Search Results (198)

Accurate melt pool geometry prediction is essential for ensuring quality and reliability in Laser Powder Bed Fusion (L-PBF). However, small experimental datasets and limited physical interpretability often restrict the effectiveness of traditional machine learning (ML) models. This study proposes a hybrid framework that integrates an explicit thermal model with ML algorithms to improve prediction under sparse data conditions. The explicit model—calibrated for variable penetration depth and absorptivity—generates synthetic melt pool data, augmenting 36 experimental samples across conduction, transition, and keyhole regimes for 316 L stainless steel. Three ML methods—Multilayer Perceptron (MLP), Random Forest, and XGBoost—are trained using fivefold cross-validation. The hybrid approach significantly improves prediction accuracy, especially in unstable transition regions (D/W ≈ 0.5–1.2), where morphological fluctuations hinder experimental sampling. The best-performing model (MLP) achieves R² > 0.98, with notable reductions in MAE and RMSE. The results highlight the benefit of incorporating physically consistent, nonlinearly distributed synthetic data to enhance generalization and robustness. This physics-augmented learning strategy not only demonstrates scientific novelty by integrating mechanistic modeling into data-driven learning, but also provides a scalable solution for intelligent process optimization, in situ monitoring, and digital twin development in metal additive manufacturing. Full article

Stainless steel is recognized for its excellent durability and anti-corrosion properties, which are essential qualities across various industrial applications. The machining of stainless steel, particularly under a dry environment to attain sustainability, poses several challenges. The poor heat conductivity and high ductility of stainless steel results in poor heat distribution, accelerating tool wear and problematic chip formation. To mitigate these challenges, the implementation of surface texturing has been identified as a beneficial strategy. This study investigates the impact of wave-type texturing patterns, developed on the flank surface of tungsten carbide ceramic tool inserts, on the machinability of AISI 316 stainless steel under dry cutting conditions. In this investigation, chip morphology and surface roughness were used as key indicators of machinability. Analysis of Variance (ANOVA) was conducted for chip thickness, chip thickness ratio, and surface roughness, while Taguchi mono-objective optimization was applied to chip thickness. The ANOVA results showed that linear models accounted for 71.92%, 83.13%, and 82.86% of the variability in chip thickness, chip thickness ratio, and surface roughness, respectively, indicating a strong fit to the experimental data. Microscopic analysis confirmed a substantial reduction in chip thickness, with a minimum observed value of 457.64 µm. The corresponding average surface roughness Ra value 1.645 µm represented the best finish across all experimental runs, highlighting the relationship between thinner chips and enhanced surface quality. In conclusion, wave textures on the cutting tool’s flank face have the potential to facilitate the dry machining of AISI 316 stainless steel to obtain favorable machinability. Full article

This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, i.e., a problem that accounts for approximately 15% of all failures, as identified in a statistical analysis of the 2022 operational data from the Uzen oilfield in Kazakhstan. The leakage is primarily attributed to the accumulation of mechanical impurities and paraffin deposits between the valve ball and seat, leading to concentrated surface wear and compromised sealing. To mitigate this issue, a novel valve assembly design was developed featuring a flow turbulizer positioned beneath the valve seat. The turbulizer generates controlled vortex motion in the fluid flow, which increases the rotational frequency of the valve ball during operation. This motion promotes more uniform wear across the contact surfaces and reduces the risk of localized degradation. The turbulizers were manufactured using additive FDM technology, and several design variants were tested in a full-scale laboratory setup simulating downhole conditions. Experimental results revealed that the most effective configuration was a spiral plate turbulizer with a 7.5 mm width, installed without axis deviation from the vertical, which achieved the highest ball rotation frequency and enhanced lapping effect between the ball and the seat. Subsequent field trials using valves with duralumin-based turbulizers demonstrated increased operational lifespans compared to standard valves, confirming the viability of the proposed solution. However, cases of abrasive wear were observed under conditions of high mechanical impurity concentration, indicating the need for more durable materials. To address this, the study recommends transitioning to 316 L stainless steel for turbulizer fabrication due to its superior tensile strength, corrosion resistance, and wear resistance. Implementing this design improvement can significantly reduce maintenance intervals, improve pump reliability, and lower operating costs in mature oilfields with high water cut and solid content. The findings of this research contribute to the broader efforts in petroleum engineering to enhance the longevity and performance of artificial lift systems through targeted mechanical design improvements and material innovation. Full article

