Search Results (4,765)

The growing need for lightweight, multifunctional, and high-performance structures in the automotive, aerospace, electronics, and medical industries has driven the development of advanced joining technologies for polymers and metal-polymer combinations. Among these, ultrasonic welding (USW) and friction stir spot welding (FSSW) have emerged as promising solid-state techniques capable of producing reliable joints with minimal thermal degradation and enhanced interfacial bonding. This review focuses on recent developments in USW and FSSW of thermoplastics, fiber-reinforced composites, and hybrid metal–polymer systems, with a particular emphasis on process mechanics, microstructural evolution, and joint performance. The mechanisms of heat generation, material flow behavior, and consolidation are discussed in relation to key process parameters, including applied pressure, rotational speed, vibration amplitude, plunge depth, and dwell time. Microstructural transformations such as polymer chain orientation, recrystallization, interfacial diffusion, and defect formation are analyzed to establish process–structure–property relationships. Mechanical performance metrics, including lap shear strength, fatigue resistance, impact behavior, and environmental durability, are critically compared across different materials and welding methods. Furthermore, recent advances in numerical and thermo-mechanical modeling, in situ process monitoring, and data-driven optimization are discussed to highlight pathways toward predictive and scalable manufacturing. Current industrial applications and existing limitations such as challenges in automation, thickness constraints, and hybrid material compatibility are also evaluated. Finally, key research gaps and future directions are identified to improve joint reliability, sustainability, and broader industrial adoption of advanced solid-state welding technologies. Full article

As a solid-state welding technique, friction stir welding (FSW) has many advantages over conventional fusion welding. Its applications in the manufacturing and joining of parts in aerospace, automotive, and shipbuilding have significantly increased. Friction heat generation is the fundamental driver of the FSW process. It governs material flow, microstructural evolution, mechanical properties, and residual stresses. Understanding the effect of heat generated on the joint quality is essential for process parameter optimization, ensuring defect-free welds and high-quality joints. Thus, evaluating the thermal history of the FSW process is a key requirement for effective analysis. This comprehensive review critically discusses research studies published over the past three decades (1991–2025) that have examined different approaches to predict and measure heat generation in FSW. A total of 136 highly relevant articles were selected from the Scopus database and systematically analyzed. The effects of various welding parameters on heat generation, microstructural evolution, and joints’ mechanical properties have been reported. Different heat generation prediction and measurement techniques, such as analytical models, finite element models (FEM), and experimental methods have been discussed in terms of their feasibility, accuracy, advantages, disadvantages, and cost. The evolution, state of the art of analytical models and FEM over the last three decades are analyzed and future research directions are outlined. Finally, the correlation between process parameters, heat generated, microstructural development, and mechanical performance of the welded joints for various workpiece materials is investigated. This review provides a critical and comparative perspective that highlights the strengths and limitations of each method, offering practical guidance for researchers and industry practitioners. Full article

PEEK coatings have been applied to sliding bearings in marine machinery and equipment, but their low bonding force, poor thermal conductivity and weak oleophilicity result in insufficient anti-adhesive wear performance. To solve this problem, the textured surface of the substrate was fabricated using laser texturing technology to enhance the bonding force. The PEEK coatings were reinforced by introducing oleophilic-modified nano-SiO₂ and graphene. The tribological properties of the PEEK composite coatings were studied using the ball–disc reciprocating friction wear test and Abaqus wear simulation. The results show that the texturing treatment of the substrate surface improves the bonding force of the coating. The addition of nano-SiO₂ and graphene enhances the hardness, thermal conductivity and oleophilicity of the composite coating, which shifts the wear mechanism from adhesive to abrasive. Under dry friction conditions, the composite coating containing 5 wt% SiO₂ and 1 wt% graphene exhibits a low friction coefficient and the lowest wear rate. Under oil lubrication conditions, the composite coating containing 2 wt% graphene shows the lowest friction coefficient and wear rate. In summary, under the load-bearing capacity enhancement of nano-SiO₂ and the thermal conductivity enhancement of graphene, the composite coating exhibits excellent anti-adhesive wear performance. Full article

