Search Results (48)

The growing need for lightweight, multifunctional, and high-performance structures in the automotive, aerospace, electronics, and medical industries has driven the development of advanced joining technologies for polymers and metal-polymer combinations. Among these, ultrasonic welding (USW) and friction stir spot welding (FSSW) have emerged as promising solid-state techniques capable of producing reliable joints with minimal thermal degradation and enhanced interfacial bonding. This review focuses on recent developments in USW and FSSW of thermoplastics, fiber-reinforced composites, and hybrid metal–polymer systems, with a particular emphasis on process mechanics, microstructural evolution, and joint performance. The mechanisms of heat generation, material flow behavior, and consolidation are discussed in relation to key process parameters, including applied pressure, rotational speed, vibration amplitude, plunge depth, and dwell time. Microstructural transformations such as polymer chain orientation, recrystallization, interfacial diffusion, and defect formation are analyzed to establish process–structure–property relationships. Mechanical performance metrics, including lap shear strength, fatigue resistance, impact behavior, and environmental durability, are critically compared across different materials and welding methods. Furthermore, recent advances in numerical and thermo-mechanical modeling, in situ process monitoring, and data-driven optimization are discussed to highlight pathways toward predictive and scalable manufacturing. Current industrial applications and existing limitations such as challenges in automation, thickness constraints, and hybrid material compatibility are also evaluated. Finally, key research gaps and future directions are identified to improve joint reliability, sustainability, and broader industrial adoption of advanced solid-state welding technologies. Full article

Biodegradable nanocomposite materials possessing self-healing behavior are emerging as an attractive option of being used in advanced mechatronic systems. The current study is focused on a thorough examination of the micromechanical properties of graphene–reinforced polylactic acid (PLA)/polycaprolactone (PCL) composite samples, followed by estimation of their self-healing behavior upon heating. Polymer blend–based nanocomposite materials were prepared using the green and reliable in terms of good nanofiller dispersion melt extrusion method. 3D printed nanocomposite specimens with impeccable flatness were subjected to fine microscratch testing by applying a constant force experimental mode. The surface resistance of the three-component polymer materials against the lateral movement of the stylus fulfilling the scratch and the impact of the dual-phase PLA/PCL ratio on the nanocomposite mechanical performance were estimated by calculation of the coefficient of friction (COF = F_x/F_z). COF values in the range of 0.8–1.4 indicated excellent nanocomposite resilience against scratch. Creating a heterogeneous polymer system that combines phase-separated soft and hard domains with close melt and glass transition temperatures, respectively, may facilitate the physical flow of macromolecular chains into voids or free volume areas. This aspect can be critical in the achievement of thermally–induced self-healing properties of the composite material. Scanning electron microscopy (SEM) imaging of the microscratches, made before and after Joule heating of the polymer samples, revealed a significant degree of surface recovery and a sensible reduction in the width of the adjusted scratch grooves. Full article

The drive systems of new energy vehicles, which employ high-speed motors and low-viscosity lubricants, often subject motor bearings to high-temperature and oil-starved conditions. This can lead to the deformation of polymer bearing cages, resulting in abnormal vibration and noise. In this study, polyimide/molybdenum disulfide (PI/MoS₂) composites were prepared, and their thermal stability was characterized using a dynamic mechanical analysis (DMA). High-temperature friction and wear tests against ceramic balls were conducted on a multifunctional tribometer. The wear behavior and surface element distribution were examined by laser confocal microscopy (LCSM), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS). Results indicate that the PI-MoS₂ composites effectively mitigate surface contact deformation with rising temperatures, reducing the wear loss by around 30% compared to pure PI. This improvement is attributed to the enhanced heat resistance from MoS₂ and the formation of a lubricating film during friction. The findings provide guidance for selecting and designing composite materials for high-speed bearing cages. Full article