Stainless steel (SS) is one of the materials most commonly utilized for fabrication of medical implants and its properties are often improved by deposition of protective coatings. This study investigates certain physico-chemical and biological properties of SS substrate coated with multilayer thin film consisting of titanium nitride and silver layers (TiN-Ag film). TiN-Ag films were deposited on the surface of AISI 316 SS substrate by a combination of cathodic arc evaporation and DC magnetron sputtering. SS substrate was analyzed by TEM, while deposited coatings were analyzed by SEM, EDS and wettability measurements. Also, mitochondrial activity assay, and osteogenic and chondrogenic differentiation were performed on dental pulp stem cells (DPSCs). SEM and EDS revealed excellent adhesion between coatings’ layers, with the top layer predominantly composed of Ag, which is responsible for antibacterial properties. TiN-Ag film exhibited moderately hydrophilic behaviour which is desirable for orthopedic implant applications. Biological assays revealed significantly higher mitochondrial activity and enhanced osteogenic and chondrogenic differentiation of DPSC on TiN-Ag films compared to TiN films. The newly designed TiN-Ag coatings showed a great potential for the surface modification of SS implants, and further detailed investigations will explore their suitability for application in clinical practice. Full article

In the Direct Energy Deposition (DED) process, the deposited material experiences intricate thermo-mechanical processes. Subsequent thermal cycling can trigger Dynamic Recrystallization (DRX) under suitable conditions, with specific strain and temperature parameters facilitating grain refinement and homogenization. While prior research has examined the impact of thermal cycling in continuous wave (CW) lasers on DRX in 316 L stainless steel deposits, this study delves into the effects of pulsed wave (PW) laser thermal cycling on DRX. Here, the thermo-mechanical response to PW cyclic thermal loading is empirically assessed, and the evolution of microstructure, grain morphology, geometric dislocation density (GND), and misorientation map during PW DED of 316 L stainless steel is scrutinized. Findings reveal that DRX is activated between the 8th and 44th thermal cycles, with temperatures fluctuating in the range of 680 K–750 K–640 K and grains evolving within a 5.6%–6.2%–5.2% strain range. After 90 thermal cycles, the grain microstructure undergoes significant alteration. Throughout the thermal cycling, dynamic recovery (DRV) occurs, marked by sub-grain formation and low-angle grain boundaries (LAGBs). Continuous dynamic recrystallization (CDRX) accompanies discontinuous dynamic recrystallization (DDRX), with LAGBs progressively converting into high-angle grain boundaries (HAGBs). Elevated temperatures and accumulated strain drive dislocation movement and entanglement, augmenting GND. The study also probes the influence of frequency and duty cycle on grain microstructure, finding that low pulse frequency spurs CDRX, high pulse frequency favors DRV, and the duty cycle has minimal impact on grain microstructure under PW cyclic thermal load. Full article

Micro-sandblasting pretreatment was applied to AlTiSiN-coated WC–Co tools to enhance cutting performance in 316 L stainless steel milling. An L₉(3³) Taguchi orthogonal array varied passivation pressure (0.1, 0.2, and 0.3 MPa), gun traverse speed (60, 80, and 100 m/min), and tool rotation speed (20, 30, and 40 r/min). Coating thickness varied only from 0.93 to 1.19 μm, and surface roughness remained within 0.044–0.077 μm, confirming negligible thickness and roughness effects. Under optimized conditions, coating adhesion strength and nano-hardness both exhibited significant improvements. A weighted-scoring method balancing these two responses identified the optimal pretreatment parameters as 0.1 MPa, 80 m/min, and 20 r/min. Milling tests at 85 m/min—using flank wear VBₘₐₓ = 0.1 mm as the failure criterion—demonstrated a cutting distance increase from 4.25 m (untreated) to 12.75 m (pretreated), a 200% improvement. Wear progressed through three stages: rapid initial wear, extended steady wear due to Al₂O₃ protective-film formation and Si-induced oxygen-diffusion suppression, and accelerated wear. Micro-sandblasting further prolonged the steady-wear phase by removing residual cobalt binder, exposing WC grains, and offsetting tensile residual stresses. These findings establish a practical, cost-effective micro-sandblasting pretreatment strategy that significantly enhances coating adhesion, hardness, and tool life, providing actionable guidance for improving the durability and machining performance of coated carbide tools in difficult-to-cut applications. Full article