With increasingly stringent requirements for wear resistance and reliability of functional coatings for heavily loaded friction units, a relevant challenge in materials science is to establish the relationships between the parameters of reactive pulsed magnetron sputtering and the tribo-mechanical properties of TiN/CrN multilayer systems. In this study, TiN/CrN multilayer coatings were deposited by reactive pulsed magnetron sputtering using separate titanium and chromium targets. The effect of the nitrogen flow rate (0.20–0.36 L/h) during chromium sputtering on the structure, phase composition, and mechanical and tribological properties of the coatings was investigated at a fixed nitrogen flow rate of 0.08 L/h for titanium. SEM, EDS, and XRD showed that increasing the nitrogen flow rate leads to a non-monotonic change in coating thickness (2.0–2.6 µm), caused by the transition of the chromium target from the metallic to the poisoned sputtering mode. At low N₂ flow rates, a subnitride Cr₂N phase forms in the structure, whereas at the optimal flow rate of 0.32 L/h the coating consists of stable TiN, CrN, and (Cr_0.5Ti_0.5)N phases. The coating nanohardness was 20–23 GPa and the Young’s modulus was 250–300 GPa. The best tribological performance was achieved at a nitrogen flow rate of 0.32 L/h, coefficient of friction μ ≈ 0.5 and a minimum wear rate of 1 × 10⁻⁵ mm³/(m·N), which correlates with the highest H³/E² value. It is shown that independent control of the CrN layer stoichiometry using separate targets can affect the tribo-mechanical properties of the TiN/CrN multilayer system. Full article

Friction pairs in wet clutches operate under complex conditions, which can cause surface damage and reduce overall clutch reliability. Surface texturing is an established technique for improving the tribological performance of such mechanical interfaces. Inspired by the wet adhesion properties of tree frog foot pads, a bionic regular hexagonal micro-texture was designed on the mating steel plate. A three-dimensional transient computational fluid dynamics (CFD) numerical methodology was developed and rigorously verified via pin-on-disc friction experiments. Subsequently, this verified numerical framework was extrapolated to establish disc-on-disc CFD models. The results demonstrated that the bionic hexagonal micro-texture altered flow field characteristics, increasing the local maximum flow velocity by 7.9% compared to untextured surfaces. Furthermore, the micro-textured grooves expanded the effective area for convective heat transfer and facilitated local fluid exchange, reducing the maximum average bulk temperature by 20.5% and the maximum radial temperature by 20.7%. Adjusting the structural parameters of these micro-textures further regulated the interfacial flow and temperature fields; notably, deeper grooves induced vortices at land region edges, accelerating flow velocity and decreasing the overall radial temperature gradient. This study provides a theoretical reference for enhancing the thermo-hydrodynamic performance of wet clutch friction pairs. Full article

The wear behavior of 3D-printed polylactic acid (PLA) components produced by fused filament fabrication and used as friction elements in aqueous environments was investigated. Despite the growing use of additively manufactured polymers in wet systems, their wear mechanisms under such conditions remain insufficiently understood. Tests were performed under a 29 N load and 30 rpm to simulate low-speed, moderately loaded applications. PolyTerra™ PLA parallelepiped and ring specimens were analyzed through gravimetric wear testing using a Baroid lubricity tester for 135 min. During the first 105 min, both geometries showed similar mass losses, with differences below 10%. In the final stage, the parallelepiped specimen exhibited accelerated wear, while the ring specimen gained mass due to material transfer. The electrical conductivity of the medium increased significantly, from 4.6 to 1846 µS/cm, and pH rose from 7.01 to 8.04. The recovered residue matched total mass loss, and FTIR analysis confirmed the presence of PLA structures, indicating mechanical wear as the dominant process. This study provides experimental insight into the tribological behavior of 3D-printed PLA in water-lubricated conditions. By combining mass loss evaluation and medium property analysis, it improves understanding of wear mechanisms and supports the reliable design of PLA components for aqueous applications. Full article

