Search Results (17)

The anodization of aluminium/aluminium alloys is widely used to produce anodic nanoporous networks for metal layered structures, with applications in energy harvesting technologies and sensor systems. Anodic aluminium oxide (AAO) with thickness of ~10 μm and average pore diameter of 13, 33, and 95 nm is prepared by tuning acids and voltages, being further used for electroless nickel deposition, performed for 10 min using conventional electrolyte with sodium hypophosphite reductor and pH 4.5. The formation of Ni nanotubes or nanorods is found to be strongly dependent on AAO pore size. Ni is detected in the whole pore depth and found to form 5–7 μm long continuous tube-like structures only in AAO with pore diameter of 95 nm, being kept just on the AAO top for smaller pore diameters. Nickel distribution in pores along cross-section of AAO is studied as well revealing continuously decreasing ratio to phosphorus amount. The magnetic properties of the resulting Ni 3D structure of a flat conductive layer and nanotubes perpendicular to it do not show significant differences in parallelly and perpendicularly oriented magnetic fields. These observations are discussed considering possible formation mechanisms for an electroless deposited Ni layer on AAO with different structures. Full article

Nickel–phosphorus (NiP) alloys have been widely used in many engineering fields such as aerospace, automotive, and optics; however, it is difficult to study the material removal mechanism and microscopic size changes in the polishing process of nickel–phosphorus alloys through simple experiments. In light of these difficulties, there is a need to improve our understanding of the surface friction and wear mechanisms of NiP materials. In the present study, molecular dynamics simulations are employed for the first time to investigate the material removal mechanism, mechanical response, phase transformation, and stress distribution of two NiP alloys with different phosphorus contents during the nano-polishing process by adjusting the polishing depth and speed. Our simulation results indicate that the mechanical response of the low-phosphorus alloy is slightly higher than that of the high-phosphorus NiP alloy. Larger polishing depths and higher speeds reduce the surface quality and lead to increased residual stress. The findings presented herein provide an atomic-level understanding of the material removal mechanism of NiP alloys via MD methodology and offer valuable guidance for selecting alloys with an appropriate NiP ratio as engineering materials and for developing processing methods to improve surface quality. Full article

The X-ray satellite “Einstein Probe” of the Chinese Academy of Sciences (CAS) was successfully launched on 9 January 2024 at 15:03 Beijing Time from the Xichang Satellite Launch Center in China with a “Long March-2C” rocket. The Einstein Probe is equipped with two scientific X-ray telescopes. One is the Wide-field X-ray Telescope (WXT), which uses lobster-eye optics. The other is the Follow-up X-ray Telescope (FXT), a Wolter-I type telescope. These telescopes are designed to study the universe for high-energy X-rays associated with transient high-energy phenomena. The FXT consists of two modules based on 54 thin X-ray Wolter-I grazing incidence Ni-replicated mirrors produced by the Italian Media Lario company, as contributions from the European Space Agency and the Max Planck Institute for Extraterrestrial Physics (MPE), which also provided the focal-plane detectors. Meanwhile, the Institute of High Energy Physics (IHEP), together with the Harbin Institute of Technology and Xi’an Institute of Optics and Precision Mechanics, has also completed the development and production of the structural and thermal model (STM), qualification model (QM) and flight model (FM) of FXT mirrors for the Einstein Probe (EP) satellites for demonstration purposes. This paper introduces the precision manufacturing adopted in China of Wolter-I X-ray mirror mandrels similar to those used for the EP-FXT payload. Moreover, the adopted electroformed nickel replication process, based on a chemical nickel–phosphorus alloy, is reported. The final results show that the surface of the produced mandrels after demolding and the internal surface of the mirrors have been super polished to the roughness level better than 0.3 nm RMS and the surface accuracy is better than 0.2 μm, and the mirror angular resolution for single mirror shells may be as good as 17.3 arcsec HPD (Half Power Diameter), 198 arcsec W90 (90% Energy Width) @1.49 keV (Al-K line). These results demonstrate the reliability and advancement of the process. As the first efficient X-ray-focusing optics manufacturing chain established in China, we successfully developed the first focusing mirror prototype that could be used for future X-ray satellite payloads. Full article

