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Machines
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Recent Advances in Surface Processing of Metals and Alloys
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Recent Advances in Surface Processing of Metals and Alloys

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Material Processing Technology".

Deadline for manuscript submissions: 30 April 2024 | Viewed by 3868

Special Issue Editor

Dr. Fatih Uzun

E-Mail Website
Guest Editor
Department of Engineering Science, The University of Oxford, Oxford, UK
Interests: eigenstrain theory; residual stress analysis; evolutionary computation; stochastic finite element; phase field modelling; computational fluid dynamics; diffraction techniques; tensegrity structures; digital image correlation

Special Issue Information

Dear Colleagues,

Surface processes are applied to alter machine elements to achieve improved properties. This Special Issue of Machines focuses on the recent advances in surface processing of metallic components within the scope of the influence of surface processes on mechanical properties, component cosmetics, energy efficiency, machine performance, and environmental concerns. Novel studies within these topics and discussing innovative destructive or non-destructive experimental techniques, such as electron microscopy, focused ion beams, diffraction beams, sectioning, profilometry or nano-indentation, and modeling techniques based on numerical and analytical approaches or principles of artificial intelligence, are welcomed.

Dr. Fatih Uzun
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Published Papers (4 papers)

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Research

22 pages, 14114 KiB  
Article
Effect of Roller Burnishing and Slide Roller Burnishing on Surface Integrity of AISI 316 Steel: Theoretical and Experimental Comparative Analysis
by Jordan Maximov, Galya Duncheva, Angel Anchev, Vladimir Dunchev, Kalin Anastasov and Petya Daskalova
Machines 2024, 12(1), 51; https://doi.org/10.3390/machines12010051 - 11 Jan 2024
Viewed by 780
Abstract
The article presents a new method called slide roller burnishing (SRB) for the cold working of cylindrical surfaces on machine tools implemented with a novel multi-functional device. The machined material is chromium–nickel austenitic stainless steel. The deforming element is a toroidal roller whose [...] Read more.
The article presents a new method called slide roller burnishing (SRB) for the cold working of cylindrical surfaces on machine tools implemented with a novel multi-functional device. The machined material is chromium–nickel austenitic stainless steel. The deforming element is a toroidal roller whose axis crosses that of the workpiece. As a result, a relative sliding velocity occurs in the contact zone between the roller and the machined surface. The sliding velocity vector is set using the burnishing device. The theoretical background of SRB is presented. When the two axes are parallel, the well-known roller burnishing (RB) method is implemented. Thus, RB is a special case of SRB. Both processes are realized using the multi-functional burnishing device. The RB process was studied experimentally and optimized according to three criteria, based on the relationship between the surface integrity and operating behavior of the respective component, to achieve three processes: smoothing, hardening, and mixed burnishing. Using the optimal RB parameters obtained, the dependence of the results of SRB on the crossing angle was investigated and optimized. A comparative analysis was performed between the optimized RB and SRB processes (respectively for their three variants: smoothing, hardening, and mixed) based on geometrical and physical–mechanical characteristics of the surface integrity. The main advantage of the SRB is that it provides smaller height roughness parameters (improvement by 42%) and a higher surface microhardness (improvement by 7%) than RB. Full article
(This article belongs to the Special Issue Recent Advances in Surface Processing of Metals and Alloys)
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19 pages, 6638 KiB  
Article
Modeling and Optimization of Surface Integrity and Sliding Wear Resistance of Diamond-Burnished Holes in Austenitic Stainless Steel Cylinder Lines
by Galya Duncheva, Jordan Maximov, Angel Anchev, Vladimir Dunchev, Yaroslav Argirov and Svetlozar Velkov
Machines 2023, 11(9), 872; https://doi.org/10.3390/machines11090872 - 30 Aug 2023
Viewed by 800
Abstract
This article outlines a technology for hole-finishing in short-length cylinder lines to improve wear resistance. The technology is based on an optimized diamond-burnishing (DB) process. The latter was implemented on conventional and CNC lathes, milling machines, and machining centers using a simple burnishing [...] Read more.
