Search Results (61)

This work presents a dynamic flowsheet model that predicts residual stress from shot peening. The peening medium is characterized by size and shape, and evolves dynamically with abrasion, fracture, classification, and replenishment. Because particle size and impact location vary stochastically, the resulting residual stress field is spatially heterogeneous. Residual stress fields are predicted in real time through a convolutional long short-term memory (ConvLSTM) neural network trained on finite element simulations, enabling fast, mechanistically grounded prediction of surface stress evolution under industrial shot peening conditions. We deploy the model in a pair of 10,000-cycle production peening case studies, demonstrating that media recharge strategy has a measurable effect on residual stress outcomes. Full article

The objective of this study was to evaluate whether any coating material would have a beneficial influence on maintaining color stability and surface roughness and to what extent an uncoated resin composite can keep its original color. The study evaluated three direct composite resins (Gradia Direct Anterior A2, Tetric EvoCeram A2, Filtek Z550 A2) using 30 samples per material (1 mm thick, 14 × 10 × 1 mm). Samples were prepared in 3D-printed molds, light-cured for 40 s, and initially smoothed with abrasive paper (grit 400–2000). The surface treatments applied were as follows: group 1—polished with a brush and Compo + polishing paste, group 2—conditioned with 37% phosphoric acid, ScotchBond adhesive applied, light-cured. All samples were cleaned ultrasonically for 5 min. Initial surface roughness and color were measured with a profilometer and spectrophotometer. Samples were then immersed in distilled water (control at 37 °C), Coca-Cola and red wine (at 10 °C) with surface roughness and color changes measurements taken on days 1, 7, 14 and 90. Immersion media were refreshed weekly. The most notable color changes after immersion in coloring solutions were observed in the groups treated with Coca-Cola and red wine compared with the control group in distilled water. Tetric EvoCeram sealed and Gradia sealed maintained the greatest resistance to perceptible coloration over 90 days, while Filtek Z550 performed the poorest. Tetric EvoCeram sealed maintained the greatest color stability (ΔE < 3.5 at 90 days), whereas Filtek Z550 sealed showed early degradation. Roughness is often decreased by surface sealing. As immersion time rises, unsealed surfaces often become noticeably rougher than sealed ones. This study simulates the oral environment and the exposure of restorative materials to staining agents. As the loss of esthetic properties over time is a continuous problem, the clinical significance of this research lies in demonstrating how a restorative material could resist pigmentation, when in contact with well-known high staining beverages, in order to maintain its esthetic properties and remain suitable for long-term use in the oral cavity. Moreover, the hypothesis that a coating material would protect the resin composite surface and reduce discoloration and surface roughness was tested. Full article

The clinical performance of interim restorations, particularly in the anterior region, largely depends on surface roughness (Ra) and color stability. This study investigated the influence of different toothbrushing durations on the surface roughness and color stability of CAD/CAM interim restorative materials subjected to varying polishing protocols. A total of 140 rectangular specimens (15 × 9 × 2 mm) were fabricated from highly cross-linked PMMA blocks (Telio-CAD, Ivoclar Vivadent, Schaan, Liechtenstein) and allocated to two surface treatment groups: conventional polishing and surface coating with Optiglaze Color (GC Corp, Tokyo, Japan). Each group was further divided into seven subgroups (n = 10), including a control (no brushing) and groups that performed simulated brushing (DentArge TB-6.1, Analitik Medikal, Gaziantep, Turkiye) with distilled water or toothpaste (Colgate Total; Colgate-Palmolive, New York, NY, USA), for 2 weeks, 3 months, or 1 year. Ra values were recorded before (Ra0) and after brushing (Ra1), and color changes (ΔE₀₀) following immersion in coffee solution were calculated. Statistical analysis was performed using a three-way ANOVA and Tukey’s HSD test (α = 0.05). Specimens coated with Optiglaze Color exhibited significantly lower Ra values compared with conventionally polished specimens (p < 0.05). The Con_Tp_1Yr group demonstrated the highest Ra value (0.53 ± 0.08 µm) compared to all other specimen groups (p < 0.05). A one-year brushing duration markedly increased ΔE₀₀ values in both surface treatment groups regardless of brushing medium (p < 0.05). While surface coating was more effective than conventional polishing in obtaining smoother surfaces at all brushing durations, prolonged brushing with toothpaste produced a progressive increase in surface roughness in both treatments. Ra values increased consistently over time, with the most pronounced changes observed after one year of brushing. Within the limitations of using a single CAD/CAM material, it may be concluded that surface coating improves the initial smoothness of interim crowns; however, extended brushing and different brushing media can intensify color changes, indicating that the long-term stability of surface-coated interim restorations may be compromised under abrasive conditions. Full article

