Search Results (159)

In this study, carbide-metal composite coatings (WC-10Co4Cr) were prepared via high-velocity oxygen-fuel (HVOF) spraying, and the influence of Mo₂C addition on the microstructure, mechanical properties, and wear performance was systematically investigated. The results indicate that Mo₂C is solid-soluted in WC during the preparation process, which induces lattice distortion. Mo₂C addition results in refinement of the grain size of WC particles, homogenization of the binder phase distribution, and reduction of the porosity of the coatings. An appropriate amount of Mo₂C addition significantly enhances coating performance. The coating containing 2 wt.% Mo₂C exhibited optimal properties. It demonstrated the highest microhardness and the lowest porosity, and wear tests revealed it had the lowest friction coefficient and wear rate at room temperature, which is primarily due to enhanced hardness and density that effectively suppressed abrasive wear. At 400 °C, the coating with 2 wt.% Mo₂C addition also showed the most stable and lowest friction coefficient. The generated Mo-containing oxides acts as a solid lubricant, isolating friction surfaces and mitigating both oxidative and adhesive wear. However, excessive Mo₂C content leads to an abnormal increase in the volume fraction of the binder phase, accompanied by reduced hardness. This induces a transition of the wear mechanism toward adhesive wear dominance, with complex nonlinear evolution characteristics. Full article

As a result of welding processes in boron-alloyed martensitic armor steels, unfavorable microstructural changes occur, leading to a significant reduction in the mechanical properties of both the weld metal and the base material. The dendritic structure of the weld metal and the partial tempering in the heat-affected zone contribute to the decreased durability of structural components, thereby deteriorating their performance. This issue is particularly important since such steels are widely used not only in the defense industry but also in the mining, construction, transportation, and metallurgical sectors, where they operate under conditions of intensive abrasive wear. For this reason, the authors attempted to improve the mechanical properties of welded joints of boron-alloyed martensitic armor steel (with a nominal hardness of 500 HBW) through post-weld heat treatment. The welded joint was evaluated based on metallographic examinations using light microscopy and scanning electron microscopy, as well as abrasive wear tests carried out on a T-07 tribotester. The conducted investigations demonstrated that, under loose abrasive conditions (using electrofused alumina), heat treatment increased the wear resistance of the joints by 55% compared to the as-welded condition. The obtained results were compared with selected grades of Hardox steel commonly used in industrial applications. Full article

This study fabricated six types of NiCr–Cr₃C₂ composite coatings using high-velocity oxygen fuel (HVOF) spraying and systematically evaluated their tribological behavior at 350 °C and 500 °C, along with their electrochemical corrosion performance in 3.5 wt.% NaCl solution. The objective was to elucidate how compositional design regulates the coatings’ microstructure, mechanical properties, and service performance. Results indicate that the 75NiCr–25Cr₃C₂ coating (C) formed a stable oxide film under both temperatures, exhibiting oxidation-dominated wear and the lowest friction coefficient and wear rate. When the temperature increased from 350 °C to 500 °C, the wear rates of coatings C, B, E, and F decreased significantly. Notably, coatings E and F, which contained CoCrFeNiMo high-entropy alloy, showed more than a 50% reduction in wear rate, demonstrating the contribution of the high-entropy phase to high-temperature wear resistance. At 350 °C, coatings B, D, E, and F experienced primarily abrasive wear; at 500 °C, however, E and F shifted to oxidative wear as the dominant mechanism, leading to a marked improvement in wear resistance. Electrochemical measurements revealed that coating E exhibited the best corrosion resistance, while the NiCr coating (A) performed the worst. The findings highlight that optimizing Cr₃C₂ content and incorporating high-entropy alloy elements can synergistically enhance both high-temperature tribological properties and corrosion resistance. Full article

