Search Results (19)

Grey cast iron brake discs remain standard in automotive braking systems due to their favourable thermal conductivity and mechanical strength. However, increasingly stringent environmental regulations, including Euro 7, necessitate enhanced surface durability to reduce particulate emissions and mitigate corrosion-related degradation. In this context, laser metal deposition (LMD) offers a promising route to engineer wear-resistant coating systems with tailored microstructures. This study investigates phase formation and microstructural evolution in a 316L/430L-WC multilayer coating deposited on grey cast iron (GJL) brake discs and subjected to brake-shock testing to replicate thermomechanical load cycles representative of real braking conditions. X-ray diffraction (XRD) performed on the interlayer region between the 316L and 430L-WC layers revealed clear evidence of σ-phase formation, indicating intermetallic transformations facilitated by thermal cycling. Microstructural characterization using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) identified localized enrichment of Cr- and Fe-rich regions that support the XRD-based interpretation of σ-phase development. These results provide insights into phase transformations and elemental diffusion in LMD-fabricated brake-disc coatings. The findings advance the understanding of thermally induced transformations in multilayer steel systems and support the optimization of LMD coatings for high-temperature and wear-intensive applications through advanced analytical evaluation. Full article

3D-printed concrete (3DPC) enables formwork-free automated construction with geometric flexibility and improved material efficiency, yet its engineering reliability remains limited by interlayer weakening generated during sequential deposition. This review critically examines the formation, cross-scale consequences, and control of weak interlayer interfaces in 3DPC. In most studies, the 3DPC printing interval ranges from 20 s to 120 min, and the average interfacial bond strength ranges from 0.1 to 16 MPa. Interfacial weakness arises from the asynchronous evolution of adjacent layers in terms of contact quality, rheological recovery, moisture exchange, and early-age hydration. This mismatch promotes pore enrichment, discontinuity of hydration products, reduced phase continuity, and consequent local mechanical softening. These defects govern interlayer bonding, crack propagation, anisotropy, and stress-transfer pathways, and their effects propagate from material properties to member response, structural performance, and durability degradation. Rather than treating the interface as a localized cold joint, this review frames it as a process-induced multiscale variable linking printing history, microstructure, mechanical response, transport behavior, and serviceability. Current research remains constrained by non-comparable testing methods, undefined quantitative thresholds, and models that still rely heavily on empirical calibration. Future work should establish standardized characterization, transferable interface descriptors, multiscale predictive models, real-time quality control, and design methods that explicitly incorporate interfacial variability. Full article

Controlling deposition parameters is fundamental to obtaining the desired properties of cathodic arc physical vapor deposition (PVD) coatings. Achieving uniform coatings on tools with complex, sharp geometries remains a significant challenge due to localized ion flux concentration. Pulsing the substrate bias is an effective way of controlling deposition energy. However, while widely used in cathodic arc PVD, the relationship between the actual bias waveform, coating integrity on sharp tool geometries, and resulting machining performance has not been systematically established. This study investigates the effect of pulsed bias duty cycle (20% to 90%) and frequency (1 to 20 kHz) on the microstructural evolution, residual stress state, and machining performance of AlTiN coated tools. Real-time oscilloscope measurements demonstrated that system inductance and capacitance significantly distort the ideal bias waveform. Microstructural analysis via Focused Ion Beam/Scanning Electron Microscopy (FIB/SEM) cross-sectioning confirmed that all bias parameters generated a dense microstructure. While pulse frequency had no significant influence on micromechanical properties or residual stress states, the duty cycle was the dominant variable. High-energy deposition (90% duty cycle) increased hardness to 33.9 GPa but generated severe compressive residual stresses (−5.2 GPa). This extreme compressive stress led to catastrophic edge delamination on sharp solid carbide endmills. Conversely, a low-energy 20% duty cycle generated a coating with lower hardness (29.4 GPa) and a near-neutral stress state (0.5 GPa), effectively preserving the edge integrity. Unlike the endmills, the turning inserts maintained their edge integrity across all deposition conditions. During the high-speed (350 m/min) dry turning of AISI 304 stainless steel, all evaluated coatings exhibited comparable tool life and cutting forces. Wear progression was characterized by rake cratering, combined with abrasion and adhesion-induced attrition on the flank. The results indicate that tool life in this extreme environment is governed primarily by high-temperature thermo-chemical stability rather than initial room-temperature hardness. Lower-energy pulsed bias deposition therefore represents a robust strategy for coating a wide range of tool geometries, delivering equivalent high-speed machining performance while preventing stress-induced delamination on sharp features. Full article

