Search Results (119)

During the service life of automotive panel stamping dies, the surface is often subjected to high loads and repeated friction, resulting in excessive wear. This leads to die failure, reduced machining accuracy, and decreased production efficiency. To enhance the anti-friction and wear-resistant performance of die steel surfaces, this study introduces the concept of biomimetic engineering in surface science. By mimicking microstructural configurations found in nature with outstanding wear resistance, biomimetic functional surfaces were designed and fabricated. Specifically, quadrilateral dimples inspired by the back of dung beetles, pentagonal scales from armadillo skin, and hexagonal scales from the belly of desert vipers were selected as biological prototypes. These surface textures were fabricated on Cr12MoV die steel using high-speed ball-end milling. Finite element simulations and dry sliding wear tests were conducted to systematically investigate the tribological behavior of surfaces with different dimple geometries. The results showed that the quadrilateral dimple surface derived from the dung beetle exhibited the best performance in reducing friction and wear. Furthermore, the milling parameters for this surface were optimized using response surface methodology. After optimization, the friction coefficient was reduced by 21.3%, and the wear volume decreased by 38.6% compared to a smooth surface. This study confirms the feasibility of fabricating biomimetic functional surfaces via high-speed ball-end milling and establishes an integrated surface engineering approach combining biomimetic design, efficient manufacturing, and parameter optimization. The results provide both theoretical and methodological support for improving the service life and surface performance of large automotive panel dies. Full article

The paper deals with the issue of obtaining iron-sulfur-containing binders through their mechanochemical treatment using mutual neutralization and detoxification structure formation, and the curing stage of arbolite concrete composites based on industrial waste under long-term loading were also studied. Due to abrasion and impact, the mutual neutralization and detoxification methods of industrial waste toxic components through their mechanochemical treatment on the structures of ball mill LShM-750, were used to obtain iron-sulfur-containing binders. Pyrite cinders acted as oxidizing agents, and elementary technical sulfur had reduced properties. To determine the rate of creep strain growth, the load on prism samples was applied in the form of specially made spring units at stress levels of 0.15 R_bn, 0.44 R_bn, and 0.74 R_bn, where R_bn is the prism strength of iron-sulfur-containing arbolite concrete in compression. The strength and fracture formations of lightweight iron-sulfur concrete were studied using strain gauge apparatus and depth strain gauges glued on shredded reed fibers using adhesive, installed before concreting. It was revealed that the introduction of a sulfur additive within the range from 10 to 13% increases the compressive strength of iron-sulfur-containing concrete composites prepared with that of mortars at a water/solid ratio equal to 0.385 in wet and dry states. It is found that the deformations occurring under applied load growth proportionally to it, and deviation from this regularity was observed for lightweight iron-sulfur-containing concrete only at high compressive stresses. It was also proved that the destruction of iron-sulfur-containing arbolite occurs sequentially. First, the destruction of the mortar component is observed, and then the organic aggregate in the form of crushed reed fiber is destroyed. It was confirmed that arbolite concrete composite can be used as an effective wall material for civil engineering structure, especially in seismic regions of Kazakhstan. Full article

This study investigates the applicability and advantages of using additive manufacturing to moderate heat generation in dry milling. Grinding medium balls of different sizes were designed and fabricated using computer-aided design (CAD) and a stereolithographic 3D printer. Milling processes with particle size distribution and warmup measurements were employed with the printed medium balls. The results were compared with the measurements executed with conventional stainless-steel balls. Differential scanning calorimetry (DSC) was employed to evaluate the effect of the warmup of the system during the milling process. A two-variable, three-level experimental design was used for the measurements. We selected two grinding parameters considered critical: speed and time. The effect of these two independent variables on heating was examined. The results show that if printed balls are applied with the same total mass as that of metal balls, the particle size reduction is increased. The greater the number of balls used, the greater the particle size reduction. In this process, where additively manufactured milling bodies were used, the temperature of the system increased by less than when stainless-steel balls were used. The use of 3D-printed medium balls demonstrated beneficial warmup behavior. Full article