The paper investigates various methods of microfinishing and arrives at the best technique to produce a very smooth surface. Various setups, with and without oscillation, were developed, together with a microfinishing attachment used on conventional lathes and milling machines. The workpiece material used was an amorphous nickel–phosphorus Ni–P alloy. The surface roughness parameters, such as Sa, Sv, and Sp, were measured with the TalySurf CCI6000 instrument. For the measurement of the surface protrusions, an “analysis of islands” technique was used at various levels of cut-off. The 2BA method—machining below the workpiece axis with oscillation—turned out to be the most effective method applied because it had the highest density of protrusions while having the smallest value of surface roughness. Non-oscillation with the machining zone below the axis also becomes effective, indicating that repositioning can compensate for a lack of oscillation. Already, the very compact surface structure achieved with minimized depths in the valleys by the 2BA method supported the improvement in tribological performance and increase in load-carrying capacity, together with lubricant retention enhancement. These results show that the microfinishing process can be optimized by parameter tuning, and also, non-oscillating methods could come to be a practical alternative, probably reducing the complexity of equipment and cutting costs. Further studies need to be aimed at the scalability of these methods and their application to other materials and fields. Full article

Conventionally used brass alloy CuZn30 shows problems with corrosion resistance in the form of dezincification when used in brass instruments. Therefore, within the scope of this investigation, a new brass alloy CuZn30 is developed in the microalloy range with corrosion-free or corrosion-inhibiting properties. First, the influence of microalloying elements on the phase composition is investigated by simulation using Thermo-Calc. On the basis of this, suitable alloying elements and contents are selected and a modified CuZn30X alloy with 0.1% phosphorus, tin, and nickel in mass fractions, respectively, is produced. The modified alloy is then investigated with regard to its mechanical and microstructural composition and its corrosion properties. The corrosion properties were examined using stress corrosion cracking tests, dezincification tests, and the recording of polarization curves. The modified alloy exhibited good cold and hot rolling properties as well as good corrosion resistance. The dezincification test confirmed the improved corrosion resistance of the modified CuZn30X alloy, which is attributed to the formation of a protective top layer due to the alloying elements. Full article

The spinning cup, a crucial component of textile equipment, relies heavily on 2A12 aluminum alloy as its primary raw material. Commonly, electroplating and chemical nickel–phosphorus (Ni-P) plating are employed to improve the surface characteristics of the object. Nevertheless, due to the growing expectations for the performance of aluminum alloys, the hardness and wear resistance of Ni-P coatings are no longer sufficient to fulfill industry standards. This study primarily focuses on the synthesis of Ni-B-PTFE nanocomposite chemical plating and its effectiveness when applied to the surface of 2A12 aluminum alloy. We examine the impact of the composition of the plating solution, process parameters, and various other factors on the pace at which the coating is deposited, the hardness of the surface, and other indicators of the coating. The research findings indicate that the composite co-deposited coating achieves its optimal surface morphology when the following conditions are met: a nickel chloride concentration of 30 g/L, an ethylenediamine concentration of 70 mL, a sodium borohydride concentration of 0.6 g/L, a sodium hydroxide concentration of 90 g/L, a lead nitrate concentration of 30 mL, a pH value of 12, a temperature of 90 °C, and a PTFE concentration of 10 mL/L. The coating exhibits consistency, density, a smooth surface, and an absence of noticeable pores or fissures. The composite co-deposited coating exhibits a surface hardness of 1109 HV_0.1, which significantly surpasses the substrate’s hardness of 232.38 HV_0.1. The Ni-B-PTFE composite coating exhibits an average friction coefficient of around 0.12. It has a scratch width of 855.18 μm and a wear mass of 0.05 mg. This coating demonstrates superior wear resistance when compared to Ni-B coatings. The Ni-B-PTFE composite coating specimen exhibits a self-corrosion potential of −6.195 V and a corrosion current density of 7.81 × 10⁻⁷ A/cm², which is the lowest recorded. This enhances its corrosion resistance compared to Ni-B coatings. Full article