Three-dimensional printed polymers produced using Fused Deposition Modelling (FDM) exhibit directional microstructures resulting from filament paths, layer interfaces, and cellular infill, leading to mechanical and tribological responses distinct from those of homogeneous bulk materials. This study presents a comparative tribomechanical evaluation of polypropylene (PP) bulk inserts and 3D-printed polyethylene terephthalate glycol (PETG) inserts with a 30% hexagonal infill, relevant for robotic gripping applications. Progressive scratch tests were performed under loads from 5 to 100 N (150 N for PP), and profilometry was applied to quantify groove morphology, ridge formation, and displaced-volume ratios. An elasto-plastic conical indentation model was used to derive indentation pressures and elastic–plastic transition radii from groove geometry. The PETG inserts exhibited heterogeneous groove depth, intermittent ridge tearing, and friction fluctuations associated with the internal infill structure, consistent with previous findings on anisotropy and architecture-dependent behaviour in additively manufactured polymers. In contrast, bulk PP demonstrated smoother friction profiles and more stable plastic flow under increasing loads. Two functional indices—specific frictional work and ridge-to-trace volumetric ratio—are introduced to support material selection for robotic gripping systems. The results show that local contact mechanics in 3D-printed inserts are governed by print-induced structural features and can be effectively evaluated through a scratch-based elasto-plastic analysis. The methods and results presented in this work support the rational selection and design of polymer inserts for robotic gripper fingertips. The proposed scratch-based elasto-plastic evaluation framework enables manufacturers and automation engineers to compare 3D-printed and conventional materials based on friction stability, wear response, and deformation resistance. This approach can be directly applied to optimise gripping performance in industrial handling, packaging, and collaborative robotics. Full article

The increasing demand for sustainable materials has accelerated the development of environmentally friendly filaments for fused deposition modeling (FDM). In this study, the surface roughness and thermal degradation behavior of sustainable PLA-based filaments, including PLA, recycled PLA (Re–PLA), and wood-filled PLA (Wood–PLA), were systematically investigated under different FDM printing conditions. A full factorial experimental design was employed to identify the dominant processing parameters and optimize surface quality. Surface roughness was evaluated using values Ra, Rz, and Rq parameters measured on three different surface orientations (top surface at 0°, top surface at 45°, and side surface). Scanning electron microscopy (SEM) was used to examine the relationship between roughness measurements and surface morphology, while thermogravimetric analysis (TGA) was performed to evaluate the thermal degradation behavior of the filaments in relation to printing temperature. The results have shown that filament material is the most important parameter affecting surface roughness. While Wood–PLA exhibited the highest roughness due to fiber-induced surface heterogeneity, recycled Re–PLA showed moderate surface irregularities resulting from degradation compared to pure PLA. Despite a rougher filament surface prior to production, recycled PLA exhibited a surface morphology similar to that of pure PLA after printing, influenced by the processing parameters. Furthermore, SEM findings indicated that the Ra parameter predominantly reflects macro-scale surface topography, while local microstructural heterogeneity can be better characterized by complementary roughness parameters such as Rz. These findings support optimizing printing conditions to improve surface quality and more widespread use of sustainable FDM filaments in applications where surface roughness is critical. Full article

