Search Results (54)

The growing request for more sustainable materials and environmentally friendly nanofabrication methods in the electronics field has recently driven the scientific community in the development of bio-derived materials as an alternative to conventional lithographic resists. In this work, we used chitosan, a biodegradable and biocompatible polysaccharide, as a green direct-write resist material for Atomic Force Microscopy-based nanolithography. Chitosan thin layers were obtained by spin coating and systematically characterized, in terms of thickness and surface roughness, demonstrating nanoscale smoothness and tunable film thickness. Three Pulse–Atomic Force Lithography (P-AFL) approaches, i.e., Constant Pulse, Gradient Pulse, and Raster Pulse AFL methods, were used to pattern nanostructures with constant-depth nanogrooves, variable-depth (2.5D) profile, and three-dimensional nanoholes on chitosan films. The results reveal high pattern fidelity, reproducibility, and tunability of feature dimensions as a function of applied force and scanning direction. Moreover, the RP-AFL technique enabled the fabrication of well-defined 3D nanostructures with depths matching the film thickness, which is a prerequisite for subsequent pattern transfer. This experimental work provided a first proof-of-concept to adopt chitosan as a more sustainable alternative with respect to conventional resists. Moreover, the results highlight P-AFL methods as a versatile and low-impact nanofabrication strategy, contributing to the development of greener micro- and nano-manufacturing technologies. Full article

To address the erosion-induced failure of large-caliber gun barrels under extreme thermochemical coupling, this study systematically investigates the microstructural evolution of multi-layered gradient regions along the radial direction of 32CrNi3MoV steel under extreme thermochemical cycling. Leveraging SEM, EBSD, TKD, and double-beam aberration-corrected TEM, combined with JMatPro thermodynamic simulations, the phase transitions, crystallographic characteristics, and substructural evolution spanning from the bore surface to the matrix are elucidated. The results demonstrate that a three-layer gradient structure forms along the radial direction. The topmost layer is a chemically stabilized metastable austenite diffusion layer with a thickness of 1.5–4.0 μm. which is attributed to the suppression of martensitic transformation due to C/N interstitial diffusion lowering the MS temperature. The observed high-density dislocation tangles and stacking faults within this austenite diffusion layer result from thermal mismatch stresses during rapid thermal cycling. The subsurface region is a martensitic transformation layer with a thickness of 70–97 μm, exhibiting a substructural gradient from nanostructured high-density twinned martensite to refined lath martensite. Thermodynamic analysis indicates that rapid heating (≈10⁵ °C/s) facilitates significant austenite nucleation and growth during the reverse phase transformation, subsequently forming nanostructured martensitic grains via non-equilibrium transformation during rapid cooling. Adjacent to this is a matrix tempering layer extending approximately 160 μm. Nanoindentation hardness profiling reveals that the peak radial hardness (≈1000 HV) occurs within the fine-grained martensitic zone approximately 40 μm from the surface. In contrast, the tempered layer exhibits reduced hardness (≈400 HV) compared to the original matrix (≈500 HV). This is primarily attributed to transient high-temperature over-tempering effects, which induces carbide coarsening and the loss of solid solution strengthening, alongside the softening of prior austenite grain boundaries. This study clarifies the micro-to-nanoscale evolution of the barrel microstructure, providing critical theoretical insights for understanding erosion mechanisms and improving lifetime predictions. Full article

Burnishing technologies are a cheap and effective means of improving the surface integrity (SI) and performance of metal components. However, there is practically no information about the integral influence of the preceding turning process on the initial (pre-burnishing) SI. This study answers the question of how the white layer resulting from flank wear on the cutting insert in pre-turning affects the SI and fatigue limit, and determines the extent to which subsequent diamond burnishing (DB) is able to improve the SI and rotating bending fatigue limit of normalised, quenched and high-temperature-tempered C45 steel. The (DB)–SI–fatigue limit correlation was investigated using a holistic approach that took into account the effects of the dynamic pattern of flank wear on the initial SI. An explicit relationship was established between the flank wear, the affected surface layer structure and the fatigue limit. Increasing flank wear to the 60th minute intensified the formation of a gradient layer with finer and thinner grains that formed a texture. As a result, a synergistic effect was observed from turning with an insert operating for 60 min and subsequent DB, which maximised the fatigue limit (741 MPa). After 60 min, the structure of the affected layer changed qualitatively towards the formation of a nanostructured (white) layer, which reversed the trend, worsening the fatigue behaviour. As the thickness of the white layer increased, the fatigue limit was sharply reduced to below 560 MPa after the 90th minute. Regardless of the degree of flank wear, DB significantly improved the SI characteristics and increased the fatigue limit after turning with a worn insert, although the absolute dimensions of the positive DB effect depend on the initial SI and fatigue limit due to pre-turning. To achieve a synergistic effect, the cutting insert should be replaced with a new one after every 60 min of operation. Full article

