Search Results (124)

Esterification is a key transformation in the production of lubricants, pharmaceuticals, and fine chemicals. Conventional processes employing homogeneous acid catalysts suffer from limitations such as corrosive byproducts, energy-intensive separation, and poor catalyst reusability. This review provides a comprehensive overview of heterogeneous catalytic systems, including ion exchange resins, zeolites, metal oxides, mesoporous materials, and others, for improved ester synthesis. Recent advances in membrane-integrated reactors, such as pervaporation and nanofiltration, which enable continuous water removal, shifting equilibrium and increasing conversion under milder conditions, are reviewed. Dual-functional membranes that combine catalytic activity with selective separation further enhance process efficiency and reduce energy consumption. Enzymatic systems using immobilized lipases present additional opportunities for mild and selective reactions. Future directions emphasize the integration of pervaporation membranes, hybrid catalyst systems combining biocatalysts and metals, and real-time optimization through artificial intelligence. Modular plug-and-play reactor designs are identified as a promising approach to flexible, scalable, and sustainable esterification. Overall, the interaction of catalyst development, membrane technology, and digital process control offers a transformative platform for next-generation ester synthesis aligned with green chemistry and industrial scalability. Full article

The current research trends of production engineering are based on optimizing the machining process concerning human and environmental factors. High-performance materials, such as hardened steels, nickel-based alloys, fiber-reinforced polymer (FRP) composites, and titanium alloys, are classified as hard-to-cut due to their ability to maintain strength at high operating temperatures. Due to these characteristics, such materials are employed in applications such as aerospace, marine, energy generation, and structural. The purpose of this article is to investigate the machinability of these alloys under various cutting conditions. The purpose of this article is to compare cryogenic cooling and cryogenic processing from the perspective of machinability and sustainability in the manufacturing process. Compared to conventional machining, hybrid techniques, which mix cryogenic and minimal quantity lubricant, led to significantly reduced cutting forces of 40–50%, cutting temperatures and surface finishes by approximately 20–30% and more than 40%, respectively. A carbon footprint is determined by several factors including power consumption, energy requirements, and carbon dioxide emissions. As a result of the cryogenic technology, the energy consumption, power consumption, and CO₂ emissions were reduced by 40%, 28%, and 35%. Full article

This study explores the machinability of Incoloy 800HT (high temperature) under a sustainable lubrication approach, employing a twin-nozzle minimum quantity lubrication (MQL) system with groundnut oil as a green cutting fluid. The evaluation focuses on key performance indicators, including surface roughness, tool flank wear, power consumption, carbon emissions, and chip morphology. Groundnut oil, a biodegradable and nontoxic lubricant, was chosen to enhance environmental compatibility while maintaining effective cutting performance. The Taguchi L₁₆ orthogonal array (three factors and four levels) was utilized to conduct experimental trials to analyze machining characteristics. The best surface quality (surface roughness, Ra = 0.514 µm) was obtained at the lowest depth of cut (0.2 mm), modest feed (0.1 mm/rev), and moderate cutting speed (160 m/min). The higher ranges of flank wear are found under higher cutting speed conditions (320 and 240 m/min), while lower wear values (<0.09 mm) were observed under lower speed conditions (80 and 160 m/min). An entropy-integrated multi-response optimization using the MOORA (multi-objective optimization based on ratio analysis) method was employed to identify optimal machining parameters, considering the trade-offs among multiple conflicting objectives. The entropy method was used to assign weights to each response. The obtained optimal conditions are as follows: cutting speed = 160 m/min, feed = 0.1 mm/rev, and depth of cut = 0.2 mm. Optimized outcomes suggest that this green machining strategy offers a viable alternative for sustainable manufacturing of difficult-to-machine alloys like Incoloy 800 HT. Full article

In the field of mechanical motion, friction loss and material wear are common problems. As one of the essential components for enhancing the lubricating performance of gel-like lubricants, nano-additives leverage their unique physical and chemical properties to form an efficient protective film on friction surfaces. This effectively reduces friction resistance and inhibits wear progression, thereby playing a significant role in promoting energy conservation, emissions reduction, and the implementation of green development principles. This study first introduces the physical and chemical preparation processes of gel-like lubricant nanoadditives. It then classifies them (mainly based on metal bases, metal oxides, nanocarbon materials, and other nanoadditives). Then, the performance of gel-like lubricant nano-additives is evaluated (mainly in terms of anti-wear, friction reduction, oxidation resistance, and load carrying capacity), and the surface analysis technology used is described. Finally, we summarize the application scenarios of gel-like lubricant nano-additives, identify the challenges faced, and discuss future prospects. This study provides new insights and directions for the design and synthesis of novel gel-like lubricants with significant lubricating and anti-wear properties in the future. Full article