This study investigates the effects of destructive climatic factors on the mechanical and performance properties of various structural materials, encompassing both polymers and metals. Over recent decades, the growing adoption of synthetic polymers has revolutionized engineering applications, yet their susceptibility to environmental degradation poses significant challenges. This research emphasizes the need for comprehensive testing under both operational and environmental stressors, including extreme temperatures, UV radiation, and moisture, to assess material durability and performance. Mechanical tests were conducted at ambient (25 °C) and low temperatures (−50 °C) to evaluate the strength and strain responses of selected materials. Additionally, a 12-month accelerated aging process using UV radiation and elevated temperatures was performed to simulate long-term environmental exposure. Parameters such as Shore D hardness, gloss, and mass were measured at regular intervals to quantify material degradation. The results revealed significant differences in performance across material types. Among polymers, laser-extruded and milky plexiglass, as well as solid polycarbonate, exhibited satisfactory resistance to aging, with minimal changes in mechanical properties. However, high-impact polystyrene displayed substantial deformation and hardness loss after prolonged UV exposure. For metals, aluminum and stainless steel (304 and 316) demonstrated exceptional durability, retaining structural and aesthetic properties after 12 months of accelerated aging, whereas galvanized steel exhibited pronounced corrosion. The study highlights the critical interplay between mechanical loading and environmental factors, stressing the importance of material selection tailored to specific climatic conditions. It further underscores the value of integrating experimental findings with predictive models, such as finite element analysis, to enhance the design and longevity of engineering materials. The findings provide actionable insights for industries operating in temperate climates, where materials are subjected to diverse and cyclic environmental stressors. Recommendations are offered for selecting resilient materials suitable for protective housings and structural components. Full article

This study investigates the effects of B₄C content (2.5, 5, 7.5, and 10 wt.%) on the microstructure and wear resistance of laser cladding 316 stainless steel coatings on a 2Cr12MoV steel substrate. The coating was prepared by laser cladding technology. The phase composition, microstructure evolution, microhardness, and tribological properties of the coating were analyzed. The results show that the decomposition of B₄C particles is complete, and the phase composition of the coating includes Austenite, Fe₂₃ (B₃C₃), Cr₂₃ (B_1.5C_4.5), and a Fe-Ni solid solution. The increase in B₄C content significantly increased the microhardness of the material from 206 HV_0.2 (substrate) to 829 HV_0.2 (10 wt.% B₄C) by 4.02 times. Wear resistance also improved, with the 10 wt.% coating exhibiting the lowest wear rate (10 × 10⁻⁸ mm³/N·m) due to fine-grained and dispersion strengthening mechanisms. However, excessive B₄C (10 wt.%) induced cracks from increased brittleness, resulting in higher friction coefficients. The wear mechanism consists of fatigue wear, adhesive wear, and oxidative wear, and the degree of wear decreases with the increase in B₄C content. This work demonstrates that the addition of B₄C effectively improves the hardness and wear resistance of 316 stainless steel coatings, providing practical insights into surface engineering in high wear applications. Full article

Knowledge of alloy behavior under industry-relevant conditions is critical to hydrogen production and processing, yet it is currently limited. To understand more about the impact of hydrogen damage on stainless steel 316 under realistic in-service conditions, we conducted a forensic investigation of two reactors exposed to various hydrogen-processing conditions. We examined samples of reactor walls exposed to hydrogen-containing atmospheres for >100 and ~1000 h at elevated temperatures during hydrogen separation and ammonia cracking. The samples were characterized by tensile testing, stretch–bend testing, and three-point bending. A loss in ductility and strength was observed for the reactor wall material compared with both untreated materials and materials annealed in neutral atmospheres at the same temperatures used during reactor operation. The three-point bend testing, which was conducted on inner and outer pipe-surface material extracted via electrical discharge machining, showed larger changes in the flexural modulus of exposed reactors but increases in the elastic limit. Microstructural observations revealed that hydrogen may play a role in stress relaxation, possibly promoting normalization at lower-than-expected temperatures. We also observed that materials exposed to ammonia undertake more damage from nitriding than from hydrogen. Full article

