Search Results (4,131)

Nickel-based alloys, including Inconel 718 and alloy 625, are indispensable in industries such as aerospace, marine, and nuclear energy due to their exceptional mechanical strength, high-temperature performance, and corrosion resistance. However, these very properties pose severe machining challenges, such as accelerated tool wear, poor surface finish, and high cutting forces. Although several studies have investigated coatings, lubrication strategies, and process optimization, a comprehensive and up-to-date integration of these advancements is still lacking. To address this gap, a systematic review was conducted using Web of Science and Scopus databases. The inclusion criteria focused on peer-reviewed journal and conference articles published in the last eleven years (2014–2025), written in English, and directly addressing machining of nickel-based alloys, with particular emphasis on tool coatings, lubrication/cooling technologies, and machinability optimization. Exclusion criteria included duplicate records, non-English documents, papers lacking experimental or modeling results, and studies unrelated to tool life or coating performance. Following this screening process, 101 high-quality articles were selected for detailed analysis. The novelty of this work lies in synthesizing comparative insights across TiAlN, TiSiN, and CrAlSiN coatings, alongside advanced lubrication methods such as HPC, MQL, nano-MQL, and cryogenic cooling. Results highlight that CrAlSiN coatings retain hardness up to 36 ± 2 GPa after exposure to 700 °C and extend tool life by 4.2× compared to TiAlN, while optimized cooling strategies reduce flank wear by over 30% and improve tool longevity by up to 133%. The integration of coating performance, thermal stability, and lubrication effects into a unified framework provides actionable guidelines for machining optimization. The study concludes by proposing future research directions, including hybrid coatings, real-time process monitoring, and sustainable lubrication technologies, to bridge the remaining gaps in machinability and promote industrial adoption. This integrative approach establishes a robust foundation for advancing machining strategies of nickel-based superalloys, ensuring improved productivity, reduced costs, and enhanced component reliability. Full article

The surface treated by laser phase transformation hardening exhibits superior hardness, enhanced wear resistance, and refined grain structure. In this study, both single-track and two-track laser phase transformation hardening processes were numerically simulated, with the simulation accuracy being verified experimentally. Furthermore, the optimal overlap rate for laser two-track overlay was predicted based on the simulation results. An S355J2G3 metal block specimen was used as a case, numerical simulations of the phase transformation coupled with the temperature field on the specimen’s surface under laser irradiation were carried out using SYSWELD2019 software. The surface temperature distribution and the evolution of phase volume fractions were analyzed. Additionally, the changes in the temperature field within the softening zone and the distribution of tempering structures resulting from two-track laser overlay were examined. The discrepancy between experimental and simulated results for the hardening layer width was approximately 10%, while the error rates for the hardening layer depth and the tempering softening zone were below 5% and 10%, respectively. Based on simulations conducted with varying overlap rates, the flatness metric produces the best results at 50% overlap under these laser processing parameters. Full article

When exposed to high contact pressure and shear conditions, the sliding and/or rolling contact interfaces of moving mechanical systems can experience significant friction and wear losses, thereby impairing their efficiency, reliability, and environmental sustainability. Traditionally, these losses have been minimized using high-performance solid and liquid lubricants or surface engineering techniques like physical and chemical vapor deposition. However, increasingly harsh operating conditions of more advanced mechanical systems (including wind turbines, space mechanisms, electric vehicle drivetrains, etc.) render such traditional methods less effective or impractical over the long term. Looking ahead, an emerging and complementary solution could be tribocatalysis, a process that spontaneously triggers the formation of nanocarbon-based tribofilms in situ and on demand at lubricated interfaces, significantly reducing friction and wear even without the use of high-performance additives. These films often comprise a wide range of amorphous or disordered carbons, crystalline graphite, graphene, nano-onions, nanotubes, and other carbon nanostructures known for their outstanding friction and wear properties under the most demanding tribological conditions. This review highlights recent advances in understanding the underlying mechanisms involved in forming these carbon-based tribofilms, along with their potential applications in real-world mechanical systems. These examples underscore the scientific significance and industrial potential of tribocatalysis in further enhancing the efficiency, reliability, and environmental sustainability of future mechanical systems. Full article

