hz to 4000 Hz, at a constant sweep rate, in a temperature range from −2 °C to 22 °C. Miniature piezoelectric acceleration sensors were used to determine the acceleration of the beam and the exciter head. The analysis of accelerations of both the object and the shaker head allowed for the determination of a Frequency Response Function (FRF) for the beam. The course of FRF was used to determine the resonance frequencies and the vibration amplitudes of the beam damped with bituminous material and butyl rubber at various temperatures. The loss factor η, calculated for each resonance using the generalized half-power method (n-dB method), was used as an indicator of damping intensity. The research results presented in this work (important from scientific point of view) also have utilitarian significance and can be used in the design of more quiet and comfortable motor vehicles, railway wagons and aircraft structures. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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16 pages, 2999 KiB

Open AccessEditor’s ChoiceArticle

Modification of Poly(3-Hydroxybutyrate) with a Linear Polyurethane Modifier and Organic Nanofiller—Preparation and Structure–Property Relationship

by Iwona Zarzyka, Beata Krzykowska, Karol Hęclik, Wiesław Frącz, Grzegorz Janowski, Łukasz Bąk, Tomasz Klepka, Jarosław Bieniaś, Monika Ostapiuk, Aneta Tor-Świątek, Magda Droździel-Jurkiewicz, Adam Tomczyk, Anna Falkowska and Michał Kuciej

Materials 2024, 17(22), 5542; https://doi.org/10.3390/ma17225542 - 13 Nov 2024

Viewed by 895

Abstract

The growing demand for products made of polymeric materials, including the commonly used polypropylene (PP), is accompanied by the problem of storing and disposing of non-biodegradable waste, increasing greenhouse gas emissions, climate change and the creation of toxic products that constitute a health [...] Read more.

The growing demand for products made of polymeric materials, including the commonly used polypropylene (PP), is accompanied by the problem of storing and disposing of non-biodegradable waste, increasing greenhouse gas emissions, climate change and the creation of toxic products that constitute a health hazard of all living organisms. Moreover, most of the synthetic polymers used are made from petrochemical feedstocks from non-renewable resources. The use of petrochemical raw materials also causes degradation of the natural environment. A potential solution to these problems is the use of biopolymers. Biopolymers include biodegradable or biosynthesizable polymers, i.e., obtained from renewable sources or produced synthetically but from raw materials of natural origin. One of them is the poly(3-hydroxybutyrate) (P3HB) biopolymer, whose properties are comparable to PP. Unfortunately, it is necessary to modify its properties to improve its processing and operational properties. In the work, hybrid polymer nanobiocomposites based on P3HB, with the addition of chain, uncross-linked polyurethane (PU) and layered aluminosilicate modified with organic salts (Cloisite^®30B) were produced by extrusion process. The introduction of PU and Cloisite^®30B to the polymer matrix (P3HB) influenced the processing parameters beneficially and resulted in a decrease in the extrusion temperature of more than 10 °C. The influence of the simultaneous addition of a constant amount of PU (10 m/m%) and the different amounts of nanoadditives (1, 2 and 3 m/m%) on the compatibility, morphology and static mechanical properties of the resulted nanobiocomposites were examined. The component interactions by Fourier transformation infrared spectroscopy (FTIR) analysis, nano- and microscale structure studies using small-angle X-ray scattering (SAXS) and morphology by scanning electron microscopy (SEM) were carried out, and the hardness and tensile strength of the obtained polymer nanobiocomposites were determined. FTIR analysis identified the compatibility of the polyester matrix, PU, and organomodified montmorillonite, the greatest being 3 m/m% Cloisite30B content. The addition of PU to the polyester elasticizes the material and decreases the material’s strength and ductility. The presence of nanoclay enhanced the mechanical properties of nanobiocomposites. The resulting nanobiocomposites can be used in the production of short-life materials applied in gardening or agriculture. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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12 pages, 3564 KiB

Open AccessArticle

Three-Dimensional Micromechanical Modeling of Martensite Particle Size Effects on the Deformation Behavior of Dual-Phase Steels

by Onur Cavusoglu and Serkan Toros

Materials 2024, 17(20), 5004; https://doi.org/10.3390/ma17205004 - 13 Oct 2024

Cited by 1 | Viewed by 1162

Abstract

The objective of this study was to examine the influence of martensite particle size on the formation of stress and strain in microstructures of dual-phase steels. In order to achieve this objective, the 3D representative volume element (RVE) method was utilized. Particle size [...] Read more.

