Materials

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20 pages, 30192 KiB

Open AccessArticle

Influence of Nanocomposite PVD Coating on Cutting Tool Wear During Milling of 316L Stainless Steel Under Air Cooling Conditions

by Jarosław Tymczyszyn, Artur Szajna and Grażyna Mrówka-Nowotnik

Materials 2025, 18(9), 1959; https://doi.org/10.3390/ma18091959 - 25 Apr 2025

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Abstract

This study examines the impact of PVD coatings on cutting tool wear during the milling of 316L stainless steel under air cooling conditions. In the experiment, a carbide milling cutter coated with a nanocomposite nACo3 (AlTiSiN) coating was used. The coating was deposited [...] Read more.

This study examines the impact of PVD coatings on cutting tool wear during the milling of 316L stainless steel under air cooling conditions. In the experiment, a carbide milling cutter coated with a nanocomposite nACo3 (AlTiSiN) coating was used. The coating was deposited using a next-generation device, the PLATIT π411PLUS, which features one central and three lateral rotating cathodes. The nanocomposite nACo3 coating obtained with this method exhibits exceptionally high structural density and excellent mechanical properties. The new generation of the nACo3 coating demonstrates improved surface properties and a lower friction coefficient compared to previous generations. The findings indicate that PVD nACo3 coatings significantly enhance wear resistance, extending tool life while maintaining acceptable surface quality. The optimal cutting time was determined to be approximately 90 min, after which a sharp increase in surface roughness and tool wear was observed. After 120 min of machining, substantial deterioration of surface quality parameters was recorded, suggesting increasing cutting forces and cutting edge degradation. SEM and EDS analyses revealed the presence of adhered material on the tool and sulfide inclusions in the microstructure of 316L stainless steel, which influenced the machining process. The nACo3 coating demonstrated high thermal and wear resistance, making it an effective solution for machining difficult-to-cut materials. This study suggests that selecting appropriate cutting parameters, tool geometry, protective coatings, and cooling strategies can significantly affect tool longevity and machining quality. The novelty of this research lies in the application of innovative nanocomposite PVD coatings during the milling of 316L stainless steel under air cooling conditions. These studies indicate potential future research directions, such as the use of minimum quantity lubrication (MQL) or cryogenic cooling as methods to reduce tool wear and improve post-machining surface quality. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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18 pages, 7543 KiB

Open AccessArticle

Effects of Prior Heat Treatment and Induction Hardening on the Properties of JIS SUJ3 Bearing Steel

by Shao-Quan Lu, Liu-Ho Chiu, Pei-Jung Chang and Chung-Kwei Lin

Materials 2025, 18(8), 1797; https://doi.org/10.3390/ma18081797 - 15 Apr 2025

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Abstract

Bearing steels are frequently used in highly loaded components, such as roller bearings, due to their excellent hardenability and wear resistance. Microstructure, hardness, and residual stress distribution of the bearings significantly affect the wear resistance of the parts. In the present study, experiments [...] Read more.

Bearing steels are frequently used in highly loaded components, such as roller bearings, due to their excellent hardenability and wear resistance. Microstructure, hardness, and residual stress distribution of the bearings significantly affect the wear resistance of the parts. In the present study, experiments investigated the effects of austenitizing temperature (850, 900, and 950 °C), with or without cryogenic treatment, and induction hardening treatment (9 and 12 kW) on the microstructure, microhardness, the amount of retained austenite, surface residual stress, and wear behavior of JIS SUJ3 steel. The experimental results revealed that the austenitized specimens’ microstructure consisted of martensite, retained austenite, and dispersed granular alloy carbide exhibiting high hardness. After cryogenic or induction hardening treatment, the surface residual stress of austenitized specimens exhibited compressive stress rather than its original tensile stress state. The induction hardening treatment can significantly increase the microhardness of austenitized specimens, followed by quenching. Furthermore, the induction-hardened surface possessed less retained austenite. For practical industrial applications, a prior austenitizing heat treatment at 950 °C followed by hardening with an induction power of 12 kW was the optimal parameter for JIS SUJ3 bearing steel. The maximum microhardness and surface residual stress were 920 HV_0.3 and −1083 MPa, respectively, while the lowest weight loss was 0.5 mg after the 10,000-revolution wear test. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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14 pages, 5900 KiB

Open AccessArticle

Punch Edge Topological Design for Reduction of Work Hardening Damage in Shearing of Non-Oriented Electrical Steel Sheets

by Ryoma Okada, Kentaro Ito, Tatsuya Funazuka, Tatsuhiko Aizawa and Tomomi Shiratori

Materials 2025, 18(4), 878; https://doi.org/10.3390/ma18040878 - 17 Feb 2025

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Abstract

A new shearing tool is necessary to reduce the iron loss of motor cores by minimizing the work hardening damage on the sheared non-oriented electrical steel sheets. The punch edge topology and the clearance between the punch and the die were controlled to [...] Read more.

