Search Results (589)

Tool–prepreg friction contributes to process-induced residual stress and distortion in thermoset composite manufacturing, but its variation with the resin cure state remains insufficiently characterized. This study experimentally characterizes the friction response of untreated and post-gel pretreated T800/bismaleimide prepregs using a pull-out apparatus. The effects of slip velocity, temperature, and normal pressure are evaluated, and the measured trends are interpreted using Coulomb-type contact, viscous film shearing, and mixed-lubrication concepts. The friction coefficient of the untreated prepreg increases with the slip velocity and decreases with temperature and pressure, indicating a substantial contribution from viscous resin-film shearing. In contrast, the post-gel pretreated prepreg is nearly insensitive to the slip velocity and pressure, while its friction coefficient increases with temperature, consistent with a predominantly solid-like interfacial response. During a cure cycle, the friction increases slowly at low cure levels and more rapidly during the later stages of curing. The results provide experimental friction data for a high-temperature bismaleimide prepreg system and suggest that the gelation state may serve as a useful reference for distinguishing early- and later-stage interfacial behavior. Full article

The tribological performance of copper-matrix sintered brake pads for high-speed rail applications is strongly influenced by ceramic reinforcement type. However, a systematic comparison of SiC, ZrO₂, and SiO₂ within Cu and Cu–Bronze (Cu–Br) matrix systems remains limited. In this study, six powder metallurgy composites were produced by cold pressing and sintering at 900 °C, with each matrix reinforced with 2 wt.% SiC, ZrO₂, or SiO₂ and containing graphite and MoS₂ as solid lubricants. Tribological tests were performed at 25, 100, and 400 °C under an 18 N normal load. Microstructural and thermal characteristics were evaluated using optical microscopy, SEM/EDS, and DTA/TGA. The coefficient of friction (COF) ranged from 0.163 to 0.364 across all formulations and temperatures. The Cu–Br-based composites exhibited a narrower reinforcement-dependent COF range than the Cu-based composites, particularly at elevated temperatures. Cu–SiO₂ showed the highest COF within the Cu-based at all test temperatures, whereas Cu–Br–SiC composite exhibited the highest COF among the Cu–Br-based composites at 400 °C. The lowest specific wear rates were obtained for Cu–SiO₂ at 25 °C and Cu–SiC at 400 °C. SiC-reinforced composites exhibited the highest hardness within both matrix systems. Full article

In the contemporary landscape of spacecraft engineering, reaction wheels, control moment gyros, and momentum wheels are standard tools for precise attitude control, functioning by exchanging angular momentum through the rotation of a solid mass around its major axis. The VEKTOR-FDA (Vector Fluid Dynamic Actuator) proposed in this paper offers an alternative by utilizing the principle of rotating liquid to generate angular momentum instead of relying on a solid body. Electromagnetic pumps drive and circulate the fluid, connecting to a hollow sphere via inlet and outlet channels. The fluid within the sphere is drawn into the pump through the outlet channel and reintroduced through the inlet channel. This circulation, combined with the spherical shape, generates a rotational fluid flow inside the hollow sphere, creating a rotating fluid volume and an angular momentum vector aligned with the rotation axis. By utilizing at least three pumps arranged orthogonally, simultaneous operation allows flow mixing, which can be precisely controlled by adjusting the individual flow velocities of each pump. This setup enables the rotation axis of the fluid flow to be directed in any desired orientation, allowing the rotating fluid volume and its angular momentum vector to be spatially aligned as needed. As a result, a single VEKTOR-FDA can manage attitude control across all three axes of the spacecraft, effectively functioning as a multiple-degree-of-freedom (MDOF) actuator. The electromagnetic pump drive in the VEKTOR-FDA actuator provides self-lubrication and eliminates the need for moving mechanical parts, minimizing potential damage from mechanical loads like shocks during launch. Its simple design also enables the use of commercial off-the-shelf components, ensuring cost-effective implementation. This paper provides a comprehensive overview of the motivation and concept behind the VEKTOR-FDA actuator. Additionally, this paper presents analyses and experimental results that investigate how rotating fluid flow can be generated within the sphere and examines its behavior. The study evaluates various factors influencing fluid flow inside the sphere, including configurations with variable cross-sectional shapes of the inlet and outlet channels. Furthermore, it determines the optimal positioning and arrangement of these channels to achieve efficient fluid flow volume, which is essential for maximizing angular momentum output. Full article