The artisanal production of paints using inorganic pigments from the Cusco Valley is considered a sustainable alternative to the use of synthetic industrial paints. This approach not only helps reduce the environmental footprint associated with the use of volatile organic compounds (VOCs) but also utilizes local materials. The present study evaluates the physical and mechanical properties of paints obtained from natural pigments through standardized tests based on the American ASTM standards, focusing on adhesion (ASTM D-3359), drying time (ASTM D-1640), surface hardness (ASTM D-3363), and the performance of the paints when exposed to the environmental factors of Cusco (under real conditions). In this regard, the pigments were extracted from traditional quarries and processed through the sedimentation method (MS) and ball milling (MG). The produced paints were formulated with the addition of polyvinyl acetate (PVA) as a binder and water as a solvent and were applied to standardized panels. The results show that all samples meet the requirements of the technical parameters, demonstrating good adhesion, appropriate drying times, and acceptable hardness for architectural coatings, Chromatic variations (ΔE*) were recorded depending on the processing method and the level of environmental exposure, with paints containing ground pigments (MG) being more resistant to fading. This study concludes that these artisanal formulations represent a technically viable and culturally relevant alternative to industrial coatings, especially in contexts of heritage restoration or sustainable architecture. Full article

Effective grinding of residual agricultural materials helps to improve yield in the production of chemical compounds through hydrothermal technology. Milling pretreatment has different types of pre-treatment where ball mills, roller mills, and finally, the knife mill stand out. The knife mill being a mill with continuous processing, its multiple benefits and contributions highlight the knife milling process; however, it is a process that is generally carried out with dry biomass that generates extra processing of the biomass before grinding, implying longer times and wear than other equipment. This work presents the design of a knife mill with an adaptation of free convection drying as a joint process of knife milling and drying. The design is based on lignocellulosic biomass, and the knife milling results are presented for two biomasses: peapods and coffee cherries. The knife mill is designed with a motor, a housing with an integrated drive system, followed by a knife system and a feeding system with a housing and finally the free convection drying system achieving particle sizes in these biomasses smaller than 30 mm, depending on the time processed. The data demonstrate the significant impact of particle size on the yields of various platform chemicals obtained from coffee cherry and peapod waste biomass. For coffee cherry biomass, smaller particle sizes, especially 0.5 mm, result in higher total yields compared to larger sizes while for peapod biomass at the smallest particle size of 0.5 mm, the total yield is the highest, at 45.13%, with notable contributions from sugar (15.63%) and formic acid (19.14%). Full article

A high-activity, low-cost, and easy-to-prepare monolithic catalyst is crucial for the industrial catalytic combustion of volatile organic compounds (VOCs) in a cost-effective manner. In this study, a highly efficient monolithic catalyst, designated as 4GM/COR, was developed by loading 4% graphene-doped α-MnO₂ (4GM) catalyst onto pre-etched cordierite (COR) blocks using a straightforward “ball-milling-assisted impregnation” method. The anchoring force of the cordierite pores, generated through oxalic acid etching, enables the uniform and robust loading of powdered 4GM onto COR, preventing detachment under high temperatures or high gas flow rates. The loading rate, specific surface area, and concentrations of Mn³⁺ and surface-lattice and absorbed oxygen species in the monolithic catalyst increase with impregnation times from 2 to 4, indicating that catalytic activity is optimized through repeated impregnation. Catalytic performance tests demonstrated that the 4-4GM/COR exhibited the highest activity, achieving 90% degradation of toluene at 200 °C under both dry and humid (relative humidity is 85%) conditions. Furthermore, the 4-4GM/COR maintains high catalytic stability and activity even at a large GHSV of 6000 h⁻¹. To conclude, the 4-4GM/COR monolithic catalyst developed in this study not only represents a promising option for industrial applications but also serves as an important reference for the synthesis of monolithic catalysts. Full article

