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Surface Processing Technology for High-Temperature Resistant Materials

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Physics".

Deadline for manuscript submissions: closed (10 November 2022) | Viewed by 21292

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Dr. Guijian Xiao

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College of Mechanical and Vehicle Engineering, Chongqing University, No.174, Shazhengjie, Shapingba, Chongqing 400444, China
Interests: grinding; polishing; surface integrity; bionic manufacturing; functional surface; micro/nano manufacturing; grinding process and mechanism
Special Issues, Collections and Topics in MDPI journals

Dr. Yun Huang

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Guest Editor

College of Mechanical and Vehicle Engineering, Chongqing University, No. 174, Shazhengjie, Shapingba, Chongqing 400044, China
Interests: belt grinding; polishing; complex surface machining; high-temperature resistant materials machining

Dr. Kun Zhou

E-Mail Website
Guest Editor

College of Mechanical and Vehicle Engineering, Chongqing University, No. 174, Shazhengjie, Shapingba, Chongqing 400044, China
Interests: grinding; ceramic matrix composites; surface integrity; material removal

Dr. Yi He

E-Mail Website
Guest Editor Assistant

College of Mechanical and Vehicle Engineering, Chongqing University, No. 174, Shazhengjie, Shapingba, Chongqing 400044, China
Interests: bionic manufacturing; functional surface and its performance; micro/nano manufacturing

Special Issue Information

Dear Colleagues,

I am pleased to inform you that the Special Issue of Materials is dedicated to “Surface Processing Technology for High-Temperature Resistant Materials” and invite you to submit your valuable research progress.

High-temperature resistant materials, such as titanium alloys, nickel-based alloys, ceramics, and their composites, are widely applied in critical components in the fields of aerospace, nuclear power, and transportation due to their excellent thermodynamic properties. However, its unique physical properties also bring significant challenges to processing, resulting in surface damage quickly during processing, and severely reducing its service life and performance. Therefore, in recent years, the processing mechanism and high-performance processing technology of high-temperature materials have received extensive attention from many scholars. The high-performance surface processing and service performance evaluation of high-temperature resistant materials have become an essential scientific issue that needs to be broken.

The current Special Issue aims at displaying the latest research advances in this field in the form of research and review papers.

Notably, the topics of interest include, but are not limited to:

Surface processing (turning, grinding, drilling, milling, etc.) of high-temperature resistant materials
Multi-energy field-assisted machining method (laser, ultrasonic, electrochemistry, etc.) of high-temperature resistant materials
Machined surface integrity characterization and prediction of high-temperature resistant materials
Testing of machined surface properties of high-temperature resistant materials (abrasion resistance, hydrophobicity/hydrophilicity, etc.)
Mechanisms of machined surface integrity on service performance of high-temperature resistant materials (fatigue, noise, fluid, etc.)

Dr. Guijian Xiao
Dr. Yun Huang
Dr. Kun Zhou
Dr. Yi He
Guest Editors

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. Materials is an international peer-reviewed open access semimonthly 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 2600 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.

Keywords

grinding
plishing
surface integrity
bionic manufacturing
functional surface
micro/nano manufacturing
grinding process and mechanism

Published Papers (12 papers)

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Research

12 pages, 3756 KiB

Open AccessArticle

On the Formability of Medium Mn Steel Treated with Varied Thermal Processing Routes

by Baolin Zhang and Binbin He

Materials 2023, 16(1), 258; https://doi.org/10.3390/ma16010258 - 27 Dec 2022

Cited by 1 | Viewed by 1006

Abstract

In this contribution, we investigate the influence of thermal processing routes on the formability of medium Mn steel by assessing the strain hardening coefficient and anisotropy factor using the uniaxial tensile test. Medium Mn steel processed by intercritical annealing (IA) at 680 °C for 4 h demonstrates better formability than steel treated with a combination of IA at 800 °C for 10 min and quenching and partitioning (Q&P), based on the much higher strain hardening coefficient (n) and comparable anisotropy factor (r, r_m, ∆r). The higher strain hardening coefficient of medium Mn steel with single IA treatment is ascribed to the enhanced transformation-induced plasticity (TRIP) effect resulting from the large amount of austenite that is transformed into martensite during deformation. In addition, the IA process allows for the production of medium Mn steel with high ductility, which is beneficial for its high formability and good ‘part ductility’ in lightweight automotive applications. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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15 pages, 4995 KiB

