Search Results (2,990)

To achieve both a high material removal rate and excellent surface quality, this paper proposes a solid-phase Fenton chemo-mechanical lapping (SF-CML) method. Using high-purity type 316 stainless-steel as the research object, a solid lapping tool containing Fe₃O₄ microparticles was employed in synergy with an H₂O₂-based slurry. Under locally high-pressure and high-temperature conditions, Fe²⁺ ions are released, which in turn catalyze the generation of highly reactive hydroxyl radicals (·OH). These radicals promote the formation of an oxide layer on the workpiece surface, which is continuously removed through mechanical action. The results show that at pH 2.5 and an H₂O₂ concentration of 0.05 wt%, SF-CML achieves the best processing performance, with an MRR of 16.64 μm/min and a Sa as low as 20.95 nm. XPS, EPR, and other characterization methods collectively provided evidence for the oxidation of the sample surface and the existence of ferrous ions and hydroxyl radicals in the slurry, thereby confirming the effectiveness of the solid-phase Fenton reaction. Compared with conventional homogeneous Fenton CMP and pure mechanical lapping, SF-CML not only significantly improves removal efficiency but also effectively enhances surface quality. This method avoids the problems of easy precipitation and low removal efficiency commonly encountered in traditional homogeneous Fenton systems, providing a new technical pathway for high-efficiency precision processing of metallic materials. Full article

This article presents a new combined post-processing concept to improve the quality of laser powder bed fusion (LPBF) of 17-4PH stainless steel (SS) cylindrical parts fabricated from N₂-atomised LaserForm 17-4PH (B) powder. The concept is based on consecutive heat treatment procedures and diamond burnishing (DB) processes. A two-stage study was conducted. The first stage was an LPBF process experiment. The following combination of LPBF parameter values was selected after optimisation: a laser power of $\mathrm{P}=150 \mathrm{W}$, laser scanning speed of v = 1200 mm/s, and layer thickness of $\mathrm{t}=40 \mathsf{\mu }\mathrm{m}$. In the second stage, this combination was used to evaluate the effects of two heat treatment procedures (HT1 and HT2) and two DB processes (using burnishing forces of 100 N and 300 N) on the tensile properties and surface integrity of LPBF 17-4PH SS cylindrical samples. The HT2 procedure, including annealing $({1200}^{\circ }$, $4 \mathrm{h})$, solution treatment (${1060}^{\circ }$, $1 \mathrm{h})$, cooling (${-70 }^{\circ }\mathrm{C},2 \mathrm{h}$), and ageing (${482}^{\circ }$, $4 \mathrm{h}$) led to yield limit, tensile strength, and Vickers hardness values of $\mathrm{Y}\mathrm{L}=1071 \mathrm{M}\mathrm{P}\mathrm{a}$, $\mathrm{T}\mathrm{S}=1410 \mathrm{M}\mathrm{P}\mathrm{a}$, and $523 \mathrm{H}\mathrm{V},$ respectively. The concept presented takes advantage of the combination of the transformation, precipitation and strain-hardening effects. The combined effect was most pronounced in the samples subjected to the HT2 procedure and subsequent DB (300 N), for which a retained austenite fraction of 6.93%, surface microhardness of ${563 \mathrm{H}\mathrm{V}}_{0.05}$ and the maximum values of the compressive axial and hoop RSs of $-1426.3 \mathrm{M}\mathrm{P}\mathrm{a}$ and $-1095.9 \mathrm{M}\mathrm{P}\mathrm{a}$, respectively, were measured. Full article

CrN/DLC composited coatings were deposited on 431 stainless steel, and their structure was analyzed, with particular emphasis on the influence of CrN content on the coating properties. X-ray photoelectron spectroscopy (XPS), nanoindentation testing, scratch testing, and reciprocating tribometry were employed to characterize the chemical composition, mechanical properties, adhesion strength, and tribological performance of the coatings, respectively. Structural analysis indicates that when the ratio of CrN/Cr₂N is relatively low (<1), a high content of chromium dinitride (Cr₂N) is formed in the interlayers, resulting in a porous and loose coating structure. When the ratio achieves 1:1, an optimal balance, with the CrN content reaching a maximum of 21.04% and the Cr₂N content decreasing to a minimum of 20.68%, the densification degree of the coatings is increased, the coating adhesion strength is improved to 11.87 N. Meanwhile, the enhanced formation of the CrN phase improves the hardness to 12.27 GPa. Tribological test results demonstrate that when the ratio is approximately 1:1, the coating exhibits the lowest friction coefficients under dry sliding, deionized water, and artificial seawater conditions (0.0932, 0.1409, and 0.1021, respectively), as well as the minimum wear rates. With the decrease in CrN content of the coatings, the interfacial mismatch degree of the coatings is aggravated, which leads to not only more interfacial defects but also a relatively loose structure, as well as a decrease in the bonding strength (6.81 N), hardness (5.22 GPa), and deformation resistance. Therefore, an excessive Cr₂N phase may degrade the hardness-to-elastic modulus ratio (H/E) of the coatings by increasing interfacial mismatch and reducing structural compactness. Full article