In this paper, we report a novel application of atomic force microscopy (AFM) for measurement of wear of prosthetic materials. In contrast to previously employed methods, we introduce AFM-based wear induction. In this way, we utilize AFM as both measurement technique and the mean for surface wear. We describe the methodology along with the metrological advantages of the approach regarding the supreme resolution of volume measurement (down to 1 μm³). We investigate wear between prosthetic gold alloy (Degulor M) and FGP polymeric material from Bredent in nanoscale. For that purpose, we modify active piezoresistive cantilever, replacing the original tip with Degulor M microsphere. We elaborate on the process of modification and present how the mass volume and topology of the tip is controlled throughout the process. Wear process was performed in reciprocal motion over the length of 5 μm in 35,000 repetitions to mimic the actual conditions occurring in human mouth cavity. We present how this method, by focusing on a small area of investigated materials, leads to shortening the overall time of wear measurements from tong term observations down to several minutes. AFM-measured data present consistent relation between wear energy and wear volume. Exemplary results seem to confirm durability of the FGP-Degulor M mechanical contact and occurring strengthening of the mechanical contact with roughening of the polymeric surface. Full article

The growing demand for precision and consistency in the forging industry has heightened the need for predictive simulation tools. While extensive research has focused on parameters such as flow stress, die wear, billet fracture, and residual stresses, the phenomenon of billet buckling, especially during cold upset forging, remains underexplored. Most existing models address only elastic buckling for slender billets using classical approaches like Euler and Rankine-Gordon formulae, which are not suitable for inelastic deformation in shorter billets. This study presents a numerical model developed to analyze inelastic buckling during cold forging and to determine associated stresses and deflection characteristics. The model was validated through finite element simulations across a range of billet geometries (10–40 mm diameter, 120 mm length), materials (aluminum, stainless steel, and copper), and friction coefficients (µ = 0.12, 0.16, and 0.35). Stress distributions were evaluated against die stroke, with particular emphasis on the influence of strain hardening and geometry. The results showed that billet geometry and strain-hardening exponent significantly affect buckling behavior, whereas friction had a secondary effect, mainly altering overall stress levels. A nonlinear regression approach incorporating material properties, geometric parameters, and friction was used to formulate the numerical model. The developed model effectively estimated buckling stresses across various conditions but could not precisely predict buckling points based on stress differentials. This work contributes a novel framework for integrating material, geometric, and process variables into stress prediction during forging, advancing defect control strategies in industrial metal forming. Full article

Background: Globally, uncorrected refractive errors are recognized as the primary cause of visual impairment and blindness. According to a report by the World Health Organization (WHO), providing spectacle lenses at an affordable cost remains a significant challenge, particularly for underprivileged populations in developing countries. This challenge contributes to the low compliance with spectacle wear worldwide. However, the benefits of wearing spectacles are influenced by the perceptions of the population regarding spectacle use. Methods: A quantitative, cross-sectional survey-based study was conducted at a superior educative center in Oman, the University of Buraimi. Participants were recruited from the four major colleges, namely, the College of Health Sciences (COHS), College of Business (COB), College of Engineering (COE), and College of Law (COL), and the Center for Foundation Studies (CFS). This study was conducted over the period from 18 December 2022 to 18 December 2023. Essential data were collected using an electronic questionnaire facilitated by the Google platform. The initial section of the questionnaire outlines this study’s objectives and its benefits to the community. The digital survey comprises three sections: the first section addresses the sociodemographic profile of the participants; the second section explores perceptions related to spectacles; and the third section examines visual symptoms associated with spectacle wear. In this study, a pre-tested survey was administered following consultation with a panel of three subject matter experts who reviewed the clarity and content validity of the test items. Data analyses were performed using descriptive statistics, and linear regression was applied to assess the effect of socioeconomic profile on perceptions of spectacles. Additionally, data entry, processing, and analysis were conducted using SPSS 25 software. The overall mean score for spectacle-related visual symptoms was 2.51 ± 0.75, indicating a moderate level of symptom occurrence. Results: A total of 415 participants (N = 415) were included in this study, comprising 133 males (32.0%) and 282 females (68.0%). The most prominent symptoms related to spectacle perception were “light sensitivity” and “eye pain”, with mean values of 3.03 ± 1.30 and 3.04 ± 1.25, respectively. Additionally, 249 participants (60%) reported moderate concern regarding spectacle-related visual symptoms. Among female participants, 118 (41.8%) exhibited little concern about visual symptoms associated with spectacle wear, whereas this was observed in 25.6% of male participants. Descriptive statistics indicated the mean perceived spectacle-related disadvantages score measured on a scale of 0 to 4 was 2.88 ± 1.16 (57.69% ± 23.15% in percentages), reflecting a moderate perception of such disadvantages. The linear regression model demonstrated statistical significance, as indicated by the likelihood ratio chi-square = 199.194 (df = 15, p < 0.001). The most significant predictor was study major (χ² = 72.922, p < 0.001). Conclusions: The present study indicates that undergraduate students generally exhibit a low perception of the disadvantages associated with wearing spectacles. Randomized sampling should be preferred in future studies to the convenience sampling technique. The most frequently reported visual symptoms include “light sensitivity and eye pain” among spectacle wearers. Therefore, it is imperative to implement health education programs and foundational studies across colleges to address these issues among undergraduate university students. Full article

