Search Results (5,435)

Machining chromium–nickel alloy steel is challenging due to its material properties, such as high strength and toughness. These properties often lead to tool damage and degradation of tool life, which overall impacts the production time, cost, and quality of the product. Therefore, it is essential to investigate early signs of tool damage to determine the effective machining conditions for chromium–nickel alloy steel, thereby increasing tool life and improving product quality. In this study, the early signs of tool wear were observed in a physical vapor deposition (PVD) carbide-coated tool (Seco Tools, Björnbacksvägen, Sweden) during the machining of X5CrNi18-10 steel under both dry and wet conditions. A finish turning operation was performed on the outer diameter (OD) of the workpiece with a 0.4 mm nose radius tool. At the early stage, the tool was examined from the functional side (f–side) and the passive side (p–side). The results indicate that dry machining leads to increased coating removal, more heat generation, and visible damage, such as pits and surface scratches. By comparison, wet machining helps reduce heat and wear, thereby improving tool life and machining quality. These findings suggest that a coolant must be used when machining chromium–nickel alloy steel with a PVD carbide-coated tool. Full article

Chromium–aluminum nitride (CrAlN) coatings were deposited on polished H13 tool steel substrates using direct current (DC) magnetron sputtering. The Cr/Al composition in the target was varied by inserting either four or eight chromium (Cr) plugs into cavities machined into an aluminum (Al) plate target. Nitrogen was introduced as a reactive gas to facilitate the formation of the nitride phase. Coatings were deposited at substrate bias voltages of −30 V, −50 V, and −60 V to study the combined effects of composition and ion energy on coating properties. Compositional analysis of coatings deposited at a −50 V bias revealed Cr/Al ratios of approximately 0.8 and 1.7 for the 4- and 8-plug configurations, respectively. This increase in the Cr/Al ratio led to a 2.6-fold improvement in coating hardness. Coatings produced using the eight-Cr-plug target exhibited a nearly linear increase in hardness with increasing substrate bias voltage. Cross-sectional scanning electron microscopy revealed a uniform bilayer structure consisting of an approximately 0.5 µm metal interlayer beneath a 2–3 µm CrAlN coating. Surface morphology analysis indicated the presence of coarse microdroplets in coatings with the lower Cr/Al ratio. These microdroplets were significantly suppressed in coatings with higher Cr/Al content, especially at increased bias voltages. This suppression is likely due to enhanced ion bombardment associated with the increased Cr content, attributed to Cr’s relatively higher atomic mass compared to Al. Coatings with lower hardness exhibited greater scratch resistance, likely due to the influence of residual compressive stresses. The findings highlight the critical role of both Cr/Al content and substrate bias in tailoring the tribo-mechanical performance of PVD CrAlN coatings for wear-resistant applications. Full article

This study investigates the wear performance of 20CrMnTi steel, a commonly used material for spiral bevel gears, after heat treatment, with a focus on the microstructural evolution and wear behavior in both the surface and gradient direction of the carburized layer. The results show that the microstructure composition in the gradient direction of the carburized layer gradually transitions from martensite and residual austenite to a martensite–bainite mixed structure, and eventually transforms to fully bainitic in the matrix. With the extension of carburizing time, both the effective carburized layer depth and the hardened layer depth significantly increase. Wear track morphology analysis reveals that the wear track depth gradually becomes shallower and narrower, and the wear rate increases significantly with increasing load. However, the friction coefficient shows little sensitivity to changes in carburizing time and load. Further investigations show that as the carburized layer depth increases, the carbon concentration and hardness of the samples gradually decrease, resulting in an increase in the average wear rate and a progressive worsening of wear severity. After the wear tests, different depths of plowing grooves, spalling, and fish-scale-like features were observed in the wear regions. Additionally, with the increase in load and carburized layer depth, both the width and depth of the wear tracks significantly increased. The research results provide a theoretical basis for optimizing the surface carburizing process of 20CrMnTi steel and improving its wear resistance. Full article

The traction behavior in cryogenic solid-lubricated ball bearings (CSLBBs) used in liquid rocket engines (LREs) affects not only the dynamic response of the bearing but also the lubricity and wear characteristics of the solid lubrication coating. The traction coefficient between the ball and raceway depends on factors such as contact material, relative sliding velocity, and contact pressure. However, existing traction curve models for CSLBBs typically consider only one or two of these factors, limiting the accuracy and applicability of theoretical predictions. In this study, a novel traction model for CSLBBs is proposed, which incorporates the combined effects of contact material, relative sliding velocity, and contact pressure. Based on this model, a tribo-dynamic framework is developed to investigate the tribological and dynamic behavior of CSLBBs. The model is validated through both theoretical analysis and experimental data. Results show that the inclusion of solid lubricant effects significantly alters the relative sliding and frictional forces between the rolling elements and the raceway. These changes in turn influence the impact dynamics between the rolling elements and the cage, leading to notable variations in the bearing’s vibrational response. The findings may offer valuable insights for the wear resistance and vibration reduction design of CSLBBs. Full article