Conductivity sensors play a vital role in monitoring production data in oil wells to ensure efficient oilfield operations, and their service performance depends on the durability of Invar alloy electrodes. The alloy electrodes are susceptible to damage from abrasive solid particles, corrosive media, and oil fluids in downhole environments. The degradation of the alloy electrodes directly compromises the signal stability of conductivity sensors, resulting in inaccurate monitoring data. Inspired by the intrinsic oleophobic properties of fish scales, we developed a fluorinated boron-doped diamond (FBDD) film with biomimetic micro–nano structures to enhance the wear resistance, corrosion resistance, and amphiphobicity of Invar alloy electrodes. The fish scale architecture was fabricated through argon-rich hot-filament chemical vapor deposition (90% Ar, 8 h) followed by fluorination. FBDD-coated electrodes surpass industrial benchmarks, exhibiting a friction coefficient of 0.08, wear rate of 5.1 × 10⁻⁷ mm³/(N·mm), corrosion rate of 3.581 × 10⁻³ mm/a, and oil/water contact angles of 95.32°/106.47°. The following underlying improvement mechanisms of FBDD films are proposed: (i) the wear-resistant matrix preserves the oleophobic nanostructures during abrasive contact; (ii) the corrosion barrier maintains electrical conductivity by preventing surface oxidation; (iii) the oil-repellent surface minimizes fouling that could mask corrosion or wear damage. Full article

This study addresses the challenges in machining the raceways and oil holes of aircraft engine bearing rings by conducting abrasive flow machining experiments on main bearing rings which had undergone ultra-precision grinding. Viscoelastic abrasive media containing cubic boron nitride of different particle sizes is used during the experiments. The results show that bearing performance is improved significantly in terms of surface roughness and residual compressive stress consequently; the overall surface quality is raised. The machining process meets the precision requirements for the main bearings of this type of aircraft engine, validating the feasibility and effectiveness of Abrasive Flow Machining (AFM), and the foundation for further optimization of this process is set through this research. Full article

Tool edge preparation is the process aimed at eliminating edge defects and optimizing the micro-geometric parameters of cutting tools. Drag finishing, the primary engineering method, subjects tools to planetary motion (simultaneous revolution and rotation) within abrasive media to remove burrs and micro-chips, thereby improving cutting performance and extending tool life. A discrete element method (DEM) model of drag finishing edge preparation was developed to investigate the effects of processing time, tool rotational speed, and rotation direction on abrasive-mediated tool wear behavior. The model was validated through milling cutter edge preparation experiments. Simulation results show that increasing the processing time causes fluctuating changes in average abrasive velocity and contact forces, while cumulative energy and tool wear increase progressively. Elevating tool rotational speed increases average abrasive velocity, contact forces, cumulative energy, and tool wear. Rotation direction significantly impacts tool wear: after 2 s of clockwise (CW) rotation, wear reached 1.45 × 10⁻⁸ mm; after 1 s of CW followed by 1 s of counterclockwise (CCW) rotation, wear was 1.25 × 10⁻⁸ mm; and after 2 s of CCW rotation, wear decreased to 1.02 × 10⁻⁸ mm. Experiments, designed based on simulation trends, confirm that edge radius increases with time and tool rotational speed. After 30 min of processing at 60, 90, and 120 rpm, average edge radius increased to 22.5 μm, 28 μm, and 30 μm, respectively. CW rotation increased the edge shape factor K, while CCW rotation decreased it. The close agreement between experimental and simulation results confirms the model’s effectiveness in predicting the impact of edge preparation parameters on tool geometry. Rotational speed control optimizes edge preparation efficiency, the predominant tangential cumulative energy reveals abrasive wear as the primary material removal mechanism, and rotation direction modulates the shape factor K, enabling symmetric edge preparation. Full article