Nanotextured thin film metallic glasses (TFMGs) have emerged as promising antimicrobial coatings for biomedical applications; however, systematic comparisons across compositionally distinct Ti- and Zr-based systems, as well as their early-stage bactericidal mechanisms, remain limited. Here, we show, for the first time, a comparative, compositionally resolved correlation linking alloy chemistry, nanotexture, and bactericidal mechanisms across polymorphic TFMGs. Three co-sputtered biocompatible coatings (Ti₄₇Fe₄₁Cu₁₂, Zr₇₁Fe₃Al₂₆, and Zr₅₈W₃₁Cu₁₁) were deposited on medical-grade titanium and stainless steel (SS316L) via magnetron co-sputtering, producing uniform amorphous films (190–298 nm) with nanoscale roughness of 1.6 ± 0.05 to 8.1 ± 0.05 nm. Surface wettability spanned hydrophilic (71.1 ± 5.6°) to hydrophobic (106.5 ± 3.5°), modulating bacterial interactions. Antimicrobial performance against Pseudomonas aeruginosa was evaluated using live/dead fluorescence imaging, quantitative image analysis, and electron microscopy after 2–4 h incubation. All coatings reduced bacterial adhesion and viability relative to bare substrates, with Zr₅₈W₃₁Cu₁₁ achieving >60% reduction in surface-associated bacterial coverage. Time-resolved analysis revealed a rapid transition to predominantly non-viable populations on coated surfaces, in contrast to sustained viability on controls. Mechanistically, bactericidal activity arises from the synergistic coupling of nanotopography-induced membrane stress, wettability-governed adhesion energetics, and in situ formation of CuO, Fe₂O₃, WO₃, and ZrO₂ oxides that promote electrostatic interactions and proposed reactive oxygen species generation, driving oxidative membrane damage. These results establish a scalable design framework for TFMGs, while highlighting the need for long-term biofilm and electrochemical validation. Full article

In this study, C/N-containing Fe₃O₄ oxide films over an inner nitride layer were fabricated on 45# steel by oxynitriding to improve corrosion resistance in chloride-containing environments. The films exhibited a dense polyhedral structure, with nanoscale Fe₃O₄ precipitates at grain boundaries. Nitrogen and carbon were uniformly distributed within the oxide grains, inducing lattice expansion and modifying the Fe-O bonding environment. First-principles calculations based on C/N substitution models suggested that C/N incorporation may increase the unit cell volume, strengthen lattice bonding, and enhance the theoretical hardness of Fe₃O₄. The optimally doped films exhibited outstanding corrosion resistance, with a corrosion potential of 0.115 V_SCE, a corrosion current density of 3.16 × 10⁻¹⁰ A/cm² in 3.5 wt.% NaCl solution, and a corrosion-free lifetime of up to 3600 h in neutral salt spray testing. This superior performance is attributed to the synergistic effects of the compact single-phase magnetite layer, grain boundary precipitates, and modified electronic structure, which collectively inhibit chloride ingress and convert localized electrochemical attack into uniform corrosion. The experimental results are consistent with first-principles predictions, which clarified the mechanism of nitrogen doping in material corrosion protection from a mechanistic perspective. Full article