The objective of this study was to examine the influence of martensite particle size on the formation of stress and strain in microstructures of dual-phase steels. In order to achieve this objective, the 3D representative volume element (RVE) method was utilized. Particle size distributions were obtained from the microstructures of DP600 and DP1000 dual-phase steels as they actually exist. Virtual dual-phase steel microstructures were generated according to the above distribution and subsequent validation analyses were performed. In the subsequent phase, microstructures of varying martensite particle sizes (1 µm, 1.98 µm, 3 µm for DP600 and 1.15 µm, 2 µm, 3 µm for DP1000) were formed, and the effects of particle size on deformation behavior under tensile loads were determined. The findings indicated that an increase in martensite particle size resulted in a reduction in tensile strength, accompanied by an increase in deformation amount. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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17 pages, 3315 KiB

Open AccessArticle

Application of the Gradient-Boosting with Regression Trees to Predict the Coefficient of Friction on Drawbead in Sheet Metal Forming

by Sherwan Mohammed Najm, Tomasz Trzepieciński, Salah Eddine Laouini, Marek Kowalik, Romuald Fejkiel and Rafał Kowalik

Materials 2024, 17(18), 4540; https://doi.org/10.3390/ma17184540 - 15 Sep 2024

Viewed by 1329

Abstract

Correct design of the sheet metal forming process requires knowledge of the friction phenomenon occurring in various areas of the drawpiece. Additionally, the friction at the drawbead is decisive to ensure that the sheet flows in the desired direction. This article presents the [...] Read more.

Correct design of the sheet metal forming process requires knowledge of the friction phenomenon occurring in various areas of the drawpiece. Additionally, the friction at the drawbead is decisive to ensure that the sheet flows in the desired direction. This article presents the results of experimental tests enabling the determination of the coefficient of friction at the drawbead and using a specially designed tribometer. The test material was a DC04 carbon steel sheet. The tests were carried out for different orientations of the samples in relation to the sheet rolling direction, different drawbead heights, different lubrication conditions and different average roughnesses of the countersamples. According to the aim of this work, the Features Importance analysis, conducted using the Gradient-Boosted Regression Trees algorithm, was used to find the influence of several parameter features on the coefficient of friction. The advantage of gradient-boosted decision trees is their ability to analyze complex relationships in the data and protect against overfitting. Another advantage is that there is no need for prior data processing. According to the best of the authors’ knowledge, the effectiveness of gradient-boosted decision trees in analyzing the friction occurring in the drawbead in sheet metal forming has not been previously studied. To improve the accuracy of the model, five MinLeafs were applied to the regression tree, together with 500 ensembles utilized for learning the previously learned nodes, noting that the MinLeaf indicates the minimum number of leaf node observations. The least-squares-boosting technique, often known as LSBoost, is used to train a group of regression trees. Features Importance analysis has shown that the friction conditions (dry friction of lubricated conditions) had the most significant influence on the coefficient of friction, at 56.98%, followed by the drawbead height, at 23.41%, and the sample width, at 11.95%. The average surface roughness of rollers and sample orientation have the smallest impact on the value of the coefficient of friction at 6.09% and 1.57%, respectively. The dispersion and deviation observed for the testing dataset from the experimental data indicate the model’s ability to predict the values of the coefficient of friction at a coefficient of determination of R² = 0.972 and a mean-squared error of MSE = 0.000048. It was qualitatively found that in order to ensure the optimal (the lowest) coefficient of friction, it is necessary to control the friction conditions (use of lubricant) and the drawbead height. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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16 pages, 7327 KiB

Open AccessArticle

The Structural and Mechanical Properties of Al₂O₃–Ni Composites Obtained by Magnetic Field-Assisted Centrifugal Slip Casting

by Justyna Zygmuntowicz, Magdalena Kosiorek, Marcin Wachowski, Lucjan Śnieżek, Ireneusz Szachogłuchowicz, Paulina Piotrkiewicz, Waldemar Kaszuwara and Katarzyna Konopka

Materials 2024, 17(16), 3902; https://doi.org/10.3390/ma17163902 - 6 Aug 2024

Cited by 2 | Viewed by 1005

Abstract

This study investigates the influence of a magnetic field on the microstructure and properties of Al₂O₃–Ni composites fabricated via centrifugal slip casting at 1500 rpm. Al₂O₃ and Ni powders were combined with water and deflocculants, homogenized, [...] Read more.