A Co-based composite powder, doped with rare earth Y, was crafted through a series of processes involving spray-drying, calcination, and low-temperature reduction. This powder was then blended with tungsten carbide (WC) powder and subjected to ball-milling. The resultant mixture was consolidated into a robust Y-doped WC-Co cemented carbide via the process of spark plasma sintering (SPS). The outcomes demonstrate that incorporating rare earth Y into Co powder to form a Co-Y₂O₃ composite powder via an innovative spray-drying, calcination, and low-temperature reduction process ensures uniform distribution of Y in the Co matrix. This uniform distribution refines the alloy’s grain structure during subsequent sintering, leading to enhanced performance. Within a specific range, increasing the Y content improves the overall alloy properties. It is notable that at a Y content of 1.5%, the alloy’s properties reach a state of stability, characterized by a density of 98.91%, a maximum hardness of 2120 Hv₃₀, and a fracture toughness of 8.24 MPa·m^1/2. The novel Y incorporation method has been shown to enhance the strength of the binder phase, impede the growth of WC grains, and thereby lead to a substantial improvement in the overall performance of the cemented carbide. Full article

Fumed silica, a nanomaterial with a high specific surface area, excellent chemical stability, and electrical insulation, serves as an effective filler for rubber compounding. Compared to traditional carbon black, silica (SiO₂), the main component of fumed silica, improves the hardness and tear resistance of tread rubber, making it a viable substitute in some formulations. However, silica-filled compounds generally exhibit lower tensile properties and abrasion resistance than carbon black. Fumed silica, with its higher structural integrity, provides additional reinforcement points within natural rubber matrices, enhancing tensile strength and abrasion resistance. Studies demonstrate that replacing carbon black with an equivalent amount of fumed silica as the primary filler significantly improves tread rubber’s hardness (by 20%) and 300% tensile modulus (by 14%) while also reducing rolling resistance and enhancing wet skid performance. Fumed silica’s large specific surface area and low density (10–15% of conventional silica) make it challenging to use directly as a tread rubber filler due to dust formation and prolonged mixing times. This study developed a process combining fumed silica with deionized water, followed by drying and ball milling. This treatment reduces the material’s volume, forming a cohesive gel that, upon processing, minimizes dust and significantly decreases mixing time and difficulty. The interaction between the hydroxyl (–OH) groups on the surface of fumed silica and water molecules likely results in hydrated silica. This interaction enhances surface polarity and forms a hydration layer, improving the hydrophilicity and dispersion of fumed silica in rubber matrices. This reduces the shear modulus difference (ΔG′) between low and high strain, maintaining a consistent elastic modulus over a wide strain range. Such stability enables rubber to perform better under dynamic loads or in complex working conditions. The experimental results demonstrate that the hydration–ball milling process enhances the tensile strength of vulcanizates, improves the dispersion of fumed silica in rubber, strengthens the filler network, boosts dynamic performance, and enhances the wet skid resistance of tread rubber. Full article

This study investigates the influence of graphene nanoplatelets (GNPs) and the formation of nanosized Al₄C₃ on the tribological performance of hot extruded aluminum-based nanocomposites. Al/GNP nanocomposites with varying GNP contents (0, 0.1, 0.5, and 1.1 wt.%) were fabricated through powder metallurgy, including ball milling, compaction, and hot extrusion at 500 °C, which was designed to facilitate the formation of nanosized carbides during the extrusion process. The effect of GNPs and nanosized carbides on the tribological properties of the composites was evaluated using dry friction pin-on-disk tests to assess wear resistance and the coefficient of friction (COF). Microstructural analyses using scanning electron microscopy and energy-dispersive X-ray spectroscopy confirmed the uniform distribution of GNPs and the formation of nanosized Al₄C₃ in the samples. Incorporating 0.1 wt.% GNPs resulted in the lowest wear mass loss (1.40 mg) while maintaining a stable COF (0.52), attributed to enhanced lubrication and load transfer. Although a higher GNP content (1.1 wt.%) resulted in increased wear due to agglomeration, the nanocomposite still demonstrated superior wear resistance compared to the unreinforced aluminum matrix. These findings underscore the potential of combining nanotechnology with precise processing techniques to enhance the wear and friction properties of aluminum-based composites. Full article