Porous concrete is widely recognized as an eco-friendly pavement material; however, existing studies mainly focus on its use as a base course, and systematic investigations on porous concrete specifically designed for heavy-traffic pavements and multifunctional surface performance remain limited. In this study, a novel multifunctional porous concrete with integrated noise reduction and drainage performance (PCNRD) was developed as a top-layer pavement material, addressing the performance gap in current applications. A comprehensive evaluation of the surface properties of porous concrete was performed based on tests of the sound absorption, void ratio, permeability, and wear resistance. The results demonstrate that the porous concrete exhibits excellent sound absorption (sound absorption coefficient 0.22–0.35) and high permeability (permeability coefficient 0.63–1.13 cm/s), and superior abrasion resistance (abrasion loss ≤ 20%) within an optimized porosity range of 17–23%. Furthermore, an optimized pavement thickness (8–10 cm) was proposed, and functional correlations among key surface performance indicators were revealed for the first time. Based on a uniform experimental design, four key mix parameters (water–cement ratio, cement content, silica fume content, and cement strength grade) were examined using strength and effective porosity as dual control indices, leading to the development of a novel mix design method tailored for PCNRD. This study not only fills the technical gap in high-performance porous concrete for heavy-traffic pavement surfaces but also provides a practical scientific framework for its broader engineering application. Full article

Round-ended bridge piers are specifically utilized for high-speed railways in mountainous areas. However, the protective measures for such piers under debris flow remain limited, especially regarding the various components in the debris flow. This study introduces a reinforced concrete (RC) composite structure to improve the debris flow impact resistance of round-ended piers and investigates the impact from three different components of debris flow, including the bulk impact of slurry, collisions of large boulders, and abrasion of rock fragments. The results indicate the following: (1) The RC composite structure effectively mitigated the macroscopic damage from all types of debris flows. This structure significantly decreased gravel accumulation in the front of the pier body and reduced the size of scouring pits. These effects are superior to those of steel casing protection. (2) The RC composite structure significantly reduced the pier top displacement and pier body bending moments and optimized the pressure distribution on the pier body. The peak pressure reduction reached 95.7%, 88.4%, and 97.7% under three different debris flows. These effects were more pronounced than those under steel casing protection, for which the corresponding reductions were 18.2%, 70.9%, and 69.7%. (3) The RC composite structure effectively absorbed impact-induced vibrations and weakened shock effects on the upstream face, exhibiting superior capabilities compared with those of steel casing. The RC composite structure showed particularly outstanding performance in gravel-dominated debris flows. Ultimately, the RC composite structure could be an effective technique for enhancing the resistance of round-ended bridge piers against debris flows. Full article

Background/Objectives: Achieving durable intraoral repairs of fractured metal and zirconia restorations requires optimal adhesion. This in vitro study evaluated the effects of mechanical surface treatments and commercial repair systems on the shear bond strength (SBS) of composite resin to nickel–chromium (Ni-Cr) alloy and zirconia, including the influence of thermocycling aging. Methods: In this study, 144 Ni-Cr and zirconia discs (12 × 12 × 2 mm) were randomly assigned to three surface treatments: untreated control, airborne particle abrasion (50 µm Al₂O₃), and medium grit diamond bur grinding. Each group was further subdivided to assess two intraoral repair kits (GC Corp (Tokyo, Japan). and Bisco Inc. (Schaumburg, IL, USA)). Composite resin cylinders were bonded following the manufacturer’s instructions. Half of the specimens (n = 12/subgroup) underwent 5000 thermocycles (5–55 °C). Micro-shear bond strength testing was performed, and failure modes were analyzed. Data were analyzed using three-way ANOVA and post hoc tests (p < 0.05). Results: Air abrasion significantly increased SBS compared to control and bur grinding for metal (p < 0.001). For zirconia, both air abrasion and bur grinding yielded similarly improved SBS over the control (p < 0.001). The GC repair kit demonstrated significantly superior bond stability after thermocycling across both substrates. Aging significantly reduced SBS in all groups (p < 0.001), with the most substantial reductions observed in untreated controls and groups repaired with the Bisco system. Conclusions: Airborne particle abrasion combined with a HEMA-free, 10-MDP-containing universal adhesive achieved the strongest and most durable resin bonds to both metal and zirconia, supporting its clinical use for the intraoral repair of ceramic and metal restorations. Full article

