Search Results (252)

This study investigated how fabrication method (milling versus 3D printing) affects the water sorption and solubility of PMMA dental materials, and how surface characteristics affect hydrolytic stability. Fifty-six PMMA samples were divided into three groups fabricated from CAD/CAM milled discs (Group A: I–III) and four groups from 3D-printed resin (Group B: IV–VII), each subjected to distinct postprocessing protocols. Water sorption (wsp) and solubility (wsl) were measured after immersion in distilled water at 37 °C for 24, 48, and 72 h, and 7 and 14 days. Surface topography and nanoroughness were assessed using atomic force microscopy (AFM). Statistical descriptive analyses were followed by correlation analyses. Milled PMMA demonstrated significantly lower water sorption and negative solubility (mass loss), indicating material dissolution. In contrast, 3D-printed PMMA showed higher water sorption and positive solubility (mass gain), reflecting water incorporation and polymer swelling. The kinetic profiles differed: milled PMMA displayed a monophasic absorption curve, while 3D-printed PMMA exhibited a biphasic pattern with accelerated water uptake after 72 h. AFM analysis revealed that 3D-printed surfaces had significantly greater nanoroughness than milled surfaces. Strong positive correlations were observed between surface roughness parameters (Sa, Sy) and water sorption capacity. The fabrication method was found to influence the hydrolytic stability of PMMA dental materials. Milled PMMA demonstrated superior stability, with lower water uptake, smoother surfaces, and lower leaching solubility. In contrast, 3D-printed PMMA exhibited increased surface roughness and water sorption, attributed to its layered microstructure and nanoporosity. Surface topography emerged as a strong predictor of wsl, related to hydrolytic degradation. For clinical applications, milled PMMA is recommended for long-term use requiring durability, whereas 3D-printed PMMA may be appropriate for short-term applications with optimised postprocessing. Full article

Wire-arc coatings have received substantial attention for corrosion protection; however, poor bonding often leads to delamination, corrosion initiation, and costly re-coating of structural components. This review combines bibliometric mapping with a focused technical synthesis to clarify how bonding performance has been studied in wire-arc coatings. Specifically, publication trends, keyword co-occurrence networks, and country-level co-authorship maps are used to map the evolution of the field and position adhesion-related studies within the broader literature. The analysis of 762 wire-arc coating publications from Web of Science (among 13,314 thermal spray coating records) reveals that research is centered on microstructure, mechanical properties, and corrosion resistance, with growing links to wire-based additive manufacturing. Keyword co-occurrence networks demonstrate clear process–structure–property relationships, while country-level collaboration maps highlight the leadership of China, the USA, and Germany. Critical to note, only eight publications systematically investigate the combined effects of substrate roughness, coating thickness, and Zn-Al coating composition on bond strength—representing less than 0.01% of the thermal spray literature. This pronounced research gap underscores the novelty of the present review, which synthesizes existing knowledge on adhesion mechanisms, identifies key process parameters, and establishes a research agenda to optimize wire-arc coatings for infrastructure corrosion protection. The technical synthesis highlights that adhesion is governed by the coupled effects of surface preparation (roughness and topography), coating build-up (thickness), and spray conditions (e.g., standoff distance and substrate preheating), which together influence coating microstructure and failure modes. These findings provide a structured framework to guide parameter selection for durable coatings. Full article

Laser surface hardening (LSH) is an efficient and flexible technique for improving the surface integrity of steel components used in high-load automotive applications. In this study, the surface changes occurring during laser hardening of 42CrMo4 steel were systematically investigated using a 4 kW high-power diode laser. The influence of laser power and scanning speed on surface roughness, hardness distribution, hardened layer depth, tribological behavior, and phase composition was analyzed. Surface topography was evaluated using three-dimensional laser scanning microscopy, while mechanical performance was assessed through microhardness and scratch testing. Phase transformations and residual structural changes were examined by X-ray diffraction (XRD) at different depths beneath the treated surface. The results demonstrate that laser processing parameters strongly affect surface integrity through competing mechanisms of surface melting, oxidation, and self-quenching. High laser power combined with low scanning speed produced deep hardened layers but promoted surface melting and retained austenite formation, whereas lower power and higher scanning speed yielded a stable martensitic surface with reduced roughness and a steep hardness gradient. XRD analysis confirmed that oxide formation was limited to the near-surface region, while the subsurface hardened zone consisted predominantly of martensitic/bainitic phases. An optimal processing window was identified that balances surface hardness, roughness, and microstructural stability without compromising surface integrity. These findings provide practical guidelines for optimizing diode laser hardening of 42CrMo4 steel gears in industrial automotive applications. Full article