The unique powder-pack boriding technique using an open retort with boriding medium was applied for the first time in order to produce boride layers on K190 ledeburitic chromium steel manufactured using powder metallurgy. The processes were carried out using the commercial Durborid^®G powder mixture at 1173 K, 1223 K, and 1273 K for 3 h, 6 h, and 9 h. As a result of the boriding of the high-carbon and high-chromium substrate, three zones were revealed in the produced surface layers: the outer FeB zone, the inner Fe₂B zone, and the transition zone, with increased carbon content. The total thickness of the boride layers (FeB + Fe₂B) ranged from 14.13 µm at the lowest temperature and shortest time to 65.49 µm at the highest temperature and longest duration. Increasing the temperature and extending the boriding time resulted in a deeper FeB zone as well as a thicker total layer (FeB + Fe₂B). The growth kinetics of the produced layers on the surface of K190 steel were analyzed for the first time using the mean diffusion coefficient model. The thicknesses of the FeB zone and the total layer (FeB + Fe₂B) were determined. The activation energies of boron for the FeB and Fe₂B phases calculated in this work are comparable with other results for the powder-pack boriding of high-carbon tool steels. As a consequence of the high chromium content in K190 steel, chromium borides were observed in the boride zones, which increased the hardness of the surface layer. The highest temperature used resulted in the formation of vanadium borides. The presence of the transition zone with an increased carbon concentration and a high percentage of carbides resulted from the movement of carbon atoms toward the core by the advancing boron diffusion front. The parameters of boriding (temperature and time) as well as the presence of alloying elements in the substrate material influenced the microhardness of the boride layers. Full article

High friction composite brake shoes containing reinforced steel fibers are now widely used in freight train tread braking systems. With the demand for higher transportation efficiency on railway lines with long steep slopes, it is necessary to explore the braking capabilities of existing general freight train high friction composite brake shoes under continuous braking conditions. In this paper, continuous braking tests at different speed levels were conducted using a friction and wear test rig. Through material characterization and interface damage analysis, it was found that reinforced steel fibers can exist as a contact platform at the brake shoe friction interface. Due to the strip-like morphology and high strength features of steel fibers, even after the steel fiber layer is fragmented, it can still promote the formation of a continuous contact platform with complex material composition on the surface, maintaining the progress of the braking process. For existing general freight train high friction composite brake shoes, at speeds up to 80 km/h, although the friction coefficient decreases to some extent, the wear rate maintains a relatively low range. When the speed increases to 100 km/h, the friction coefficient of the braking interface deteriorates severely, and the wear rate of the brake shoe increases sharply, seriously endangering braking safety. The research results reveal the evolution of wear behavior of high friction composite brake shoes containing reinforced steel fibers at different speed levels, providing theoretical support for exploring the braking capabilities and design optimization of brake shoes. Full article

The deterioration of steel reinforcement through corrosion triggers cracking and loss of concrete cover, ultimately weakening the structure’s strength and ductility. In practical design and assessment, it is vital to precisely quantify the shear capacity of corroded reinforced concrete beams (CRCBs). In this paper, machine learning (ML) models are developed to predict the shear capacity of CRCBs, including kernel ridge regression (KRR), K-nearest neighbors (KNN), decision trees (DT), random forest (RF), gradient-boosted regression trees (GBRT), and extreme gradient boosting (XGBoost). A total of 408 data entries on the shear strength of CRCBs under different corrosion conditions were collected to establish an extensive database. The reliability of the proposed ML models is examined by contrasting their outputs with the experimental data. The XGBoost model demonstrated superior predictive capability, achieving an R² value of 0.994 and outperforming all other tested models, including RF, GBRT, and DT. The Shapley Additive Explanations (SHAP) algorithm is adopted to reveal the contribution of each input feature to the predicted shear capacity of CRCBs. The interpretive SHAP results show that the ultimate shear capacity of CRCBs is most influenced by beam depth (h), with the shear span-to-depth ratio (λ) and concrete compressive strength ($f_{cl,150}$) being the subsequent key contributors. A comparative assessment between the XGBoost model and traditional analytical models was carried out to estimate the shear strength of CRCBs. Results demonstrate that the XGBoost model delivers enhanced predictive accuracy and improved performance. A parametric investigation examined its robustness under variations in geometry and material properties, while a user-friendly interface was created to support its practical use. Full article