In the present study, the bioactivity, cytotoxicity, and tribological properties of a nickel-free austenitic stainless steel produced via the mechanical alloying of elemental iron, chromium, and manganese nitride powders following by hot isostatic pressing was investigated. Powders after 90 h of mechanical alloying were consolidated via hot isostatic pressing at 1150 °C (1425 K) and heat treated at 1175 °C (1448 K) for 1 h in a vacuum with furnace cooling. Tribological tests were performed to determine the resistance of the as-received nickel-free steel. It was noticed that applying heat treatment after hot isostatic pressing decreases the average friction coefficient and wear rate of the austenitic steel. An immersion test in a simulated body fluid for 28 days at 37 ± 1 °C has been used to determine the biocompatibility of the tested material. The SEM-EDS analysis allowed us to characterise the morphology of the films and the elements of the steel on the thin-film layer. Elements typical of apatite (calcium and phosphorus) were detected on the surface of the sample. Cellular toxicity tests showed no significant toxic side effects for Saos-2 human osteosarcoma cells and the number of Saos-2 human osteosarcoma cells on the nickel-free steel was greater than on the 316LV grade steel. Full article

In this study, we synthesized three low-sulfur and low-phosphorus ionic liquids (ILs). These were N₈₈₈₁₆P₈, P₈₈₈₁₆P₈, and P₈₈₈₁₆DOSS. The viscosity and thermal stability of the three ILs were analyzed. The tribological properties and lubrication mechanisms of the three ILs were investigated as lubricants for a carbide ball–Inconel 690 nickel-based alloy friction pair and compared at 50 °C and 150 °C. The wear spots of the carbide ball and nickel-based alloy disc samples were characterized using SEM and EDS. The experimental results revealed that P₈₈₈₁₆P₈ had excellent tribological properties. The lubrication mechanism of P₈₈₈₁₆P₈ as a lubricant for the carbide ball–Inconel 690 nickel-based alloy friction pair was investigated using XPS. The excellent friction reduction and anti-wear properties of P₈₈₈₁₆P₈ could be attributed to the tribo-chemistry between P₈₈₈₁₆P₈ and Inconel 690 as well as the formation of a tribo-film on the wear-spot surface. This high-performance IL, suitable for carbide ball–Inconel 690 contact, will be applied to a cutting process of Inconel 690. Full article

Electroless nickel composite coatings have the potential for high-temperature tribological applications, and a combination of high wear resistance and low friction factor is one of the desirable solutions but still a tricky problem. The addition of self-lubricating WS₂ and hard Si₃N₄ nanoparticles to the Ni-P coatings is expected to obtain good high-temperature tribological performance. In this work, Ni-P-Si₃N₄-WS₂ composite coatings with various contents of WS₂ nanoparticles were prepared using electroless plating and subsequently annealed at 400 °C in an inert atmosphere. The tribological properties of the coatings were evaluated using a ball-on-disc wear instrument at operating temperatures from 25 to 600 °C. The microstructure, chemical composition, and surface morphology of the coatings were characterized by X-ray diffractometry (XRD), energy disperse spectroscopy (EDS), and scanning electron microscopy (SEM). Upon increasing the WS₂ dosage in the bath, the WS₂ content in the coating increased and the micro-hardness of the as-plated coating increased from 539 to 717 HV. After heat treatment, the coating underwent a crystallization process, and the hardness increased from 878 to 1094 HV. The main wear mechanism of the coating changed from adhesive wear in the as-plated state to abrasive wear in the annealed state. The annealed Ni-P-Si₃N₄-WS₂ coating with a WS₂ dosage of 2.5 g/L in the bath exhibited excellent mechanical properties, with a hardness of 10.9 GPa, a friction coefficient of ~0.51, and a wear rate of 8.4 × 10⁻¹⁵ m³N⁻¹⋅m⁻¹ at room temperature, and maintained optimal performance at high temperatures. At operating temperatures of 200, 400, and 600 °C, the form of wear was adhesive wear for coatings with a WS₂ dosage <1.5 g/L and abrasive wear for coatings with a WS₂ dosage ≥1.5 g/L. The synergism of WS₂ and Si₃N₄ particles refined the grains of the Ni-P matrix in as-plated coatings and obviously reduced the friction coefficient of friction pairs in annealed coatings at all operating temperatures. Full article