Copper (Cu) is widely used in electrical and thermal management systems; however, its low hardness and limited dry sliding wear resistance reduce long-term reliability in friction-loaded conductive components. In this study, Cu–Hf and Cu–Hf–rGO hybrid composites were fabricated by powder metallurgy using 1.0–5.0 wt.% Hf and 1.0–2.0 wt.% reduced graphene oxide (rGO). The microstructure and phase evolution were characterized by SEM/EDS and XRD. Electrical conductivity and hardness were measured, while tribological performance was evaluated by dry sliding wear tests based on mass loss. Post-wear surface characteristics were analyzed by AFM and LFM to assess nanoscale topography and frictional behavior. The hybrid composites exhibited composition-dependent multifunctional enhancements. Electrical conductivity increased from approximately 3.0 × 10⁶ S/m (~5.2% IACS) for pristine Cu to about 2.0 × 10⁷ S/m (~34.5% IACS) for the composite reinforced with 3.0 wt.% Hf and 2.0 wt.% rGO, indicating an optimum Hf–rGO combination that preserves continuous conductive pathways. Hardness increased from 60 ± 3 HV_0.30 to 159 ± 12 HV_0.30 for the composite containing 5.0 wt.% Hf and 2.0 wt.% rGO, demonstrating the dominant contribution of Hf to matrix strengthening and load-bearing capacity. The mass loss after 1000 m of sliding distance decreased from about 0.12 g for Cu to approximately 0.01 g for the 5.0 wt.% Hf–2.0 wt.% rGO hybrid composite, consistent with the concurrent increase in hardness and reduction in frictional shear during sliding. Nanoscale surface analyses revealed reduced surface roughness and frictional response, supporting the formation of a smoother and lower-friction sliding interface in rGO-containing composites. Overall, Hf enhanced load-bearing capacity through matrix strengthening, while rGO contributed to stabilizing conductive pathways and solid lubrication. Full article

In mechanical engineering, interest in reliable and practicable technologies for nano- and microstructuring of tool surfaces is increasing. Femtosecond laser structuring offers a promising approach that combines high processing speeds with high precision. However, a knowledge gap remains regarding the optimal process parameters for achieving specific surface patterns on hot-work tool steel substrates. The current study aims to investigate the effects of laser scanning parameters on the formation of self-organized surface structures and the resulting topography and morphology. Therefore, samples were irradiated using a 300 fs laser with linearly polarized light (λ = 1030 nm). Scanning electron microscopy revealed four structure types: laser-induced periodic surface structures (LIPSSs), micrometric ripples, micro-crater structures, and pillared microstructures. The results for surface area and line roughness indicate that high laser pulse overlaps lower the strong ablation threshold more effectively than high scanning line overlaps, promoting the formation of pillared microstructures. For efficient ablation and increased surface roughness, higher pulse overlaps are therefore advantageous. In contrast, at low fluences, higher scanning line overlaps support a more homogeneous formation of nanostructures and reduce waviness. Full article

In this study, polylactic acid (PLA) was blended with poly(ε-caprolactone) (PCL) and reinforced with nanosilica (SiO₂) to tailor surface characteristics and improve adhesion in biopolymer-based printed packaging applications. The surface microstructure and topography were analyzed using FTIR-ATR, SEM, and surface profilometry. Surface wettability and surface free energy (SFE), along with the adhesion properties of printed ink layers on polymer blends, were assessed, and the optical properties of the substrates and prints were evaluated. SEM revealed that PLA/PCL blends exhibited phase-separated morphologies with PCL droplet domains, whereas incorporation of 3 wt% SiO₂ resulted in finer dispersion and reduced surface irregularities. Surface roughness (Ra) increased from 1.92 µm for PLA/SiO₂ 100/3 to 4.45 µm for PLA/PCL/SiO2 50/50/0, while water contact angle decreased from 70.9° for neat PLA to 43.4° for PLA/SiO₂ 100/3 surface, reflecting enhanced hydrophilicity. SFE components ranged from 26 to 40.7 mJ/m² (dispersive) and 3.2 to 21.5 mJ/m² (polar). Adhesion parameters (interfacial tension ranging from 0.01 to 5.54 mJ/m², work of adhesion from 76.9 to 97.3 mJ/m², and wetting coefficient from 3.04 to 11.1 mJ/m²) indicated favorable ink compatibility for most blends, and optical density of the printed layers (1.85–2.35) confirmed potential for good printability. These findings demonstrate that PLA/PCL/SiO₂ blends allow controlled tuning of surface morphology, wettability, and adhesion, providing a promising approach for biodegradable and print-ready packaging substrates. Full article