Waste heat recovery from automotive exhaust gases represents an important strategy for improving vehicle energy efficiency. This study experimentally investigates the performance of a thermoelectric generator (TEG) system based on TEC1-12706 modules running under different cold-side cooling conditions and incorporating a Hot Rolled Steel (HRS) protective layer on the hot side. The HRS plate was used to ensure uniform heat distribution and protect the thermoelectric module against thermal shocks generated by a 250 °C heat source. Four cooling regimes were experimentally analyzed: natural convection and forced airflows equivalent to 40, 60, and 90 km/h. The results proved that increasing airflow intensity significantly improved the temperature difference across the module, from approximately 16 ± 2 °C under natural convection to nearly 40 ± 2 °C at the highest airflow velocity. Correspondingly, the steady-state voltage generated increased from approximately 0.25 ± 0.01 V to over 0.60 ± 0.01 V under an 82 Ω resistive load. The measured hot-side temperature remained below 75 °C in all experimental conditions, confirming the thermal protection capability of the HRS layer. The experimental data also revealed a near-linear relationship between voltage and temperature difference, consistent with the Seebeck effect. The proposed configuration shows the feasibility of combining thermal protection and forced convection cooling to improve the stability and electrical performance of thermoelectric waste heat recovery systems intended for low-power automotive auxiliary applications. Full article

Phosphogypsum (PG) is an industrial solid waste whose use in cementitious materials is limited by strength reduction at high dosages. This study evaluated a clinker-free multi-solid-waste binder containing 40 wt.% PG for cemented paste backfill using steel slag powder (SSP) and granulated blast-furnace slag (GBFS) as co-binders, with phosphate mine tailings and slime as aggregates. Uniaxial compressive strength (UCS), X-ray diffraction, scanning electron microscopy, and nuclear magnetic resonance were combined with image-based pore-structure sensitivity analysis to examine the relationships among hydration products, pore evolution, and strength development. The results showed that AFt and C–S–H-like gels were associated with pore refinement and strength gain. All mixtures reached UCS values above 0.5 MPa at 7 days and 1.0 MPa at 28 days. The A2 mixture achieved the highest 7-day UCS of 0.8 MPa, whereas A1 showed the highest 28-day UCS of 1.6 MPa. Porosity, pore probability entropy, and fractal dimension were negatively correlated with UCS, with pore probability entropy showing the highest sensitivity to 7-day strength. These findings support the use of high-PG clinker-free binders for targeted phosphate-mine backfill. Full article

Aiming at the problems of high friction coefficient, severe wear, and unsatisfactory service life and operational reliability of brass under complex working conditions such as dry friction, wet friction, and oil-lubricated friction, H62 brass was taken as the research object to improve its friction and wear properties via surface micro-texture technology. This study systematically compares the tribological performance of three typical geometric micro-textures under three coupled working conditions for the first time. Circular, rectangular, and hexagonal micro-dimple textures were fabricated on the brass surface using ultraviolet laser micromachining. The control variable method was adopted to systematically investigate the effects of micro-texture parameters including shape, size, and area density on the friction and wear properties of brass under the three typical working conditions, combined with reciprocating friction and wear tests and ultra-depth-of-field microscope characterization. The results show that the hexagonal micro-dimple texture (200 μm in size, 10% in area density) exhibits the optimal friction-reducing and anti-wear performance. Compared with the smooth surface, the friction coefficient decreases from 0.51 to 0.43, and the wear rate of the GCr15 steel ball is reduced by 2.8% under dry friction; the friction coefficient decreases from 0.43 to 0.12 with an 11.8% reduction in wear rate under wet friction; and the friction coefficient decreases from 0.29 to 0.24 with an 8.3% reduction in wear rate under oil lubrication. Relative to dry friction, the wear rates are further reduced by 16.7% and 8.3% under wet friction and oil lubrication, respectively. Different from most existing studies that only focus on a single texture type or a single friction condition, this paper systematically reveals the coupling regulation mechanism between texture parameters and working conditions, clarifies the optimal micro-texture design strategy for multi-working conditions, verifies that hexagonal micro-textures can significantly improve the wear resistance of brass, and provides technical support for the surface optimization design of brass workpieces under complex working conditions. Full article