Municipal solid waste (MSW) refers to solid and semi-solid waste generated during human production and daily activities. The process of incinerating such waste, known as municipal solid waste incineration (MSWI), serves as a critical method for reducing waste volume and recovering resources. Automatic online recognition of flame combustion status during MSWI is a key technical approach to ensuring system stability, addressing issues such as high pollution emissions, severe equipment wear, and low operational efficiency. However, when manually selecting optimized features and hyperparameters based on empirical experience, the MSWI flame combustion state recognition model suffers from high time consumption, strong dependency on expertise, and difficulty in adaptively obtaining optimal solutions. To address these challenges, this article proposes a method for constructing a flame combustion state recognition model optimized based on reinforcement learning (RL), long short-term memory (LSTM), and parallel differential evolution (PDE) algorithms, achieving collaborative optimization of deep features and model hyperparameters. First, the feature selection and hyperparameter optimization problem of the ViT-IDFC combustion state recognition model is transformed into an encoding design and optimization problem for the PDE algorithm. Then, the mutation and selection factors of the PDE algorithm are used as modeling inputs for LSTM, which predicts the optimal hyperparameters based on PDE outputs. Next, during the PDE-based optimization of the ViT-IDFC model, a policy gradient reinforcement learning method is applied to determine the parameters of the LSTM model. Finally, the optimized combustion state recognition model is obtained by identifying the feature selection parameters and hyperparameters of the ViT-IDFC model. Test results based on an industrial image dataset demonstrate that the proposed optimization algorithm improves the recognition performance of both left and right grate recognition models, with the left grate achieving a 0.51% increase in recognition accuracy and the right grate a 0.74% increase. Full article

Fibre-reinforced composites are facing new challenges in the context particular in sustainability and recyclability. Vitrimers could be useful as new matrices to support the increase in sustainability. Due to their high strength, which is comparable to that of thermosets often used in composites, and their covalent adaptive networks, which make them reshapeable for scaled-up manufacturing and recycling purposes, they are very useful. Orthogonal cutting is used for precise reshaping and functional integration into carbon fibre reinforced plastics. Vitrimers could improve processing results at the cutting edge as well as surface quality thanks to their self-healing properties compared to brittle matrices, as well as enabling the recycling of formed chips and scrap. This study showcases the manufacturing of a carbon fibre-reinforced vitrimer using 4-aminophenyl disulfide as a hardener, with vacuum-assisted resin infusion. The temperature of chip formation and the cutting parameters are then shown for different fibre orientations, cutting widths and speeds. The observed cutting forces are lower (less than 140 N) and more irregular for fibre orientations 45°/135°, increasing with cutting depth, and fluctuating periodically during machining. Despite varying cutting speeds, the forces remain relatively constant in range between 85 N and 175 N for 0°/90° fibre orientation and 50 N and 120 N for 45°/135° fibre orientation, with no significant tool wear observed and lower-damage depth and overhanging fibres observed for 0°/90° fibre orientation. Damage observation of the cutting tool shows promising results, with lower abrasion observed compared to thermoset matrices. Microscopic images of the broached surface also show good quality, which could be improved by self-healing of the matrix at higher temperatures. Temperature measurements of chip formation using a high-speed camera show a high temperature gradient as cutting speeds increase, but the temperature only ever exceeds 180 °C at cutting speeds of 150 m/min, ensuring reprocessability since this is below the degradation temperature. Therefore, orthogonal cutting of vitrimers can impact sustainable composite processing. Full article

