Search Results (472)

Hot extrusion tools operate under severe thermal and mechanical conditions, which significantly limit their service life. During operation, the punch and die absorb large amounts of heat from the hot billet while being subjected to high pressures and intense friction, leading to severe abrasive wear and progressive hardness reduction. In practice, the punch generally exhibits a shorter service life than the die. The present study proposes a technological solution for reconditioning worn extrusion punches using vibration-assisted welding (VAW). A wear-resistant layer was deposited by MIG welding using DUR 600 filler material, while mechanical vibrations were introduced through a vibrating welding table. The applied vibration regime consisted of a frequency of 50 Hz–108 Hz and acceleration components of a_x = 30–60 m/s² and a_z = 35–70 m/s². The experimental investigations included macroscopic analysis, hardness and microhardness measurements, microstructural observations, and SEM-EDS line scanning analysis of the dilution zone between the cladding material and the base metal. The results suggest that vibration-assisted welding may influence the microstructural characteristics, hardness distribution, and dilution behavior of the cladded layer. The vibrated specimens exhibited higher hardness values in the range of 702 to 908 HV5–10. Under the investigated conditions, the process did not require additional hardening treatment, and only a stress-relief annealing stage was applied. The proposed VAW approach appears to be a promising option for the reconditioning of hot extrusion tools; however, further investigations are required to validate its performance under industrial conditions. Full article

To improve the dry cutting performance of YG8 cemented carbide tools, CaF₂/[BMIM]PF₆@PPSU solid–liquid dual-core microcapsules were incorporated into microtextures on the rake face, thereby constructing a microcapsule–microtexture composite self-lubricating tool system. Cutting experiments were conducted to systematically investigate the effects of microcapsule content and microtexture edge spacing on the cutting performance of the tools. The results indicate that optimal cutting performance is achieved at a microcapsule content of 20 wt.% and an edge spacing of 100 μm. Under these conditions, the tool embedded with dual-core microcapsules exhibited a main cutting force as low as 88.6 N, a cutting temperature of 237.8 °C, a machined surface roughness of 1.08 μm, and an extended cutting distance of 9497 m. Compared with the unlubricated tool, the main cutting force, axial force, and radial force decreased by approximately 40%, 45.6%, and 47.4%, respectively; the cutting temperature decreased by 43.9%, and the surface roughness was reduced by 24.5%. Micromorphological analysis reveals that, under optimal conditions, the TC2 tool effectively mitigates adhesive and delamination wear on both the rake and flank faces. Energy-dispersive spectroscopy (EDS) analysis demonstrates that the rupture of microcapsules releases two core materials, forming a stable solid–liquid biphasic lubricating film that effectively suppresses adhesive and abrasive wear. Full article

Wire arc additive manufacturing (WAAM) demands aluminum feedstock with tightly controlled diameter and high surface integrity. Adding hard TiC nanoparticles is a viable route to enhance the mechanical response of Al wires, yet the associated increase in contact severity can accelerate the wear of wire processing tools, particularly cemented carbide dies. This study elucidates the unidirectional sliding interaction between a TiC reinforced Al WAAM wire, and a WC/Co die material containing 5 wt% Co, using a modified scratch testing configuration under dry and lubricated conditions. Two dominant mechanisms are identified: (i) aluminum adhesion on the die surface and (ii) third body abrasion arising from WC particle pull out, promoted by preferential degradation of the cobalt binder. The presence of TiC nanoparticles reduces both the extent of Al transfer and the intensity of third body abrasion, an effect that is further amplified by lubrication. Consistently, lubrication also diminishes surface defects on the wire after sliding. The results provide a mechanistic basis to balance wire strengthening with tool life and highlight practical levers—nanoparticle reinforcement and lubrication strategies—for mitigating die damage while preserving WAAM wire surface quality. Full article

Cermet tools possess favorable mechanical and tribological properties and are widely adopted for machining hard-to-cut materials. However, their performance can further be enhanced with different cooling and lubrication techniques. In this study, the tool wear mechanisms of cermet tools during hard turning of AISI 4340 alloy steel are investigated under dry and minimum quantity lubrication (MQL) environments to identify the prevalent causes of tool failure through comprehensive analysis of tool wear progression, chip temperature, and chip morphological analysis. The results revealed that the application of MQL exhibited prolonged and stable steady-state tool wear progression with retained cutting-edge geometry, thus demonstrated 30.27% improvement in tool life compared to dry cutting. On the contrary, a rapid increase in tool wear due to excessive friction and higher thermal load is noticed with dry cutting in the absence of any heat-dissipating medium. Chip temperature measurements supported these observations, as chip temperature increases sharply from 358 °C (with a fresh tool) to about 1090 °C (with a worn tool) under a dry environment. Conversely, with MQL, the corresponding increase was in the range between 294 °C and 843 °C with a fresh and worn tool, respectively. Chip analysis revealed a serrated type of chip morphology. Dry cutting exhibited intensified feed marks, indicative of severe tool–chip friction, whereas MQL demonstrated smoother morphology with closely spaced saw-tooth patterns. Tool wear mechanisms indicate abrasion, adhesion, and edge chipping as dominant wear mechanisms under both environments; however, in the absence of any lubricant, these mechanisms were more intensified with higher crater formation. Full article