Background: The long-term success of total knee arthroplasty (TKA) is often compromised by stress shielding, which can lead to bone resorption and even implant loosening. This study employs finite element analysis (FEA) to compare the stress-shielding effects of a knee prosthesis made from polyether ether ketone (PEEK) with a traditional titanium Ti6Al4V implant on an osteoporotic tibial bone model. Methods: Stress distribution and the stress-shielding factor (SSF) were evaluated at seven critical points in the proximal tibia under physiological loading conditions. Results: Results indicate that the PEEK prosthesis yields a more uniform stress transmission, with von Mises stress levels within the optimal 2–3 MPa range for bone maintenance and consistently negative or near-zero SSF values, implying minimal stress shielding. Conversely, titanium implants exhibited significant stress shielding with high positive SSF values across all points. Additionally, stress concentrations on the polyethylene liner were lower and more evenly distributed in the PEEK model, suggesting reduced wear potential. Conclusions: These findings highlight the biomechanical advantages of PEEK in reducing stress shielding and preserving bone integrity, supporting its potential use to improve implant longevity in TKA. Further experimental and clinical validation are warranted. Full article

Pressure therapy combined with silicone has a significant effect on scar hyperplasia, but limitations such as long-term wearing of compression garments (CGs) can easily cause bacterial infection, cleanliness, and lifespan problems of CGs caused by the tedious operation of applying silicone. In this study, a compression garment fabric (CGF) with both inhibition of scar hyperplasia and antibacterial function was prepared. A polydimethylsiloxane (PDMS)-loaded microcapsule (PDMS-M) was prepared with chitosan quaternary ammonium salt (HACC) and sodium alginate (SA) as wall materials and PDMS as core materials by the complex coagulation method. The PDMS-Ms were finished on CGF and modified with (3-aminopropyl)triethoxysilane (APTES) to obtain PDMS-M CGF, which was further treated with HACC to produce PDMS-M-HACC CGF. X-ray Photoelectron Spectroscopy(XPS) and Fourier transform infrared spectroscopy (FTIR) analysis confirmed the formation of covalent bonding between PDMS-M and CGF. The PDMS-M CGF exhibited antibacterial rates of 94.2% against Gram-negative bacteria Escherichia coli (E. coli, AATCC 6538) and of 83.1% against Gram-positive bacteria Staphylococcus aureus (S. aureus, AATCC 25922). The antibacterial rate of PDMS-M-HACC CGF against both E. coli and S. aureus reached 99.9%, with wash durability reaching grade AA for E. coli and approaching grade A for S. aureus. The finished CGF maintained good biocompatibility and showed minimal reduction in moisture permeability compared to unfinished CGF, though with decreased elastic recovery, air permeability and softness. The finished CGF of this study is expected to improve the therapeutic effect of hypertrophic scars and improve the quality of life of patients with hypertrophic scars. Full article

Gear wear degrades transmission performance, necessitating highly reliable fault diagnosis methods. To address the limitations of existing approaches—where dynamic models rely heavily on prior knowledge, while data-driven methods lack interpretability—this study proposes an integrated bidirectional verification framework combining dynamic modeling and deep learning for interpretable gear wear diagnosis. First, a dynamic gear wear model is established to quantitatively reveal wear-induced modulation effects on meshing stiffness and vibration responses. Then, a deep network incorporating Gradient-weighted Class Activation Mapping (Grad-CAM) enables visualized extraction of frequency-domain sensitive features. Bidirectional verification between the dynamic model and deep learning demonstrates enhanced meshing harmonics in wear faults, leading to a quantitative diagnostic index that achieves 0.9560 recognition accuracy for gear wear across four speed conditions, significantly outperforming comparative indicators. This research provides a novel approach for gear wear diagnosis that ensures both high accuracy and interpretability. Full article

Enhancing the wear resistance of structural steels used in demanding industrial applications is critical for extending components’ lifespan and ensuring mechanical reliability. In this study, we investigated the influence of flux-cored arc welding (FCAW) hardfacing on the tensile behavior of S355MC steel. Protective Fe-Cr-C alloy layers were deposited in one and two successive passes using automated FCAW, followed by tensile testing of specimens oriented at varying angles relative to the weld bead direction. The methodology integrated 3D scanning and digital image correlation to accurately capture geometric and deformation parameters. The experimental results revealed a consistent reduction in tensile strength and ductility in all the welded configurations compared to the base material. The application of the second weld layer further intensified this effect, while specimen orientation influenced the degree of mechanical degradation. Microstructural analysis confirmed carbide refinement and good adhesion, but also identified welding-induced defects and residual stresses as factors that contributed to performance loss. The findings highlight a clear trade-off between improved surface wear resistance and compromised structural properties, underscoring the importance of process optimization. Strategic selection of welding parameters and bead orientation is essential to balance functional durability with mechanical integrity in industrial applications. Full article

