Search Results (304)

GH3536 superalloy is widely used in the high-temperature components of aerospace applications for its excellent high-temperature strength and corrosion resistance. However, under such a harsh environment, surface defects can make the superalloy prone to corrosion and fatigue fractures. Therefore, it is important to eliminate surface defects through polishing. However, the existing polishing methods usually suffer from some issues such as surface integrity damage, low efficiency, and poor environmental sustainability. More importantly, these methods fail to account for the requirement of surface roughness below 0.05 μm in some high-precision aerospace components. Herein, the plasma electrolytic polishing (PEP) of GH3536 superalloy is systematically investigated and optimized through single-factor experiments and response surface methodology (RSM). A minimum surface roughness Ra of 0.044 μm with a mirror-like surface was achieved at a voltage of 303.8 V, electrolyte temperature of 66.2 °C, polishing time of 5 min, and submersion depth of 7.5 cm. At the same optimized condition, the material removal rate was 59.12 mg·min⁻¹. After polishing, the surface composition of GH3536 superalloy varied negligibly, while its corrosion resistance improved markedly, with a 53.72% increase in polarization resistance and a 43.46% decrease in corrosion current density. Meanwhile, the microhardness slightly decreased due to the removal of the work-hardened layer and the compressive residual stress exhibited a more uniform distribution across the surface, contributing to improved near-surface mechanical stability. This study establishes an optimized PEP parameter for improving the surface quality of GH3536 superalloy, offering a practical method for the precision finishing of aerospace-grade superalloy components. Full article

Rapid urbanization has significantly increased energy demand in buildings, which now represent nearly 30% of global energy use. In India, buildings are built across highly varied climatic conditions, from hot-dry and warm-humid to cold, high-altitude areas, making climate-responsive envelope design essential to enhance thermal performance. Among envelope components, roofs are the most exposed to solar and outdoor thermal loads, playing a key role in managing indoor heat transfer. This study offers a parametric analysis of climate-responsive roof design strategies for India’s five main climatic zones, using transient simulations and statistical evaluation. The effectiveness of insulation placement, insulation material and thickness, and external surface absorptivity was systematically assessed based on roof heat gain and heat loss. Results indicate that over-slab insulation can lower roof heat gain by approximately 15–35% compared to under-slab insulation in warm-humid, hot-dry, composite, and temperate zones. In comparison, under-slab insulation decreases heat loss by about 10% in colder areas. Among insulation materials, 50 mm polyurethane foam (U = 0.433 W/m²·K) consistently outperformed extruded polystyrene and expanded polystyrene, achieving 82–83% reductions in maximum heat gain in cooling-dominated climates and 89% reductions in heat loss in cold regions relative to uninsulated roofs. When combined with a white reflective surface finish (α = 0.26), the total heat transfer reduction increased further to 89–92%. Surface treatments alone cut heat gain by 37–51% in non-cold climates, highlighting their potential as cost-effective retrofit options. Statistical analysis confirmed that dry-bulb temperature is the primary climatic factor influencing roof heat transfer (R² = 0.86–0.98, p < 0.0001), while solar radiation had a weaker effect, especially in optimized roof systems. The findings emphasize the importance of climate-specific roof design and demonstrate that insulation U-value has a greater impact on thermal performance than surface absorptivity, although both are significant. This research offers practical, climate-adjusted guidance for architects, engineers, and policymakers to enhance the thermal performance of roofs in Indian buildings. It supports the development of more resilient, energy-efficient building envelopes. Full article

Diamond coatings with three distinct surface textures, namely spherical, pyramidal, and prismatic morphologies, were fabricated using the hot-filament chemical-vapor deposition (HFCVD) method. Scanning electron microscopy (SEM) was employed to analyze the surface morphological characteristics and differences among the coatings. Raman spectroscopic analysis further confirmed that all three diamond films exhibited excellent deposition uniformity and high crystalline quality. A three-dimensional optical microscopy system was used to measure the surface roughness values, which were determined to be Ra 0.423 μm, Ra 0.515 μm, and Ra 0.809 μm, respectively. An HFCVD diamond-coated tool was innovatively employed for the lapping of sapphire wafers, enabling a systematic investigation of the tribological behavior during the lapping process. Based on the experimental results, three morphological material removal models were established. The study demonstrates that the spherical diamond coating achieves a superior surface finish (Ra 0.22 μm) due to its continuous multi-point contact geometry, governed by the agglomerated nanocrystalline structure. Sample 3 had the highest removal rate of 24.3 μm/min. This is related to its surface morphology characteristics and is also due to the two-body contact between the diamond-coated tool and sapphire, offering a high-efficiency alternative for precision machining. Full article