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. Full article

Polyaryletherketone (PAEK) materials, including polyetheretherketone (PEEK) and polyetherketoneketone (PEKK), possess excellent mechanical properties and biocompatibility; however, their inherently low surface energy limits effective bonding with resin cements. This study investigated the effects of hydrofluoric acid (HF) etching and handheld nonthermal plasma (HNP) treatment on enhancing the adhesive performance of PAEK surfaces. Disk-shaped PEEK (BP) and PEKK (PK) specimens were divided into four groups: APA (airborne-particle abrasion), PLA (nonthermal plasma treatment), LHF (5.0% HF), and HHF (9.5% HF). Surface characterization was performed using a thermal field emission scanning electron microscope (FE-SEM). Surface wettability was evaluated using contact angle goniometry. Cytotoxicity was evaluated using HGF-1 cells exposed to conditioned media and analyzed via PrestoBlue assays. Shear bond strength (SBS) was measured after three aging conditions—NT (no aging), TC (thermocycling), and HA (highly accelerated aging)—using a light-curing resin cement. Failure modes were categorized, and statistical analysis was performed using one-way and two-way ANOVA with Tukey’s HSD test (α = 0.05). Different surface treatments did not affect surface characterization. PLA treatment significantly improved surface wettability, resulting in the lowest contact angles among all groups, followed by HF etching (HHF > LHF), while APA showed the poorest hydrophilicity. Across all treatments, PK exhibited better wettability than BP. Cytotoxicity results confirmed that all surface treatments were nontoxic to HGF-1 cells, indicating favorable biocompatibility. SBS testing demonstrated that PLA-treated specimens achieved the highest and most stable bond strength across all aging conditions. Although HF-treated groups exhibited lower bond strength overall, BP samples treated with HF showed relatively less reduction following aging. Failure mode analysis revealed a shift from mixture and cohesive failures in the NT aging condition to predominantly adhesive failures after TC and HA aging conditions. Notably, the PLA-treated groups retained mixture failure patterns even after aging, suggesting improved interfacial durability. Among the tested methods, PLA treatment was the most effective strategy, enhancing surface wettability, bond strength, and aging resistance without compromising biocompatibility. In summary, the PLA demonstrated the greatest clinical potential for improving the adhesive performance of PAEK when used with light-curing resin cements. Full article

An experiment examined the impact of 0.2% to 1.0% w/w graphite nanoparticles in 15W40 lubricating oil on tribological and rheological behavior. The analysis, conducted with a Pin on Disc machine and Four-Ball tester, revealed improved tribological properties and a 30% reduction in the friction coefficient compared to fresh 15W40. Wear was negligible, and extreme pressure performance increased by approximately 20%. SEM morphology confirmed the presence of graphite nanoparticles on the tribopair surface, indicating enhanced lubricant performance. Full article

This study focuses on preparing and characterizing functionalized silver nanoparticle-based (Ag-F NPs) finishing agents for leather treatment. Ag-F NPs were synthesized and functionalized through a ligand exchange process with citric acid, enhancing their dispersion stability in aqueous media. The nanoparticles were incorporated into polyurethane- and nitroemulsion-based finishing formulations and applied to ovine and bovine leather via a spray coating process. Morphological (SEM, TEM), structural (XRD), thermal (TGA), and spectroscopic (FT-IR) analyses confirmed successful functionalization and uniform dispersion within the finishing layer. Leather samples treated with Ag-F NPs exhibited a significant improvement in antibacterial properties, with microbial growth reduction of up to 90% after 72 h. Additionally, accelerated aging tests demonstrated enhanced UV resistance, with a 30% lower color change (∆E) compared to control samples. The Ag-F NPs-based finishing layers also exhibited superior abrasion and micro-scratch resistance, maintaining a stable coefficient of friction over time. These findings demonstrate the potential of Ag-F NPs as multifunctional leather-finishing agents, making them highly suitable for applications in the automotive, footwear, and leather goods industries. Full article

Al₂O₃ with SiC, silver, and graphene nanoplatelets (GNPs) powder mixture was produced by ball milling using ethanol as dispersion media. The GNP-reinforced Al₂O₃-SiC-Ag ceramic–metal composites were densified by spark plasma sintering technology (SPS). A homogeneous dispersion of GNPs in Al₂O₃-SiC-Ag was observed from the sintered samples, and the GNPs were embedded between the grains, which resulted in increasing the contact area. The trans-granular mechanism of crack propagation becomes increasingly dominant by adding GNPs. The hardness reaches 27 GPa, as tested by the Vickers microhardness method, which reflects an increase of 11% compared to Ag-GNPs-free Al₂O₃-SiC. On the other hand, by adding Ag-GNP content, the improvement in density is limited. Wear mechanisms, as determined through ball-on-flat testing, including adhesion, abrasion, and microcracks, are observed and discussed. The composite demonstrated remarkable self-lubricating properties, exhibiting a lower coefficient of friction (COF) and wear rate in an air environment compared to monolithic Al₂O₃-SiC. This improvement is attributed to the formation of a self-lubricating film, enabled by the uniform distribution of Ag and GNPs within the Al₂O₃-SiC matrix. The findings of this study propose a novel material design approach for developing self-lubricating ceramic composites with hybrid solid lubricants. Full article