This study investigates the mechanical, tribological, and electrochemical behaviour of a novel precipitation-hardenable martensitic alloy produced by selective laser melting (SLM). The alloy was specifically engineered with an optimised composition, free from cobalt and molybdenum, and featuring reduced nickel content (7 wt.%) and 8 wt.% chromium. It has been developed as a cost-effective and sustainable alternative to conventional maraging steels, while maintaining high mechanical strength and a refined microstructure tailored to the steep thermal gradients inherent to the SLM process. Several ageing heat treatments were assessed to evaluate their influence on microstructure, hardness, tensile strength, retained austenite content, dislocation density, as well as wear behaviour (pin-on-disc test) and corrosion resistance (polarisation curves in 3.5%NaCl). The results indicate that ageing at 540 °C for 2 h offers an optimal combination of hardness (550–560 HV), tensile strength (~1700 MPa), microstructural stability, and wear resistance, with a 90% improvement compared to the as-built condition. In contrast, ageing at 600 °C for 1 h enhances ductility and corrosion resistance (Rp = 462.2 kΩ; Ecorr = –111.8 mV), at the expense of a higher fraction of reverted austenite (~34%) and reduced hardness (450 HV). This study demonstrates that the mechanical, surface, and electrochemical performance of this novel SLM-produced alloy can be effectively tailored through controlled thermal treatments, offering promising opportunities for demanding applications requiring a customised balance of strength, durability, and corrosion behaviour. Full article

This paper introduces a robust and efficient Localized Spline-based Path-Planning (LSPP) algorithm designed to enhance autonomous vehicle navigation on highways. The LSPP approach prioritizes smooth maneuvering, obstacle avoidance, passenger comfort, and adherence to road constraints, including lane boundaries, through optimized trajectory generation using quintic spline functions and a dynamic speed profile. Leveraging real-time data from the vehicle’s sensor fusion module, the LSPP algorithm accurately interprets the positions of surrounding vehicles and obstacles, creating a safe, dynamically feasible path that is relayed to the Model Predictive Control (MPC) track-following module for precise execution. The theoretical distinction of LSPP lies in its modular integration of: (1) a finite state machine (FSM)-based decision-making layer that selects maneuver-specific goal states (e.g., keep lane, change lane left/right); (2) quintic spline optimization to generate smooth, jerk-minimized, and kinematically consistent trajectories; (3) a multi-objective cost evaluation framework that ranks competing paths according to safety, comfort, and efficiency; and (4) a closed-loop MPC controller to ensure real-time trajectory execution with robustness. Extensive simulations conducted in diverse highway scenarios and traffic conditions demonstrate LSPP’s effectiveness in delivering smooth, safe, and computationally efficient trajectories. Results show consistent improvements in lane-keeping accuracy, collision avoidance, enhanced materials wear performance, and planning responsiveness compared to traditional path-planning methods. These findings confirm LSPP’s potential as a practical and high-performance solution for autonomous highway driving. Full article

A multi-objective optimal trajectory planning method is proposed for manipulators in this paper to enhance motion efficiency and to reduce component wear while ensuring motion smoothness. The trajectory is initially interpolated in the joint space by using quintic non-uniform B-splines with virtual points, achieving the C⁴ continuity of joint motion and satisfying dynamic, kinematic, geometric, synchronization, and boundary constraints. The interpolation reformulates the trajectory planning problem into an optimization problem, where the time intervals between desired adjacent waypoints serve as variables. Travelling time and the integral of the squared jerk along the entire trajectories comprise the multi-objective functions. A constrained multi-objective dream optimization algorithm is designed to solve the time–jerk optimal trajectory planning problem and generate Pareto solutions for optimized trajectories. Simulations conducted on 6-DOF manipulators validate the effectiveness and superiority of the proposed method in comparison with existing typical trajectory planning methods. Full article