This study presents a novel numerical framework that elucidates the critical, yet previously underexplored, role of Marangoni vortex dynamics in determining the final surface quality during the laser polishing of Ti6Al4V (TC4). TC4 titanium alloy is widely used in aerospace, biomedicine, and other high-precision applications due to its excellent specific strength, corrosion resistance, and biocompatibility. However, its surface quality directly affects the fatigue life and service performance of parts, and traditional polishing methods suffer from low efficiency and high pollution. As a non-contact, controllable surface treatment technology, nanosecond laser polishing has demonstrated unique advantages in balancing processing efficiency and surface quality. This study systematically discussed the influence of key process parameters (spot overlap rate, laser power, and scanning times) on the nanosecond laser polishing of TC4 titanium alloy. It revealed the internal physical mechanism by analyzing the temperature and velocity fields and vortex dynamics during molten-pool evolution. It is found that the polishing effect is determined by the process parameters, which adjust the thermal–fluid coupling physical field (temperature distribution, melt flow, and vortex structure) in the molten pool. There is an optimal combination of parameters (spot overlap rate of 79%, laser power of 0.8 W, scanning speed of 5 m/min, scanning 3 times) that can place the molten pool in an optimal dynamic balance state and achieve effective flatness. The experimental results show that, under this parameter, the surface roughness of the specimen with an initial roughness of 1.223 μm is reduced by about 32%. The research further clarified the mechanism by which the initial roughness of the base metal influences the molten pool: the greater the initial roughness, the more pronounced the “peak shaving and valley filling” effect. Under the same parameters, the improvement rate of the specimen with the initial roughness of 1.623 μm could reach about 40%. This study not only establishes the optimized process window but also reveals the essential relationship between “process parameters–bath behavior–surface quality” from the level of the physical field of the molten pool. The findings provide a practical guideline for parameter optimization, directly applicable to the high-precision laser finishing of critical titanium components in the aerospace and biomedical industries. Full article

Conventional microlens arrays (MLAs) are often constrained by their static focal properties, which limit post-fabrication adaptability in dynamic optical systems. To address this, we demonstrate a tunable beam shaper capable of real-time spot-size modulation by introducing an adjustable axial displacement between a primary lens and an MLA. A critical advancement of this work is the fabrication of ultra-thin MLAs featuring an exceptionally low aspect ratio (1:187.5) and continuous surface profiles. Through optimizing 3D lithography and ion beam etching (IBE) workflows, we achieved an optical-grade surface finish with a roughness (Sa) of 3 nm. This high-fidelity, low-profile component enables efficient beam homogenization with reconfigurable working distances and spot dimensions. The proposed architecture provides a versatile and robust solution for advanced laser material processing, bridging the gap between static beam shaping and dynamic laser delivery. Full article

Reducing the surface roughness of thermal barrier coatings (TBCs) improves engine aerodynamic efficiency and mitigates CMAS adhesion, but turbine blades’ complex geometries demand low-cost, damage-mzitigated finishing. This work employed drag finishing with spherical ceramic media, establishing a discrete element method (DEM) model to quantify abrasive trajectories, contact forces, and energy distributions, combined with surface characterization to study abrasive effects on columnar YSZ and modified GZO topcoats. Results show roughness reduction is constrained by fracture toughness and columnar unit local fracture, leading to different decay rates and late-stage improvement between YSZ and GZO. Introducing smaller abrasives enhances packing density via void filling, strengthens microscale cutting, and reduces strong normal impacts, promoting surface uniformization and suppressing localized damage. These findings guide mechanistic understanding of drag finishing on multi-material TBCs, as well as abrasive grading design and process parameter optimization. Full article