This study examines the effect of tool rotational speed on the microstructure and dry sliding wear behavior of brass–tungsten (brass/W) surface composites fabricated through friction stir processing. Microstructural analysis confirmed a uniform distribution of tungsten particles within the stir zone, with no observable clustering. Improved properties were achieved at a lower traverse speed of 40 mm/min combined with a higher rotational speed of 1168 rpm, which promoted finer grain formation (~4 µm) and better particle dispersion. An increase in rotational speed led to a corresponding rise in hardness, from 142 HV at 832 rpm to 165 HV at 1168 rpm. In terms of wear behavior, the sample processed at lower rotational speed exhibited abrasive and micro-cutting wear, whereas the sample processed at higher rotational speed predominantly showed adhesive wear. Full article

We report on tool wear and surface roughness for hybrid additive manufacturing of Inconel 718 components. The hybrid additive manufacturing comprises laser powder bed fusion (PBF-LB/M) and an in situ high-speed milling process, i.e., milling is performed within the powderbed, which deteriorates the surface quality by additionally occurring wear mechanisms. Therefore, in this comparative study milling path suction is used to improve tool wear characteristics and thus enhance surface quality. As a result, we quantify the improvement of the maximum tool life according to the flank wear, which is granted by the milling path suction. Additionally, the dominant wear mechanisms are investigated, revealing adherence and abrasion as the main contributing factors to wear. Furthermore, surface analysis shows an improvement of surface quality by the use of the milling path suction. Specifically, a reduction in surface roughness of hybrid manufactured Inconel 718 components down to a minimum of $Ra$ = 0.55 μm is highlighted. Full article

Tool wear remains a critical limiting factor in machining performance, particularly in dry cutting conditions where friction and tribological interactions dominate. This study investigates the influence of a 5–8 μm PVD-deposited TiN coating on the wear behavior of high-speed steel (HSS) end mills during milling of three representative wood species (oak, beech, and fir). A spatially resolved wear evaluation methodology was employed, based on ten measurement points distributed along a 20 mm active cutting edge, enabling simultaneous assessment of mean wear and maximum localized wear (Umax). A factorial experimental design combining material type and feed rate (1500–2500 mm/min) was analyzed using two-way ANOVA with effect size quantification (η²). The results reveal a statistically significant reduction in mean wear for TiN-coated tools (F = 7.46, p = 0.0195, η² = 0.34), corresponding to an average decrease of approximately 46% compared to uncoated tools. Maximum wear was influenced by both coating (F = 14.73, p = 0.0028, η² = 0.399) and material (F = 4.37, p = 0.040, η² = 0.237). The experimental findings are interpreted through a tribological framework, indicating a transition from abrasion- and micro-chipping-dominated degradation in uncoated tools to a controlled wear regime in TiN-coated tools, characterized by reduced asperity penetration, delayed crack initiation, and limited tribochemical interactions. These results demonstrate that coating effects dominate global wear evolution, while material properties influence localized degradation. The proposed combined experimental–statistical–mechanistic approach provides a robust framework for understanding and optimizing tool performance in dry machining environments. Full article

The present study investigates the surface integrity and flank wear of uncoated cermet inserts during dry turning of AISI 304 stainless steel. Three-dimensional metrology techniques were employed to assess both surface roughness and cutting-tool flank wear. Cutting speed and feed rate were the process parameters varied in the experiments. Both parameters exhibited a significant influence on the final surface quality. Specifically, increasing the cutting speed resulted in a deterioration of the surface finish under the evaluated conditions. Considering an average flank wear (VBB) of 0.1 mm as the tool life criterion, tool lives of 15 min and 9 min were achieved at cutting speeds of 120 m/min (lowest level) and 150 m/min (highest level), respectively. At lower cutting speeds, abrasive wear and adhesion were the predominant wear mechanisms, whereas chipping and diffusion became more pronounced at the higher cutting speed. The dry turning of AISI 304 stainless steel with uncoated cermet inserts proved viable in terms of sustainability and surface integrity; however, effective chip evacuation remains a critical concern. The use of compressed air or minimum quantity lubrication (MQL) may help mitigate this issue. Full article