The precise control of droplet movement on surfaces remains a major challenge in the field of smart surfaces. Conventional systems based on light, electric, or magnetic stimuli often require the addition of corresponding photothermal, conductive, or magnetic particles into the droplets, which may lead to droplet contamination and hinder encapsulation of drugs or cells for practical application. In the present study, a photo-responsive composite functional surface was designed and prepared. The functional surface contains a liquid crystal elastomer (LCE) layer which is placed underneath a pre-lubricated polydimethylsiloxane surface. Taking advantage of the photo-induced thermal response of the cross-linked LCE network, upon local irradiation with ultraviolet light, the illuminated region of the LCE layer rapidly generates dynamic heating, creating a temperature gradient across the droplet. This gradient alters the surface tension of the solid surface, disrupts the symmetry of contact angles of the droplet, thereby inducing directional droplet movement along the surfaces. The present study provides a non-contact and fast approach for the fabrication of smart surfaces towards more complex droplet manipulation. Full article

This paper comprehensively investigates the ultraviolet (UV) nanosecond laser fabrication of micro-groove textures on planar PEEK surfaces, as well as their surface performance in terms of wettability and frictional properties. Firstly, a three-dimensional finite element model, incorporating a moving Gaussian heat source, solid heat transfer and deformed geometry, was established to simulate the transient temperature field and ablation profile of PEEK during UV laser ablation. The predicted groove depth agreed with the experimental value with a low deviation of 11.19%. Based on the simulation and single-factor experiments, the optimized single-track laser parameters were determined as a laser power of 1.2 W, a scanning speed of 100 mm/s and a repetitive frequency of 100 kHz. Secondly, systematic single-factor and multi-pass laser ablation experiments of PEEK surfaces were conducted to fabricate micro-groove textures with precisely tailored geometric parameters. Furthermore, ablated surface characterization showed that the laser-textured surfaces exhibited increased roughness, apparent crystallinity up to 22.13%, and pronounced anisotropic wettability, with improved liquid spreading along the groove direction and restricted spreading across the grooves. Finally, fretting wear tests under simulated body fluid lubrication were carried out. The research findings reported in this paper provide a systematic theoretical and experimental basis for the application of UV nanosecond laser surface texturing in the fabrication of PEEK-based components. Full article

Surface roughening is a common defect in plastic deformation processing, directly affecting product surface quality and service performance. This study investigates the mechanisms of surface roughness evolution during plastic deformation by considering both intrinsic and extrinsic factors. A macro–meso-scale modelling framework is developed by coupling crystal plasticity finite element modelling, fluid–solid interaction modelling, and macro–meso boundary conditions. The crystal plasticity model incorporates a constitutive model based on crystal plasticity theory, a Voronoi-based geometric model, and a real rough-surface topography model to capture non-uniform grain-scale plastic deformation. Fluid–solid interaction modelling is introduced to analyze the influence of liquid lubricant on the deforming solid material. Boundary interpolation and continuous displacement theories are then used to transfer macro-scale boundary constraints to the meso scale. The proposed framework is numerically implemented and applied to the aluminum alloy tube drawing process. The effects of intrinsic factors, including grain size, grain orientation, and initial surface roughness, and extrinsic factors, including deformation path, strain rate, and lubrication condition, are systematically examined. From a practical point of view, effective strategies to improve surface quality are by reducing grain size, lowering initial surface roughness, decreasing the strain rate and using low-viscosity lubricants. Full article