Dental resin composites are routinely exposed to chemically aggressive beverages that may compromise long-term functional performance. This study investigated the structure–property–tribology relationships of four restorative composites (Filtek Z250, Filtek Z550, Herculite, and Herculite Ultra) subjected to cyclic immersion in beverages with different pH values. A total of 120 cylindrical specimens (7 mm diameter, 2 mm thickness; n = 5 per material per condition) were fabricated and exposed to mineral water, tea, coffee, Coca-Cola^®, Cola Light^®, and red wine for 28 days under cyclic conditions. Microhardness, surface roughness (Ra), steady-state coefficient of friction (COF), and mass variation were evaluated. All composites exhibited significant microhardness reduction after acidic exposure (p < 0.05), with the greatest decrease observed for Herculite Ultra in red wine (−47.4%) and Coca-Cola^® (−35.3%). Filtek Z250 demonstrated the highest baseline hardness and the lowest degradation susceptibility. Surface roughness changes were formulation-dependent, with Herculite Ultra showing pronounced roughening (ΔRa up to +0.074 µm), whereas Filtek Z550 exhibited erosion-driven smoothing (ΔRa down to −0.068 µm). Tribological behaviour was primarily governed by matrix softening rather than roughness alterations, with softened systems displaying unstable frictional responses (COF range: 0.127–0.697; p < 0.05). The results indicate that polymer matrix stability plays a more critical role in long-term functional performance than surface roughness or mass variation alone. Clinically, frequent exposure to acidic and solvent-containing beverages may accelerate mechanical and tribological degradation of susceptible composite formulations. Full article

Conventional tribological materials such as metals, ceramics, and synthetic polymers demand energy-intensive processing and create end-of-life waste. This motivates the search for more sustainable alternatives. Recent research demonstrates that agricultural residues, industrial by-products, post-consumer waste, and recycled polymers can be engineered into tribological systems that provide competitive wear resistance, stable friction, and multifunctional benefits, including thermal dissipation and vibration damping. This review summarizes progress across these material categories, highlighting how fillers like rice husk ash, fly ash, tire-derived carbon black, and reprocessed plastics transition from low-value waste into high-performance tribomaterials. System-level strategies such as interface engineering, hybrid reinforcement, and advanced processing are essential for overcoming material variability and achieving reliable tribological performance. In parallel, optimization approaches, including predictive modeling and smart material design, are increasingly enabling improved consistency, reproducibility, and scalability. Applications in automotive braking systems, recycled carbon black composites, acoustic damping structures, coatings, and reinforced polymers confirm the industrial viability of waste-derived materials. While challenges remain in feedstock variability, standardization, and long-term durability, these developments point to waste-based tribology as a practical pathway toward circular economy solutions that unite sustainability with engineering performance. Full article

Carbon-fiber-reinforced polymer (CFRP) composites possess outstanding specific stiffness and strength but typically exhibit low intrinsic damping, which limits vibration attenuation in lightweight dynamic structures. Herein, a hybrid toughening strategy combining carboxyl-terminated butadiene nitrile rubber (CTBN) and hexagonal boron nitride (h-BN) is developed to enhance the damping of CFRP laminates while preserving cure feasibility and thermomechanical stability. An E51/DICY/accelerator epoxy system (100:6.5:1.2, mass ratio) is used as the baseline matrix. Differential scanning calorimetry shows that both CTBN and h-BN shift the cure peak temperature upward (Tp: 160.6 → 170.3 °C) and reduce the reaction enthalpy (ΔH: 386.5 → 255.1 J/g), indicating dilution/transport effects and altered cure kinetics. Dynamic mechanical analysis (DMA) reveals that CTBN exhibits an optimum damping enhancement at 25 phr (tan δ_max = 0.300), whereas h-BN provides a stronger monotonic increase up to 25 phr (tan δ_max = 0.437). Notably, the CTBN/h-BN hybrid (25/25 phr) delivers a high tan δ_max of 0.468 together with the broadest effective damping window (ΔT_half = 28.6 °C), exceeding 85% of the linear additivity criterion proposed herein. When the materials are transferred into CFRP laminates, free-vibration tests (using the logarithmic decrement method) demonstrate a clear structural damping improvement (ζ: 0.021 → 0.035; δ: 0.132 → 0.221; t₁/₂: 0.48 → 0.27 s). Overall, the results suggest that the damping enhancement arises from a combination of EPBN-mediated ductile energy dissipation and h-BN-related interfacial/interlayer frictional losses, which can be jointly tuned to balance processability, thermal response, and damping performance in CFRPs. Full article