This study aims to optimize the process parameters for manufacturing stainless steel AISI 316L (SS316L) components using Laser Powder Bed Fusion (LPBF) with a Laser-Adapted Powder Deposition System. The influence of volumetric energy density (VED), laser intensity, and interaction time on the topography, defect formation, and hardness of the manufactured parts was investigated. The LPBF process parameters were systematically varied, including laser power (50–250 W) and scanning speed (15–250 mm/s). This resulted in VED values ranging from 55.6 to 647.5 J/mm³. The optimization process revealed ideal process conditions at VED values of 170.9, 256.4, and 641.0 J/mm³, with a minimum laser intensity of 11.8 kW/mm² and interaction times ranging from 0.36 to 2.70 ms. Microstructural analysis revealed a predominantly austenitic phase with residual stresses associated with the LPBF process’s high cooling rates. Mechanical testing showed that parts manufactured under optimized conditions exhibited superior hardness (234–244 HV) compared to conventionally processed SS316L (170–220 HV). It was demonstrated that the laser-adapted powder deposition system can effectively fabricate high-precision components by understanding the interdependencies of parameters in LPBF. This approach contributes to optimizing manufacturing strategies for SS316L components. Full article

To address the severe surface imperfections induced during ultrafast pulsed laser fabrication of fused silica microfluidic chips, a high-precision CO₂ laser polishing strategy based on shallow-layer melting and reflow was employed. This method enables localized melting within an extremely thin surface layer, effectively smoothing the topography without altering the original microstructure geometry. An L9(3³) orthogonal experimental design was conducted to systematically investigate the influence of key parameters on polishing quality, identifying defocus distance as the dominant factor affecting surface roughness, followed by scanning speed and laser power. The optimal parameter combination was determined to be a laser power of 8 W, a defocus distance of 6 mm, and a scanning speed of 5 mm/s. Furthermore, an overlap rate between 38% and 63% was found to ensure sufficient fusion without excessive remelting, with the minimum surface roughness of 0.157 µm achieved at a 50% overlap rate. Based on the optimized parameters, adaptive scanning paths were designed for different functional units of a fused silica microfluidic chip. Surface characterization demonstrated that the surface roughness was remarkably reduced from 303 nm to 0.33 nm, meeting optical-grade surface quality requirements. Full article

Chromium-doped diamond-like carbon (DLC-Cr) nanocomposite films were successfully deposited using a high-power impulse magnetron sputtering (HiPIMS) system. The Cr content in the films was controlled by adjusting the Cr target powers. The influence of Cr content on the microstructure, mechanical properties, tribological performance, and wettability of the films was systematically investigated. The results show that the Cr content and deposition rate of the films increased with increases in the target power. The surface topography of the films evolved from smooth to rough as the Cr target increased from 10 W to 70 W. At low Cr doping rates, the film mainly exhibited an amorphous structure, whereas the nanocomposite structure was formed at proper Cr doping rates. Raman and XPS analyses revealed that Cr incorporation altered the I_D/I_G ratio and promoted the formation of Cr-C bonds, leading to a more graphitic and nanocomposite-like structure. The nanoindentation results show that an optimal Cr content enhances both hardness and elastic modulus, while higher Cr concentrations lead to a decline in mechanical strength due to more graphitization and decreasing stress. Tribological tests exhibited a significant reduction in the friction coefficient (0.21) and wear rate (0.63 × 10⁻¹⁴ m³/N·m) at a moderate Cr level. Additionally, the surface wettability evolved toward enhanced hydrophilicity with increasing Cr power, as evidenced by reduced water contact angles and increased surface energy. These findings demonstrate that controlled Cr incorporation effectively tailors the structure, stress state, and surface chemistry of DLC films, offering a tunable pathway to achieving optimal mechanical performance and tribological stability for advanced engineering applications. Full article