Dental wear provides valuable evidence for reconstructing past human behaviour, including diet abrasiveness and non-masticatory activities such as the use of teeth as a “third hand”. This study investigates activity-induced dental modifications (AIDMs) in two adult human skeletons recovered from a 15th–19th-century necropolis at the St. Athanasius Church in Niculițel (Tulcea County, Romania). Dental remains and associated dental calculus were examined using low- and high-magnification optical microscopy and scanning electron microscopy (SEM). Well-polished grooves with parallel striations were identified on the incisor crowns, consistent with repetitive extra-masticatory activities related to fibre drafting during spinning and textile production. Dental calculus analysis revealed the presence of plant and animal fibres, providing direct micro-contextual evidence for textile-related practices. These results offer new insights into the use of teeth as tools and contribute to the reconstruction of textile-related craft activities during the Ottoman and early modern periods in southeastern Europe. Full article

Titanium carbonitride (TiCN) has emerged as a significant material, bridging the gap between traditional binary carbides and nitrides to offer a comprehensive combination of superior mechanical strength, exceptional wear resistance, and excellent chemical stability. This review comprehensively surveys the research progress in TiCN materials, tracing their evolution from coating technologies to the forefront of nanoparticle synthesis and application. We begin by examining conventional physical vapor deposition (PVD) and chemical vapor deposition (CVD) techniques for producing TiCN coatings, highlighting their roles in extending the service life of cutting tools, forming tools, and components subjected to abrasive and corrosive environments. The discussion then shifts to the synthesis of TiCN nanoparticles, covering advanced methods such as laser ablation, solvothermal processes, and precursor pyrolysis, with a critical analysis of their advantages and limitations in controlling particle size, morphology, and stoichiometry. The enhancement in the nanoscale formulation of TiCN on mechanical properties including hardness, fracture toughness, and load-bearing capacity is through grain refinement and nanocomposite strengthening mechanisms. Furthermore, the review delves into the corrosion protection mechanisms imparted by TiCN, whether as a dense coating/film or as a reinforcing nanophase in composite matrices. Finally, we identify current challenges in scalable synthesis and phase stability, and propose future directions, such as the development of multi-functional TiCN-based nanocomposites and hybrid coating architectures for next-generation applications in extreme environments. This work aims to provide a structured reference that connects fundamental material properties with applied technological advancements across the micro- to nanoscale. Full article

In this study, the material removal behavior of abrasive brushing tools on zirconia-toughened alumina cutting edges is experimentally investigated. Three different brushing tool specifications with bonded diamond grains are tested, varying in filament diameter, filament length, and grain size. Using an industrial robot setup, structured brushing experiments are performed on the cutting edges of indexable inserts under controlled variations of key process parameters, such as brushing velocity v_b, axial feed rate v_fa, infeed a_e, and contact angle φ. The resulting edge rounding is quantified using three-dimensional optical scanning. Key metrics, such as edge radius r_β and form factor K, are evaluated to assess the suitability of abrasive brushing processes for the preparation of ceramic cutting edges. The results showed that the edge radius ranged from r_β = 20 to 80 µm, while the form factor varied from K = 1 to 3. The brushing velocity v_b and axial feed rate v_fa were identified as the primary parameters influencing the rounding radius r_β, whereas the infeed a_e was the dominant parameter affecting the form factor K. While cutting edge preparation of metal and carbide tools is well studied, little research exists on abrasive brushing of zirconia-toughened alumina (ZTA) cutting inserts. Because ZTA behaves differently from metals, this study systematically investigates robot-assisted abrasive brushing of ZTA, analyzing how key process parameters affect edge radius, shape, and uniformity along the cutting edge. Full article

Due to recent developments across the aerospace, power generation and defense sectors, the demand for flat-surfaced components with extremely high surface quality is rapidly increasing. In this regard, although abrasive machining processes often produce fine, contaminated swarf that is frequently relegated to landfill, these processes remain critical for the engineering sector. Motivated by increasing sustainability and circularity pressures, this narrative review examines the current state of the art in recycling and repurposing the chips, tooling and cutting fluids that are typically generated or consumed within grinding processes. In doing so, a number of methodologies for extracting useful materials from swarf slurries are identified, including pyrometallurgical routes (applied successfully to Ni–Co alloys, for example), hydrometallurgical strategies (e.g., iron leaching from ferrous swarf) and, in the case of non-metallic materials such as CMCs and CFRPs, chemical processing methods. Various means of separating abrasive constituents and removing contaminants from grinding swarf are also highlighted, within which centrifugation and heat treatment are found to be particularly useful for non-ferrous materials such as titanium alloys or composites, whilst ferrous materials are largely magnetically separated. Prospective applications for spent abrasive tooling are also explored, including reuse as shot, waterjet machining feedstock, road surface additives, or mortar in the context of cement production. Likewise, heat- and radiation-based strategies for prolonging cutting-fluid life are highlighted, and their associated sustainability benefits and limitations discussed, despite ultimate disposal still being relegated to fuel usage or landfill. Ultimately, this review identifies the scarcity of grinding-specific recycling process data and highlights the need for robust, publicly accessible recycling strategies for novel material systems. Full article