In the river environments of Xinjiang characterized by high sediment content and high flow velocities, hydraulic concrete is highly susceptible to damage from the impact and abrasion of bed load. Consequently, this imposes more stringent requirements on its mechanical properties and abrasion resistance. The incorporation of crumb rubber, a recyclable material, into concrete presents a dual benefit: it enables resource recycling while simultaneously offering a novel pathway for the development of concrete technology. This study takes rubber powder concrete as the research object. With the same water-to-binder ratio, rubber powder was incorporated at three volume fractions: 0%, 5%, and 10% of the cementitious material. The drop weight impact test and underwater steel ball method are adopted to evaluate its impact resistance and anti-scouring-abrasion performance, respectively. By testing the compressive strength, impact toughness, wear rate, anti-scouring-abrasion strength and three-dimensional morphological characteristics, the influence of rubber powder content on the mechanical properties and anti-scouring-abrasion performance of concrete is systematically analyzed. The research results show that the addition of rubber powder reduces the compressive strength of concrete, but significantly improves its impact resistance and anti-scouring-abrasion performance. Among all test groups, the concrete with 10% rubber powder content has the most significant decrease in compressive strength, with a decrease of about 37% compared with the 5% content group, while the 5% content group has a decrease of about 27% compared with the control group. However, its impact toughness at 3d, 7d and 15d is increased by about 84.7%, 88.4% and 84.4%, respectively, compared with the control group, showing the largest improvement range. At the same time, the wear rate of this group is reduced by about 42.5%, and the anti-scouring-abrasion strength is increased by about 61%. Combined with the three-dimensional morphology analysis, it can be seen that the specimens in this group exhibit the optimal anti-scouring-abrasion performance. In terms of microstructure, the porosity of rubber powder concrete increases, the generation of C-S-H gel decreases and its continuity is damaged, leading to a significant decrease in compressive strength. The reduction in the generation of delayed ettringite enhances the toughness and anti-scouring-abrasion performance. In general, the increase in rubber powder content will lead to a decrease in the compressive strength of concrete, but within a certain range, it can significantly improve its impact resistance and anti-scouring-abrasion performance. Crumb rubber effectively enhances the impact and abrasion resistance of hydraulic concrete, demonstrating strong application potential in high-flow, sediment-laden river environments. Full article

This research examined the mechanical, physical, thermal, and durability properties of plastic-based composites made from MSW, namely ultra-high-temperature (UHT) cartons, plastic bags, aluminum foil, and foil bags under both unweathered and accelerated weathering conditions to evaluate their potential as paving slab materials. Composite samples with varying mixing ratios were fabricated and tested based on an experimental design. Statistical analyses using one-way ANOVA confirmed the significant effects of composition on material performance (p < 0.05). The results demonstrated that the mixing ratio markedly influenced mechanical properties. The composite containing 50 wt% UHT carton and 50 wt% foil bags (U50F50) achieved the highest modulus of rupture (121.20 MPa) and modulus of elasticity (2.98 GPa), as well as compressive strength (28.56 MPa), compressive modulus (2.12 GPa), screw withdrawal resistance (54.25 MPa), and hardness (66.25). Under accelerated weathering, all of the composites showed moderate reductions in strength (10 to 30%) due to plastic degradation and surface cracking. In contrast, the composites containing high paperboard fractions (U80P15A5) exhibited greater WA (3.55%) and TS (3.04%), attributed to the hydrophilic nature of cellulose. The inclusion of foil bags effectively reduced WA and TS by limiting moisture penetration. Density measurements demonstrated a gradual increase (0.99 to 1.05 g/cm³) with higher foil content, while accelerated weathering induced an average 10% density reduction. Abrasion resistance improved in foil-rich composites, with U50F50 showing the lowest weight loss (8.56 to 14.02%), confirming its superior structural integrity under mechanical wear. Thermal analysis indicated low conductivity values (0.136 to 0.189 W/m·K), demonstrating favorable insulation performance compared to conventional paving materials. However, higher foil bag fractions enhanced heat conduction, balancing mechanical strength with thermal functionality. Overall, MSW-derived composites containing 30 to 50 wt% foil bags exhibited optimal mechanical durability, abrasion resistance, and thermal stability, making them promising candidates for sustainable paving slab production with low environmental impact and enhanced service life. Full article

