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Advances in Surface Engineering Technologies and Their Impact on Surface Integrity and Functional Performance of Additively Manufactured Parts

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Thin Films and Interfaces".

Deadline for manuscript submissions: 10 September 2025 | Viewed by 1353

Special Issue Editor


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Guest Editor
UniSA STEM, University of South Australia, Mawson Lakes, SA 5095, Australia
Interests: surface engineering; additive manufacturing; microstructures; surface integrity; wear performance; functional performance; mechanical properties
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Any failure in a component starts from its surface, so enhancing surface properties can prevent the component from failing if it is subject to intense loading conditions. Additively manufactured (AM) components are no different from traditional manufacturing ones. Inherent to its process mechanics, AM components suffer from defects, including cracks, inhomogeneous microstructures, and internal stress, compromising the surface integrity and the resulting functional performance.

Surface engineering, often known as surface modification, is a post-processing technique applied to address surface integrity issues. Machining, grinding, shot peening, ball burnishing, and laser shock peening are surface modification processes that improve surface properties. The advantages, disadvantages, and process optimization of these techniques are overwhelmingly studied in the literature. As AM components are growing rapidly, applying surface modification to them is of great interest. How surface engineering influences functional performance, e.g., corrosion, wear, and impact resistance in real-world applications, must be studied further to leverage its benefits.

This Special Issue aims to publish innovative research, innovative methodologies, and practical applications, fostering a comprehensive understanding of the capabilities and limitations within surface engineering of AM materials and components. Within this Special Issue, an emphasis is placed on showcasing the innovations of new experimental techniques and configurations of surface engineering techniques. This Special Issue seeks to advance the knowledge frontier, stimulate interdisciplinary collaboration, and address critical challenges in surface engineering and its impact on functional performance by providing a platform for researchers.

Topics of Interest:

  • Novel Approaches and Advanced Techniques in Surface Engineering;
  • AM Component Microstructural Transformations, Phase Evolution, and Property Enhancements due to Surface Engineering;
  • Material Compatibility and Application Specificities in AM Components;
  • Surface Modification and Property Development in AM Components;
  • Developments in Process Monitoring, Control, and Optimization;
  • Advances in Numerical Modeling and Simulation in Surface Engineering;
  • Real-world Applications and Case Studies.

Dr. Mohammad Uddin
Guest Editor

Manuscript Submission Information

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Keywords

  • surface engineering
  • surface integrity
  • additive manufacturing
  • functional performance

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Published Papers (2 papers)

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Research

27 pages, 16069 KiB  
Article
Effect of Laser Surface Texturing and Fabrication Methods on Tribological Properties of Ti6Al4V/HAp Biocomposites
by Julia Sadlik, Edyta Kosińska, Agnieszka Tomala, Magdalena Bańkosz, Marko Polajnar, Rahul Kumar, Mitjan Kalin, Gaia Kravanja, Luka Hribar, Irina Hussainova, Marek Nykiel, Agnieszka Sobczak-Kupiec and Josef Jampilek
Materials 2025, 18(11), 2468; https://doi.org/10.3390/ma18112468 - 24 May 2025
Viewed by 454
Abstract
Bone diseases lead to an increasing demand for implants to treat long bone defects and for load-bearing applications. Osteoporosis care and accidental injuries are major contributors to this rising need. Our research aims to demonstrate innovative material systems and methods for preparing implants [...] Read more.
Bone diseases lead to an increasing demand for implants to treat long bone defects and for load-bearing applications. Osteoporosis care and accidental injuries are major contributors to this rising need. Our research aims to demonstrate innovative material systems and methods for preparing implants that can be used in regenerative medicine. We hypothesize that by combining titanium alloys (Ti6Al4V) with hydroxyapatite (Hap), we can enhance biocompatibility and tribo-mechanical performance, which are critical for the longevity of Ti-based surgical implants. Additionally, we investigate the application of laser surface treatments to expose the underlying porosity, thereby enhancing cell transport and promoting cell growth. In this study, we investigate the effects of two fabrication techniques—Spark Plasma Sintering (SPS) and powder metallurgy (PM)—on the properties of laser-textured Ti64/Hap biocomposites. Our findings demonstrate that the selected processing route significantly influences the microstructure, tribological performance, and surface properties of these materials. An X-ray diffraction (XRD) analysis corroborates our results from incubation studies in simulated body fluids, highlighting the impact of phase transformations during sintering on the chemical properties of Ti-Hap composites. Additionally, while laser surface texturing was found to slightly increase the friction coefficient, it markedly enhanced the wear resistance, particularly for the PM and SPS Ti + 5%Hap composites. Full article
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23 pages, 9879 KiB  
Article
Carbon-Halloysite Nanocomposites and Their Adsorption Characteristics for Pharmaceuticals—A Naproxen Case Study
by Piotr Słomkiewicz, Beata Szczepanik, Piotr Sakiewicz, Klaudiusz Gołombek and Krzysztof Piotrowski
Materials 2025, 18(11), 2433; https://doi.org/10.3390/ma18112433 - 22 May 2025
Viewed by 480
Abstract
The synthesis of carbon-halloysite nanocomposites was carried out using aqueous sucrose solutions as a carbon precursor. Raw and calcined halloysite with different grain size classes were used as a carbon support. The influence of halloysite grain size and the calcination process on the [...] Read more.
The synthesis of carbon-halloysite nanocomposites was carried out using aqueous sucrose solutions as a carbon precursor. Raw and calcined halloysite with different grain size classes were used as a carbon support. The influence of halloysite grain size and the calcination process on the carbon concentration in the composites and their adsorption characteristics towards the separation of naproxen from aqueous solutions was identified experimentally. The kinetic conditions of the process (pseudo-second-order kinetic model) indicate a favorable increase in the number of active sites formed after the deposition of the carbon layer on the surface of halloysite particles. Validation of the Langmuir multi-center isotherm adsorption model indicates a separation mechanism associated with the occurrence of multiple active centers on the nanocomposite adsorbent surface and the effect of separation without dissociation of naproxen particles. The obtained carbon-halloysite nanocomposite, due to the relatively cheap and simple, environmentally friendly production methodology and the required inexpensive raw materials, can be widely used in effective and common, economical treatment of wastewater streams from naproxen. The observed naproxen separation process effects are significant. Full article
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