Ocean energy is an abundant, eco-friendly, and renewable energy resource that is useful for powering sensor networks connected to the maritime Internet of Things (MIoT). These sensor networks can be used to measure different marine environmental parameters that affect ocean infrastructure integrity and harm marine ecosystems. This ocean energy can be harnessed through hybrid nanogenerators that combine triboelectric nanogenerators, electromagnetic generators, piezoelectric nanogenerators, and pyroelectric generators. These nanogenerators have advantages such as high-power density, robust design, easy operating principle, and cost-effective fabrication. However, the performance of these nanogenerators can be affected by the wear of their main components, reduction of wave frequency and amplitude, extreme corrosion, and sea storms. To address these challenges, future research on hybrid nanogenerators must improve their mechanical strength, including materials and packages with anti-corrosion coatings. Herein, we present recent advances in the performance of different hybrid nanogenerators to harvest ocean energy, including various transduction mechanisms. Furthermore, this review reports potential applications of hybrid nanogenerators to power devices in marine infrastructure or serve as self-powered MIoT monitoring sensor networks. This review discusses key challenges that must be addressed to achieve the commercial success of these nanogenerators, regarding design strategies with advanced simulation models or digital twins. Also, these strategies must incorporate new materials that improve the performance, reliability, and integration of future nanogenerator array systems. Thus, optimized hybrid nanogenerators can represent a promising technology for ocean energy harvesting with application in the maritime industry. Full article

Ecotribology focuses on both saving energy resources and reducing environmental pollution. Considering environmental concerns, water-based nanolubricants have gained significant attention over conventional oil-based ones. Non-ecotoxic and highly environmentally friendly nanoadditives were chosen for nanolubricant synthesis, especially considering their use at elevated temperatures. In this study, hexagonal boron nitride nanosheets (hBNNSs) and titanium dioxide nanoparticles (TiO₂ NPs) were used to prepare water-based lubricants with glycerol and surfactant sodium dodecyl benzene sulfonate (SDBS) in water under ultrasonication. An Rtec ball-on-disk tribometer was used to investigate the tribological performance of the synthesised water-based lubricants containing different nano-hBN/TiO₂ concentrations, with dry and water conditions used as benchmarks. The results indicated that the water-based nanolubricant containing 0.5 wt% hBN and 0.5 wt% TiO₂ exhibited the best tribological performance at both ambient (25 °C) and elevated (500 °C) temperatures. This optimal concentration leads to a reduction in the coefficient of friction (COF) by 72.9% and 37.5%, wear of disk by 62.5% and 49%, and wear of ball by 74% and 69% at ambient and elevated temperatures, respectively, compared to that of distilled water. Lubrication mechanisms were attributed to the rolling, mending, tribofilm, solid layer formation, and synergistic effects of hBNNSs and TiO₂ NPs. Full article

In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber laser (λ = 1064 nm, spot size = 0.05 mm) was used, and Ø1.6 mm × 20 mm cylindrical rods were processed under ambient conditions without auxiliary cooling. The experimental framework systematically evaluated the influence of scanning speed, pulse frequency, and the number of laser passes on dimensional accuracy and material removal efficiency. The results indicate that a maximum diameter reduction of 0.271 mm was achieved at a scanning speed of 3200 mm/s and 50 kHz, whereas 0.195 mm was attained at 6400 mm/s and 200 kHz. A robust second-order polynomial correlation (R² = 0.99) was established between diameter reduction and the number of passes, revealing the high predictability of the process. Crucially, when the scanning speed was doubled, the effective fluence was halved, considerably influencing the ablation characteristics. Despite the low fluence, evidence of material evaporation at elevated frequencies due to the incubation effect underscores the complex photothermal dynamics governing the process. This work constitutes the first comprehensive quantification of pass-dependent diameter modulation in DLBT and introduces a transformative, noncontact micromachining strategy for hard-to-machine alloys. The demonstrated precision, repeatability, and thermal control position DLBT as a promising candidate for next-generation manufacturing of high-performance miniaturized components. Full article

As a new type of alloy system composed of five or more principal components, high-entropy alloys demonstrate outstanding comprehensive performance in the field of friction and wear through the synergistic effects of the high-entropy effect, lattice distortion effect, hysteresis diffusion effect and cocktail effect. This paper systematically reviews the research progress on the friction and wear properties of high-entropy alloys. The mechanisms of metal elements such as Al, Ti, Cu and Nb through solid solution strengthening, second-phase precipitation and oxide film formation were analyzed emphatically. And non-metallic elements such as C, Si, and B form and strengthen the regulation laws of their tribological properties. The influence of working conditions, such as high temperature, ocean, and hydrogen peroxide on the friction and wear behavior of high-entropy alloys by altering the wear mechanism, was discussed. The influence of test conditions such as load, sliding velocity and friction pair matching on its friction coefficient and wear rate was expounded. It is pointed out that high-entropy alloys have significant application potential in key friction components, providing reference and guidance for the further development and application of high-entropy alloys. Full article