With the increasing demand for energy conservation and emission reduction in the automotive industry, optimizing the performance of cylinder liner and piston ring pairs in engines has become crucial. Aluminum–silicon alloy cylinder liners, known for their lightweight and excellent thermal conductivity, have emerged as a new trend in cylinder liner materials. Given the relatively moderate hardness of Al-Si alloys, judicious selection of piston rings is imperative to ensure optimal performance. This study investigates the tribological properties of aluminum–silicon alloy cylinder liners paired with CKS and DLC piston rings. The surface morphology and hardness of the test materials were characterized, and reciprocating friction and wear tests were conducted, using a tribometer to simulate operating conditions. The friction coefficient and wear volume were used as indicators to evaluate the tribological properties of the piston rings. The results show that, when the aluminum–silicon alloy cylinder liner was paired with a DLC piston ring, the friction coefficient was 27.82% lower, and the wear volume of the cylinder liner was 83.52% lower, compared to pairing with a CKS piston ring. When paired with a CKS piston ring, wear was exacerbated because silicon particles were easily dislodged to form abrasive particles. This particle detachment is mainly caused by the collision between the fine ceramic particles embedded in the CKS coating and the silicon particles (≤5 μm) uniformly distributed in the Al-Si alloy cylinder liner during the sliding process. The DLC piston ring, containing both sp² and sp³ hybridized carbon–carbon bonds, combined excellent lubrication properties with high hardness, resulting in minimal wear on both the cylinder liner and piston ring. Specifically, the DLC coating has a hardness of 2300 HV_0.3, which is 2.42 times that of the CKS piston ring (950 HV_0.3); the sp³-hybridized carbon in the DLC coating enhances its wear resistance to resist scratching from silicon particles in the cylinder liner, while the sp²-hybridized carbon forms a graphite-like transfer layer at the friction interface to reduce frictional resistance. In conclusion, the aluminum–silicon alloy cylinder liner paired with a DLC piston ring exhibits superior tribological properties. Selecting an appropriate piston ring can significantly enhance the tribological properties of the cylinder liner–piston ring pair, thereby extending the engine’s service life. Full article

The structural integrity of adhesively bonded composites is critically dependent on manufacturing process fidelity. While the MGS L418 epoxy system is widely used in aerospace applications, a quantitative hierarchy of its process variables is absent from the literature, leading to reliance on qualitative guidelines and inherent performance variability. This study closes this gap through a comprehensive sensitivity analysis. A 2^6-2 fractional factorial Design of Experiments (DOE) quantified the effects of six variables on single-lap shear strength. An Analysis of Variance (ANOVA) established a definitive hierarchy: induction time was the dominant factor, with a sub-optimal 15 min period causing a 74% strength reduction (p < 0.000). Surface preparation was the second most significant factor, with mechanical abrasion increasing strength by 17% (p = 0.000). Ambient humidity was a marginal factor (p = 0.013), linked to amine blush formation. The interaction effects were statistically insignificant, simplifying the control strategy. This work provides a validated, quantitative model that defines a robust process window, prioritizing induction time and surface preparation to de-risk manufacturing and ensure the reliability of safety-critical bonded structures. Full article

The surface quality of high-performance electroformed components, such as the matrix material of the rocket thrust chamber wall, is critical to the overall performance of the devices. However, under high current density and elevated cathode rotation speeds, excessive internal stress often leads to layer detachment, compromising coating adhesion and stability. This study introduces an improved electroforming process termed microbead fusion flexible friction-assisted electroforming (MF³AEF) and examines its effect on the surface roughness of electroformed copper layers. By comparing conventional direct current electroforming (DCEF), abrasive-assisted electroforming (AAEF) with free ceramic beads, and the proposed MF³AEF process, this work investigates the variations in surface quality and roughness under different current densities and cathode rotation speeds. The results indicate that at a current density of 6.8 A/dm² and a cathode rotation speed of 90 rpm, the surface roughness of the MF³AEF-produced layer is reduced to Ra0.24 µm, representing a 98.2% reduction compared to the Ra13.35 µm achieved by DCEF. This demonstrates that MF³AEF significantly enhances surface properties and markedly reduces the surface roughness of electroformed layers. Full article

This study investigates the influence of ball burnishing (BB) path strategies on the surface integrity and functional performance of laser-cladded Inconel 718. Three BB strategies—(1) BB-Longitudinal, (2) BB-Transverse, and (3) BB-Crosshatch—relative to the laser scan trajectory were evaluated and compared against ground surfaces as a baseline. Post-processing BB treatment were demonstrated to be effective in modifying the subsurface layer of the cladded Inconel 718 material, extending to depths of up to 100 µm, increasing dislocation density by over 2.5 times, and enhancing hardness from 260 HV5 (ground) to as high as 461 HV5. These microstructural improvements led to significant gains in corrosion and impact resistance, despite a rise in surface roughness from Ra 0.35 µm (ground) to up to 2.38 µm for BB-Longitudinal surfaces. Impact testing revealed up to 35% reduction in indentation volume, particularly with BB-Transverse and BB-Crosshatch strategies. Nonetheless, sliding wear tests did not confirm improvements in wear resistance, as wear depths exceeded the hardened layer and abrasive wear remained dominant. Electrochemical testing in 3.5 wt.% NaCl solution showed a positive shift in corrosion potential (E_corr) exceeding 200 mV compared to the ground condition, indicating reduced corrosion susceptibility for BB-Longitudinal condition. Among the tested strategies, BB-Transverse offered the most balanced enhancements, highlighting the complex interplay between laser cladding heterogeneities and post-processing response in optimizing surface and mechanical properties of Inconel 718 claddings. Full article