X-band copper resonating cavities are key components of future pulsed GHz normal-conductive multi-TeV accelerators. High electric field gradients are required for emerging applications; however, as gradients increase, components’ lifetime decreases, primarily due to radiofrequency (RF) breakdown. Coating technologies are being investigated in several laboratories to improve RF structure, performance and lifetime. To this end, we investigated the feasibility of fabricating nanometer-periodic Cu/Mo metallic multilayers on three-dimensional (3D) aluminum mandrels designed to replicate X-band copper resonating cavities. These nanometer-period multilayers are proposed to mitigate surface degradation due to electric breakdown at high accelerating gradients by stabilizing inner cavity surfaces against dislocation evolution and roughening caused by thermo-mechanical fatigue. High-Power Impulse Magnetron Sputtering (HiPIMS) in a bias-controlled dual closed-field magnetron configuration was employed to deposit alternating Mo and Cu nano-layers onto the 3D geometries. Given the complexity of HiPIMS technology, plasma pulse evolution was studied by combining time-resolved optical emission spectroscopy with electrical measurements of the pulse discharge. The influence of the process parameters, particularly the applied DC bias, on film growth was studied using non-destructive microprobe α-particle elastic backscattering spectrometry (µEBS) and scanning transmission electron microscopy (STEM). STEM and µEBS analyses confirmed that Mo layers with thicknesses of approximately 5–35 nm were successfully deposited repeatedly on thicker Cu layers (30–150 nm), preserving individual layer properties with minimal interdiffusion and alloying. The layers were deposited inside trenches with an aspect ratio of 5:1 representative of X-band irises. This technology, coupled with the replica process, could be applied to highly engineered nanostructured coatings for X-band cavity treatment in compact particle accelerator prototypes, as it may improve electrical breakdown lifetime under high accelerating fields, at least for degradation processes driven by the high mobility of copper dislocations. Full article

This study investigates the synergistic effects of an electropulsing (EP) and ultrasonic impact treatment (UIT) hybrid process on the mechanical and corrosion properties of D36 low-carbon steel. Conventional UIT has been shown to enhance surface hardness and induce compressive residual stress but is limited by a shallow affected depth and potential for increased surface roughness, which can exacerbate corrosion. In this work, we integrate high-energy electropulsing with UIT to overcome these limitations. The EP-UIT process leverages the combined effects of acoustoplasticity, thermal softening, and electroplasticity to achieve a significantly deeper hardened layer, extending beyond 2 mm, which is an order of magnitude thicker than that obtained by UIT alone. Microstructural analysis reveals that the process induces continuous dynamic recrystallization (CDRX), resulting in a gradient nanostructured layer with equiaxed grains near the surface and submicron ferrite grains at greater depths. Additionally, cementite dissolution and reprecipitation lead to a dual-phase microstructure comprising a supersaturated ferrite matrix and spheroidized Fe₃C particles. The EP-UIT treatment also forms a dense oxide scale composed primarily of magnetite (Fe₃O₄) and hematite (α-Fe₂O₃), significantly enhancing corrosion resistance. Potentiodynamic polarization tests demonstrate that EP-UIT reduces the corrosion current density by 68% compared to UIT-treated samples, while electrochemical impedance spectroscopy confirms the improved barrier properties of the oxide layer. This innovative approach offers a promising strategy for significantly extending the service life of welded marine structures by concurrently enhancing their mechanical properties and corrosion resistance. Full article

In high-precision optical systems such as laser optics, astronomical observation, and semiconductor lithography, anti-reflection coatings are crucial for light transmittance, imaging quality, and stability, but traditional designs face modeling challenges in balancing ultralow reflectivity, high wavefront quality, and manufacturability amid multi-dimensional parameter coupling and multi-objective constraints. This study addresses these by proposing a unified mathematical modeling framework integrating a Symmetric five-layer high-low refractive index alternating structure (V-H-V-H-V) with dual-scale nanostructures, employing a constrained quasi-Newton optimization algorithm (L-BFGS-B) to minimize reflectivity, wavefront root-mean-square (RMS) error, and surface roughness root-mean-square (RMS) in a six-dimensional parameter space. The Sellmeier equation is adopted to calculate wavelength-dependent material refractive indices, the model uses the transfer matrix method for the Symmetric five-layer high-low refractive index alternating structure’s reflectivity, incorporates nano-surface height function gradient correction, sub-wavelength modulation, and radial optimization, applies Zernike polynomials for low-order aberration correction, quantifies surface roughness via curvature proxies, and optimizes via a weighted objective function prioritizing low reflectivity. Numerical results show the spatial average reflectivity at 632.8 nm reduced to 0.13%, the weighted average reflectivity across five representative wavelengths in the 550–720 nm range to 0.037%, the reflectivity uniformity to 10.7%, the post-correction wavefront RMS to 11.6 milliwavelengths, and the surface height standard deviation to 7.7 nm. This framework enhances design accuracy and efficiency, suits UV nanoimprinting and electron beam evaporation, and offers significant value for high-power lasers, lithography, and space-borne radars. Full article