Electropolishing is an essential process for the surface treatment of metallic materials. To determine the appropriate replacement timing of electropolishing solutions for their efficient use and improved productivity, it is important to periodically analyze the amounts of dissolved metals in the solutions. However, these solutions are typically highly corrosive, and on-site analytical techniques that can be easily applied at production sites have not yet been established. In this study, we demonstrated microvolume liquid analysis using low-energy laser-induced breakdown spectroscopy (LIBS) combined with a porous silicon substrate fabricated by metal-assisted etching (metal-assisted chemical etching) and a non-contact gas-blowing pretreatment. In the analysis of electropolishing solutions used for niobium superconducting cavities and stainless steel products, emission lines of niobium and of iron and chromium were successfully detected after blowing the respective microdroplet samples on porous silicon, and linear correlations were observed between the spectral line intensity and the polished amounts. The present results provide a basis for future on-site application of LIBS to highly corrosive electropolishing solutions in the metal finishing industry. Full article

Background: Nickel–titanium (NiTi) endodontic instruments have undergone significant improvements in heat treatment processing and geometric design, aimed at enhancing flexibility, cutting efficiency, and fatigue strength. Reciprocating motion was introduced to increase cyclic fatigue resistance, which remains the predominant mode of failure in NiTi endodontic file systems. Although these instruments are widely used in both clinical practice and research, few comparative studies have integrated geometric, metallurgical and mechanical evaluations of the most commonly used reciprocating systems. Methods: In the present study, four single-file reciprocating NiTi systems (Reciproc Blue, WaveOne Gold, EdgeOne Fire, and Easy-File Flex) were evaluated for their geometric design, metallurgical composition, and cyclic fatigue strength. Stereomicroscopy and scanning electron microscopy were employed to assess active blade length, spiral configuration, and surface finish, while elemental composition and phase transformation temperatures were analyzed using energy-dispersive X-ray spectroscopy and differential scanning calorimetry. Ten instruments from each group were tested for cyclic fatigue using a standardized curved stainless-steel canal at room temperature, and the time to fracture was recorded. Fatigue data were statistically analyzed using Mood’s median test, with significance set at p < 0.05. Results: Reciproc Blue exhibited the longest active blade length, highest spiral density, and superior surface finish. R-phase start and finish temperatures were highest in WaveOne Gold and lowest in Easy-File Flex. Reciproc Blue demonstrated the higher cyclic fatigue strength, whereas Easy-File Flex showed the lowest. Conclusions: These findings suggest that the metallurgical and geometric characteristics of the Reciproc Blue file significantly enhance its strength to cyclic fatigue compared with the other instruments evaluated. Full article

Abrasive water jet machining (AWJM) is a non-traditional machining process that is increasingly employed for shaping hard-to-machine materials, particularly titanium (Ti)-based alloys such as Ti-6Al-4V. Owing to its non-thermal nature, AWJM enables effective material removal while minimising metallurgical damage and preserving subsurface integrity. The process performance is governed by several interacting parameters, including jet pressure, abrasive type and flow rate, nozzle traverse speed, stand-off distance, jet incident angle, and nozzle design. These parameters collectively influence key output responses such as the material removal rate (MRR), surface roughness, kerf geometry, and subsurface quality. The existing studies consistently report that the jet pressure and abrasive flow rate are directly proportional to MRR, whereas the nozzle traverse speed and stand-off distance exhibit inverse relationships. Nozzle geometry plays a critical role in jet acceleration and abrasive entrainment through the Venturi effect, thereby affecting the cutting efficiency and surface finish. Optimisation studies based on the design of the experiments identify jet pressure and traverse speed as the most significant parameters controlling the surface quality in the AWJM of titanium alloys. Recent research demonstrates the effectiveness of artificial neural networks (ANNs) for process modelling and optimisation of AWJM of Ti-6Al-4V, achieving high predictive accuracy with limited experimental data. This review highlights research gaps in artificial intelligence-based fatigue behaviour prediction, computational fluid dynamics analysis of nozzle wear mechanisms and jet behaviour, and the development of hybrid AWJM systems for enhanced machining performance. Full article