The demands of the green economy necessitate modern polymer materials that are not only environmentally friendly but also durable and capable of long service life. Bio-based polylactide (PLA) polyesters have gained significant traction in various industrial markets; however, their application in specialized sectors is hindered by high brittleness. This study extensively examines the effects of 1–5% of synthetically obtained tetracyclosiloxane (CS) and octaspherosilicate (OSS) derivatives with methacrylate (MA) and trimethoxysilyl (TMOS) groups as functional modifiers for PLA. The research provides a detailed characterization of PLA/CS and PLA/OSS materials, including a comparative analysis of mechanical properties such as tensile, flexural, and dynamic resistance. Notably, incorporating 5% CS-2MA-2TMOS into PLA resulted in a remarkable 104% increase in impact resistance. The study further evaluates the influence of these modifications on thermal properties (DSC, TGA), heat deflection temperature (HDT), and surface character (WCA). The miscibility between the organosilicon additives and PLA was assessed using oscillatory rheometry and SEM-EDS analysis. The melt-rheology analysis explained the mechanisms behind the interaction between the CS and OSS additives with the PLA matrix, highlighting their lubricating effects on the melt flow behavior. The study was complemented by XRD structural analysis and verification of the structure of PLA-based materials by optical microscopy and SEM analysis, demonstrating a plasticizing effect and uniform distribution of the modifiers. The findings strongly suggest that, even at low concentrations, organosilicon additives serve as effective impact modifiers for PLA. Full article

During the operation of mechanical equipment, due to the intense friction among raw material or filler particles, there is conspicuous wear on the contact surfaces of components. Using green lubricants assumes a crucial role in mitigating the friction and wear, enhancing the equipment’s service life and the production’s reliability. This review centers on investigating the wear mechanism of green lubricants and undertakes a comprehensive summary and in-depth analysis of the research approach, integrating numerical simulation and friction and wear experiments. Moreover, the construction of the friction and wear testing machine and the intelligence of the testing system were probed, offering valuable design theories and research schemes for the development of effective anti-wear green lubricants. Full article

Cultural Heritage is a vital socioeconomic driver that must contend with works of art continuously exposed to degradation processes, which are further exacerbated by climate change. Aged coatings, varnishes, and soil can compromise the appearance of artworks, preventing their preservation and valorization. In response, soft matter and colloidal systems, such as nanostructured cleaning fluids (NCFs), have proved to be valuable solutions for safely and effectively cleaning works of art. Here, a novel cleaning system is proposed, for the first time employing microgels of poly(N-isopropylacrylamide) (PNIPAM) with surface chains of oligoethylene glycol methyl ether methacrylate (OEGMA) to favor shear deformation by lubrication. These microgels are loaded with NCFs featuring “green” solvents and different kinds of bio-derived or petroleum-based surfactants (non-ionic, zwitterionic). Rheological characterization of the combined systems highlighted a sharp transition from solid to liquid-like state in the 21–24 °C range when the zwitterionic surfactant dodecyldimethylamine oxide was used; the system displays a solid-like behavior at rest but flows easily at intermediate strains. At slightly higher temperature (>24 °C), an inversion of the G′, G″ values was observed, leading to a system that behaves as a liquid. Such control of rheological behavior is significant for feasible and complete removal of soiled polymer coatings from textured ceramic surfaces, which are difficult to clean with conventional gels, without leaving residues. These results position the PNIPAM-OEGMA microgels as promising cleaning materials for the conservation of Cultural Heritage, with possible applications also in fields where gelled systems are of interest (pharmaceutics, cosmetics, detergency, etc.). Full article

Tribology is the branch of science and engineering that focuses on understanding friction, wear, and lubrication, which is essential for saving energy, improving performance, reducing vibration, and creating eco-friendly lubricants and wear resistance. Over the past decade, nanomaterials have captured the immense interest of tribology science. This review aimed to analyze how graphene and its derivatives can be incorporated into lubricants to enhance their properties, particularly in mitigating friction and wear. This is due to graphene’s excellent specific properties, such as a low friction coefficient, mechanical strength, high thermal and electrical conductivity, biocompatibility, high load-carrying capacity, wear resistance, and chemical stability. This study briefly introduces graphite, graphene, and graphene oxide, as well as presents graphene as a material for tribological applications. Among other things, the environmentally friendly possibilities of chemical reduction of reduced graphene oxide are analyzed here, as well as the macro-, micro-, and nano-tribological examination of graphene and its derivatives. Despite what is already known about graphene in tribology, further research is needed to gain a deeper understanding of development regarding integration with different materials, long-term performance, eco-friendly synthesis using green reducing agents, and comprehending how these approaches may affect systems at various scales. Full article