Water-lubricated bearings are critical components in marine propulsion systems, necessitating materials with exceptional tribological properties to ensure reliability. Filament-winding technology is an effective molding method for enhancing the comprehensive properties of polymers, and the selection of fiber materials has a significant impact on the performance of polymers. In this study, three types of polyurethane (PU) matrix filament-winding composites were fabricated via filament-winding technology. Under water-lubricated conditions, a friction test (disk-to-disk) with a duration of 2 h was performed, followed by systematic observations of the resultant wear behavior. The results indicate that aramid fibers exhibited the superior reinforcing effect on the PU matrix, effectively suppressing wear while enhancing mechanical properties. Specifically, under the conditions of 0.5 MPa-250 r/min (0.314 m/s), the minimum friction coefficient of the aramid fiber-wound composite material was 0.093, which was 57.73% lower than that of pure polyurethane. Under the conditions of 0.7 MPa-50 r/min (0.0628 m/s), the wear mass of the sample was limited to only 1.5 mg, which was 12% lower than that of polyurethane. This research can provide a practical reference for the application of filament-wound composite materials in water-lubricated bearings. Full article

In this research, we assess the feasibility of employing hybrid friction stir channeling (HFSC) to produce composite panels that combined an 8 mm thick AA6082-T6 aluminum alloy and 5 mm thick glass-fiber-reinforced Noryl GFN2. HFSC is an innovative solid-state technology that combines both friction stir joining and channeling characteristics, which enable the generation of integral internal channels while joining different components. A parametric study was outlined to explore the effects of the travel speed, probe length, and tool plunging on the resulting composite panels. The resulting composite panels were subsequently subjected to a comprehensive analysis encompassing exterior ceiling quality, internal channel, and joining interface morphology. Depending on the processing parameters, the geometry of the channels was found to be quasi-rectangular or quasi-trapezoidal, with significant variability on cross-sectional area, resulting in hydraulic diameters ranging from 1.2 to 2.9 mm. The joining interface was characterized by a concavity of aluminum that was extruded downwards into the polymeric molten pool, which was clinched after polymeric re-solidification. The experimental results prove the ability to join metals and polymers while creating an integral channel in a single process step using HFSC. Despite the positive effect of irregular shaped channels on heat exchange, the numerical models evidenced a detrimental effect of 14.3 and 16.3% on ultimate tensile and flexural loads, respectively. This way, this fabrication technology evidenced promising characteristics that are suitable for manufacturing thermal management systems such as conformal cooling for plastic injection molding or battery trays for EVs. Full article

Acoustic emission (AE) technology has emerged as a highly sensitive and non-destructive method for the real-time monitoring of defect formation and microstructural changes during the manufacturing and early service life of polymeric materials and composites. This review highlights the fundamental principles and applications of AE in detecting crystallization-induced defects, such as cavities, dislocations, and microcracks, as well as plastic deformation mechanisms, including chain orientation, cavitation, and stress release. It is shown that AE activity correlates strongly with crystallinity and processing conditions, providing critical insights into microstructure–property relationships. The possible mechanisms can be the friction between grain boundaries, the local stress release, chain movement, phase changing, and fiber/filler debonding, among others. A comprehensive understanding can help with the prediction/prevention of early defects in the crystalline polymer processing. Furthermore, integrating AE with artificial intelligence and multi-sensor data fusion offers promising pathways toward smart, adaptive manufacturing systems capable of real-time quality control and early defect diagnosis in high-performance polymer composites. Full article