(WMoTaNb)SiN refractory high-entropy nitride films were deposited via magnetron cosputtering, and the Si content was systematically regulated by varying the Si target power to investigate its influence on the microstructure, mechanical properties, oxidation resistance, and oxyhydrogen-flame ablation behavior. All the films exhibited dense columnar architectures with a distinct FCC + BCC dual-phase structure, whereas increasing the Si target power led to a gradual increase in the deposition rate and Si incorporation. The mechanical properties displayed a non-monotonic relationship with the Si target power, with film applied at an intermediate level of Si target power showing the highest hardness, approximately 28.5 GPa, and improved elastic recovery. Tribological evaluations using a GCr15 steel ball revealed that this film exhibited the lowest wear rate of 4.1 × 10⁻⁶ mm³·N⁻¹·m⁻¹ and a narrower wear track, which was attributed to reduced plastic deformation and the development of an oxygen-enriched tribofilm during sliding. High-temperature oxidation at 1000 °C in air revealed that Si incorporation significantly modified oxide-scale evolution by refining the oxidation products and altering the scale architecture, while the protection of the scale was governed by its continuity and compactness rather than its thickness alone. Oxyhydrogen-flame ablation tests revealed that the degradation behavior was primarily driven by the competition between oxidation-induced mass increase and ablation-induced material loss, with localized film disruption and substrate exposure playing a decisive role. In summary, the findings illustrate that an optimal Si target power establishes a favorable equilibrium between mechanical strength, tribological efficiency, oxidation resistance, and ablation performance, underscoring the potential of (WMoTaNb)SiN films for protective applications in complex mechanical and extreme thermal environments. Full article

The Polyether ether ketone (PEEK) suffers from insufficient interlayer molecular chain diffusion and weak interfacial fusion during Fused Filament Fabrication (FFF) due to its high melt viscosity and rapid cooling characteristics, restricting the mechanical properties and engineering applications of printed parts. To improve the interlayer bonding quality of FFF-printed PEEK, an in situ preheating technology integrated into the print nozzle was proposed and implemented. Through a high-temperature controllable preheating system that moves synchronously with the nozzle, local precise heating is performed on the surface of the deposited layer to actively regulate the thermal history of the interlayer interface. Systematic studies on the effect of preheating temperature were conducted. The results show that the influence of preheating temperature on part performance follows a trend of first increasing and then decreasing. When the preheating temperature is 280 °C, the comprehensive performance of the specimens is optimal: the tensile strength reaches 69.47 MPa, which is 21.3% higher than that of the non-preheated reference group; the elongation at break is 71.07%; and the porosity decreases to 8.36%. Microstructural analysis reveals that moderate preheating facilitates molecular chain diffusion and interfacial fusion, whereas excessive heating induces thermal oxidative degradation of PEEK, resulting in deteriorated mechanical performance. These findings confirm that in situ preheating represents an effective approach for enhancing interlayer bonding, thereby offering a practical solution for the additive manufacturing of high-performance PEEK components. Full article

High-strength quenched and tempered steels such as EN 42CrMo4, widely used for marine shaft applications due to their high strength, toughness, and fatigue resistance, are nevertheless susceptible to surface degradation under severe dry sliding conditions. To enhance surface integrity and tribological performance, this study investigates laser-cladded AISI 410L and mixed AISI 410L/AISI 4140 (50/50 wt.%) coatings deposited on EN 42CrMo4 steel using a high-power diode laser (HPDL). Two-layer coatings were produced, and selected specimens underwent post-cladding stress-relief heat treatment to mitigate residual stresses and temper as-solidified microstructures. Microstructural characterization revealed refined dendritic and martensitic morphologies, while the mixed-alloy coatings showed increased carbide formation and improved hardness homogeneity. The mixed AISI 410L/AISI 4140 coatings achieved significantly higher microhardness values (≈530–555 HV) compared to single-alloy 410L coatings (≈310–420 HV). Tribological testing under dry sliding conditions (Al₂O₃ counterbody, 5 N load, 0.5 m/s sliding speed) demonstrated that the mixed-alloy coatings exhibited substantially lower steady-state friction coefficients (μ ≈ 0.65–0.69) and markedly reduced specific wear rates (≈11–17 × 10⁻¹⁴ m³/Nm) compared to the 410L coatings (≈150–175 × 10⁻¹⁴ m³/Nm). Post-cladding heat treatment further stabilized friction behaviour and reduced wear in the mixed-alloy system by tempering martensite and alleviating localized stress concentrations. Wear mechanism analysis revealed a transition from severe abrasive wear with fatigue-induced delamination in the 410L coatings to predominantly mild abrasive wear in the mixed-alloy coatings, accompanied by localized plastic deformation. Overall, the results establish clear correlations between microstructure, hardness, and tribological response, demonstrating that mixed-alloy laser cladding is an effective strategy for enhancing the dry sliding performance of EN 42CrMo4 steel in demanding marine applications. Full article