In the present study, the possibility of synthesizing high-entropy hexacationic layered double hydroxide MgCoNi/AlFeY via mechanochemical synthesis was demonstrated. In the synthesis, the activation rate, activation time, and NaOH amount were varied. The main synthesis stages were as follows: the mechanical activation of salts, NaOH addition, washing with distilled water before achieving neutral pH, and drying at 100 °C. The stage of aging in aqueous solution was omitted. During the synthesis, the activation conditions were varied, the activation time ranged from 1 to 120 min, the rotation speed of the ball mill was changed from 200 to 400 rpm, and the ratio values of sodium hydroxide weight to the mass of cations were specified as 1.0, 1.5, or 2.0. The samples were characterized by X-ray diffraction, transmission electron microscopy, scanning electron microscopy combined with an energy-dispersive analyzer, thermal analysis, Fourier transform infrared spectroscopy, and Raman spectroscopy. The following optimal synthesis conditions for obtaining single-phase sample were determined: an activation rate of 300 rpm, an activation time of 30 min, and an m(cation)-to-m(NaOH) ratio of 1:1. Full article

Background/Objectives: Curcumin is well known for its great anti-inflammatory and antioxidant efficacy, representing a potential strategy for the treatment of respiratory disorders. However, several drawbacks, such as chemical instability, poor water solubility and rapid metabolism, result in low bioavailability, limiting its clinical applications. In this study, curcumin nanocrystals were incorporated into mannitol-based microparticles to obtain an inhalable dry powder. Methods: A curcumin nanosuspension was produced by wet-ball media milling and thoroughly characterized. Spray drying was then used to produce mannitol microparticles incorporating curcumin nanocrystals. In vitro release/dissolution tests were carried out in simulated lung fluids, and the aerosolization properties were evaluated using a Next-Generation Impactor (NGI, Apparatus E Ph. Eu.). Results: The incorporation of curcumin nanocrystals into mannitol-based microparticles influenced their morphological properties, such as geometric diameters, and flowability. Despite these changes, nebulization studies confirmed optimal MMAD values (<5 µm), while multi-step dissolution/release studies evidenced the influence of mannitol. Conclusions: The developed curcumin nanocrystals-loaded mannitol microparticles show promise as an inhalable treatment for respiratory diseases, combining effective aerodynamic properties with controlled drug release. Full article

Background/Objectives: This study aims to broaden the knowledge on co-amorphous phospholipid systems (CAPSs) by exploring the formation of CAPSs with a broader range of poorly water-soluble drugs, celecoxib (CCX), furosemide (FUR), nilotinib (NIL), and ritonavir (RIT), combined with amphiphilic phospholipids (PLs), including soybean phosphatidylcholine (SPC), hydrogenated phosphatidylcholine (HPC), and mono-acyl phosphatidylcholine (MAPC). Methods: The CAPSs were initially prepared at equimolar drug-to-phospholipid (PL) ratios by mechano-chemical activation-based, melt-based, and solvent-based preparation methods, i.e., ball milling (BM), quench cooling (QC), and solvent evaporation (SE), respectively. The solid state of the product was characterized by X-ray powder diffraction (XRPD), polarized light microscopy (PLM), and differential scanning calorimetry (DSC). The long-term physical stability of the CAPSs was investigated at room temperature under dry conditions (0% RH) and at 75% RH. The dissolution behavior of the CCX CAPS and RIT CAPS was studied. Results: Our findings indicate that SE consistently prepared CAPSs for CCX-PLs, FUR-PLs, and RIT-PLs, whereas the QC method could only form CAPSs for RIT-PLs, CCX-SPC, and CCX-MAPC. In contrast, the BM method failed to produce CAPSs, but all drugs alone could be fully amorphized. While the stability of each drug varied depending on the PLs used, the SE CAPS consistently demonstrated the highest stability by a significant margin. Initially, a 1:1 molar ratio was used for screening all systems, though the optimal molar ratio for drug stability remained uncertain. To address this, various molar ratios were investigated to determine the ratio yielding the highest amorphous drug stability. Our results indicate that all systems remained physically stable at a 1.5:1 ratio and with excess of PL. Furthermore, the CAPS formed by the SE significantly improves the dissolution behavior of CCX and RIT, whereas the PLs provide a slight precipitation inhibition for supersaturated CCX and RIT. Conclusions: These findings support the use of a 1:1 molar ratio in screening processes and suggest that CAPSs can be effectively prepared with relatively high drug loads compared to traditional drug–polymer systems. Furthermore, the study highlights the critical role of drug selection, the preparation method, and the PL type in developing stable and effective CAPSs. Full article

