Forthcoming and Online First Articles

International Journal of Surface Science and Engineering

International Journal of Surface Science and Engineering (IJSurfSE)

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International Journal of Surface Science and Engineering (7 papers in press)

Regular Issues

  • Investigation of Corrosion Mechanisms and Protective Performance of Thermal Sprayed Aluminum Coatings on Steel Structures   Order a copy of this article
    by Huili Wang, Shan Cong, Dong Li, Chenbo Zhang, Zhaoqun Tian 
    Abstract: This paper aims to investigate the corrosion and protection mechanisms of thermal sprayed aluminium (TSA) coatings. The open circuit potential (OCP), the linear polarisation resistance and the impedance spectrum were conducted by electrochemical measurement tests to analyse TSA coating corrosion behaviour. The microstructure analysis results revealed that the TSA coating formed a dense oxide layer, preventing contact between corrosive substances and the substrate. The polarisation resistance initially decreases and then increases, suggesting that the TSA coating possesses self-filling capability. The corrosion process of TSA coating consists of three stages: passivation film formation, pore blockage by corrosion product, and accumulation of corrosion products. The TSA coating provides cathodic protection in the damaged area, reducing the corrosion rate. Corrosion products accumulate over time, reinforcing material resistance to infiltration. A three-stage failure model describes the coating’s degradation, comprising intact coating, localised damage, and final failure with the highest corrosion rate.
    Keywords: corrosion mechanisms; TSA; coatings; steel structures.
    DOI: 10.1504/IJSURFSE.2024.10061326
     
  • Tribological investigations of AZ91D hybrid composite developed by friction stir processing   Order a copy of this article
    by Sathiskumar M, Kamaraj M 
    Abstract: This work describes the fabrication of a self-lubricating and surface wear-resistant hybrid composite. It has an AZ91D base composite reinforced with a combination of WS2 and MoS2 particles. The friction stir processing (FSP) technique was utilised to produce all composite specimens by varying the volume fraction to 5, 10, and 15%. The samples were prepared, as per the ASTM standards, for conducting various tests to obtain the mechanical properties. The specimens with 15% volume fractions demonstrated the lowest wear rate and the lowest friction coefficient in the wear tests. The sliding speed of 3 m/s and load 30 N results in a lower roughness value of 0.285
    Keywords: friction stir process; hybrid composite; solid lubricant; roughness; wear rate; sliding speed.
    DOI: 10.1504/IJSURFSE.2024.10062127
     
  • TRIBOLOGICAL BEHAVIOUR OF TITANIUM ALLOY DUE TO SURFACE MODIFICATION TECHNIQUE   Order a copy of this article
    by Prem Ananth M, Poovazhagan L, Risikesh J, Sai Vignesh Tanari, Sidheswaren J 
    Abstract: Alloys of titanium, widely used in aerospace, biomedical implants, and automotive industries for their exceptional strength-to-weight ratio, face challenges in wear resistance during tribological applications. This study targets improved wear resistance in titanium alloys by employing techniques like laser surface texturing and physical vapour deposition coating. Laser surface texturing (LST) proves effective in enhancing sliding surface tribological properties. The research explores applying a wear-resistant coating, aluminium chromium nitride (AlCrN), using physical vapour deposition (PVD) on surface-textured specimens. Unidirectional sliding wear tests on a pin-on-disc tribometer under varied loads (10 N, 20 N, and 30 N) and a velocity of around 2 m/s were conducted. Scanning electron microscopy and energy-dispersive X-ray analysis scrutinized coating morphology, wear mechanisms, and composition. Evaluation of the AlCrN coating’s specific wear rate, wear volume, and friction coefficient compared various dimple geometries.
    Keywords: titanium alloy; laser surface texturing; LST; physical vapour deposition; AlCrN coating; specific wear rate.
    DOI: 10.1504/IJSURFSE.2024.10062552
     