This study investigates the influence of a magnetic field on the microstructure and properties of Al₂O₃–Ni composites fabricated via centrifugal slip casting at 1500 rpm. Al₂O₃ and Ni powders were combined with water and deflocculants, homogenized, and then cast into a porous plaster mold surrounded by Nd-Fe-B magnets. The resulting composites, sintered in a reducing atmosphere, exhibited a three-zone structure with varying Ni content due to the combined effects of the magnetic field and centrifugal force. SEM, EDX, and XRD analyses confirmed the distribution and composition of the phases. Hardness tests revealed the highest values at the outermost zone, with a gradual decrease toward the inner zones. Compression tests employing digital image correlation revealed high internal stresses and a significant improvement in compressive strength compared to non-magnetic field methods. This study confirms that magnetic field-assisted centrifugal slip casting significantly enhances the structural, hardness, and compressive strength properties of Al₂O₃–Ni composites, indicating promising potential for advanced applications. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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22 pages, 2629 KiB

Open AccessArticle

Materials and Products Development Based on a Novelty Approach to Quality and Life Cycle Assessment (QLCA)

by Dominika Siwiec and Andrzej Pacana

Materials 2024, 17(15), 3859; https://doi.org/10.3390/ma17153859 - 4 Aug 2024

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Abstract

The development of materials and the products made from them should respond to new challenges posed by market changes and also by climate change. Therefore, the objective of this investigation was to develop a method that supports the sustainable development of materials and [...] Read more.

The development of materials and the products made from them should respond to new challenges posed by market changes and also by climate change. Therefore, the objective of this investigation was to develop a method that supports the sustainable development of materials and the products made from them based on an aggregated indicator of quality and environmental load in the life cycle (QLCA). The testing and illustration of the QLCA method included a passenger car tyre and nine prototypes. These prototypes were described using eight quality criteria: season, class, size of the load index, speed index, rolling, adhesion, and external noise. Then, customer expectations regarding the importance of the criteria and satisfaction with the indicators in the current and modified states were obtained. Based on the customer assessment, the quality indicators of the prototypes were assessed. This assessment was supported by the weighted sum model (WSM) and the entropy method. Then, life cycle assessment for the reference tyre was performed using the Ecoinvent database in the OpenLCA program. LCA indicators were modelled for other prototypes, taking into account quality changes. As a result of the verification of the method, an aggregated QLCA indicator was estimated, based on which it was possible to select the most favourable (qualitatively and environmentally) prototype out of nine. This was the P4 prototype (QLCA = 0.57). The next position in the ranking was taken by P7 (QLCA = 0.43). The QLCA method can be used to determine the direction of development of materials and products in terms of their sustainable development. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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16 pages, 6346 KiB

Open AccessArticle

Thermo-Mechanical Numerical Simulation of Friction Stir Rotation-Assisted Single Point Incremental Forming of Commercially Pure Titanium Sheets

by Marcin Szpunar, Tomasz Trzepieciński, Robert Ostrowski, Krzysztof Żaba, Waldemar Ziaja and Maciej Motyka

Materials 2024, 17(13), 3095; https://doi.org/10.3390/ma17133095 - 24 Jun 2024

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Abstract

Single point incremental forming (SPIF) is becoming more and more widely used in the metal industry due to its high production flexibility and the possibility of obtaining larger material deformations than during conventional sheet metal forming processes. This paper presents the results of [...] Read more.

Single point incremental forming (SPIF) is becoming more and more widely used in the metal industry due to its high production flexibility and the possibility of obtaining larger material deformations than during conventional sheet metal forming processes. This paper presents the results of the numerical modeling of friction stir rotation-assisted SPIF of commercially pure 0.4 mm-thick titanium sheets. The aim of this research was to build a reliable finite element-based thermo-mechanical model of the warm forming process of titanium sheets. Finite element-based simulations were conducted in Abaqus/Explicit software (version 2019). The formability of sheet metal when forming conical cones with a slope angle of 45° was analyzed. The numerical model assumes complex thermal interactions between the forming tool, the sheet metal and the surroundings. The heat generation capability was used to heat generation caused by frictional sliding. Mesh sensitivity analysis showed that a 1 mm mesh provides the best agreement with the experimental results of total forming force (prediction error 3%). It was observed that the higher the size of finite elements (2 mm and 4 mm), the greater the fluctuation of the total forming force. The maximum temperature recorded in the contact zone using the FLIR T400 infrared camera was 157 °C, while the FE-based model predicted this value with an error of 1.3%. The thinning detected by measuring the drawpiece with the ARGUS non-contact strain measuring system and predicted by the FEM model showed a uniform thickness in the drawpiece wall zone. The FE-based model overestimated the minimum and maximum wall thicknesses by 3.7 and 5.9%, respectively. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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14 pages, 6477 KiB

Open AccessArticle

Selected Errors in Spatial Measurements of Surface Asperities

by Karol Grochalski, Dominika Podbereska, Michał Wieczorowski, Rafał Talar and Wiesław Graboń

Materials 2024, 17(12), 2918; https://doi.org/10.3390/ma17122918 - 14 Jun 2024

Cited by 1 | Viewed by 949

Abstract

This work presents issues related to selected errors accompanying spatial measurements of surface roughness using contact profilometry. The influence of internal heat sources, such as engines or control electronics, on the thermal expansion of the drive responsible for the measurement probe’s movement in [...] Read more.