Five carbide powders, TiC, Cr₃C₂, ZrC, NbC and SiC, were selected as raw materials and mixed by dry or wet milling. Then (TiCrZrNb)C₄-SiC multiphase ceramics were successfully prepared by spark plasma sintering (SPS) at 1900 °C, using D-HECs-1900 (dry milling method) and W-HECs-1900 (wet milling method), respectively. In this study, the effects of the ball milling method on the microstructure and mechanical properties of the multiphase high-entropy ceramics were systematically investigated. Compared to D-HECs-1900, W-HECs-1900 has a more uniform elemental distribution and smaller grain size, with an average grain size of 1.8 μm, a higher Vickers hardness HV_0.1 = 2178.41 kg/mm² and a higher fracture toughness of K_IC = 4.42 MPa·m^1/2. W-HECs-1900 also shows better wear resistance with a wear rate 1.01 × 10⁻⁸ mm³·N⁻¹·m⁻¹. The oxide friction layer formed during friction is beneficial for reducing frictional wear, making W-HECs-1900 a potential wear-resistant material. Full article

Silicon anodes present a high theoretical capacity of 4200 mAh/g, positioning them as strong contenders for improving the performance of lithium-ion batteries. Despite their potential, the practical application of Si anodes is constrained by their significant volumetric expansion (up to 400%) during lithiation/delithiation, which leads to mechanical degradation and loss of electrical contact. This issue contributes to poor cycling stability and hinders their commercial viability, and various silicon–carbon composite fabrication methods have been explored to mitigate these challenges. This review covers key techniques, including ball milling, spray drying, pyrolysis, chemical vapor deposition (CVD), and mechanofusion. Each method has unique benefits; ball milling and spray drying are effective for creating homogeneous composites, whereas pyrolysis and CVD offer high-quality coatings that enhance the mechanical stability of silicon anodes. Mechanofusion has been highlighted for its ability to integrate silicon with carbon materials, showing the potential for further optimization. In light of these advancements, future research should focus on refining these techniques to enhance the stability and performance of Si-based anodes. The optimization of the compounding process has the potential to enhance the performance of silicon anodes by addressing the significant volume change and low conductivity, while simultaneously addressing cost-related concerns. Full article

Carbon-based materials with excellent catalytic activity provide new ideas for the development of magnesium-based hydrogen storage. C-H bonding interactions may play a key role in performance improvement. In this work, we comprehensively compare the magnesium-carbon cloth composites (CC) prepared by method of dry ball milling and wet impregnation. The results were that the hydrogen release activation energy (E_a) of MgH₂@CC composites prepared by wet immersion method was 175.1 ± 19.5 kJ·mol⁻¹, which was lower than that of pure MgH₂ (E_a = 213.9 ± 6.4 kJ·mol⁻¹), and the activation energy of MgH₂-CC composites prepared by ball milling method was 137.3 ± 8.7 kJ·mol⁻¹, which provided better results. The kinetic enhancement should be attributed to C-H interactions. The presence of carbon carriers and electron transfer to reduce the activation energy of Mg-H bond fracture. These results will provide further insights into the promotion of hydrogen ab-/desorption from metal hydrides. Full article