The present study proposes an overall recycling process for spent hydrodesulfurization (HDS) catalysts. The process put together stages already known in the technical literature, tested again with samples coming from the roasting stage in a pilot kiln, which is the most limiting stage of metal recovery from spent catalysts. These catalysts contain valuable metals like cobalt (Co), molybdenum (Mo), nickel (Ni), and vanadium (V). In particular, one Co-Mo catalyst was treated in order to optimize the roasting step (time, soda ash, and temperature) at a pilot scale and thus maximize the extraction yield of molybdenum (Mo) and vanadium (V). In particular, a dry Co-Mo catalyst was used. After roasting at 700 °C for 2.5 h, the best conditions, the catalysts underwent water leaching, separating Mo and V from Co and the alumina carrier, which remained in the solid residue. The pregnant solution was treated to remove arsenic (As) and phosphorus (P), representing the main impurities for producing steel alloys. V was precipitated as NH₄Cl, and further calcined to obtain commercial-grade V₂O₅, whereas Mo was recovered as molybdic acid by further precipitation at a pH of around one. Thus, molybdic acid was calcined and converted into commercial-grade MoO₃ by calcination. The hydrometallurgical section was tested on a lab scale. The total recovery yield was nearly 61% for Mo and 68% for V, respectively, compared with their initial concentration in the spent Co-Mo catalysts. Full article

This work uses the solvent casting method to fabricate an elastomeric tool with polyurethane as the base material and silicon carbide (SiC) as embedded abrasive particles. The distribution of abrasive particles and the pore structure in the fabricated tools are analyzed. The fabricated tools are porous in nature and have self-replenishing as well as self-lubrication properties. Aluminum 6061 alloy and electroless nickel-phosphorus plating having different initial roughness are selected as workpieces to study the wear mechanisms and loading of the flexible abrasive tool. The rotational speed of the tool, tool compression, and feed rate are fixed input process parameters. Total finishing time, sliding distance, and roughness are varied to obtain output responses. The workpiece material is also taken into account as a variable parameter in this study. These materials are classified as different counter surfaces as their surface roughness and mechanical properties vary. The finishing time and sliding distance for these counter surfaces differ in order to relate their effects on tool wear and loading. The nickel-plated surface shows a higher percentage reduction in surface roughness of 92% as compared to the aluminum surface, with a 62% reduction in surface roughness. The coefficient of friction, wear, and tool condition are analyzed to understand the mechanism of tool wear and tool loading. In this process, both two-body and three-body abrasions occur simultaneously and continuously. Full article

Electric furnace ferronickel slag (EFS) is a typical magnesium-rich industrial by-product discharged from the manufacture of nickel and iron-nickel alloys. The approach to use it as the raw material for the preparation of magnesium phosphate cement (MPC) has potential and proves effective. In this study, three different phosphorus sources (PS) including phosphoric acid (H₃PO₄, PA), sodium dihydrogen phosphate (NaH₂PO₄, SDP) and potassium dihydrogen phosphate (KH₂PO₄, PDP) were used to react with EFS to prepare the EFS-based MPC (EMPC), and the effects of raw material mass ratio (EFS/PA, EFS/SDP, EFS/PDP) on the compressive strength, early hydration temperature and microstructure of EMPC pastes were investigated. Results showed that the compressive strength of EMPC paste is significantly impacted by the type of phosphorus source and the raw materials mass ratio. When the EFS/PDP ratio is 4.0, the compressive strength of the MPC paste reaches up to 18.8, 22.8 and 27.5 MPa at 3, 7 and 28 d, respectively. Cattiite (Mg₃(PO₄)₂·22H₂O), K-struvite (KMgPO₄·6H₂O) and/or Na-struvite (NaMgPO₄·6H₂O) were identified as the main hydration products of EMPC. The development of EMPC mainly involves the dissolution of a phosphorus source, MgO and Mg₂SiO₄, formation of hydration product as binder, and combination of the unreacted raw materials together by binders to build a compact form. Full article