A new shearing tool is necessary to reduce the iron loss of motor cores by minimizing the work hardening damage on the sheared non-oriented electrical steel sheets. The punch edge topology and the clearance between the punch and the die were controlled to investigate their influence on the sheared surface condition and the work hardening damage of steel sheets. A non-oriented electrical steel sheet with the thickness of 500 µm was used and sheared at the speed of 5 mm/s. After that, the sheared surface was investigated. In particular, hardness mapping was utilized to quantitatively analyze the work-hardened area of the sheared steel sheets and the dissipation of the plastic work. Among the four punch edge topological configurations explored, the nano-grooved punch employed straight along the shearing direction reduced the damage dealt to the sheared steel sheets and the plastic dissipation work to one-third compared to conventional punches. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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18 pages, 5797 KiB

Open AccessArticle

Numerical Fatigue Analysis of Dissimilar Lap Joints Fabricated by Dimple Spot Welding for Automotive Application

by Paolo Livieri and Michele Bortolan

Materials 2025, 18(3), 627; https://doi.org/10.3390/ma18030627 - 30 Jan 2025

Viewed by 585

Abstract

This paper presents a numerical analysis of dimple spot welding (DSW) as an innovative joining technique for dissimilar materials, namely steel and aluminium alloys. Employing a finite element (FE) model, the study simulates the fatigue performance of DSW joints, considering crucial factors such [...] Read more.

This paper presents a numerical analysis of dimple spot welding (DSW) as an innovative joining technique for dissimilar materials, namely steel and aluminium alloys. Employing a finite element (FE) model, the study simulates the fatigue performance of DSW joints, considering crucial factors such as contact friction and cyclic loading conditions. While various numerical models are proposed, the simulation incorporating friction and fatigue loading appears to offer the highest accuracy. The research highlights that the fatigue behaviour of DSW joints can be effectively investigated through the non-local theory of the implicit gradient approach by utilising the fatigue curve of arc-welded structures composed of steel or aluminium alloys. Specifically, simulations incorporating friction and fatigue loading demonstrate that the steel spot weld does not represent the weakest point within the joints. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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13 pages, 8911 KiB

Open AccessArticle

Microstructure, Hardness, and Wear Behavior of Layers Obtained by Electric Arc Hardfacing Processes

by Sebastian Balos, Danka Labus Zlatanović, Petar Janjatović, Milan Pećanac, Olivera Erić Cekić, Milena Rosić and Srećko Stopić

Materials 2025, 18(2), 299; https://doi.org/10.3390/ma18020299 - 10 Jan 2025

Viewed by 648

Abstract

Hardfacing is a welding-related technique aimed at depositing a harder and tougher layer onto a softer, less wear-resistant substrate or base metal. This process enhances the abrasion resistance of the component, increasing its durability under working conditions. A key feature of hardfacing is [...] Read more.

Hardfacing is a welding-related technique aimed at depositing a harder and tougher layer onto a softer, less wear-resistant substrate or base metal. This process enhances the abrasion resistance of the component, increasing its durability under working conditions. A key feature of hardfacing is dilution, which refers to the mixing of the hardfacing layer and the base metal. In this study, shielded metal arc welding (SMAW) was employed to hardface structural steel using chromium carbide vanadium consumables, with results compared to AISI D2 cold-work tool steel. Four different SMAW parameters were tested, and the abrasive test was conducted against SiC discs. Wear rate, represented by the wear loss rate, was correlated to microstructure, scanning electron microscopy, energy-dispersive X-ray spectroscopy, hardness, microhardness, and surface roughness. The results showed that key SMAW parameters, such as welding speed and current, significantly influence wear resistance. Specifically, slower welding speeds and higher currents, which result in greater heat input, led to the increased wear resistance of the deposited layer through the mechanism of the inoculation of larger and harder carbides. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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27 pages, 8507 KiB

Open AccessArticle

Mechanical Characterization and Computational Analysis of TPU 60A: Integrating Experimental Testing and Simulation for Performance Optimization

by Luan Lang, Rodrigo Antunes, Thiago Assis Dutra, Martim Lima de Aguiar, Nuno Pereira and Pedro Dinis Gaspar

Materials 2025, 18(2), 240; https://doi.org/10.3390/ma18020240 - 8 Jan 2025

Cited by 2 | Viewed by 803

Abstract

This study investigates the mechanical properties of thermoplastic polyurethane (TPU) 60A, which is a flexible material that can be used to produce soft robotic grippers using additive manufacturing. Tensile tests were conducted under ISO 37 and ISO 527 standards to assess the effects [...] Read more.