Francis turbines operating in sediment-laden flows experience efficiency loss and reduced service life due to abrasive wear. To enhance wear resistance, this study optimized the turbine at Mupo Hydropower Station in Sichuan Province. Using the Plackett–Burman design, three runner parameters were identified as most influential: blade number, inlet setting angle, and outlet setting angle. A central composite design based on response surface methodology was then applied to these factors. Multiple regression models linking the parameters to turbine head, efficiency, and wear rate were established, revealing a trade-off between hydraulic performance and wear resistance. Multi-objective optimization, a method that simultaneously addresses and balances multiple competing goals, was performed to minimize wear rate while maintaining the original head. The optimal parameter combination was obtained as follows: blade number Z₃ = 17, inlet setting angle ${\alpha }_1$ = 65°, and outlet setting angle ${\alpha }_2$ = 22°. Numerical results demonstrate a 32.3% reduction in runner wear under these parameters, with the head requirement satisfied, confirming a significant improvement in overall turbine performance. Full article

This study investigates the structure–property–performance (SPP) relationships of two thermoplastic polyurethanes (TPUs), FILAFLEX FOAMY 70A and SMARTFIL^® FLEX 98A, manufactured by fused filament fabrication (FFF). Disc specimens were produced with varying gyroid infill densities (10–100%) and Archimedean surface textures, and their tribological and surface characteristics were analyzed through Ball-on-Disc tests, profilometry, and optical microscopy. SMARTFIL^® FLEX 98A exhibited a sharp reduction in the coefficient of friction (μ) with increasing infill, from 1.174 at 10% to 0.371 at 100%, linked to improved structural stability at higher densities. In contrast, FILAFLEX FOAMY 70A maintained a stable but generally higher coefficient of friction (0.585–0.729) across densities, reflecting its foamed microstructure and bulk yielding behavior. Surface analysis revealed significantly higher roughness in SMARTFIL^® FLEX 98A, while FILAFLEX FOAMY 70A showed consistent roughness across infill levels. Both TPUs resisted inducing abrasive wear on the steel counterpart, but their stress-accommodation mechanisms diverged. These findings highlight distinct application profiles: SMARTFIL^® FLEX 98A for energy-absorbing, deformable components, and FILAFLEX FOAMY 70A for applications requiring stable surface finish and low adhesive wear. The results advance the design of functionally graded TPU materials through the controlled tuning of infill and surface features. Full article

This article presents the results of a comprehensive investigation into geopolymer composites synthesized from fly ash, incorporating ground asphalt derived from reclaimed road pavement and quartz sand. The primary objective of this study was to elucidate the influence of mixture composition on the mechanical, physical, and microstructural characteristics of the developed materials. The innovative aspect of this research lies in the integration of two distinct filler types—mineral (quartz sand) and organic-mineral (milled asphalt)—within a single geopolymer matrix, while preserving key performance parameters required for engineering applications, including compressive and flexural strength, density, water absorption, and abrasion resistance. The experimental methodology encompassed the characterization of the raw materials by X-ray diffraction (XRD), chemical composition analysis via X-ray fluorescence (XRF), and assessment of particle size distribution. Additionally, the produced geopolymer materials underwent density determination, compressive and flexural strength measurements, abrasion testing, and mass water absorption evaluation. The chemical composition was further examined using XRF, and the surface morphology of the specimens was analyzed by scanning electron microscopy (SEM). The findings demonstrate that the incorporation of quartz sand enhances the density and mechanical strength of the composites, whereas the addition of recycled asphalt, despite causing a modest reduction in mechanical performance at elevated dosages, augments water resistance. Moreover, ternary composite material provide an optimal compromise between mechanical strength and durability under humid conditions. Overall, the results substantiate the feasibility of utilizing asphalt waste for the fabrication of functional and sustainable geopolymer materials suitable for construction applications. Full article