Electroless Nickel–Phosphorus (Ni-P) coating is recognized mostly for its outstanding corrosion and wear-resistant behavior. The intrinsic corrosion and wear-resistant properties of Ni-P-based coating could be further upgraded by incorporating appropriate second-phase additive particles into the coating matrix. However, such properties of the Ni-P-based coating greatly rely on the surface and microstructural evolution arising with the co-deposition of the additive particles. In this study, submicron Si₃N₄ (average size ~200 nm) and nano Si₃N₄ (average size ~20 nm) particles were incorporated while depositing a Ni-P alloy in a low-carbon steel substrate to develop the Ni-P-Si₃N₄ composites through the electroless coating method. The 20 nm Si₃N₄-incorporated composite coating constituted fewer defects such as cavities and micropores on the surface, but such defects significantly appeared on the surface of the composite after the incorporation of 200 nm Si₃N₄ nanoparticles. Subsequently, the composite Ni-P-Si₃N₄, developed with the co-deposition of 20 nm nanoparticles, is enriched with enhanced anticorrosion characteristics compared with the composite developed with 200 nm nanoparticles. The enhancement of anticorrosion behavior was attributed mainly to the Si₃N₄ nanoparticles that covered the substantial volume of the coating and led to inhibit the formation of corrosion active sites such as defects and metallic Ni phase. Full article

The electromagnetic rail catapult is a device that converts electrical energy into kinetic energy, which means that the strength of electrical energy directly affects the muzzle speed of armature. In addition, the electrical conductivity, electromagnetic rails and armature surface roughness, and the holding force of the rail are influencing factors that cannot be ignored. However, the electric ablation on the surface of the electromagnetic rails caused by high temperatures seriously affects the service life performance of the electromagnetic catapult system. In this study, electrochemically deposited nickel-phosphorus and nickel-molybdenum alloy coatings are plated on the surface of electromagnetic iron rails and their effects on the reduction of ablation are investigated. SEM (scanning electron microscopy) with EDS (energy dispersive spectroscopy) detector, XRD (X-ray diffraction), 3D optical profiler, and Vickers microhardness tester are used. Our results show that the sliding velocity of the armature decreases slightly with the increased roughness of the rail coating surface. On the other hand, the area of electric ablation on the rail surface is inversely related to the hardness of the rail material. The electrically ablated surface areas of the rails are in: annealed nickel–molybdenum < nickel–molybdenum < annealed nickel–phosphorus < nickel–phosphorus < iron material. Heat treatment at 400 and 500 °C, respectively for Ni–P and Ni–Mo alloys, significantly increases hardness due to the precipitation of intermetallic compounds such as Ni₃P and Ni₄Mo phases. Comprehensive data analysis shows that the annealed nickel–molybdenum coating has the best electrical ablation wear resistance. The possible reason for that might be attributed to the high hardness of the heat-treated nickel–molybdenum coating. In addition, the thermal resistance capability of molybdenum is better than that of phosphorus, which might also contribute to the high wear resistance to electric ablation. Full article

Corrosion and heat treatment studies are essential to predict the performance and sustainability of the coatings in harsh environments, such as the oil and gas industries. In this study, nickel phosphorus (NiP)–titanium (Ti) nanocomposite coatings (NiP-Ti nanoparticles (TNPs)), containing various concentrations of Ti nanoparticles (TNPs) were deposited on high strength low alloy (HSLA) steel through electroless deposition processing. The concentrations of 0.25, 0.50 and 1.0 g/L TNPs were dispersed in the electroless bath, to obtain NiP-TNPs nanocomposite coatings comprising different Ti contents. Further, the effect of TNPs on the structural, mechanical, corrosion, and heat treatment performance of NiP coatings was thoroughly studied to illustrate the role of TNPs into the NiP matrix. Field emission scanning electron microscope (FESEM) and energy dispersive spectroscopy (EDX) results confirm the successful incorporation of TNPs into the NiP matrix. A substantial improvement in the mechanical response of the NiP matrix was noticed with an increasing amount of TNPs, which reached to its ultimate values (hardness 675 Hv, modulus of elasticity 18.26 GPa, and stiffness 9.02 kN/m) at NiP-0.5TNPs coatings composition. Likewise, the electrochemical impedance spectroscopy measurements confirmed a tremendous increase in the corrosion inhibition efficiency of the NiP coatings with an increasing amount of TNPs, reaching ~96.4% at a composition of NiP-0.5TNPs. In addition, the NiP-TNPs nanocomposite coatings also unveiled better performance after heat treatment than NiP coatings, due to the presence of TNPs into the NiP matrix and the formation of more stable (heat resistant) phases, such as Ni₃P, Ni₃Ti, NiO, etc., during the subsequent processing. Full article