Recent studies have focused on developing temporary metallic implants made from biodegradable biomaterials, such as iron and its alloys, along with the associated manufacturing methods. These biomaterials allow the implant to gradually degrade after fulfilling its function, which reduces the risks of complications associated with permanent implants. Iron is particularly appealing from a structural standpoint, and adding manganese enhances its potential for use. The Fe-35Mn alloy demonstrates excellent mechanical properties and degradation characteristics, making it an ideal choice within the Fe-Mn system. As a result, new processing techniques can be applied to this alloy to further improve its performance. The objective of this research is to propose a new processing route and evaluate its impact on the properties of the Fe-35Mn alloy. The experimental alloy was produced using an arc melting furnace, followed by homogenization, hot swaging, and solution treatment. Alloy characterization was conducted using various techniques, including X-ray fluorescence (XRF), optical microscopy (OM), X-ray diffraction (XRD), differential scanning calorimetry (DSC), microhardness testing, tensile strength measurements, Young’s modulus determination, and potentiodynamic polarization analysis. The microstructural evolution throughout the applied processing route was analyzed in relation to the alloy’s mechanical performance and corrosion resistance. The typical microstructure of the Fe-35Mn alloy is primarily composed of austenitic grains stabilized at room temperature. Its mechanical properties—yield strength (297 MPa), ultimate tensile strength (533 MPa), and elongation to failure (39%)—are comparable to, or even surpass, those of conventional biomedical materials such as 316 L stainless steel and pure iron. The reduced Young’s modulus (171 GPa), compared to other alloys, further underscores its potential for biomedical applications. Electrochemical testing revealed lower corrosion resistance than that of similar alloys reported in the literature, with a corrosion potential of −0.76 V and a current density of 3.88 µA·cm⁻², suggesting an enhanced corrosion rate. Full article

This study explores the enhancement of antimicrobial and biomedical properties in Fe-based bulk metallic glasses (BMGs) through the addition of Ag. Fe_55-xCr₂₀Mo₅P₁₃C₇Ag_x (x = 0, 1, 2, 3 at.%) master alloy ingots were synthesized by the induction melting technique and industrial-grade raw materials, the master alloy ingots were prepared as bulk metallic glasses (referred to as Ag0, Ag1, Ag2, and Ag3) by the water-cooled copper-mold suction casting technique, and their glass-forming ability, corrosion resistance, biocompatibility, and antimicrobial properties were systematically investigated. The results indicate that the glass forming ability (GFA) decreased with increasing Ag content, reducing the critical diameter for fully amorphous formation from 2.0 mm for Ag0 to 1.0 mm for Ag3. Electrochemical tests in Hank’s solution revealed the superior corrosion resistance of the Fe-based BMGs as compared with conventional 316 L stainless steel (316L SS) and Ti6Al4V alloy (TC4), with Ag3 demonstrating the lowest corrosion current density and the most stable passivation. Biocompatibility assessments, including fibroblast cell viability and adhesion tests, showed enhanced cellular activity and morphology on Fe-based BMG surfaces as compared with 316L SS and TC4, with minimal harmful ion release. Antimicrobial tests against E. coli and S. aureus revealed significantly improved performance with the Ag addition, achieving bacterial inhibition rates of up to 87.5% and 86.7%, respectively, attributed to Ag⁺-induced reactive oxygen species (ROS) production. With their excellent corrosion resistance, biocompatibility, and antimicrobial activity, the present Ag-containing Fe-based BMGs, particularly Ag3, are promising candidates for next-generation biomedical implants. Full article