Open AccessArticle

Structure Formation and Tribological Properties of Mo-Si-B-Hf Electrospark Coatings Based on Mo₂Ni₃Si Laves Phase

by Evgenia Igorevna Zamulaeva, Alexander Nikolaevich Sheveyko, Yuri Yurievich Kaplanskii and Evgeny Alexandrovich Levashov

Materials 2022, 15(16), 5613; https://doi.org/10.3390/ma15165613 - 16 Aug 2022

Viewed by 1123

Abstract

Coatings were produced on the EP741NP nickel alloy substrates by electrospark deposition (ESD) in argon using an MoSi₂-MoB-HfB₂ electrode. In situ high-resolution transmission electron microscopy and X-ray diffraction analysis studies have identified the temperature above which the strengthening Mo₂Ni₃Si Laves phase is formed in the coatings. At 25 °C, the coatings with a predominant content of the Laves phase are characterized by enhanced wear resistance, as well as a lower coefficient of friction compared to the non-annealed coatings containing binary silicides. At 700 °C, the EP741NP substrate was characterized by the lowest friction coefficient (Ktr = 0.35), and its wear was approximately at the same level as the wear of both coatings. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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16 pages, 8896 KiB

Open AccessArticle

Aluminide Diffusion Coatings on IN 718 by Pack Cementation

by Mihai Ovidiu Cojocaru, Mihai Branzei and Leontin Nicolae Druga

Materials 2022, 15(15), 5453; https://doi.org/10.3390/ma15155453 - 08 Aug 2022

Cited by 3 | Viewed by 1625

Abstract

This paper addressed the issues of both direct and indirect synthesis of Ni aluminides by pack cementation (pure Ni and IN 718 superalloy). On the Al-Ni diffusion twosome under pressure, at temperatures below and above the Al melting temperature, the appearance and evolution of diffusion porosity because of the Kirkendall–Frenkel effect manifestation was highlighted. It has been confirmed that, as the temperature rises above the Al melting temperature, the porosity decreases. Nickel-based superalloys, and in particular IN 718, significantly increase their performance by increasing the aluminides proportion in the top diffusion coating. This is made possible by changing the value of the Al and Ni weight percentage ratio in this area (noted as Al/Ni). In the case of the diffusion twosome between IN 718 and pack aluminizing mixtures, having in their composition as active components Al powder, Ferroaluminum (FeAl40) or mixtures of Al and Fe powders, at processing temperatures above the Al melting temperature, by modifying the active component of the mixture, substantial changes in the Al/Ni values were observed, as well as in the maximum %Al in the diffusion coating and of its thickness. It was found that, when switching from Al to FeAl40 or powder mixture (Al + Fe), the Al/Ni value changes between 3.43 and 1.01, from initial subunit values. The experiments confirmed that the highest %Al in the top aluminized diffusion coating, for IN 718, was obtained if the powder mixture contained 66.34 wt.% Al. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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16 pages, 3616 KiB

Open AccessArticle

Comparison of Chemical and Mechanical Surface Treatments on Metallic Precision Spheres for Using as Optical Reference Artifacts

by Víctor Meana, Eduardo Cuesta, Braulio J. Álvarez, Sara Giganto and Susana Martínez-Pellitero