During the extrusion of novel nickel-based powder superalloy bars, the die is subjected to elevated temperatures, high pressures, and severe friction, which readily lead to abrasive wear and thermal-fatigue damage. These failures deteriorate the quality of the extruded products and significantly shorten the service life of the die. Frequent repair and replacement of the tooling ultimately increase the overall manufacturing cost. This study investigates the friction and wear behavior of H13 and 5CrNiMo hot-work tool steels under extreme transient high-temperature conditions by combining finite element simulation with tribological testing. The temperature and stress distributions of the billet and key tooling components during extrusion were analyzed using DEFORM-3D. In addition, pin-on-disk friction and wear tests were conducted at 1000 °C to examine the friction coefficient, wear morphology, and subsurface grain structural evolution under various loading conditions. The results show that the extrusion die and die holder experience the highest loads and most severe wear during the extrusion process. For 5CrNiMo tool steel, the wear mechanism under low loads is dominated by mild abrasive wear and oxidative wear, whereas increasing the load causes a transition toward adhesive wear and severe oxidative wear. In contrast, H13 tool steel exhibits a transition from abrasive wear to severe oxidative wear. In 5CrNiMo steel, friction-induced recrystallization, grain refinement, and softening lead to the formation of a mechanically mixed layer, which, together with a stable third-body layer, markedly reduces and stabilizes the friction coefficient. H13 steel, however, undergoes surface strain localization and spalling, resulting in persistent fluctuations in the friction coefficient. The toughness and adhesion of the oxide film govern the differences in wear mechanisms between the two steels. Owing to its higher Cr, V, and Mo contents, H13 forms a dense but highly brittle oxide scale dominated by Cr and Fe oxides at 1000 °C. This oxide layer readily cracks and delaminates under frictional shear and thermal cycling. The repeated spalling exposes the fresh surface to further oxidation, accompanied by recurrent adhesion–delamination cycles. Consequently, the subsurface undergoes alternating intense shear and transient load variations, leading to localized dislocation accumulation and cracking, which suppresses the progression of continuous recrystallization. Full article

Plastic waste is a global issue due to the popularity of the product. Over time, plastic degrades into smaller particles known as microplastics and becomes harder to deal with as it easily disperses and can be missed by physical catches. Conventional degradation involves environmental forces like ultraviolet (UV) light, water, temperature, and physical abrasion. However, there is increasing interest in microbial plastic degradation, which could positively impact the transformation of (micro)plastics in various environmental matrices. Most of the available research has focused on bacterial degradation, but there is mounting evidence on the impact of fungal degradation. This review discusses conventional and bacterial degradation, then discusses the advantages of fungal involvement in the degradation of microplastics. Biodegradation enhanced by fungal enzymes is a valuable tool that could greatly improve the removal of these microplastic pollutants from the environment. Due to some biochemical complexities, fungi are naturally omnipresent in marine and terrestrial environments under all sorts of climates. Fungi could thrive by themselves or in association with other microorganisms, which could also be applied in non-biotic plastic degradation processes as an alternative to other forms of plastic management in the environment. Full article

This paper investigates the applicability of plasma transferred arc (PTA) cladding for extending the service life of biomass shredder tools. The study evaluates the possibility of replacing Hardox 500 steel with a lower-cost structural steel S355J2 whose functional surfaces are modified by PTA cladding. Three commercially available powder fillers were examined: CoCrWNi (PL1), FeCoCrSi (PL2), and NiCrMoFeCuBSi (PL3). The quality and performance of the cladded layers were assessed through hardness measurements, microstructural analysis using SEM and EDX, and tribological testing focused on abrasive and adhesive wear at room temperature. The results showed that the PL1 cladding achieved the highest surface hardness, reaching up to 602 HV0.1, due to the presence of hard carbide phases. In contrast, the PL2 cladding exhibited the best resistance to abrasive wear, demonstrating the lowest mass loss for both as-deposited and machined surfaces. The PL3 cladding showed intermediate performance in terms of wear resistance. Overall, the findings indicate that PTA cladding using an FeCoCrSi-based filler on an S355J2 substrate represents a promising and cost-effective alternative to Hardox 500 for biomass shredder applications. Full article