In the present paper, the fatigue performance of a TC6 titanium alloy with a microstructure gradient and residual stress gradient produced by laser shock peening (LSP) is investigated. After LSP, a 1 mm thickness gradient compressive residual stress layer with a maximum surface compressive residual stress of −708 MPa is introduced into the materials. Electron back-scattering diffraction (EBSD) and transmission electron microscopy (TEM) techniques are used to characterize the microstructural evolution of the TC6 titanium alloy subjected to LSP. The results show that a nanostructured layer forms on the surface of the TC6 titanium alloy. At a depth of 20 μm, high dense dislocation and nanocrystalline are observed on the top surface. Based on the results of the microstructural characterization, it is found that dislocation movement is the main reason for the formation of nanocrystalline on the top surface. A high-cycle fatigue test showed that the fatigue limit of the TC6 titanium alloy treated by LSP improves from 431 ± 10 MPa to 486 ± 14 MPa, increasing by 12.8%. Full article

Fabrication of gradient nanostructure on metal surfaces is recognized as an effective approach for enhancing mechanical and surface properties, as well as serving as a pretreatment for subsequent surface engineering. Unfortunately, their fabrication on high-strength and low-ductility metal surface poses a significant challenge due to the prevalent issue of process-induced surface damage. In this study, we report the successful fabrication of a gradient nanostructured surface layer with low roughness (Ra ~ 0.17 μm) on high-strength 38CrMoAl steel through an optimized ultrasonic severe surface rolling (USSR) processing. By systematically varying the tempering temperature of quenched-and-tempered samples, the strength and ductility of the 38CoMoAl steel are tailored to facilitate gradient nanostructure formation. Microstructural analysis via advanced electron microscopy reveals the gradient nanostructure features progressively coarser martensite/ferrite grains and decreasing dislocation density along the depth. As the tempering temperature increases from 600 °C to 700 °C, the yield strength of 38CrMoAl steel decreases from 915 ± 16 MPa to 815 ± 16 MPa, while the elongation increases from 18.7 ± 0.6 to 27.3 ± 1.2%, resulting in an increase in the thickness of the gradient nanostructured surface layer from 300 μm to 400 μm. Following USSR processing, samples tempered at 600 °C, 650 °C, and 700 °C exhibit significant enhancements in surface hardness by 7.3%, 22.7%, and 21.5%, respectively, along with substantial reduction in wear volume by 73%, 78%, and 60%. USSR processing also leads to a reduction in coefficient of friction. This work provides valuable insights into the fabrication of high-quality gradient nanostructures on high-strength, low-ductility metallic materials. Full article

This study systematically investigates the surface nanocrystallization of 35CrMo steel induced by Ultrasonic Surface Rolling Processing (USRP). It reveals the formation of a gradient nanostructure, where martensite lath fragmentation under high-frequency impacts leads to a surface layer of equiaxed nanocrystals and high-density dislocations. This novel microstructure yields exceptional surface integrity: roughness is minimized to 0.029 μm due to plastic flow, residual stress is transformed into high compressive stress, and surface microhardness is significantly enhanced by 32.3%, primarily governed by grain refinement and dislocation strengthening. Consequently, the treated material exhibits a 28.9% reduction in wear mass loss, which is directly attributed to the combined effects of the strengthened gradient layer’s improved load-bearing capacity and the effective suppression of crack initiation by compressive residual stresses. Our findings not only provide direct microstructural evidence for classic strengthening theories but also offer a practical guide for optimizing the surface performance of high-strength alloy components. Full article