This study examined the association between biofilm growth and surface properties of 3D printed, milled, and conventional materials used for manufacturing fixed dental prostheses. Disc-shaped specimens were produced and finished from five 3D-printing resins (VarseoSmile Crown plus [VSC], NextDent C&B MFH [ND], VarseoSmile Temp [VST], Temp PRINT [TP], P Pro Crown & Bridge [P]), two polymer milling blocks (composite: TetricCAD [TC], PMMA: TelioCAD [TEL]), two conventional polymer materials (Tetric EvoCeram [TEC], Protemp 4 [PT]), and zirconia (ZR). Surface roughness (R_a), wettability, interfacial tension (IFT) and surface topography were examined. Three-day biofilms were grown on the specimens using A. naeslundii, S. gordonii, S. mutans, S. oralis, and S. sanguinis in a multi-species suspension. Biofilms were quantified by crystal violet staining and with a plating and culture method (CFU/mL). Linear regression analysis was computed to demonstrate associations between the surface properties and biofilm growth. The strength of this relationship was quantified by calculating Spearman’s ρ. TC exhibited the highest, and TP the lowest IFT. TEC showed the highest R_a, while TEL had the lowest, with significant differences detected particularly between milled and 3D-printed specimens. TP specimens exhibited the highest biofilm mass, while ZR surfaces retained the least. Bacterial viability within the biofilms remained similar across all tested materials. There was a strong negative correlation between total IFT and biofilm mass, and a moderate positive correlation between R_a and CFU/mL. Surface properties are shaped by material composition, microstructure, and manufacturing methods and play a crucial role in biofilm formation on dental restorations. Full article

The influence of nitrate (NO₃⁻) concentration on the corrosion resistance of the Inconel 625 (superalloy) was investigated. The surface of Inconel 625 was chemically modified by oxidation in an alkaline sodium nitrate(V) solution. The surface and microstructure of specimens were observed by a scanning electron microscope (SEM). The mechanical properties of Inconel 625 were characterized by microhardness (HV) measurements. The corrosion tests of materials were carried out by using the electrochemical method in the acidic chloride solution. The adsorption of the (Me_mO_n)_ads layer effectively separates the Inconel 625 surface from contact with the aggressive corrosive environment. The microhardness (HV10) value increased (about 13%) with the increase in nitrate concentration. A more-than-five-times-lower corrosion rate (CW) value was obtained for the Inconel 625 sample, whose surface was modified in an alkaline solution with the highest NO₃⁻ concentration. Chemical modification improves the structure and surface topography of the superalloy. After exposing Inconel 625 to an oxidizing environment (1.00 M NO₃⁻), the surface coverage degree (SC) was 80%. Full article

Interfacial adhesion between selective laser-melted (SLM) AlSi10Mg and polyimide (PI) insulating coatings is often limited by mismatched physicochemical properties. To improve adhesion, Al-rich and Si-rich microstructured surfaces were fabricated on the XY plane (perpendicular to the build direction) and the Z plane (parallel to the build direction) by acidic and alkaline etching, exploiting the characteristic microstructure of SLM AlSi10Mg. Surface topography, chemical composition, and wettability were characterized, and interfacial mechanical performance was evaluated by shear and pull-off tests. The microstructures increased surface roughness and improved wettability. The shear strength rose from 2.6 ± 1.5 MPa for the polished surface to 43.2 ± 8.6 MPa. The polished surface showed a pull-off strength of 2.2 ± 0.25 MPa. In pull-off tests, failure mainly occurred within the dolly/adhesive/PI system, indicating that the interfacial tensile strength exceeded the strength of the adhesive system; the maximum measured pull-off strength was 29.0 ± 1.3 MPa. Fractography predominantly showed cohesive failure in PI on Al-rich microstructures. Si-rich microstructures exhibited mixed failure, including fracture of the Si skeleton and tearing of PI, together with interfacial microcracks. Full article