Silver (Ag)-based conductive coatings are widely used in electrical contacts due to their excellent electrical conductivity, low contact resistance, good thermal stability and oxidation resistance, although their susceptibility to sulfidation and environmental corrosion is a concern under certain service conditions. In recent years, significant progress has been achieved in both the manufacture and performance optimization of Ag-based coatings to satisfy the demanding requirements of modern electrical and electronic systems. This review summarizes recent advances in fabrication techniques and processing parameters for Ag-based coatings, including electroplating, electroless deposition, magnetron sputtering, electrospark deposition, thermal spraying, and electrical explosion spraying on metallic substrates, particularly on copper and steel substrates. More attention is given to microstructural design strategies, such as the incorporation and homogeneous dispersion of reinforcement or solid lubricant phases within the Ag matrix, to enhance contact reliability and operational endurance. The performance of Ag-based coatings is analyzed in terms of their physical, chemical and mechanical properties, electrical contact resistance, friction and wear behavior, arc erosion resistance, and environmental durability under different service conditions. Key challenges, including coating degradation under high electrical loads, mechanical wear, and corrosive environments, are highlighted. Future research directions are outlined, focusing on multifunctional coating structures that enhance surface performance and ensure the long-term durability of electrical contacts. Full article

Existing piston–cylinder lubrication studies often simplify the pressure boundary as a constant load or a single field, making it difficult to capture pump-level pressure excitation, local oil-film response, and non-concentric posture under variable loading. This paper establishes a thermo–fluid–solid coupling framework integrating an AMESim full-pump model, a Fluent transient oil-film model, and a Transient Structural model; UDF transfer of periodic pressure, dynamic meshes, and a calibrated Roelands law were used to analyze parallel-offset and center-tilted postures. As the load pressure increased from 10 to 30 MPa, the maximum discharge–half-cycle temperature rose from 28.39 to 36.95 °C, and the average positive leakage during the third-cycle high-pressure stage increased from 0.0201 to 0.1026 L/min; increasing speed from 1000 to 3000 r/min reduced cycle-averaged leakage by 8.93%. At 500 r/min and 30 MPa, the parallel-offset case reached 46.34 °C, 41 kPa, and 0.0990 L/min in maximum temperature, maximum shear stress, and average leakage, whereas the center-tilted case produced a peak resultant force of 3537.12 N, a cylinder inner-wall high-stress band of 76.96 MPa, and a maximum piston deformation and equivalent stress of 4.31 μm and 83.16 MPa. These results clarify the distinct lubrication behavior and potential uneven-wear risk associated with the two representative non-concentric postures, and provide a basis for clearance design and posture-sensitive condition assessment of axial piston pumps. Full article

In saline strata, lubricating slurry for pipe jacking deteriorates due to salt ion intrusion, causing stratum instability and increased frictional resistance, which pose major risks in underground construction in coastal and inland saline areas. This study investigates the evolution of filter cake impermeability under salt intrusion and establishes a three-stage evaluation method covering forward grouting, post-damage recovery, and reverse water sealing. Using a self-designed permeation apparatus, comparative tests were conducted on ordinary bentonite slurry (4% bentonite) and salt-resistant composite slurry (5% attapulgite + 5% bentonite + 0.8% HV-CMC + 0.35% NaOH) in sand layers of 0.25–2.0 mm particle sizes. Results show that the salt-resistant slurry achieves a forward pressure attenuation rate of 97% (formation pressure of 3–7 kPa at 250 kPa grouting pressure), versus only 10% for the ordinary slurry (formation pressure of 45–51 kPa)—a difference of approximately one order of magnitude. After mechanical filter cake damage, the salt-resistant slurry restores impermeability within 15–180 s through re-grouting, while the ordinary slurry cannot recover. The salt-resistant slurry resists approximately 20 kPa of reverse groundwater pressure, whereas the ordinary slurry fails at 10 kPa. Optimal performance occurs in 0.5–1.0 mm medium sand, where the filter cake and seepage zone exhibit the strongest synergy, with post-damage recovery of only 15 s. Solid particles retained in the seepage zone provide a substrate for filter cake reconstruction—the core mechanism for impermeability recovery under repeated damage during pipe jacking advancement. A three-stage evaluation framework integrating pressure attenuation rate, recovery time, and critical breakthrough pressure is proposed to guide slurry selection and grouting parameter optimization in saline strata. Full article