Difficult, extreme operating conditions of parabolic antennas under precipitation and sub-zero temperatures require the creation of effective heating systems. The purpose of the research is to develop a multilayer coating containing two metal-ceramic layers, epoxy composite layers, carbon fabric, and an outer layer of basalt fabric, which allows for effective heating of the antenna, and to study the properties of this coating. The multilayer coating was formed on an aluminum base that was subjected to abrasive jet processing. The first and second metal-ceramic layers, Al₂O₃ + 5% Al, which were applied by high-speed multi-chamber cumulative detonation spraying (CDS), respectively, provide maximum adhesion strength to the aluminum base and high adhesion strength to the third layer of the epoxy composite containing Al₂O₃. On this not-yet-polymerized layer of epoxy composite containing Al₂O₃, a layer of carbon fabric (impregnated with epoxy resin) was formed, which serves as a resistive heating element. On top of this carbon fabric, a layer of epoxy composite containing Cr₂O₃ and SiO₂ was applied. Next, basalt fabric was applied to this still-not-yet-polymerized layer. Then, the resulting layered coating was compacted and dried. To study this multilayer coating, X-ray analysis, light and raster scanning microscopy, and transmission electron microscopy were used. The thickness of the coating layers and microhardness were measured on transverse microsections. The adhesion strength of the metal-ceramic coating layers to the aluminum base was determined by both bending testing and peeling using the adhesive method. It was established that CDS provides the formation of metal-ceramic layers with a maximum fraction of lamellae and a microhardness of 7900–10,520 MPa. In these metal-ceramic layers, a dispersed subgrain structure, a uniform distribution of nanoparticles, and a gradient-free level of dislocation density are observed. Such a structure prevents the formation of local concentrators of internal stresses, thereby increasing the level of dispersion and substructural strengthening of the metal-ceramic layers’ material. The formation of materials with a nanostructure increases their strength and crack resistance. The effectiveness of using aluminum, chromium, and silicon oxides as nanofillers in epoxy composite layers was demonstrated. The presence of structures near the surface of these nanofillers, which differ from the properties of the epoxy matrix in the coating, was established. Such zones, specifically the outer surface layers (OSL), significantly affect the properties of the epoxy composite. The results of industrial tests showed the high performance of the multilayer coating during antenna heating. Full article

The structural units with different characteristic scales in gradient nanostructured (GS) 316L stainless steel act synergistically to achieve the matching of strength and plasticity, and the intrinsic plasticity of nanoscale and ultrafine grains is fully demonstrated. The macroscopic stress–strain responses of each material unit in the GS surface layer can be measured directly by tension or compression tests on microspecimens. However, the experimental results based on microspecimens do not reflect either the extraordinary strengthening effect caused by non-uniform deformation or the intrinsic plasticity of nanoscale and ultrafine grains. In this paper, a method for constructing depth-dependent constitutive relationships of GS materials was proposed, which combines strain hardening parameter (hardness) with physics-informed neural networks (PINNs). First, the microhardness distribution on the specimen cross-sections was measured after stretching to different strains, and the hardness–strain–force test data were used to construct the depth-dependent PINNs model for the true strain–hardness relationship (PINNs_εH). Hardness–strain–force test data from specimens with uniform coarse grains were used to pre-train the PINNs model for hardness and true stress (PINNs_Hσ), on the basis of which the depth-dependent PINNs_Hσ model for GS materials was constructed by transfer learning. The PINNs_εσ model, which characterizes the depth-dependent constitutive relationships of GS materials, was then constructed using hardness as an intermediate variable. Finally, the accuracy and validation of the PINNs_εσ model were verified by a three-point flexure test and finite element simulation. The modeling method proposed in this study can be used to determine the position-dependent constitutive relationships of heterogeneous materials. Full article

This study investigates the fabrication, nanomechanical behavior, and tribological performance of nanostructured superlattice coatings (NSCs) composed of alternating TiAlSiNb-N/TiCr-CN bilayers. Deposited via High-Power Ion-Plasma Magnetron Sputtering (HiPIPMS) onto 100Cr6 steel substrates, the coatings achieved nanohardness values of ~25 GPa and elastic moduli up to ~415 GPa. A novel empirical method was applied to extract stress–strain field (SSF) gradient and divergence profiles from nanoindentation load–displacement data. These profiles revealed complex, depth-dependent oscillations attributed to alternating strain-hardening and strain-softening mechanisms. Fourier analysis identified dominant spatial wavelengths, DWL, ranging from 4.3 to 42.7 nm. Characteristic wavelengths WL1 and WL2, representing fine and coarse oscillatory modes, were 8.2–9.2 nm and 16.8–22.1 nm, respectively, aligning with the superlattice period and grain-scale features. The hyperfine structure exhibited non-stationary behavior, with dominant wavelengths decreasing from ~5 nm to ~1.5 nm as the indentation depth increased. We attribute the SSF gradient and divergence spatial oscillations to alternating strain-hardening and strain-softening deformation mechanisms within the near-surface layer during progressive loading. This cyclic hardening–softening behavior was consistently observed across all NSC samples, suggesting it represents a general phenomenon in thin film/substrate systems under incremental nanoindentation loading. The proposed SSF gradient–divergence framework enhances nanoindentation analytical capabilities, offering a tool for characterizing thin-film coatings and guiding advanced tribological material design. Full article