The corrosion of carbon steel in marine–industrial atmospheric environments remains a significant challenge due to the combined effect of aggressive ions such as chlorides and sulfates. In this context, this study aims to explore the inhibitory action of expired omeprazole applied to mild steel AISI 1018 evaluated on a solution simulating atmospheric corrosion (0.1 M Na₂SO₄ + 3% wt NaCl) over 72 h. The material was characterized using EDS to determine its composition of AISI 1018 steel, while Raman spectroscopy was employed to identify the functional groups and heteroatoms present on the molecular structure of omeprazole. Electrochemical noise (EN) measurements were used to evaluate the corrosion rate, type of corrosion and mechanism. Also, quantum chemical calculations of density function theory (DFT) were performed to predict the relationship between molecular structure and inhibition efficiency. The results indicate that 50 ppm provides the most stable and effective corrosion inhibition over time, as evidenced by increases in noise resistance and inhibition efficiency. In contrast, 75 ppm exhibits improved surface morphology at the end of the exposure period, which indicates enhanced surface coverage. The DFT results reveal that omeprazole possesses suitable electronic properties for corrosion inhibition, including moderate reactivity, electron-donating ability, and favorable charge distribution that promotes adsorption onto the metal surface. SEM analysis corroborates that surface damage is significantly reduced in the presence of the inhibitor, particularly at 75 ppm. This study provides new insights into the use of expired pharmaceutical compounds as corrosion inhibitors and demonstrates the capability of combining electrochemical noise analysis with DFT to evaluate both inhibition efficiency and film stability. Full article

This study establishes an integrated qualification workflow combining mechanical testing, microstructural characterization, and statistically defined eddy current testing (ECT) on the same material heats to provide a coherent and traceable material qualification methodology. Forged 316 and rolled 304L were fully annealed and subsequently subjected to a 700 °C/1 h low-temperature stress-relief (recovery) treatment. Room-temperature tensile testing and Charpy impact testing at room and cryogenic temperatures were performed alongside optical and electron microscopy to quantify grain size, δ-ferrite content, and representative fracture morphology under the investigated conditions. ECT responses were evaluated using a statistically defined threshold (T = μ + 3σ) as a decision criterion for indication screening under assumed noise conditions and calibrated near-surface inspection sensitivity. The tested specimens showed stable measured mechanical responses, the examined fracture surfaces were consistent with predominantly ductile fracture behavior, and no reportable ECT indications were observed above the adopted threshold. The proposed framework provides a reproducible and scalable strategy for reducing uncertainty in material qualification and strengthening integration between destructive and non-destructive evaluation in stainless steel applications. Full article

Against the global carbon neutrality backdrop, amine-based CO₂ capture technology is critical for industrial greenhouse gas emission reduction. However, mixed amine absorbents can cause severe corrosion of Q235B carbon steel, restricting the stable operation of carbon capture, utilization, and storage (CCUS) projects. This study systematically investigated the corrosion behavior of Q235B carbon steel in a novel mixed amine system under simulated industrial conditions using weight loss tests, electrochemical measurements (EIS, potentiodynamic polarization), and advanced characterizations (FT-IR, ¹³C NMR, SEM-EDS, XRD). The temperature was the dominant factor: corrosion rate increased significantly with rising temperature. Under CO₂-saturated conditions, 15–30% absorbent concentrations showed no significant effect on corrosion rate owing to similar molar loading and pH. At 60 °C and 30% concentration, the corrosion rate peaked at 30 L/L CO₂ loading. Carbamate accumulation promoted corrosion at low loading, while increased bicarbonate inhibited corrosion at high loading. The main corrosion products (Fe₃O₄, Fe₂O₃) formed loose, porous films with poor protectiveness. This work clarifies the electrochemical corrosion mechanism and provides data support for corrosion prevention in CCUS equipment. Full article

Austenitic stainless steels exhibit excellent corrosion resistance owing to the formation of passive films composed of a dense Cr-rich inner layer and porous Fe-rich outer layer. The corrosion resistance and passive film characteristics of N-containing austenitic stainless steel (NASS) were investigated in various pH and Cl⁻-containing environments and compared with those of commercial 304 SS. Microstructural analysis revealed that NASS had larger grains but more favorable crystal structures for the adsorption of passivating species. NASS exhibited a lower corrosion current density, higher pitting potential, and superior repassivation behavior in acidic and neutral environments, whereas 304 SS exhibited better corrosion resistance under strongly alkaline conditions. NASS formed a passive film with lower defect density and a higher fraction of compact Cr-rich species, contributing to its enhanced passive film stability and repassivation ability. Immersion tests demonstrated that pit initiation was delayed in the NASS group compared with the 304 SS group. These results indicate that the corrosion resistance of NASS in acidic and neutral environments originates from the improved stability and protective characteristics of the passive film. Full article