This study investigates the mechanical properties of thermoplastic polyurethane (TPU) 60A, which is a flexible material that can be used to produce soft robotic grippers using additive manufacturing. Tensile tests were conducted under ISO 37 and ISO 527 standards to assess the effects of different printing orientations (0°, 45°, −45°, 90°, and quasi-isotropic) and test speeds (2 mm/min, 20 mm/min, and 200 mm/min) on the material’s performance. While the printing orientations at 0° and quasi-isotropic provided similar performance, the quasi-isotropic orientation demonstrated the most balanced mechanical behavior, establishing it as the optimal choice for robust and predictable performance, particularly for computational simulations. TPU 60A’s flexibility further emphasizes its suitability for handling delicate objects in industrial and agricultural applications, where damage prevention is critical. Computational simulations using the finite element method were conducted. To verify the accuracy of the models, a comparison was made between the average stresses of the tensile test and the computational predictions. The relative errors of force and displacement are lower than 5%. So, the constitutive model can accurately represent the material’s mechanical behavior, making it suitable for computational simulations with this material. The analysis of strain rates provided valuable insights into optimizing production processes for enhanced mechanical strength. The study highlights the importance of tailored printing parameters to achieve mechanical uniformity, suggesting improvements such as biaxial testing and G-code optimization for variable thickness deposition. Overall, the research study offers comprehensive guidelines for future design and manufacturing techniques in soft robotics. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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27 pages, 17020 KiB

Open AccessArticle

Evaluation of the Wear of Ni 200 Alloy After Long-Term Carbon Capture in Molten Salts Process

by Piotr Palimąka, Stanisław Pietrzyk, Maciej Balcerzak, Krzysztof Żaba, Beata Leszczyńska-Madej and Justyna Jaskowska-Lemańska

Materials 2024, 17(24), 6302; https://doi.org/10.3390/ma17246302 - 23 Dec 2024

Viewed by 691

Abstract

Reducing CO₂ emissions is one of the major challenges facing the modern world. The overall goal is to limit global warming and prevent catastrophic climate change. One of the many methods for reducing carbon dioxide emissions involves capturing, utilizing, and storing it [...] Read more.

Reducing CO₂ emissions is one of the major challenges facing the modern world. The overall goal is to limit global warming and prevent catastrophic climate change. One of the many methods for reducing carbon dioxide emissions involves capturing, utilizing, and storing it at the source. The Carbon Capture in Molten Salts (CCMS) technique is considered potentially attractive and promising, although it has so far only been tested at the laboratory scale. This study evaluates the wear of the main structural components of a prototype for CO₂ capture in molten salts—a device designed and tested in the laboratories of AGH University of Kraków. The evaluation focused on a gas barbotage lance and a reactor chamber (made from Nickel 200 Alloy), which were in continuous, long-term (800 h) contact with molten salts CaCl₂-CaF₂-CaO-CaCO₃ at temperatures of 700–940 °C in an atmosphere of N₂-CO₂. The research used light microscopy, SEM, X-ray, computed tomography (CT), and 3D scanning. The results indicate the greatest wear on the part of the lance submerged in the molten salts (3.9 mm/year). The most likely wear mechanism involves grain growth and intergranular corrosion. Nickel reactions with the aggressive salt environment and its components cannot be ruled out. Additionally, the applied research methods enabled the identification of material discontinuities in the reactor chamber (mainly in welded areas), pitting on its surface, and uneven wear in different zones. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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27 pages, 38081 KiB

Open AccessArticle

Dynamic Testing of Materials for Galvanising Pot Roll Bearings with Improved Performance

by Giovanni Paolo Alparone, James Sullivan, Christopher Mills, James Edy and David Penney

Materials 2024, 17(23), 5837; https://doi.org/10.3390/ma17235837 - 28 Nov 2024

Viewed by 623

Abstract

Galvanising pot roll bearings are subjected to severe deterioration due to the corrosion of the bearing materials in liquid Zn, resulting in maintenance stops that can cost thousands of pounds per hour in downtime. Dynamic wear testing in molten Zn-Al and Zn-Al-Mg was [...] Read more.

Galvanising pot roll bearings are subjected to severe deterioration due to the corrosion of the bearing materials in liquid Zn, resulting in maintenance stops that can cost thousands of pounds per hour in downtime. Dynamic wear testing in molten Zn-Al and Zn-Al-Mg was conducted to assess the corrosion and wear resistance of three material pairs using a bespoke testing rig. The materials investigated in this study were Wallex6^TM coated with WC-Co, stainless steel 316L coated with Al₂O₃, and as-received Wallex6^TM and Wallex4^TM alloys. It was found that only the Al₂O₃ coating remained unreactive in Zn alloy, whereas the materials containing Co were corroded, as evidenced by the formation of intermetallic compounds containing Al-Co-Zn-Fe. The results also highlighted that the dissolution of the Co matrix and diffusion of Zn and Al from the bath occurred in Wallex6^TM and Wallex4^TM. However, the diffusion of Zn into the Wallex^TM alloys was reduced by approximately 60% in the Zn-Al-Mg bath compared to Zn-Al. The wear scars were analysed to determine the wear coefficient of the worn specimens. Out of the three material couplings investigated in this study, minimal wear damage in both Zn-Al and Zn-Al-Mg was only obtained by pairing Wallex6^TM with Al₂O₃ coatings. Full article

(This article belongs to the Special Issue New Trends in Mechanical and Tribological Properties of Materials and Components)

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