The floating oil seal (FOS) is a critical component in coal mining machinery, where frictional wear and high stress on the O-ring can lead to oil leakage and eventual FOS failure, significantly impairing equipment performance. To address this issue, this study proposes a novel ceramic-coated floating oil seal (NCCFOS) composite structure that enhances wear resistance without modifying the existing sealing cavity configuration. A two-dimensional axisymmetric finite element model of the NCCFOS was developed based on the Mooney–Rivlin constitutive model, considering the O-ring assembly process for improved accuracy. The model was analyzed under oil pressure loading, with parametric studies examining the influence of oil pressure, assembly clearance, and material hardness on O-ring stress, contact pressure, and frictional stress distribution in the floating seal ring. The results demonstrate that accounting for the assembly process yielded more realistic stress predictions compared to conventional modeling approaches. The NCCFOS design effectively mitigated stress concentrations, reduced O-ring wear, and extended fatigue life, offering a practical solution for enhancing the reliability of coal mining machinery seals. Full article

In this paper, silver oxide (AgO) and copper oxide (CuO) coatings are placed on a single sputtering target with the direct-current magnetron sputtering (DCMS) and high-power impulse magnetron sputtering (HIPIMS) methods. All the tested coatings are obtained in a reactive process using a metallic target made by the Kurt Lesker company. The investigated coatings are deposited at room temperature on substrates made of pure iron (ARMCO) and polypropylene (PP) without substrate polarization. The deposition time for all the coatings is the same. The results of SEM and TEM investigations clearly show that using the HIPIMS method for the deposition of AgO and CuO coatings reduces their thickness and increases their structure density. Coatings produced with the HIPIMS method are characterized by a higher hardness and Young’s modulus. The value of hardness for AgO and CuO coatings deposited by the HIPIMS method is around 50% higher for AgO coatings and around 24% higher for CuO coatings compared to the coatings obtained by the DC method. This is also true of Young’s modulus values, which are around 30% higher for AgO coatings and 15% higher for CuO coatings produced by the HIPIMS method compared to those of coatings obtained with the DC method. AgO and CuO coatings deposited with both the methods (HIPIMS and DCMS) showed 100% reduction in the viability of two reference laboratory bacteria strains—Escherichia coli (Gram−) and Staphylococcus aureus (Gram+)—on both types of substrates. Additionally, these coatings are characterized by their hydrophobic properties, which means that they can create a protective barrier, making it difficult for bacteria to stick to the surface, limiting their development and preventing the phenomenon of biofouling. The HIPIMS technology allows for the deposition of coatings with better mechanical properties than those produced with the DCMS method, which means that they are more resistant to brittle fractures and wear and have very good antimicrobial properties. Full article

This article presents studies of surface layers produced by electro-spark deposition (ESD) on cast iron using a W-Ni-Co sintered electrode. To minimize the number of required experiments, a two-factor, five-level Hartley experimental design was chosen. The assessment involved observing the effect of voltage and capacitor capacity during the ESD process (on layer thickness and wear of the sample and counter-sample under technically dry friction conditions). Microscopic and tomographic observations were performed to analyze the thickness and structure of the layers. Image analysis methods were employed to examine the cross-section of the layers. ESD diffusion analyses were performed on the produced layer. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) were performed to characterize the microstructure and composition of the coating. In addition, in order to evaluate the performance properties of tungsten coatings, the tribological tests were also conducted on a TRB³ Ball-on-Disc testing device. Hardness tests confirm an increase in the hardness of cast iron with a tungsten layer by over 400 µHV. The tests showed that higher voltages during the ESD process result in thicker layers and reduced wear of the sample with a tungsten layer at the expense of increased wear of the counter-sample (ball). Full article