Shape-memory polymers (SMPs) are a unique class of smart materials capable of recovering their original shape upon external stimuli, with thermoresponsive polyurethane (PU) being one of the most widely studied systems. However, the relatively low mechanical strength, thermal stability, and durability of PU limit its broader functional applications. PU/ND composites containing 0.1–0.5 wt.% ND were fabricated via melt blending and injection molding method. The objective was to evaluate the effect of ND reinforcement on the mechanical, scratch, thermal, rheological, and shape-memory properties. Results show that tensile strength increased up to 114% and Young’s modulus by 11% at 0.5 wt.% ND, while elongation at break decreased due to restricted chain mobility. Hardness improved by 21%, and scratch resistance was significantly enhanced, with the coefficient of friction reduced by 56% at low loads. Thermal stability was improved, with the maximum degradation temperature shifting from 350 °C (pure PU) to 362 °C (0.5 wt.% PU/ND) and char yield increasing by 34%. DSC revealed an increase in glass transition temperature from 65 °C to 68.6 °C. Rheological analysis showed an 89% reduction in damping factor (tan δ), indicating enhanced elasticity. Shape-memory tests confirmed notable improvements in both shape fixity and recovery ratios across successive cycles compared to neat PU, with the highest enhancements observed for the 0.5 wt.% PU/ND nanocomposite—showing up to 7.6% higher fixity and 32% higher recovery than pure PU. These results demonstrate that ND reinforcement effectively strengthens PU while preserving and improving its shape-memory behavior, making the composites promising candidates for high-performance smart materials in sensors, actuators, and aerospace applications. Full article

MXenes, an emerging class of two-dimensional (2D) transition metal carbides, nitrides, and carbonitrides, have demonstrated exceptional potential in tribology: the study of friction, wear, and lubrication. Their remarkable mechanical strength, thermal stability, and tunable surface chemistry make them ideal candidates for solid lubricants, lubricant additives, and protective coatings in mechanical systems. This review comprehensively examines the tribological performance of MXenes under diverse environmental conditions, including high temperatures, vacuum, humid atmospheres, and liquid lubricants. A particular emphasis is placed on the influence of surface terminations (-OH, -O, -F) on friction reduction and wear resistance. Additionally, we discuss strategies for enhancing MXene performance through hybridization with polymers, nanoparticles, and ionic liquids, enabling superior durability in applications ranging from micro/nano-electromechanical systems (MEMS/NEMS) to aerospace and biomedical devices. We also highlight recent advances in experimental characterization techniques and computational modeling, which provide deeper insights into MXene tribomechanics. Despite their promise, key challenges such as oxidation susceptibility, high synthesis costs, and performance variability hinder large-scale commercialization. Emerging solutions, including eco-friendly synthesis methods and optimized composite designs, are explored as pathways to overcome these limitations. Overall, MXenes represent a transformative avenue for developing next-generation tribological materials that combine high efficiency, sustainability, and multifunctionality. Continued research and innovation in this field could unlock groundbreaking advancements across industrial and engineering applications. Full article

Self-lubricating polymer composites based on polydicyclopentadiene (PDCPD) were reinforced with carbon nanomaterials to evaluate the effect of filler type and loading on their mechanical and tribological performance. Four carbon forms were introduced: carbon nanotubes (0.3 and 0.5 wt.%), carbon fibers (5 and 10 wt.%), flake graphite (5 and 10 wt.%) and dusty graphite (5 and 10 wt.%). Tensile tests showed that carbon fibers—and graphite-filled matrices reached ~50 MPa tensile strength, while the addition of carbon nanotubes resulted in a reduction in strength by half compared to the pure resin, indicating poor compatibility of carbon nanotubes with the matrix. The highest compressive strength, ~90 MPa, was obtained for PDCPD containing 5 wt.% carbon fibers. Tribological behavior was evaluated in a pin-on-disk configuration under dry sliding. All fillers lowered the coefficient of friction; the most pronounced, three-fold reduction was achieved with both graphite variants. The combined high load-bearing capacity and greatly reduced friction of the graphite and carbon fibers modified systems highlight their potential as self-lubricating bearing materials capable of replacing conventional metal or oil-lubricated components. Full article