As a potential strategic resource of critical metals, deep-sea cobalt-rich crusts represent one of the most promising metal reservoirs within oceanic seamount systems, and their metallogenic mechanism constitutes a frontier topic in deep-sea geoscience research. This review focuses on the cobalt-rich crusts from the Magellan Seamount region in the northwestern Pacific and synthesizes existing geological, mineralogical, and geochemical studies to systematically elucidate their mineralization processes and metal enrichment mechanisms from a microstructural perspective, with particular emphasis on cobalt enrichment and its controlling factors. Based on published observations and experimental evidence, the formation of cobalt-rich crusts is divided into three stages: (1) Mn/Fe colloid formation—At the chemical interface between oxygen-rich bottom water and the oxygen minimum zone (OMZ), Mn²⁺ and Fe²⁺ are oxidized to form hydrated oxide colloids such as δ-MnO₂ and Fe(OH)₃. (2) Key metal adsorption—Colloidal particles adsorb metal ions such as Co²⁺, Ni²⁺, and Cu²⁺ through surface complexation and oxidation–substitution reactions, among which Co²⁺ is further oxidized to Co³⁺ and stably incorporated into MnO₆ octahedral vacancies. (3) Colloid deposition and mineralization—Mn–Fe colloids aggregate, dehydrate, and cement on the exposed seamount bedrock surface to form layered cobalt-rich crusts. This process is dominated by the Fe/Mn redox cycle, representing a continuous evolution from colloidal reactions to solid-phase mineral formation. Biological processes play a crucial catalytic role in the microstructural evolution of the crusts. Mn-oxidizing bacteria and extracellular polymeric substances (EPS) accelerate Mn oxidation, regulate mineral-oriented growth, and enhance particle cementation, thereby significantly improving the oxidation and adsorption efficiency of metal ions. Tectonic and paleoceanographic evolution, seamount topography, and the circulation of Antarctic Bottom Water jointly control the metallogenic environment and metal sources, while crystal defects, redox gradients, and biological activity collectively drive metal enrichment. This review establishes a conceptual framework of a multi-level metallogenic model linking macroscopic oceanic circulation and geological evolution with microscopic chemical and biological processes, providing a theoretical basis for the exploration, prediction, and sustainable development of potential cobalt-rich crust deposits. Full article

Niobium nitride (δ-NbN) coatings were deposited on AISI 316L austenitic steel using reactive DC magnetron sputtering. This study investigates the effects of air oxidation on the surface morphology, topography, roughness, nanohardness, adhesion, and wear resistance of NbN coatings. Their microstructure and thickness were analyzed by scanning electron microscopy (SEM), while surface morphology and roughness were assessed using atomic force microscopy (AFM), and surface topography was assessed by an optical profilometer. Nanohardness was measured using a Berkovich indenter. Adhesion was evaluated via progressive-load scratch testing and Rockwell indentation (VDI 3198 standard). Wear resistance was assessed using the “ball-on-disk” method. Both as-deposited and oxidized NbN coatings improved the mechanical performance of the substrate surface. Air oxidation led to the formation of an orthorhombic Nb₂O₅ surface layer, which increased surface roughness and reduced hardness. However, the brittle oxide also contributed to a lower coefficient of friction. Despite reduced adhesion and increased surface development, the oxidized coating exhibited a significantly lower wear rate than the uncoated steel, though several times higher than that of the non-oxidized NbN. Considering its good wear and corrosion performance, along with the bioactivity confirmed in earlier research, the oxidized NbN coating can be considered a promising candidate for biomedical applications. Full article

In physiological environments, several metallic alloys, including titanium, stainless steel, cobalt–chromium, and emerging biodegradable systems such as magnesium (Mg), zinc (Zn), and iron (Fe), offer mechanical properties and biocompatibility suitable for load-bearing implants. With the rapid advancement of 3D printing technologies, these alloys can now be fabricated into patient-specific, complex geometries that enhance both structural performance and functional integration. Beyond serving as structural supports, 3D-printed alloys are increasingly engineered as localized drug-delivery platforms to release anti-inflammatory, antibacterial, anticancer, and osteogenic agents at the implant–tissue interface, addressing the dual clinical needs of site-specific therapy and mechanical stabilization. Nevertheless, this field remains underexplored because studies differ widely in alloy chemistry, surface topography, porosity, coating strategy, drug-loading methods, and release profiles, as well as in how material degradation or passivation interacts with pharmacokinetics. For the first time, this review consolidates drug-loading and elution strategies across 3D-printed alloy platforms, compares therapeutic categories in relation to alloy and coating types, and critically evaluates how the surface microstructure or alloy geometry influences release behavior. Full article