This study collected 155 sets of test data for granite residual soils from the Fujian–Guangdong region and applied the chi-square test to analyze the distributions of eight common physical and mechanical parameters. Drained triaxial tests were then simulated using the Unified Hardening (UH) model, and a Sobol global sensitivity analysis of model parameters was conducted based on the distributions of soil properties. The results show that natural density and cohesion approximately follow Weibull distributions; void ratio, liquid limit and plastic limit follow lognormal distributions; water content and internal friction angle follow normal distributions; and plasticity index follows a Gumbel distribution. The Sobol analysis indicates that the critical state deviatoric stress mainly depends on the critical state stress ratio (M), the critical state volumetric strain is jointly controlled by M and the slope of the normal compression line (λ). The overall evolution of deviatoric stress mainly depends on M, and the overall evolution of volumetric strain mainly depends on λ, whereas Poisson’s ratio (ν) has little influence on the soil stress–strain response. These findings provide references for parameter selection and numerical simulation of granite residual soils in the Fujian–Guangdong region. Full article

Under the conditions of laser power of 1500 W, scanning speed of 5 mm/s, spot diameter of 3.5 mm, and powder feeding rate of 10 r/min, this study systematically investigated the influence of different tempering temperatures (200 °C and 600 °C) on the microstructure, friction and wear properties, and corrosion resistance of laser cladding Ni25 coatings, as well as the underlying mechanisms. The phase composition, microstructure, chemical composition, wear resistance, and corrosion resistance of the coatings were characterized and analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), pin-on-disk friction and wear tests, and electrochemical workstations. The results showed that the as-clad coating was composed of γ-Ni supersaturated solid solution and various metastable borides/carbides (such as Cr₃B₄), presenting fine-grained and non-equilibrium features. Tempering at 200 °C mainly achieved stress relaxation, enhancing and shifting the diffraction peaks to the left without changing the phase composition, while tempering at 600 °C drove significant diffusion-type phase transformation, leading to the decomposition of metastable Cr₃B₄ and the precipitation of stable phases such as Ni₂Si, accompanied by grain growth and microstructure coarsening. Friction tests indicated that the coating tempered at 600 °C exhibited the lowest average friction coefficient (0.679) and wear volume (0.0582 mm³) due to stable microstructure and hard phase strengthening, demonstrating the best wear resistance. However, electrochemical tests revealed a “trade-off” effect: the fine-grained microstructure of the as-clad coating, with its uniform composition, had the lowest corrosion current density (8.10 × 10⁻⁵ A/cm²) in 3.5% NaCl solution, showing the best resistance to uniform corrosion, while tempering, especially at 600 °C, caused grain growth, coarsening of the second phase, and micro-galvanic effects, slightly reducing the anodic dissolution resistance and increasing the corrosion current. This study clarified that heat treatment can significantly enhance the mechanical and tribological properties of Ni25 coatings by regulating their transformation from metastable to stable states, but at the potential cost of some corrosion resistance, providing a theoretical basis for optimizing post-treatment processes for different service conditions (wear resistance or corrosion resistance). Full article

This article explores the affective and material complexities of creating arts-based artefacts to explore and represent sexual violence. It does so through attending to both the materials used and the embodied practices of those making them. Focusing on collage, it examines how the physical properties of materials mediate what can be imagined, simultaneously enabling expression and constraining it within familiar visual vocabularies often shaped by state, security, and punitive logics. I argue that materiality operates not only through objects but through the bodies, gestures, and decisions of makers, shaping what can be imagined. Through engagement with Nancy Naples’ (2003) formative work on survivor discourse alongside novel empirical data and cultural texts, the article makes the subtle yet significant contention that attending to these entangled materialities—of both maker and medium—reveals how friction between imaginative intent and material affordances can generate methodological insights, open alternative futures, and disrupt dominant discourses. Full article