Basalt fiber-reinforced polymer (BFRP) composites are increasingly utilized in photovoltaic mounting systems due to their excellent mechanical properties and durability. Bolted connections, valued for their simplicity, ease of installation, and effective load transfer, are widely employed for joining composite components. An orthogonal experimental design was adopted to investigate the effects of key parameters—including bolt end distance, number of bolts, bolt material, bolt diameter, preload, and connection length—on the load-bearing performance of three bolted BFRP plate configurations: lap joint (DJ), single lap joint (DP), and double lap joint (SP). Test results showed that the DJ connection exhibited the highest average tensile load capacity, exceeding those of the SP and DP connections by 45.3% and 50.2%, respectively. This superiority is attributed to the DJ specimen’s longer effective shear length and greater number of load-bearing bolts. Conversely, the SP connection demonstrated the largest average peak displacement, with increases of 29.7% and 52.9% compared to the DP and DJ connections. The double-sided constraint in the SP configuration promotes more uniform preload distribution and enhances shear deformation capacity. Orthogonal sensitivity analysis further revealed that the number of bolts and preload magnitude significantly influenced the ultimate tensile load capacity across all connection types. Finally, a calculation model for the tensile load capacity of bolted BFRP connections was established, incorporating a friction decay coefficient (α) and shear strength (τ). This model yields calculated errors under 15% and is applicable to shear slip-dominated failure modes, thereby providing a parametric basis for optimizing the tensile design of bolted BFRP joints. Full article

In this work, γ-irradiated poly(tetrafluoroethylene) (i-PTFE) and short carbon fibre (SCF) along with different types of ceramic inorganic nanoparticles (i.e., SiC, SiO₂, ZnO, TiO₂, and CaCO₃) were employed to improve the mechanical and tribological performance of polyphenylene sulphide (PPS) composites. The results showed that the flexural strength and modulus of PPS composites increased with the addition of inorganic nanoparticles. Moreover, the inorganic nanoparticles not only exhibited a ‘micro-bearing’ effect during friction tests, but also promoted the formation of high-quality transfer film on the surface of a friction pair, significantly improving the self-lubricating performance of PPS composites. XPS analysis confirmed the occurrence of friction-induced chemical reactions during the friction process in nanoparticle-containing PPS/i-PTFE/SCF composites, which was helpful in improving the tribological performance. PPS/i-PTFE/SCF/SiC composite demonstrated an average friction coefficient of 0.083 and specific wear rate of 9.04 × 10⁻⁶ mm³/Nm, which was the best among the studied systems. This work provided valuable insights for developing high-performance self-lubricating polymer composites that can be applied in high-end engineering sectors. Full article

Polymers derived from renewable polysaccharides offer promising avenues for the development of high-temperature, environmentally friendly drilling fluids. However, their industrial application remains limited by inadequate thermal stability and poor colloidal compatibility in complex mud systems. In this study, we report the rational design and synthesis of epichlorohydrin-crosslinked carboxymethyl xylan (ECX), developed through a synergistic strategy combining covalent crosslinking with hydrophilic functionalization. When incorporated into water-based drilling fluid base slurries, ECX facilitates the formation of a robust gel suspension. Comprehensive structural analyses (FT-IR, XRD, TGA/DSC) reveal that dual carboxymethylation and ether crosslinking impart a 10 °C increase in glass transition temperature and a 15% boost in crystallinity, forming a rigid–flexible three-dimensional network. ECX-modified drilling fluids demonstrate excellent colloidal stability, as evidenced by an enhancement in zeta potential from −25 mV to −52 mV, which significantly improves dispersion and interparticle electrostatic repulsion. In practical formulation (1.0 wt%), ECX achieves a 620% rise in yield point and a 71.6% reduction in fluid loss at room temperature, maintaining 70% of rheological performance and 57.5% of filtration control following dynamic aging at 150 °C. Tribological tests show friction reduction up to 68.2%, efficiently retained after thermal treatment. SEM analysis further confirms the formation of dense and uniform polymer–clay composite filter cakes, elucidating the mechanism behind its high-temperature resilience and effective sealing performance. Furthermore, ECX demonstrates high biodegradability (BOD₅/COD = 21.3%) and low aquatic toxicity (EC₅₀ = 14 mg/L), aligning with sustainable development goals. This work elucidates the correlation between molecular engineering, gel microstructure, and macroscopic function, underscoring the great potential of eco-friendly polysaccharide-based crosslinked polymers for industrial gel-based fluid design in harsh environments. Full article