The continuous advancement of technology has led to escalating demands for superior tribological performance in industrial applications, necessitating the enhancement of ceramic materials’ frictional properties through innovative approaches. Solid-lubricant embedding is a widely employed lubrication strategy in metals. However, the challenge of machining holes on ceramic surfaces remains a significant barrier to applying this lubrication technique to ceramics. Gel casting, as a near-net-shaping process, offers several advantages, including uniform green body density, low organic content, and the capability to fabricate components with complex geometries, making it a promising solution for addressing these challenges. In this study, alumina ceramics with small surface holes designed for embedding oil-containing microcapsules were fabricated via gel casting using an N-hydroxy methylacrylamide gel system, which demonstrates lower toxicity compared to conventional acrylamide systems. The fabricated alumina ceramic materials exhibited a high density of 98.2%, a hardness of 16 GPa, and a bending strength of 276 MPa. The oil-containing microcapsules were self-synthesized using hexafluorophosphate ionic liquid as the core material and polyurea-formaldehyde as the wall material. The research results show that under conditions of using an alumina ball, sliding speed of 10 cm/min, load of 5 N, and at room temperature, the material with a microcapsule content of 15 wt% and embedded hole diameter of 1.2 mm reduced the friction coefficient from 0.696 in an unlubricated condition to 0.317. Moreover, the embedding of microcapsules further improved the wear resistance of the alumina. Full article

Background: Besides conventional norms that recognize synovial fluid (SF) as a joint lubricant, nutritional channel, and a diagnostic tool in knee osteoarthritis (kOA), based on the authors previous studies, this study aims to define functional role of SF in kOA. Methods: U937, a monocytic, human myeloid cell line, was induced with progressive grades of kOA SF, and the induction response was assessed on various pro-inflammatory parameters. This ‘SF challenge test model’ was further extended to determine the impact of SF on U937 differentiation using macrophage-specific markers and associated transcription factor genes. Mitochondrial membrane potential changes in SF-treated cells were evaluated with fluorescent JC-1 probe. Results: a significant increase in nitric oxide, matrix metalloproteinase (MMP) 1, 13, and vascular endothelial growth factor (VEGF)-1 was noted in the induced cells. A marked increase was seen in CD68, CD86, and the transcription factors –activator protein (AP)-1, interferon regulatory factor (IRF)-1, and signal transducer and activator of transcription (STAT)-6 in the SF-treated cells indicating active monocytes to macrophage differentiation. Reduced mitochondrial membrane potential was reflected by a reduced red-to-green ratio in JC-1 staining. Conclusions: these results underline the active role of OA SF in stimulating and maintaining inflammation in joint cells, fostering monocyte differentiation into pro-inflammatory macrophages. The decline in the membrane potential suggestive of additional inflammatory pathway in OA via the release of pro-apoptotic factors and damaged associated molecular patterns (DAMPs) within the cells. Overall, biochemical modulation of SF warrants a potential approach to intervene inflammatory cascade in OA and mitigate its progression. Full article

To investigate the lubrication mechanism of phytic acid (PA) solution, a “copper–PA solution–copper” confined model with varying concentrations was established. Molecular dynamics (MD) simulations were employed to model the behavior of compression and the confined shear process. By examining the variations in key parameters such as dynamic viscosity, compressibility, radial distribution function, relative concentration distribution, and velocity distribution of PA solutions under different normal loads or shear rates, we elucidated the lubrication mechanism of PA solutions at the molecular level. The results demonstrate that under standard loading conditions, higher PA concentrations facilitate the formation of denser hydrated layers with decreased compressibility compared to free water, thereby significantly enhancing the load-bearing capacity. The shear stress at the solution–copper interface exhibits a substantial increase as the shear rate rises. This phenomenon originates from shear-driven migration of PA to the copper interface, disrupting the hydration layers and weakening hydrogen bonds. Consequently, this reduction in PA–water interactions amplifies slip velocity differences, ultimately elevating interfacial shear stress. The load-bearing capacity of the PA solution and the interfacial shear stress between the PA and copper are critical factors that influence the lubrication mechanism at the PA/Cu interface. This study establishes a theoretical foundation for the design and application of PA solution as a water-based lubricant, which holds significant importance for advancing the development of green lubrication technology. Full article