Gears, as critical power-transmission components in most power equipment, have a particularly urgent need for in situ inspection systems. Traditional gear inspection methods rely on contact inspection instruments, which are not only time-consuming, but also potentially damage the gear surface due to contact. This study delves into the detection requirements in the gear manufacturing process and establishes a rapid, non-contact detection mechanism and model using a CHCS. This model employs a CHCS to achieve high-speed, non-contact measurement on various surfaces with extremely high accuracy, enabling real-time monitoring of production process details, thereby improving production efficiency and ensuring product quality. Through actual inspection and comparison with a standard involute spur gear tooth profile model, this study implements a complete inspection system in a prototype. The results of gear inspection using a CHCS with an accuracy of 1 μm showed that the interquartile range of qualified gears under test (GUTs) was within 2.5 μm, and the beard line value was within 10 μm. The experiment demonstrated a layout equipped with a CHCS where the rotating axis represents the hobbing machine spindle. This method can be completed without moving the gear, enabling subsequent finishing processes. Full article

As LED devices continue to advance toward miniaturization and higher power density, heat dissipation has become a critical factor constraining their reliability and service life. Molybdenum is widely employed as a substrate material in LED devices owing to its high thermal conductivity and low coefficient of thermal expansion. However, substrate applications impose stringent requirements on surface finish, flatness, and low-damage processing. Chemical mechanical polishing (CMP) can effectively balance global and local flatness and serves as the final step in producing high-quality molybdenum substrate surfaces. To enable efficient and precise processing of molybdenum substrates, this study adopts an orthogonal experimental design for double-sided CMP to systematically investigate the effects of polishing pressure, polishing slurry pH, additives in the polishing slurry, and abrasive particle size on the material removal rate (MRR) and surface roughness (Sa). An optimal parameter combination was identified via weight-matrix optimization: a polishing pressure of 115 kPa, pH 11, H₂O₂ (0.5%) and glycine (5 mg/L) as additives, and an abrasive particle size of 0.6 μm. Under these conditions, the MRR reached 80 nm·min⁻¹ and Sa decreased to 1.1 nm, yielding a smooth, mirror-like surface. The results indicate that multi-factor synergistic optimization can substantially enhance both surface quality and processing efficiency in double-sided CMP of molybdenum substrates, providing a process basis for applications in high-power LED devices. Full article

Background: Composite restorations are the standard of care for posterior teeth due to their aesthetic properties and conservative nature. However, the choice between direct and semi-direct techniques can influence clinical longevity and performance. Objectives: This study aimed to compare the clinical performance of two restorative approaches: a direct technique and the semi-direct onlay technique in terms of aesthetic quality, surface finish, wear resistance, marginal integrity, and overall clinical efficiency over a two-year period. Methods: A total of 348 composite restorations were placed in 192 patients. Each restoration was evaluated at four timepoints: baseline (T0), 6 months (T1), 1 year (T2), and 2 years (T3). Clinical performance was assessed using standardised 5-point rating scales across the five dimensions. Repeated-measures ANOVA assessed changes over time, while Wilcoxon signed-rank and Mann–Whitney U tests were used for intra- and inter-group comparisons. Results: Significant time effects were observed across all clinical parameters (p < 0.0001). The direct technique exhibited superior initial results in aesthetics and surface finish at T0 and T1 (p < 0.001), but differences diminished by T3. In contrast, the semi-direct technique demonstrated improved performance in wear resistance and marginal integrity at T2 and T3. Both techniques showed progressive deterioration, particularly in marginal adaptation. Conclusions: The direct technique offers enhanced short-term aesthetics and procedural efficiency, while the semi-direct approach provides superior long-term durability and marginal adaptation. Full article