This study investigates the surface characteristics and corrosion behavior of a high-C martensitic stainless steel (AISI 440C) at different stages of its manufacturing process. As a class, these steels prioritize high mechanical properties and wear resistance over superior corrosion resistance. Hot working operations, such as rolling, create a surface oxide scale that must be removed via pickling to restore the material’s inherent corrosion resistance. This process also eliminates the underlying Cr-depleted layer, allowing for the re-establishment of a protective passive film. Using potentiodynamic polarization curves and micrographic analysis, the material’s behavior in different conditions, as-rolled, with a post-heat treatment oxide scale, and in a bare, oxide-free state, has been assessed. The results showed that the material lacks stable passive behavior under all conditions. The as-rolled and heat-treated conditions both exhibited active behavior and formed thick, non-adherent corrosion products. The oxide layer formed after heat treatment performed the worst, showing a significant increase in corrosion current density. These findings confirm the material’s susceptibility to corrosion in Cl⁻ ion-rich environments, highlighting the need for limited storage in such conditions and rapid pickling after thermal processing to mitigate surface damage. Full article

One of the key measures of cutting tool efficiency in machining processes is tool wear. In recent decades, numerical modeling of this phenomenon—primarily through finite element cutting models—has gained increasing importance. A crucial requirement for the reliable application of such models is the selection of an appropriate friction model, which strongly affects the accuracy of wear predictions. However, choosing the friction model type and its parameters remains a nontrivial challenge. This paper examines the effect of different friction model types and their parameters on the Archard and Usui wear model indicators, as well as on the main cutting process characteristics: cutting force components, temperature in the primary cutting zone, contact length between the tool rake face and the chip, shear angle, and chip compression ratio. To evaluate their impact on predicted tool wear—expressed qualitatively through the wear indicators of the aforementioned models—several widely used friction models implemented in commercial FEM software were applied: the shear friction model, Coulomb friction model, hybrid friction model, and constant tau model. The simulated values of these cutting process characteristics were then compared with experimental results. Full article

Mining, mineral processing, and power generation are just a few of the industries that have made extensive use of pneumatic conveying systems in recent years. The market for pneumatic conveying is anticipated to grow to a value of $30 billion by 2025. However, problems with the pneumatic conveying process are common and include coal particle damage, pipe wall wear, and excessive system energy consumption. A new systematic framework for decision-making is created by combining the Theory of Inventive Problem Solving (TRIZ) with the Decision-Making Trial and Evaluation Laboratory (DEMATEL). This methodology employs TRIZ-Ishikawa to determine the underlying causes of issues from six different perspectives. It then suggests remedies based on TRIZ technical contradictions and uses DEMATEL to examine how the solutions interact to determine the best course of action. This study confirms the viability of this approach in recognizing fundamental contradictions, producing workable solutions, and reaching scientific conclusions in challenging issues by using instances such as wear and tear, obstructions, and low conveying efficiency in pneumatic conveying system elbows. It offers particular references for real engineering projects and suggests practical solutions like employing quick-release flanges and installing multiple sets of airflow regulators. Full article

This study investigates the formation of hydroxyl radicals (OH radicals) in cavitation bubble plasma-treated water (CBPTW) using a chemical probe method. CBPTW samples were prepared with different electrode materials (W, Fe, Cu, and Ag), and the chemical scavenger was added two minutes after the completion of cavitation and plasma treatments. The concentrations of metal ions and hydrogen peroxide (H₂O₂) generated in the CBPTW were also measured over time. This study reveals a novel mechanism whereby metal nanoparticles and ions released from electrodes catalyze the continuous generation of hydroxyl radicals in CBPTW, which has not been fully addressed in previous studies. The results suggest a continuous generation of OH radicals in CBPTW prepared with W, Fe, and Cu electrodes, with the amount of OH radicals produced in the order Cu > Fe > W. The study reveals a correlation between OH radical production and electrode wear, suggesting that the continuous generation of OH radicals in CBPTW results from the catalytic decomposition of H₂O₂ by metal nanoparticles or ions released from the electrodes. It should be noted that cavitation bubble plasma (CBP) is fundamentally different from sonochemistry. While sonochemistry utilizes ultrasound-induced cavitation to generate radicals, CBP relies on plasma discharge generated inside cavitation bubbles. No ultrasound was applied in this study; therefore, all observed radical formation is attributable exclusively to plasma processes rather than sonochemical effects. However, the precise mechanism of continuous OH radical formation in CBPTW remains unclear and requires further investigation. These findings provide new insights into the role of electrode materials in continuous OH radical generation in cavitation bubble plasma treated water, offering potential applications in water purification and sterilization technologies. Full article