Materials 2022, 15(11), 3741; https://doi.org/10.3390/ma15113741 - 24 May 2022

Cited by 3 | Viewed by 1260

Abstract

The improvement of industrial manufacturing processes requires measurement procedures and part inspection tasks to be faster and faster while remaining effective. In this sense, the capabilities of noncontact measuring systems are of great help, not only because of the great amount of data they provide but also for the ease of the integration of these systems as well as their automation, minimising the impact on the industry. This work presents a comparative study on the influence of two surface treatments performed on low-cost, high-precision metallic spheres on the suitability of these spheres to be used as artefacts for the calibration of optical sensors, specifically laser triangulation sensors. The first surface treatment is sandblasting (a mechanical process), whose effect has been studied and presented in previous work. The second treatment focused on in this paper is acid etching (a chemical process). The comparison has been performed by evaluating the same metrological characteristics on two identical groups of spheres of similar type (diameter and accuracy), each of which was subjected to a different treatment. It was necessary to obtain the reference values of the metrological parameters with high accuracy, which involved measuring the spheres with a coordinate measuring machine (CMM) by contact probing. Likewise, spheres were scanned by a laser triangulation sensor mounted on the same CMM. The results derived from both the contact and laser measurements and before and after treating the surfaces were used to compare four parameters: point density, sphere diameter, sphere form deviation, and standard deviation of the best-fit sphere to the corresponding point cloud. This research has revealed that acid etching produces better optical qualities on the surfaces than the mirror-like original ones, thus enhancing the laser sensor capturing ability. However, such chemical etching has affected the metrological characteristics of the spheres to a greater extent than that produced by sandblasting. This difference is due to the variability of the chemical etching, caused by the high aggressiveness of the acid, which makes the process very sensitive to the time of exposure to the acid and the orientations of the spheres in the bath. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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15 pages, 11709 KiB

Open AccessArticle

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

by Xiaolong Ke, Wei Wu, Chunjin Wang, Yongheng Yu, Bo Zhong, Zhenzhong Wang, Tianyi Wang, Jianji Fu and Jiang Guo

Materials 2022, 15(5), 1642; https://doi.org/10.3390/ma15051642 - 22 Feb 2022

Cited by 8 | Viewed by 2165

Abstract

Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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12 pages, 4705 KiB

Open AccessArticle

Surface Properties of Ultrasonic Vibration-Assisted ELID Grinding ZTA Ceramics

by Zongxia Fu, Fan Chen, Wenbo Bie, Bo Zhao and Xiaobo Wang

Materials 2022, 15(2), 636; https://doi.org/10.3390/ma15020636 - 15 Jan 2022

Cited by 4 | Viewed by 1440

Abstract

This study aimed to explore the evolution of surface properties of nanocomposite ceramics during ultrasonic vibration-assisted electrolytic in-process dressing (UVA-ELID) grinding. First, the trajectory of the grain was analyzed, and the motion was simulated using MATLAB to demonstrate the mechanism of UVA-ELID grinding. The critical grinding depth was also calculated under the effect of ultrasonic vibration. Then, the conventional ELID (C-ELID) and UVA-ELID grinding were compared. The surface properties, including surface residual stress, surface microstructure, surface roughness, and surface morphology, were used to evaluate the effectiveness and feasibility of UVA-ELID grinding. Whether it was conventional C-ELID or UVA-ELID grinding, the residual compressive stress was introduced into the machined surface, while the former was lower than the latter. The microstructure of the UVA-ELID grinding was evenly distributed, and the ductility removal occurred during material removal. The surface roughness of Ra and Rz was reduced by 14.5% and 20.6%, respectively, during the UVA-ELID grinding. The surface morphology was dramatically changed with the help of ultrasonic vibration. In a word, for nanocomposite ceramic, the UVA-ELID grinding can significantly improve surface performance and achieve a better machining effect. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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15 pages, 2995 KiB

Open AccessArticle

Study on the P-S-N Curve of Sucker Rod Based on Three-Parameter Weibull Distribution