Developing Cu-based composites with excellent electrical and mechanical properties under multiphysics-coupled service conditions remains challenging. Novel Cu-Nb-Gr composites were fabricated by high-energy ball milling and High-pressure Multi-field Assisted Rapid Sintering. Experiments combined with computational fluid dynamics (CFD) and finite element method (FEM) simulations were used to investigate how Gr regulates material performance. The incorporation of 3 vol.% Gr promoted the formation of a semi-continuous Gr-rich structure coupled with an Nb-rich load-bearing structure. Under arc erosion, the semi-continuous Gr-rich structure provided efficient heat-conduction pathways, reducing the peak temperature and metal-vapor recoil force, while the Nb-rich load-bearing structure suppressed liquid–metal spattering and stabilized the molten pool. Simultaneously, Gr dynamically spread to form a continuous solid-lubricating film during sliding friction, significantly reducing the coefficient of friction and interfacial shear stress. Furthermore, under compressive loading, the semi-continuous Gr-rich structure coupled with the Nb-rich load-bearing structure alleviated interfacial elastic–modulus mismatch and extreme stress concentration, limiting macroscopic plastic deformation of the matrix. Consequently, Cu-Nb-3Gr achieved a favorable balance of arc-erosion resistance, wear resistance, and compressive performance, providing a new strategy for improving conventional Cu-based composites. Full article

Carbon fiber-reinforced polymer (CFRP) composites are increasingly used in lightweight structures; however, their poor thermal conductivity poses challenges during drilling, where excessive heat degrades the epoxy matrix. This study investigates the individual and combined effects of wax (0–2%) as a solid lubricant and graphene nanoplatelets (0–2%) as a heat dissipation enhancer on cutting temperature during CFRP drilling. A data-driven modeling approach based on response surface methodology (RSM) with dummy variables was developed using a full factorial design comprising 225 unique experimental conditions (9 formulations × 5 cutting speeds × 5 feed rates) with three replicates per condition, resulting in 675 individual drilling tests. The RSM model was fitted to the 225 condition means. The global RSM model achieved high predictive accuracy (R² = 0.9250, RMSE = 2.83 °C). Results show that increasing the feed rate reduces temperature by up to 29% and improves process stability, contrary to conventional metal cutting behavior. The addition of 2% wax reduced mean temperature by 11.3% and decreased thermal variability by 26%. Graphene exhibited an optimal concentration at 0.25%, yielding a 4.3% reduction in cutting temperature, with higher concentrations providing no additional benefit due to agglomeration. The combined effects of wax and graphene resulted in an optimal formulation containing 2% wax and 0.25% graphene, which provided the most favorable balance between low cutting temperature (46.1 °C) and enhanced thermal consistency (standard deviation = 3.53 °C). These findings provide practical guidelines for designing thermally regulated CFRP composites for high-performance drilling operations. Full article

This study explores the direct synthesis of carbon nanostructures on AISI 1018 low-carbon steel via spray pyrolysis, using α-pinene—a turpentine-derived terpene—as a sustainable carbon source. Two synthesis routes were evaluated: a catalyst-aided approach using ferrocene and a catalyst-free approach. Both methods yielded homogeneous coatings; however, the addition of ferrocene produced carbon nanotube (CNT) films (~70 μm), while the catalyst-free method resulted in carbon nanofiber (CNF) films (~50 μm). Tribological testing revealed that CNF coatings maintained a consistently low friction coefficient of ~0.12. In contrast, CNT coatings exhibited higher friction, increasing from 0.15 to 0.35 under loads of 2–5 N. SEM and Raman spectroscopy of the wear tracks suggest that CNFs retain their crystalline structure during friction, whereas CNTs become increasingly defective, leading to higher friction levels. Full article

Surface-dominated failures such as micropitting, scuffing, and rolling contact fatigue remain critical challenges for 20CrMnTi gear steel under high-stress and poor lubrication conditions. Inspired by the composite bionic “checkerboard + dot-matrix dimple” architecture found in natural surfaces, this study aims to develop an optimized biomimetic texture combined with a graphene solid lubricant coating to enhance the tribological performance of 20CrMnTi alloy. Laser surface texturing was employed to fabricate the bionic pattern on 20CrMnTi substrates, followed by deposition of an oxysilane-graphene coating. Reciprocating ball-on-disc tribological tests were conducted under both dry friction and oil-lubricated conditions. The results showed that under dry friction, the optimized textured and coated specimen achieved an average friction coefficient of ~0.18, representing a ~62% reduction compared to the untextured surface (~0.47). Under oil lubrication, the friction coefficient was further reduced to ~0.10–0.11, demonstrating a synergistic effect among the texture, graphene coating, and lubricant. Wear volume decreased by over 70% under dry conditions. The dominant wear mechanism shifted from severe adhesive–abrasive–oxidative wear to mild adhesive and abrasive wear. These findings suggest that the proposed composite bionic texture combined with a graphene coating offers an effective strategy for improving the tribological durability of 20CrMnTi gear. Full article