Ionic liquid molecules exhibit a variety of properties that are well suited for use as lubricants or additives for lubricants, since they form tribolayers that reduce friction and wear. As additives in the design of new water-based biolubricants, ionic liquids present the advantages of polar nature to use in aqueous lubrication, whilst being biocompatible and with null toxicity, opening up the opportunity to develop novel biolubricants. Choline is a cation present in numerous ionic liquids and is widely recognized for its water solubility, biodegradability, low toxicity, and role as a green solvent in different applications. This work presents the comparative studies of several water-based biolubricants and thin-layer films on stainless steel using a low proportion of Choline-based ionic liquids. The results of friction and wear using water-based biolubricants with 1 wt% of different Choline-based ionic liquids showed good tribological performance. In addition, Choline Lysinate, an amino-acid ionic liquid which is biocompatible, nontoxic, and biodegradable, presented excellent performance and was used as a precursor of thin-layer films on stainless steel showing outstanding behavior in pin-on-disc configuration and sapphire/stainless-steel contacts. Subsequent X-ray photoelectron spectroscopy confirmed the presence of a tribolayer containing the amino acid compound on the metallic surface. Full article

The lubrication of mining reducer is subjected to the contamination of coal rock dust, and this contamination has extremely serious influence on the wear life of reducers. This paper examines the effects of coal dust and rock dust contamination on the wear of mine gearboxes, especially the wear mechanisms and particle characteristics under lubrication conditions of coal dust and rock dust mixtures of different particle sizes and contents. In the paper, 18CrNiMo7-6 alloy steel was used as the reducer gear material to simulate the actual working conditions, and friction and wear tests were conducted by CFT-1 comprehensive tester to analyze the wear particle characteristics under different contamination conditions. In the experiment, 80-mesh and 200-mesh coal dust and silica particles were used (80-mesh pore size is about 180 μm; 200-mesh pore size is about 75 μm), and different mass fractions of contaminant mixtures were set. The results show that under 80-mesh coal dust contamination, punctate pits, scratches and green halos appeared on the surface of wear particles, and the corrosion and abrasive effects were enhanced when the concentration increased, while 200-mesh coal dust contamination was characterized by black pits and green halos, and the abrasive effect was not obvious. Silica contamination showed significant cutting effects with red oxide wear particles. The synergistic effect of the two contaminants accelerated the wear of the material, and the wear particles were characterized by delamination, flaking and black pits. The study shows that the concentration and type of contaminants have a significant effect on the wear performance of the reducer. Full article

The development of green lubrication requires nano-lubricants to possess more environmentally friendly fabrication modes and materials with superior tribological properties. This study investigates the tribological properties of nano-biochar in PAO6 base oil and in combination with different additives. The effect of adsorption on friction reduction and anti-wear performance is demonstrated by replacing the friction sub-materials in the four-ball friction test. Based on the comparison of wear region characterization, the incorporation of nano-biochar improves the friction reduction performance of detergent and dispersant base oils with a reduction in coefficient of friction (COF) by 16.7% and 19.0%, respectively, and produces a synergistic effect on the anti-wear performance. When nano-biochar is compounded with anti-wear agents and friction reducer, there is a synergistic effect on friction reduction performance, and COF decreases by 9.4% and 4.5% compared with anti-wear agents and friction reducer base oils, respectively. A method to analyze the friction reduction and anti-wear mechanism of nano-additives in complex lubrication system is proposed, which reveals in depth the interaction law and synergistic lubrication mechanism between NBC and additives in the friction process. Full article

Cutting fluid has been widely used to enhance the heat dissipation of cutting systems. However, whether cutting fluid can fully play its role is closely correlated with its thermophysical characteristics, such as viscosity, surface tension, etc. In this work, to study the effect of the thermophysical characteristics of cutting fluid on cutting performance, three green vegetable oils (semi-synthetic fluid (L1), rapeseed oil (L2), canola oil (L3)) were selected as cutting fluids of the MQL system, and differences in cutting performance were compared and analyzed under varied lubrication environments. Firstly, the thermophysical characteristics of the vegetable oils were determined by experimental methods. Afterwards, parameters, including tool wear, cutting force, and temperature, as well as the quality of machined workpieces, were selected to evaluate cutting performance, and essential reasons for the difference in cutting performance under varied lubrication environments were clarified. The results demonstrated that the cutting force, cutting temperature, and tool wear produced in the three MQL environments were lower than those in the dry cutting environment, while only the L1 and L2 MQL environments exhibited higher machined surface quality than the dry cutting environment. Moreover, obvious differences in cutting performance under the three MQL environments were also observed due to the different thermophysical characteristics of the three vegetable oils. The best cutting performance was achieved when L2 was used as the MQL cutting fluid. The efforts of this study will give an important reference for the choosing of green cutting fluid in the cutting process of difficult-to-cut materials and be of great significance for accelerating the development of green processing. Full article