CO₂ laser processing has emerged as an efficient dry-finishing technique capable of inducing controlled chemical and morphological transformations in cotton and denim textiles. The strong mid-infrared absorption of cellulose enables localised photothermal heating, leading to selective dye decomposition, surface oxidation, and micro-scale ablation while largely preserving the bulk fabric structure. These laser-driven mechanisms modify colour, surface chemistry, and topography in a predictable, parameter-dependent manner. Low-fluence conditions predominantly produce uniform fading through fragmentation and oxidation of indigo dye; in comparison, moderate thermal loads promote the formation of carbonyl and carboxyl groups that increase surface energy and enhance wettability. Higher fluence regimes generate micro-textured regions with increased roughness and anchoring capacity, enabling improved adhesion of dyes, coatings, and nanoparticles. Compared with conventional wet processes, CO₂ laser treatment eliminates chemical effluents, strongly reduces water consumption and supports digitally controlled, Industry 4.0-compatible manufacturing workflows. Despite its advantages, challenges remain in standardising processing parameters, quantifying oxidation depth, modelling thermal behaviour, and assessing the long-term stability of functionalised surfaces under real usage conditions. In this review, we consolidate current knowledge on the mechanistic pathways, processing windows, and functional potential of CO₂ laser-modified cotton substrates. By integrating findings from recent studies and identifying critical research gaps, the review supports the development of predictable, scalable, and sustainable laser-based cotton textile processing technologies. Full article

This study presents an environmentally sustainable finishing approach for hemp fabrics by combining soy protein isolate (SPI) pretreatment with an in situ infrared (IR)-assisted synthesis of zinc oxide nanoparticles (ZnO NPs). IR heating was employed to reduce energy consumption while promoting efficient nanoparticle formation compared to conventional thermal processing, while SPI acted as a bio-based stabilizer to enable uniform ZnO NP distribution on the fabric surface. Transmission electron microscopy revealed predominantly spherical to polyhedral ZnO NPs with minimal agglomeration, and X-ray diffraction confirmed their characteristic wurtzite crystalline structure. Scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy mapping further verified the homogeneous deposition of ZnO NPs on hemp fibers. The treated fabrics exhibited multifunctional performance, showing significantly enhanced ultraviolet (UV) protection with a UV protection factor (UPF) of 50+ compared with untreated hemp. Antibacterial activity against Staphylococcus aureus and Escherichia coli was confirmed by the AATCC TM147 test, while a quantitative AATCC TM100 assessment demonstrated an excellent antibacterial efficiency of 99.99% bacterial reduction against S. aureus. Additionally, the incorporation of 2 wt% SPI significantly improved fabric hydrophilicity and wettability. Overall, this work demonstrates a green and effective strategy for producing antibacterial and UV-protective hemp textiles. Full article

Active screen plasma nitriding (ASPN) of additively manufactured nickel-based superalloys represents an understudied surface enhancement pathway. This study presents the first systematic investigation of ASPN applied to additively manufactured Inconel 939 (IN 939), evaluating four distinct post-processing routes combining heat treatment atmospheres (argon versus air cooling), vibratory finishing, and lapping under identical nitriding parameters (450 °C, 8 h, 25% N₂ + 75% H₂, 3 hPa). Contrasting nitriding behaviours emerged as a function of the post-processing route: the air-cooled thermal treatment (HT-air-vibr-lap) promotes formation of a thick Al/Cr-rich oxide layer (10–15 µm) that substantially inhibits nitrogen diffusion, resulting in thin and discontinuous nitrided layers. Conversely, the inert atmosphere route (HT-Ar-vibr-lap) circumvents oxide formation, enabling continuous S-phase (expanded austenite, γN) layer development of a 6.4 ± 0.3 µm thickness with exceptional surface hardness (~1200 HV, representing 3–4× enhancement relative to base material). X-ray diffraction confirmed S-phase formation with refined lattice parameter (3.609 Å) and secondary nitride phases (CrN-type and NbN/TaN-type precipitates). The post-processing sequence—particularly heat treatment atmosphere and mechanical finishing methodology—emerged as a critical controlling parameter for S-phase formation efficiency and mechanical properties of nitrided layers in additively manufactured nickel-based superalloys. This work addresses a knowledge gap distinct from the existing literature on conventional Inconel systems, establishing that controlled surface modification through post-processing can achieve the required properties. Full article