This work presents issues related to selected errors accompanying spatial measurements of surface roughness using contact profilometry. The influence of internal heat sources, such as engines or control electronics, on the thermal expansion of the drive responsible for the measurement probe’s movement in the X-axis direction was investigated. In terms of starting measurements on a thermally unstable device, the synchronization error of individual profile paths was 16.1 µm. Based on thermographic studies, the time required for full thermal stabilization of this drive was determined to be 6–12 h from when the device was turned on. It was demonstrated that thermal stabilization of the profilometer significantly reduced positioning errors of the measurement probe on the X-axis. Thermal stabilization time should be determined individually for a specific device variant. This research also determined how changes in the center of gravity caused by the measurement probe’s movement affected the overall rigidity of the profilometer structure and the leveling of the tested surface. Laser interferometry was used for this purpose. The determined vulnerability of the profilometer structure was 0.8 µm for a measurement section of 25 mm. Understanding the described relationships will reduce errors associated with conducting measurements and preparing equipment for tests. Additionally, it will enable the correct evaluation of surface geometry. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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20 pages, 11159 KiB

Open AccessArticle

Effect of Zonal Laser Texturing on Friction Reduction of Steel Elements in Lubricated Reciprocating Motion

by Slawomir Wos, Waldemar Koszela, Andrzej Dzierwa and Pawel Pawlus

Materials 2024, 17(10), 2401; https://doi.org/10.3390/ma17102401 - 16 May 2024

Cited by 1 | Viewed by 917

Abstract

During co-action between contact elements in reciprocating motion, different working conditions exist in outer and inner zones of stationary elements. Because the tribological effects of surface texturing depend on the operating conditions, various dimple patterns were created in the middle part of the [...] Read more.

During co-action between contact elements in reciprocating motion, different working conditions exist in outer and inner zones of stationary elements. Because the tribological effects of surface texturing depend on the operating conditions, various dimple patterns were created in the middle part of the steel disc and near the reversal points. The behaviors of variable dimple patterns were compared with those of uniform texturing and untexturing. It was found that the dimple patterns in the middle disc zone depended on the resistance to motion. The best tribological behavior was obtained for a pit area ratio of 13% and diameter of 0.4 mm in the inner zone, and pit area ratio of 3% and diameter of 0.2 mm in the outer zones. Low resistance to motion and the smallest friction variation of all tested sliding pairs were achieved. For the same pit area ratio of 13% in a disc of 0.4 mm, the dimple diameter behaved better than in the 0.2 mm diameter disc. The greatest decrease in the coefficient of friction of 85% compared to untextured sliding pair was achieved for uniform laser texturing with a pit area ratio of 13% and dimple diameter of 0.4 mm, when the normal load was 40 N and frequency of displacement was 20 Hz. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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22 pages, 10485 KiB

Open AccessArticle

Optimization of 2024-T3 Aluminum Alloy Friction Stir Welding Using Random Forest, XGBoost, and MLP Machine Learning Techniques

by Piotr Myśliwiec, Andrzej Kubit and Paulina Szawara

Materials 2024, 17(7), 1452; https://doi.org/10.3390/ma17071452 - 22 Mar 2024

Cited by 22 | Viewed by 2669

Abstract

This study optimized friction stir welding (FSW) parameters for 1.6 mm thick 2024T3 aluminum alloy sheets. A 3 × 3 factorial design was employed to explore tool rotation speeds (1100 to 1300 rpm) and welding speeds (140 to 180 mm/min). Static tensile tests [...] Read more.

This study optimized friction stir welding (FSW) parameters for 1.6 mm thick 2024T3 aluminum alloy sheets. A 3 × 3 factorial design was employed to explore tool rotation speeds (1100 to 1300 rpm) and welding speeds (140 to 180 mm/min). Static tensile tests revealed the joints’ maximum strength at 87% relative to the base material. Hyperparameter optimization was conducted for machine learning (ML) models, including random forest and XGBoost, and multilayer perceptron artificial neural network (MLP-ANN) models, using grid search. Welding parameter optimization and extrapolation were then carried out, with final strength predictions analyzed using response surface methodology (RSM). The ML models achieved over 98% accuracy in parameter regression, demonstrating significant effectiveness in FSW process enhancement. Experimentally validated, optimized parameters resulted in an FSW joint efficiency of 93% relative to the base material. This outcome highlights the critical role of advanced analytical techniques in improving welding quality and efficiency. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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