This article outlines a technology for hole-finishing in short-length cylinder lines to improve wear resistance. The technology is based on an optimized diamond-burnishing (DB) process. The latter was implemented on conventional and CNC lathes, milling machines, and machining centers using a simple burnishing device with an elastic beam. The material used in this study was AISI 321 austenitic stainless steel. The governing factors used were the radius of the diamond insert, burnishing force and feed rate. The objective functions relating to surface integrity characteristics were selected on the basis of their functional importance relative to the wear resistance of the processed hole surface: height and shape roughness parameters, surface microhardness, and surface residual axial and hoop stresses. The one-factor-at-a-time method (used to reduce the factor space), a planned experiment, and regression analyses were used. The multi-objective optimization tasks, which were defined for three diamond insert radius values of 2, 3, and 4 mm, were solved via the Pareto-optimal solutions approach available for a non-dominated sorting genetic algorithm (NSGA-II). Using the optimal values of the governing factors selected from the Pareto fronts, cylinder lines were processed. Samples were then cut from these cylinder lines for reciprocating sliding wear tests under two modes: dry friction and boundary lubrication friction. Additionally, wear test samples were cut from the cylinder line, which was finished with traditional grinding. A finite element simulation was then used to select an appropriate pressing force. The results obtained from the reciprocating sliding wear tests under both the dry and boundary lubrication friction regimes show that to minimize the wear on cylinder lines made of AISI 321 steel, DB with a diamond insert of radius 2 mm is the optimal finishing process. Full article
(This article belongs to the Special Issue Recent Advances in Surface Processing of Metals and Alloys)
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16 pages, 5650 KiB  
Article
Investigation of the Layer Effects Formed by W-EDM on Electrochemical Grooving of Stellite 21
by Semih Ekrem Anil, Hasan Demirtas, Adnan Kalayci and Abdulkadir Cebi
Machines 2023, 11(8), 823; https://doi.org/10.3390/machines11080823 - 10 Aug 2023
Viewed by 767
Abstract
Machining hard-to-cut materials, such as cobalt (Co)-based superalloys, is a common problem in manufacturing industries. Background: wire electrical discharge machining (W-EDM) is one of the widely used cutting processes that causes layer (white layer—WL and heat-affected zone—HAZ) formation, and microcracks on the material’s [...] Read more.
Machining hard-to-cut materials, such as cobalt (Co)-based superalloys, is a common problem in manufacturing industries. Background: wire electrical discharge machining (W-EDM) is one of the widely used cutting processes that causes layer (white layer—WL and heat-affected zone—HAZ) formation, and microcracks on the material’s surface. Purpose: this study investigates the effects of WL and HAZ on the electrochemical grooving (EC grooving) performance of Co-based superalloys. Two different surface types (W-EDMed and VFed) were used in the experiments. Result: the experiments showed that material removal rate (MRR) values increased up to 212.49% and 122.23% for vibratory finished (VFed) and wire-electrical-discharge-machined (W-EDMed) surfaces, respectively. Conclusion: This result indicates the presence of HAZ and WL that prevent current transition between two electrodes. However, increased voltage causes an increase in surface roughness, with increment rates at 71.13% and 36.08% for VFed and W-EDMed surfaces, respectively. Moreover, for the VFed surfaces, the groove lost its flatness at the bottom after an approximately 100 µm depth due to the different electrochemical machineabilities of HAZ and real surface texture. This result can be attributed to the different microstructures (HAZ and surface texture) showing different electrochemical dissolution rates. Therefore, high-depth distance HAZ and WL must be removed from the workpiece. Full article
(This article belongs to the Special Issue Recent Advances in Surface Processing of Metals and Alloys)
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20 pages, 20014 KiB  
Article
Development, Characterization and High-Temperature Oxidation Behaviour of Hot-Isostatic-Treated Cold-Sprayed Thick Titanium Deposits
by Parminder Singh, Harpreet Singh, Surinder Singh, Eklavya Calla, Harpreet Singh Grewal, Harpreet Singh Arora and Anand Krishnamurthy
Machines 2023, 11(8), 805; https://doi.org/10.3390/machines11080805 - 04 Aug 2023
Cited by 1 | Viewed by 909
Abstract
In this work, thick deposits of pure titanium (Ti), with a thickness of around 15 mm, were additively manufactured using high-pressure cold spraying. Nitrogen was employed as the process gas. Subsequently, the deposits were subjected to hot isostatic pressing (HIP). The HIP-treated Ti [...] Read more.
In this work, thick deposits of pure titanium (Ti), with a thickness of around 15 mm, were additively manufactured using high-pressure cold spraying. Nitrogen was employed as the process gas. Subsequently, the deposits were subjected to hot isostatic pressing (HIP). The HIP-treated Ti deposits were analyzed for their metallurgical and mechanical characteristics with the aim of exploring the viability of using cold spraying for the additive manufacturing of Ti components. Moreover, high-temperature cyclic oxidation testing was also performed on the HIP-treated Ti deposit to understand its stability at high temperatures. SEM/EDS showed a dense structure with marginal porosity for the HIP-treated Ti deposits, without any oxide formation, which was further confirmed via XRD analysis. An average microhardness of 214 HV was measured for the HIP-treated Ti deposits, which is close to that of the commercially available bulk titanium (202 HV). The high-temperature oxidation studies revealed that the cold-sprayed HIP-treated Ti has very good oxidation resistance, which could be attributed to the formation of protective titanium dioxide in its oxide scale. Full article
(This article belongs to the Special Issue Recent Advances in Surface Processing of Metals and Alloys)
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