The broad use of (stainless steel) SS 316 L bipolar plates (BPs) in proton exchange membrane fuel cells relies (PEMFC) on high conductivity and corrosion resistance. To enhance the properties of stainless steel, this study applies ion implantation and heat treatment to form a non-homogeneous modified layer on SS 316 L. The injection of C and Mo ions on the SS 316 L surface caused irradiation damage, producing holes. But with the heat treatment of the ion-implanted samples, the irradiation-damaged surface will be repaired to a certain extent. The corrosion current density (I_corr) of the 600 °C sample in the kinetic potential test (5.32 × 10⁻⁴ A/cm²) was 54% lower than that of the naked SS 316 L (1.17 × 10⁻³ A/cm²). In the electrostatic potential test, the corrosion current of the 600 °C sample stabilized at a low value (about 0.26 μA/cm²), with the lowest concentration of dissolved metal ions (Fe²⁺ 2.908 mg/L). After anodic electrostatic potential polarization, the interfacial contact resistance (ICR) of (Mo+C)_600-1 was much lower than that of the untreated SS 316 L. Heat treatment experiments show that samples treated at 600 °C for 1 h exhibit significantly higher conductivity and anodic corrosion resistance than naked SS 316 L. This improvement is mainly due to the heat treatment under these conditions, which facilitated the formation of Mo carbides from the implanted C and Mo elements. Ion implantation and heat treatment enhance stainless steel surface conductivity and passive film corrosion resistance. These findings are useful in altering stainless steel BPs. Full article

This paper adopts an atmospheric plasma spraying and laser cladding process to prepare WC-10Co-4Cr cemented carbide coatings on the substrate surfaces of 304 stainless steel and 316 stainless steel, respectively, and comparatively analyzes the microstructures, phase compositions, average hardness, and friction and wear performances of the coatings prepared under the two processes. The analysis showed that the plasma sprayed coating showed a lamellar structure, and the interface between the coating and the substrate was mechanically occluded, while the laser melting coating showed a dendritic structure, and the interface between the coating and the substrate was metallurgically bonded. After decarburization of the plasma sprayed coatings, the W2C phase dominated, while the laser cladding coatings were still dominated by the WC phase. In addition, the average microhardness, coefficient of friction, and mass loss of the plasma sprayed coatings were about 1341.7 HV, 0.45, and 0.005 g, respectively, while those of the laser cladding coatings were about 1440.5 HV, 0.4, and 0.002 g. The overall performance of the laser cladding coatings was better than that of the plasma sprayed coatings. The quality of the prepared WC-10Co-4Cr coatings was improved, which provides guidance for the preparation of WC-10Co-4Cr coatings by laser melting. Full article

AISI 316 is a stainless steel known for its exceptional corrosion resistance and excellent mechanical properties. It is used in the chemical and pharmaceutical industries, food processing equipment, and medical devices. This alloy’s wide range of applications underscores its importance in industries requiring materials that can withstand extreme conditions while maintaining structural integrity and performance. Additionally, the excellent weldability and formability of AISI 316 allow for versatile design and production processes, ensuring durable and reliable performance in marine environments. This work aims to examine the behavior of AISI 316L and its welded joints under high-cycle fatigue loadings using infrared thermography (IR). Two kinds of experimental tests are performed on specimens with the same geometry: static tests and stepwise succession tests. The results of the static tests are in accordance with the stepwise succession test results in predicting the fatigue properties. Full article

Tungsten carbide (WC) coatings of varying thicknesses were prepared using electrical discharge deposition technology. Relevant characterizations were conducted to analyze the residual stress in the WC coatings from a microscopic perspective, and this residual stress was measured using X-ray diffraction technology. Under isothermal conditions, a novel method for detecting the residual stress of the coatings utilizing critical refractive longitudinal (LCR) waves was employed to investigate the relationship between the residual stress of the WC coatings and their thickness. According to acoustic elastic theory, LCR stress measurement is based on the principle that stress within the material alters the propagation characteristics of ultrasonic waves. After correcting the effect of coating thickness on LCR propagation, the detection results of the LCR wave indicate that the compressive stress present in the coating may cause the substrate to exhibit a certain degree of tensile stress. At a coating thickness of 6–13 µm, as the thickness of the WC coating increases, the residual compressive stress within the coating gradually rises, leading to an increase in tensile stress on the substrate. However, at coating thicknesses of 13–16 µm, the changes in tensile stress on the substrate become minimal or even decrease, despite the continued increase in compressive stress within the WC coating. The relationship curve derived from the matrix surface aligns more closely with a quadratic function, while the curve obtained from the coating surface corresponds more to a linear function. This study employs LCR waves to detect residual stress in coatings, and the results indicate that LCR waves hold significant potential for application in the field of residual stress detection in coatings. Full article