Quench–polish–quench (QPQ) of 40Cr steel was performed to improve its tribological properties and corrosion resistance, thereby enhancing the service performance of components such as gears and bearings. The 40Cr steel was treated by QPQ at 580 °C and 620 °C for 90 or 120 min. Optical microscopy (OM, Sunny Group, Ningbo, China), scanning electron microscopy (SEM, Hitachi, Tokyo, Japan), and X-ray diffraction (XRD Rigaku Corporation, Tokyo, Japan) were used to characterise the microstructure and phase constitution. Ball-on-disk tribometry, electrochemical tests, and salt spray tests in 3.5 wt.% NaCl evaluated surface performance. At 580 °C, a composite structure of Fe₃O₄ and ε-Fe₂₋₃N formed on the surface. When the temperature rose to 620 °C, ε-Fe_2–3N gradually transformed into γ′-Fe₄N. Within the scope of this study, the diffusion layer depth exhibits an approximately linear relationship with increasing processing temperature and holding time, and the surface hardness is 67–112% higher than that of the untreated sample. After QPQ treatment, the wear mechanism changed from adhesive wear to abrasive wear. However, under the treatment conditions of 620 °C × 120 min, brittle surface spalling increased roughness, thereby increasing the coefficient of friction. As treatment time increases, nitrogen atoms continue to diffuse outward as Fe₂N transforms to the γ′ phase. This increases the composite layer’s porosity and decreases its corrosion resistance. The best corrosion resistance was observed at 580 °C for 120 min, with a corrosion potential of −0.4325 V, corrosion current density of 1.80 × 10⁻⁶ A·cm⁻², and polarisation resistance of 24,500 Ω. Corrosion performance depends on overall surface integrity. Porosity morphology strongly influences this property. For 40Cr steel, the results show that surface properties are primarily determined by the quality of the compound layer’s microstructure. Specifically, density, phase-composition stability, and defect control are more important than the commonly held view of layer thickness. Full article

With the rapid advancement of exoskeletons and rehabilitation robotics, modern healthcare increasingly demands high dynamic accuracy and reliability from medical devices. However, the dynamic response and durability of mechanical systems are greatly influenced by the inevitable existence of clearances in kinematic joints. Existing studies predominantly focus on simplified planar or spatial mechanisms, offering limited guidance for complex mechanical structures in medical applications. To address this issue, a unified modeling framework is proposed in this study to explore the nonlinear dynamic behavior and wear properties of bionic humanoid rigid mechanisms incorporating revolute joint clearances. A dynamic model that accounts for revolute joint clearances is established, employing the Lankarani–Nikravesh contact model alongside a refined Coulomb friction approach to characterize contact behavior. To characterize the wear progression between the shaft and the bushing, the Archard wear model is employed, while the system’s dynamic equations are formulated using the Lagrange multiplier approach. Systematic simulations are conducted to examine the effects of clearance size, location, and multi-clearance coupling on dynamic response and wear behavior. The results reveal that clearances at the hip joint have the most pronounced impact on system performance, tibiofemoral joint clearances exacerbate precision disturbances, and foot-end clearances considerably undermine system robustness. Increased clearance sizes and the coexistence of multiple clearances aggravate wear and induce more severe nonlinear dynamic phenomena. Phase portraits and Poincaré maps further illustrate that the system may exhibit complex or chaotic behavior under certain conditions. This study offers theoretical insights into performance degradation mechanisms in humanoid robots with joint clearances and introduces a modular “driving–mid–terminal” structure that enhances model generality, enabling its application to exoskeletons and rehabilitation devices for design optimization, service life prediction, and health monitoring. Full article

In this article, four grades of brake pads reinforced with loofah fiber were developed, serving as examples of renewable biomass-based products currently receiving significant attention. In addition to the performance characteristics of the developed brake pads, such as friction coefficient and wear rate, macroscopic and microscopic surface analyses of the worn surfaces were performed. Furthermore, unlike other studies in this field, the effect of biopolymer brake pads on the brake disk surface was also investigated. The average friction coefficients of the brake pads are 0.32, 0.28, 0.28, and 0.27, respectively, and the developed brake pads are within industrial limits of 0.20–0.70. The wear rates were also found to be within industrial limits, with values of 2.6 × 10⁻⁸ cm³/Nm, 1.47 × 10⁻⁸ cm³/Nm, 1.28 × 10⁻⁸ cm³/Nm, and 1.05 × 10⁻⁸ cm³/Nm, respectively. It was determined that the differences in brake disk roughness were also at the desired level for all samples. The desired results in brake friction materials were confirmed by macroscopic and microscopic surface examinations, as well as other properties of the developed samples. Full article