by Wenbin Cai, Wen Li and Jinze Xu

Materials 2022, 15(2), 560; https://doi.org/10.3390/ma15020560 - 12 Jan 2022

Cited by 10 | Viewed by 1539

Abstract

During the oil production process, sucker rods are subjected to cyclic alternating load. After a certain number of cycles, a sucker rod can experience fatigue failure. The number of cycles is called fatigue life (N), and the accurate relationship between maximum stress (S) and fatigue life (N) under a certain reliability (P), namely the P-S-N curve, is an important basis for the reliability analysis and fatigue life prediction of sucker rods. The Basquin model, based on log-normal distribution, is widely used for fitting the P-S-N curves of sucker rods. Due to the limitation of this model, it is difficult to extrapolate the conclusion obtained from a finite fatigue region to the high-cycle or ultra-high-cycle fatigue region, which makes it impossible to estimate the fatigue limit of the sucker rod. Compared to the log-normal distribution, Weibull distribution causes the sucker rod to have a minimum safety life, namely the safety life at 100% survival rate, which complies with the fatigue characteristics of the sucker rod and is more in line with the actual situation. In this study, the fatigue data for ultra-high-strength HL and HY grade sucker rods were obtained through experimental fatigue tests. A new fatigue life model was established and the P-S-N curves of two types of ultra-high strength sucker rods were obtained. For HL- and HY-type ultra-high strength sucker rods, the average error between the fitting result and fatigue test value is 1.25% and 4.39%, respectively. Compared to the S-N curve fitting result obtained from the Basquin model commonly used for sucker rods, the new model based on three-parameter Weibull distribution provides better fitting precision and can estimate fatigue limit more accurately, so this model is more suitable for estimating fatigue life and can better guide the design of ultra-high strength sucker rod strings. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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17 pages, 3521 KiB

Open AccessArticle

Prediction of Surface Roughness of Abrasive Belt Grinding of Superalloy Material Based on RLSOM-RBF

by Ying Liu, Shayu Song, Youdong Zhang, Wei Li and Guijian Xiao

Materials 2021, 14(19), 5701; https://doi.org/10.3390/ma14195701 - 30 Sep 2021

Cited by 11 | Viewed by 1612

Abstract

It is difficult to accurately predict the surface roughness of belt grinding with superalloy materials due to the uneven material distribution and complex material processing. In this paper, a radial basis neural network is proposed to predict surface roughness. Firstly, the grinding system of the superalloy belt is introduced. The effects of the material removal process and grinding parameters on the surface roughness in belt grinding were analyzed. Secondly, an RBF neural network is trained by reinforcement learning of a self-organizing mapping method. Finally, the prediction accuracy and simulation results of the proposed method and the traditional prediction method are analyzed using the ten-fold cross method. The results show that the relative error of the improved RLSOM-RBF neural network prediction model is 1.72%, and the R-value of the RLSOM-RBF fitting result is 0.996. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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21 pages, 15324 KiB

Open AccessArticle

Cavitation Effect in Ultrasonic-Assisted Electrolytic In-Process Dressing Grinding of Nanocomposite Ceramics

by Guangxi Li, Fan Chen, Wenbo Bie, Bo Zhao, Zongxia Fu and Xiaobo Wang

Materials 2021, 14(19), 5611; https://doi.org/10.3390/ma14195611 - 27 Sep 2021

Cited by 1 | Viewed by 1713

Abstract

Ultrasonic-assisted electrolytic in-process dressing (UA-ELID) grinding is a promising technology that uses a metal-bonded diamond grinding wheel to achieve a mirror surface finish on hard and brittle materials. In this paper, the UA-ELID grinding was applied to nanocomposite ceramic for investigating the cavitation effect on the processing performance. Firstly, the ultrasonic cavitation theory was utilized to define the cavitation threshold, collapse of cavitation bubbles, and variation of their radii. Next, the online monitoring system was designed to observe the ultrasonic cavitation under different ultrasonic amplitude for the actual UA-ELID grinding test. A strong effect of ultrasonic cavitation on the grinding wheel surface and the formed oxide film was experimentally proved. Besides, under the action of ultrasonic vibration, the dressing effect of the grinding wheel was improved, and the sharpness of grain increased by 43.2%, and the grain distribution was dramatically changed with the increase of ultrasonic amplitude. Compared with the conventional ELID (C-ELID) grinding, the average protrusion height increased by 14.2%, while the average grain spacing dropped by 21.2%. The UA-ELID grinding reduced the workpiece surface roughness R_z and R_a by 54.2% and 46.5%, respectively, and increased the surface residual compressive stress by 44.5%. The surface morphology observation revealed a change in the material removal mechanism and improvement of the surface quality by ultrasonic cavitation effect. These findings are considered instrumental in theoretical and experimental substantiation of the optimal UA-ELID grinding parameters for the processing of nanocomposite ceramics. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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11 pages, 9606 KiB