High-entropy carbide (HEC) coatings have emerged as promising candidates for extreme tribological and high-temperature applications; therefore, the objective of this work is to systematically investigate the correlation between carbon stoichiometry and the microstructural evolution, mechanical response, and thermal stability of (TiAlTaZrNb)Cx high-entropy carbide coatings. Here, HEC coatings were synthesized via reactive unbalanced-field pulsed-bias magnetron sputtering, with methane flow rates precisely tuned to yield carbon concentrations ranging from 24 to 55 at.%. XRD and Raman analyses reveal a transition from a dense, columnar FCC NaCl-type solid solution with a (200) preferential orientation to a (111)-textured matrix containing secondary carbides (TiC, TaC) and sp²-bonded free carbon at elevated carbon levels. Nanohardness and elastic modulus reach an optimal plateau at ~35 at.% C (29 GPa and 350 GPa, respectively), followed by a decline to ~20 GPa and 223 GPa at 55 at.% C due to the percolation of soft carbon-rich phases. Remarkably, increasing carbon content drastically enhances tribological performance: the coefficient of friction decreases from 0.40 to 0.20, and the specific wear rate drops from 35 × 10⁻⁶ to 1.7 × 10⁻⁶ mm³/(N·m), consistent with a solid-lubrication mechanism inferred from as-deposited Raman trends and wear-track compositional analysis, though direct post-wear spectroscopic validation remains a priority for future work. Thermal stability assessments at 600 °C at an intermediate low pressure demonstrate excellent microstructural and mechanical retention for low-to-intermediate carbon compositions, with oxidation confined to a ~200 nm surface layer attributed to the formation of stable titanium and tantalum oxides and oxycarbides, which possibly forms an oxygen diffusion barrier at that temperature. An optimal carbon content of ~35 at.% C delivers a superior synergy of high hardness, exceptional wear resistance, and robust thermal stability, establishing (TiAlTaZrNb)Cx as a highly tunable coating system for next-generation protective applications. This work provides the first systematic composition–performance map for this quinary HEC system across a broad stoichiometric range, demonstrating that carbon stoichiometry serves as a master variable to tailor the balance between mechanical integrity and tribological functionality. Full article

With the continuous increase in horizontal displacement during unconventional oil and gas drilling, drilling operations are commonly plagued by high frictional resistance, severe pipe sticking issues and difficulties in directional drilling. Conventional single-component water-based drilling fluid lubricants fail to satisfy multifunctional demands, including high-temperature resistance, salt tolerance and long-term lubrication. In this work, a novel microsphere lubricant, RB-Si, with high-temperature and high-salinity resistance was developed by combining the merits of solid and liquid lubricants. The product was synthesized using myristic acid and triethanolamine as raw materials via co-reaction with boric acid and nano-silica. Laboratory tests reveal that after aging at 180 °C, the lubrication coefficient reduction rates of based mud, saturated salinity-based mud and a high-density (2.0 g/cm³) drilling fluid gel system containing 1.0 wt% RB-Si reached 90.1%, 83.3% and 62.8%, respectively. Meanwhile, RB-Si can effectively plug the micropores in the filter cake, reduce fluid loss, inhibit shale hydration and swelling, and exhibit excellent compatibility with drilling fluids. RB-Si rapidly adsorbs onto the surfaces of metallic drill strings and formation rocks to construct a durable and high-strength lubricating film, accompanied by the rolling friction of the incorporated microspheres, thereby reducing frictional drag between the drill string/casing and the drill string/borehole wall. This lubricant effectively mitigates high frictional resistance under prolonged friction conditions, and is expected to provide technical support for long-horizontal-well drilling. Full article