Protein droplets exhibit complex self-assembly and deposition behaviors driven by evaporation, which has attracted increasing attention in recent years. Under evaporation, limited volume and locally concentrated protein solutions can undergo liquid–liquid phase separation (LLPS) and liquid–liquid crystalline phase separation (LLCPS), inducing the formation of concentrated droplets and anisotropic structures. The combined effects of interfacial tension and internal flow field induce a variety of deposition patterns on the substrate, providing great significance for the development of functional biomaterials. This paper reviews the physical processes experienced by protein/fibril droplets during evaporation, focusing on the formation mechanism of evaporation and their phase separation behaviors. At the same time, the review systematically summarized the key factors affecting the deposition patterns, and a variety of methods were introduced to pattern deposition, such as external electric field and micro-structured substrates. Furthermore, the potential applications of proteins/fibrils droplet deposition were discussed in multiple fields. This review aims to provide systematic theoretical support and experimental reference for understanding and controlling the deposition behavior of proteins/fibrils droplets, and to promote their further application in functional materials and biomedical engineering. Full article

Reactive multilayer foils (RMFs) for joining processes have attracted a great deal of attention over the last few years. They are capable of exothermic self-propagating reactions and can serve as localized heat sources for joining applications when ignited by suitable means. Using short and ultrashort pulsed lasers with carefully selected parameters, cutting and shaping of RMFs makes it possible to tailor heat release characteristics without triggering the reaction. The present study is an investigation of microstructural changes induced by femtosecond laser machining of a commercially available Ni/Al-based RMF. The effects of the specific laser parameters pulse duration and repetition rate on the heat-affected zone (HAZ) are investigated by scanning and transmission electron microscopy. Debris consisting of oxide deposits can be found at a distance of several tens of microns from the cut edge. A negligible HAZ extending to less than 100 nm was observed for all parameters tested and no signs of ignition of a self-propagating reaction were observed. These results underline the suitability of femtosecond lasers for metal machining with minimal heat input. Full article

Controlling the shape and internal strain of nanowires (NWs) is critical for their safe and reliable use and for the exploration of novel functionalities of nanodevices. In this work, transmission electron microscopy was employed to examine bent Si NWs prepared by asymmetric electron-beam evaporation. The asymmetric deposition of Cr caused the formation of nanosized amorphous-Si domains; the non-crystallinity of the Si NWs was controlled by the bending radius. No other intermediate crystalline phase was present during the crystalline-to-amorphous transition, indicating a direct phase transition from the original crystalline phase to the amorphous phase. Moreover, amorphous microstructures caused by compressive stress, such as amorphous Cr domains and boxes, were also observed in the asymmetric Cr layer used to induce bending, and the local non-crystallinity of Cr was lower than that of Si under the same bending radius. Full article

Corrosion inhibiting conversion coating formation is triggered by the activity of micro-galvanic couples in the microstructure and subsequent local increase in pH at cathodic sites, which in the case of aluminium alloys are usually intermetallics. Ceria coatings are formed spontaneously upon immersion of aluminium alloys in a cerium conversion coating solution, the high pH gradient in the vicinity of intermetallics drives the local precipitation of ceria conversion compounds. Cu-rich intermetallics demonstrate a highly cathodic nature and have shown the local precipitation reaction to occur readily. Fe-rich intermetallics are, however, weaker cathodes and have shown varied extents of localized deposits and are in focus in the current work. Model cast Al-7wt.%Si alloys have been designed with 1 wt.% Fe, solidified at different cooling rates to achieve two different microstructures, with big and small intermetallics, respectively. Upon subjecting the two microstructures to the same conversion coating treatment (immersion in a 0.1 M CeCl₃ solution) for a short period of 2 h, preferential heavy deposition on the boundaries of the big intermetallics and light deposition on the small intermetallics was observed. Based on these observations, a mechanism of localized coating initiation at these Fe-rich intermetallic particles (IM) is proposed. Full article