Open AccessArticle

Effect of Surface Integrity on Hot Fatigue Life of Ti₂AlNb Intermetallic Alloy

by Yanju Wang, Yi Zhou, Aixue Sha and Xingwu Li

Materials 2021, 14(17), 4841; https://doi.org/10.3390/ma14174841 - 26 Aug 2021

Cited by 6 | Viewed by 1430

Abstract

The effect of surface integrity on the hot fatigue performance of Ti₂AlNb alloy was investigated. A turning process was used to prepare the standard specimens for hot fatigue tests. The surface integrity characterization and axial fatigue tests were performed. The results show that the influence of surface roughness on the hot fatigue performance of the Ti₂AlNb alloy is a secondary factor. The compressive residual stress and enhanced microhardness in the surface layer has a significant effect on the hot fatigue life and they are dominant in the hot fatigue behavior of the Ti₂AlNb alloy. Through the investigation on the characteristics of the fatigue fractures, the fatigue propagation process was significantly suppressed because of the strong residual compressive stress and microhardness distribution on the surface layer of the Ti₂AlNb specimen. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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26 pages, 11245 KiB

Open AccessArticle

Phase Formation during Heating of Amorphous Nickel-Based BNi-3 for Joining of Dissimilar Cobalt-Based Superalloys

by Mojtaba Naalchian, Masoud Kasiri-Asgarani, Morteza Shamanian, Reza Bakhtiari, Hamid Reza Bakhsheshi-Rad, Filippo Berto and Oisik Das

Materials 2021, 14(16), 4600; https://doi.org/10.3390/ma14164600 - 16 Aug 2021

Cited by 8 | Viewed by 1908

Abstract

Phase transformations and the melting range of the interlayer BNi-3 were investigated by differential scanning calorimetry, which showed three stages of crystallization during heating. There were three exothermic peaks that indicated crystallization in the solid state. The cobalt-based X-45 and FSX-414 superalloys were bonded with interlayer BNi-3 at a constant holding time of 10 min with bonding temperatures of 1010, 1050, 1100, and 1150 °C using a vacuum diffusion brazing process. Examination of microstructural changes in the base metals with light microscopy and scanning electron microscopy coupled with X-ray spectroscopy based on the energy distribution showed that increasing temperature caused a solidification mode, such that the bonding centerline at 1010 °C/10 min included a γ-solid solution, Ni₃B, Ni₆Si₂B, and Ni₃Si. The athermally solidified zone of the transient liquid phase (TLP)-bonded sample at 1050 °C/10 min involved a γ-solid solution, Ni₃B, CrB, Ni₆Si₂B, and Ni₃Si. Finally, isothermal solidification was completed within 10 min at 1150 °C. The diffusion-affected zones on both sides had three distinct zones: a coarse block precipitation zone, a fine and needle-like mixed-precipitation zone, and a needle-like precipitation zone. By increasing the bonding temperature, the diffusion-affected zone became wider and led to dissolution. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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13 pages, 2981 KiB

Open AccessArticle

Study on Cutting Chip in Milling GH4169 with Indexable Disc Cutter

by Gensheng Li, Chao Xian and Hongmin Xin

Materials 2021, 14(11), 3135; https://doi.org/10.3390/ma14113135 - 07 Jun 2021

Cited by 3 | Viewed by 2108

Abstract

The study and control for chip have a significant impact on machining quality and productivity. In this paper, GH4169 was cut with an indexable disc milling cutter. The chips corresponding to each group of cutting parameters were collected, and the chip parameters (chip curl radius, chip thickness deformation coefficient, and chip width deformation coefficient) were measured. The qualitative relationship between the chip parameters and cutting parameters was studied. The quadratic polynomial models between chip parameters and cutting parameters were established and verified. The results showed that the chip parameters (chip curl radius, chip thickness deformation coefficient and chip width deformation coefficient) were negatively correlated with spindle speed; chip parameters were positively correlated with feed speed; chip parameters were positively correlated with cutting depth. The maximum deviation rate between measured values and predicted values for chip curl radius was 9.37%; the maximum deviation rate for cutting thickness deformation coefficient was 13.8%, and the maximum deviation rate of cutting width deformation coefficient was 7.86%. It can be seen that the established models are accurate. The models have guiding significance for chip control. Full article

(This article belongs to the Special Issue Surface Processing Technology for High-Temperature Resistant Materials)

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