  • The Effect of Powder-Pack Aluminizing on The Corrosion Performance of FeCoGx Low Entropy Alloys   Order a copy of this article
    by Mehmet Küçükilhan, Ersan Mertgenç, Fatih Çolak 
    Abstract: Non-reinforced, 3% and 5% nano graphene reinforced FeCo alloy was produced by powder metallurgy and TIG melting methods, and the coating was made using the pack aluminising method. Scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and microhardness measurements were used in characterisation processes. Co7Fe3Al10, Co2Al5, FeCoAl, FeAl, Fe2Al5, Al2O3 phases were detected on the coated sample surfaces. The coating layer thicknesses were obtained between 86
    Keywords: FeCo alloy; graphene; low entropy alloy; pack aluminising; corrosion.
    DOI: 10.1504/IJSURFSE.2024.10062553
     
  • Effects of temperature-dependent viscosity, the impact parameters and substrate’s conditions in the alumina splats deposition on stainless-steel substrates using atmospheric plasma spraying   Order a copy of this article
    by Mohamed Elhoriny, Andreas Killinger, José Andrés Moreno Nicolás, Joaquín Solano 
    Abstract: Thermal spraying technology has proved to be a reliable technique for depositing reproducible functional surface coatings with predefined dimensional tolerances and properties. To optimise the selection of the manufacturing parameters, numerical simulation is increasingly applied, because it can provide useful information in a short time. Directly observing the particle impact, spreading, and solidification is very difficult owing to the extremely short process time and size scale. In the study, the values for the thermal contact resistance, contact angle, high impact velocity, high impact temperature, and different substrate initial temperatures were addressed. The slip conditions at the splat-substrate interface were also considered through the creation of separate models using either Marangoni shear stress or no-slip conditions at the interface. The results obtained have been compared with experimental data. Finally, the effect of preheating the substrate on the droplet’s dynamic viscosity is shown.
    Keywords: APS; alumina coating; droplet flattening.
    DOI: 10.1504/IJSURFSE.2024.10062554
     
  • Characteristics of rolling interface lubrication considering contact topography variation based on fractal theory   Order a copy of this article
    by Huajie Wu, Qiaoyi Wang, Laihua Tao 
    Abstract: This paper investigates the lubrication characteristics of line contact in the rolling interface, and applies the predictive method of surface roughness deformation amplitude. Based on the data of the surface roughness of the strip, an initial profile function of the rolling interface is constructed by the Weierstrass-Mandelbrot function. By incorporating the rolling lubrication model and modifying relevant algorithms, the oil pressure reference factor and film thickness reference factor are introduced to study the relationship between rolling load, rolling speed, reduction ratio, and the lubrication characteristics of the deformed surface roughness of the rolling strip. The research results show that there is a pressure peak appears at the inlet, and the oil film thickness exhibits a wedge shape in the work zone. Considering surface roughness deformation results in significant differences, with the oil pressure reference factor increasing by approximately 24% and the film thickness reference factor increasing by about 2.9 times.
    Keywords: fractal theory; roughness deformation; rolling interface; lubricating oil film; oil film pressure.
    DOI: 10.1504/IJSURFSE.2024.10063005
     
  • A SINGLE ASPERITY ELASTIC-PLASTIC CONTACT MODEL WITH THE EFFECT OF KINEMATIC STRAIN HARDENING   Order a copy of this article
    by Chinnusamy T.R., A. Sivakumar, V.L. Raja, Kathan Ambujam 
    Abstract: Explaining the contact interaction of rough surfaces through spherical asperity contact model is an effective one. In current work, a single asperity deforming against a flat surface is modelled and investigated through finite element approach. The combined impact of elastic modulus, yield strength, Poisson’s ratio and bilinear kinematic strain hardening rate on contact parameters is studied. The results revealed that the kinematic strain hardening rate significantly affects the contact load, contact area and contact pressure in elastic-plastic and fully plastic deformation states. Due to increase in kinematic strain hardening rate, the impact of Poisson’s ratio on contact parameters increases at high interference ratios in high strength materials. While increasing the kinematic strain hardening rate, high load carrying capacity can be achievable in low strength materials at elastic-plastic and fully plastic contact states. The empirical expressions are established to compute contact parameters with function of Poisson’s ratio, elastic modulus to yield strength ratio and interference ratio.
    Keywords: single asperity; elastic-plastic contact; material property; finite element approach; contact parameters; kinematic strain hardening.
    DOI: 10.1504/IJSURFSE.2024.10063006