Fused deposition modeling (FDM) is currently the most popular 3D printing method, where thermoplastic polymers are predominantly used. Among them, the biobased poly(lactic acid) (PLA) governs the FDM filament market, with demand higher than supply, since not all grades of PLA are suitable for FDM filament production. In this work, the effect of a food grade chain extender (Joncryl ADR^® 4400) on the physicochemical properties and printability of PLA marketed for injection molding was examined. All samples were characterized in terms of their mechanical and thermal properties. The microstructure of the filaments and 3D-printed fractured surfaces following tensile testing were examined with optical and scanning electron microscopy, respectively. Molecular weight and complex viscosity increased, while the melt flow index decreased after the incorporation of Joncryl, which resulted in filaments of improved quality and 3D-printed constructs with enhanced mechanical properties. Dielectric spectroscopy revealed that the bulk properties of PLA with respect to molecular mobility, both local and segmental, were, interestingly, not affected by the modifier. Indirectly, this may suggest that the major effects of the extender are on chain length, without inducing chain branching, at least not to a significant extent. Full article

Magnesium alloys are used in the motorsport and aerospace fields because of their high specific strength. However, due to their low corrosion resistance, protective surface treatments, such as conversion coating or electroless plating, are necessary when they are used in humid or corrosive environments. The present study aimed at evaluating the effect of plasma electrolytic oxidation (PEO), followed by the deposition of a polymeric layer by powder coating, on the rotating bending fatigue behaviour of the wrought magnesium alloy ZK60A-T5. The specimens were extracted from forged wheels of racing motorbikes and were PEO treated and powder coated. Microstructural characterization was carried out by optical (OM) and scanning electron microscopy (SEM) to analyse both the bulk material and the multilayer, consisting of the anodic oxide interlayer with the powder coating top layer (about 40 µm total thickness). Rotating bending fatigue tests were carried out to obtain the S–N curve of PEO-treated specimens. The results of the rotating bending tests evidenced fatigue strength equal to 104 MPa at 10⁶ cycles and 90 MPa at 10⁷ cycles. The results of the investigation pointed out that PEO led to a reduction in fatigue strength between 14% and 17% in comparison to the untreated alloy. Fracture surface analyses of the fatigue specimens, carried out by SEM and by 3D digital microscopy, highlighted multiple crack initiation sites at the interface between the PEO layer and substrate, induced by the concurrent effects of coating defects, local tensile stresses in the substrate, and increased roughness at the substrate–coating interface. Full article

Magnetocaloric materials based on field-induced first order transformations such as Ni-Mn-Ga-Co are promising for more environmentally friendly cooling. Due to the underlying martensitic transformation, a large hysteresis can occur, which in turn reduces the efficiency of a cooling cycle. Here, we analyse the influence of the film microstructure on the thermal hysteresis and focus especially on large angle grain boundaries. We control the microstructure and grain boundary density by depositing films with local epitaxy on different substrates: Single crystalline MgO(0 0 1), MgO(1 1 0) and Al${}_2$O${}_3$(0 0 0 1). By combining local electron backscatter diffraction (EBSD) and global texture measurements with thermomagnetic measurements, we correlate a smaller hysteresis with the presence of grain boundaries. In films with grain boundaries, the hysteresis is decreased by about 30% compared to single crystalline films. Nevertheless, a large grain boundary density leads to a broadened transition. To explain this behaviour, we discuss the influence of grain boundaries on the martensitic transformation. While grain boundaries act as nucleation sites, they also lead to different strains in the material, which gives rise to various transition temperatures inside one film. We can show that a thoughtful design of the grain boundary microstructure is an important step to optimize the hysteresis. Full article