This study provides new insight into the mechanisms governing solid state dewetting (SSD) in SiGe alloys and underscores the potential of this bottom-up technique for fabricating self-organized defect-free nanostructures for CMOS-compatible photonic and nanoimprint applications. In particular, we investigate the SSD of Si_1−xGe_x thin films grown by molecular beam epitaxy on silicon-on-insulator (SOI) substrates, focusing on and clarifying the interplay of dewetting dynamics, strain elastic relaxation, and SiGe/SOI interdiffusion. Samples were annealed at 820 °C, and their morphological and compositional evolution was tracked using atomic force microscopy (AFM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), and Raman spectroscopy, considering different annealing time steps. A sequential process typical of the SiGe alloy has been identified, involving void nucleation, short finger formation, and ruptures of the fingers to form nanoislands. XRD and Raman data reveal strain relaxation and significant Si-Ge interdiffusion over time, with the Ge content decreasing from 29% to 20% due to mixing with the underlying SOI layer. EDX mapping confirms a Ge concentration gradient within the islands, with higher Ge content near the top. Full article

This study introduces a novel gradient dual-phase structure design in brass, achieved through ultrasonic severe surface rolling (USSR) processing, which enables an unconventional asymmetric bilayer structure—comprising a hardened surface layer (>1 mm thick) and a ductile substrate—distinct from conventional hard-soft-hard sandwich configurations in gradient nanostructured materials. Microstructural characterization reveals a gradient dual-phase (α + β′) structure in the hardened layer, progressively transitioning into a homogenized dual-phase structure in the substrate. This unique architecture endows the USSR brass with exceptional mechanical properties, including a yield strength of 582.4 ± 31.0 MPa, ultimate tensile strength of 775.3 ± 33.9 MPa, and retained ductility (9.3 ± 1.0%), demonstrating an outstanding strength-ductility synergy. The USSR brass also demonstrates superior wear resistance with a 42.32% reduction in wear volume and 40.82% decrease in coefficient of friction compared to its as-received counterpart under oil lubrication. This architectural paradigm establishes a robust framework for engineering high-performance brass that simultaneously achieve an exceptional strength-ductility balance and enhanced wear resistance. Full article

Traditionally, structural wire is characterized by a homogeneous microstructure, where the average grain size in different parts of the wire is uniform. According to the classical Hall–Petch relationship, a homogeneous polycrystalline metal can be strengthened by decreasing the average grain size since an increase in the volume fraction of grain boundaries will further impede the motion of dislocations. However, a decrease in the grain size inevitably leads to a decrease in the ductility and deformability of the material due to limited dislocation mobility. Putting a gradient microstructure into the wire has promising potential for overcoming the compromise between strength and ductility. This is proposed a new combined technology in this paper in order to obtain a gradient microstructure. This technology consists of deforming the wire in a rotating equal-channel step die and subsequent traditional drawing. Deformation of copper wire with a diameter of 6.5 mm to a diameter of 5.0 mm was carried out in three passes at room temperature. As a result of such processing, a gradient microstructure with a surface nanostructured layer (grain size ~400 nm) with a gradual increase in grain size towards the center of the wire was obtained. As a result, the microhardness in the surface zone was 1150 MPa, 770 Mpa in the neutral zone, and 685 MPa in the central zone of the wire. Such a symmetrical spread of microhardness, observed over the entire cross-section of the rod, is a direct confirmation of the presence of a gradient microstructure in deformed materials. The strength characteristics of the wire were doubled: the tensile strength increased from 335 MPa to 675 MPa, and the yield strength from 230 MPa to 445 MPa. At the same time, the relative elongation decreased from 20% to 16%, and the relative contraction from 28% to 23%. Despite the fact that the ductility of copper is decreased after cyclic deformation, its values remain at a fairly high level. The validity of all results is confirmed by numerous experiments using a complex of traditional and modern research methods, which include optical, scanning, and transmission microscopy; determination of mechanical properties under tension; and measurement of hardness and electrical resistance. These methods allow reliable interpretation of the fine microstructure of the wire and provide information on its strength, plastic, and electrical properties. Full article