Successive ionic layer adsorption reaction (SILAR) was used to deposit Cu₂O nanosheets on anodized TiO₂ nanotubes at different deposition cycles (4, 8, 15, and 20). Compared to the bare TiO₂ nanotubes, these coatings were investigated for their tribological behavior (friction, wear and energy loss), scanning and transmission electron microscopy (SEM, TEM), X-ray Diffraction (XRD) was used to characterize Cu₂O/TiO₂ coatings to study the effect of number of cycles on the morphological and structural properties of the samples; these characteristics engage in determining the wear mechanisms. The assessment of the coating’s adhesion was determined by the obtained critical loads from the scratch test; the 15 cycles Cu₂O/TiO₂ exhibited higher critical loads, which corresponds to improved adhesion. This sample also showed a low wear volume of 7.5 × 10⁶ µm³ compared to other samples but higher energy loss due to the low shear strength of copper oxide. The friction coefficient, however, decreased from 0.7 for bare TiO₂ nanotubes to 0.48 for 20 cycles Cu₂O/TiO₂ coatings at higher loads, which proves the wear resistance enhancement. Since these coatings will be manufactured for orthopedic and dental implant applications, the corrosion resistance was tested, and the 15 cycles Cu₂O-NPs/TiO₂-NTs where these coatings exhibited the most favorable combination of a low corrosion current density (1.9 × 10⁻⁴ A/cm²) and a noble corrosion potential (−0.3 V/SCE); furthermore, there was a polarization resistance of 2.4 × 10⁴ Ω·cm² and a protection efficiency of 96.7%, indicating significantly enhanced corrosion resistance as opposed to the other samples. Full article

In this study, polysiloxane-containing polyimide (si-PI) composite coatings containing hexagonal boron nitride (hBN) particles of four different sizes and at different contents were prepared, and their mechanical and tribological properties were investigated. The coatings were deposited on steel substrates via dip coating and cured at 160 °C. Their tribological properties were measured using reciprocating sliding tests under unlubricated conditions against a steel ball. The composite coatings containing nano-hBN with the smallest mean primary particle size of 0.05 μm exhibited the lowest wear. Subsequently, coatings containing 1–15 wt% nano-hBN were prepared to examine the effect of filler content. The results showed that the coatings with low nano-hBN contents (1–2 wt%) had relatively high friction coefficients and significantly reduced wear on both the coating and the counterpart. Cross-sectional scanning electron microscopy (SEM) observations revealed that dispersed small hBN aggregates suppress crack propagation through dispersion strengthening. Coatings with low nano-hBN contents (1–2 wt%) also exhibited sufficient electrical insulation. However, as the hBN content increased further, hBN agglomeration was promoted, weakening the crack-propagation suppression effect and increasing wear. These findings indicate that low-content nano-hBN/si-PI composite coatings are promising electrical erosion-resistant coatings for the outer rings of the bearings used in electric vehicle motors. Full article

To develop cosmetic film-forming agents that combine sustainability with functionality, this study synthesized a series of bio-based polyols using epoxidized soybean oil (ESO) as raw material through acid-catalyzed ring-opening reactions. These polyols partially replaced petroleum-based polyols and reacted with isophorone diisocyanate (IPDI). By incorporating β-cyclodextrin (β-CD), a water-based polyurethane (CPS-ESO) was successfully developed that combines degradability with active ingredient delivery capability. Experiments demonstrated that the resulting CPS-M film exhibits excellent water repellency (contact angle 66.7°), mechanical properties (tensile strength 14.21 MPa, elongation at break 229.42%), adhesion (Level 0), and breathability, while displaying controllable degradation behavior under both enzymatic and alkaline hydrolysis conditions. Due to the cavity structure of β-cyclodextrin, this material efficiently loaded resveratrol (RES) at a loading rate of 0.16%. Formulated into a setting spray (F1), the product demonstrated outstanding makeup longevity (lowest ΔE value after water/sweat immersion), anti-friction performance (ΔE value after friction only one-third of the control group), and antioxidant activity (DPPH scavenging rate of 86.25%), with RES remaining stable under high-temperature storage conditions. This study provides new insights for designing green multifunctional cosmetic film-forming agents. Full article