A carbon brush/collector ring set will have phenomena such as firing and ablation during operation, which is due to the existence of various abnormal contact modes of the brush/ring during operation, thus changing the carbon brush/collector ring interface state. To analyze the effects of different contact modes on the performance of the brush/ring, in this paper, we construct the contact modes of the air gap (loss of contact leads to the existence of a small gap between the two surfaces), direct contact (contact with abrasive particulate media), and surface porosity contact (contact when there is a large pit on the surface of the collector ring due to manufacturing quality defects and abnormal abrasion), and analyze the effects of the various states on the core parameters such as current conduction, ring surface damage, and carbon brush abrasion, which provide a basis for the active suppression of the damage. Full article

This study examined the surface-grinding-induced microstructural modifications and corrosion attacks in a penetrating form of a high-Mn–low-Cr casting steel slab under humid environments. Various experimental and analytical findings from field-emission scanning electron microscopy, electron backscatter diffraction, transmission electron microscopy, and electrochemical analyses revealed that the abrasive grinding process led to the formation of a surface deformed region, comprising a recrystallized fine grain layer and multiple streamlines. Corrosion initially occurs preferentially along the boundary areas where Cr(Mn)₂₃C₆ particles are precipitated. Moreover, the corrosion products (Fe-based oxy/hydroxides) with a high volumetric expansion ratio detach readily from the surface deformed regions, facilitating the easy penetration of corrosive media. In contrast to conventional low-alloyed steels, which exhibit uniform corrosion behavior, corrosion-assisted penetrating attacks on ground high-Mn–low-Cr casting steel slabs occur more severely and frequently during the summer/dry season (i.e., relative humidity levels around 60% to 80%, rather than 100%) when a thin water film can form on the steel surface. Based on the result, effective technical strategies in terms of metallurgical and environmental aspects to mitigate the risk of corrosion-assisted penetrating attack of high-Mn–low-Cr casting steel were discussed. Full article

The purpose of this study was to determine the effect of selected vibratory strengthening machining factors on the properties of CuZn30 brass. Vibratory strengthening machining was carried out using metal media dedicated to polishing processes, which also contributed to strengthening the treated surfaces. The test samples were cut with an abrasive water jet and recrystallized to obtain a soft microstructure. An orthogonal, two-factor five-level plan was used for the study. The effect of vibration frequency and vibratory machining time on selected changes in parameters of the geometric structure of the surface and hardness of the surface layer was determined using Statistica software version 10 (64-bit). Higher vibration frequencies for vibratory machining increased the hardness of machined surfaces by as much as 50 HV_0.02. The arithmetic mean deviation of the height of surface irregularities from the reference plane, Sa, decreases with increasing the time of vibratory machining. A value of Sa = 0.168 µm was obtained after 87 min of consolidation, compared to an initial surface of S_a = 0.65 µm. Full article

The liner is a wear-prone component in ball mills, subject to continuous impacts, squeezing, and abrasion from the grinding media during operation. Its service performance directly affects the working efficiency of the ball mill. The service life of mining ball mill liners is about 8 months, and frequent downtimes occur due to liner wear and loss of effectiveness, with liner replacement accounting for about 6% of the total cost, resulting in huge economic losses. This paper focuses on a Φ305 mm × 150 mm experimental ball mill, using the discrete element software Rocky Discrete Element Method (DEM) (software version number Rocky 2022 R2) for simulation modeling analysis. With Φ10 mm and Φ20 mm mono-size particle simulations serving as reference groups, this study investigates the motion states and liner abrasion patterns under different liner heights for both sizes of grinding media in Equilibrium Quality Manufacturer (EQM) and Original Equipment Manufacturer (OEM) gradations. The results indicate that the impact of liner height on the wear of the ball mill liners is related to the size and gradation of the grinding media. The degree of liner wear from highest to lowest is as follows: EQM > Φ20 mm > OEM > Φ10 mm. Due to the effect of the cylinder end cap, the wear at the axial center of the ball mill liner is more severe than at both ends, and the wear on the facing side of the liner is more severe than on the backside. A thorough study of the influence of ball mill grinding media gradation on the wear pattern of liners is of great theoretical significance for optimizing liner structures, improving grinding efficiency, and promoting energy saving and cost reduction in ball mills. This study provides theoretical guidance for understanding the mechanisms behind liner wear in ball mills and predicting the liner lifespan. Full article