Effect of Expanded Graphite on the Reaction Sintering of Boron Carbide

This paper presents novel results of research focused on reaction sintering of a mixture of expanded graphite and amorphous boron. It has been shown that as a result of combining the synthesis from the elements with sintering under pressure, dense boron carbide polycrystals (95% TD) can be obtained in which stable structures dominate, i.e., boron carbides of stoichiometry B₁₃C₂ and B₄C. Sintering was carried out on boron excess systems, and reaction mixtures with the following mass ratios (B:C = 5:1; 10:1; and 15:1) were used. Boron excess systems were used due to the presence of additional carbon during sintering since the matrix, reactor lining, and heating elements were made of graphite. 1850 °C was considered to be the optimum reaction sintering temperature for all of the systems tested. This shows that a reduction in the sintering temperature of 200–300 °C was observed with respect to traditional sintering techniques. Micro-cracks are present in the sinters, the presence of which is most likely due to the difficulty in removing the gaseous products which accompany the boron carbide synthesis reaction. The elimination of these defects of sintering requires further research.     

An Effective Expanded Graphite Coating on Polystyrene Bead for Improving Flame Retardancy

Although foamed plastic insulation is widely used in construction in the Korean market, it is vulnerable to fire. To improve the flame retardancy, the method of flame-retardant coating with the EG in water-soluble state on the surface of expanded polystyrene (EPS) beads has been widely used. However, polystyrene beads coated with a water-soluble flame retardant easily separate the coated flame retardant in manufacturing. In this study is devised a flame-retardant coating and two steps of coating process for adhering the flame-retardant coating film evenly to the surface of the polystyrene bead without exfoliation. It was analyzed whether a flame-retardant EPS (FR-EPS) with excellent flame retardancy could be manufactured using polystyrene beads coated in this way. Ten FR-EPS samples satisfied the HF-1 and V-0 levels in horizontal and vertical burning tests, respectively. The THR of eight FR-EPS samples for ten minutes did not exceed 8 MJ∙m⁻² and the maximum HRR did not exceed 200 kW∙m⁻² for more than ten consecutive seconds. FR-EPS passed the building material standard of semi-nonflammability in Korean regulations, in contrast to commercial EPS, which have not passed the semi-nonflammability standard. It was also analyzed how effective the designed coating is in this study, comparing it with composites that were planned to improve the flame resistance of polystyrene, as reported in the literature. Flame Retardancy Index (FRI) values of FR-EPS proved the “excellent” level and had higher values compared with other polystyrene composites. These results demonstrated that the coated EPS containing a water-soluble flame retardant manufactured from EG and two steps of application with the coating solution achieved fire safety standard regulations.     

Research and Statistical Analysis on Impact Resistance of Steel Fiber Expanded Polystyrene Concrete and Expanded Polystyrene Concrete

Steel fiber foamed concrete (SFFC) combines the impact resistance of steel fiber concrete (SFC) and the energy absorption characteristics of foamed concrete (FC), and it has brought attention to the impact field. Using the mechanical properties of SFFC expanded polystyrene concrete, we prepared (EPSC) specimens with 10%, 20%, 30%, 40%, 50% by volume of expanded polystyrene (V_eps), and steel fiber expanded polystyrene concrete (SFEPSC) specimens by adding 1% steel fiber (SF) based on the EPSC in this study. The relationship between compressive strength, the V_eps and apparent density was revealed. The relationship between the first crack and the ultimate failure impact of SFEPSC specimens was obtained by a drop-weight test. The impact resistance of SFEPSC and EPSC and the variation law of V_eps were studied by mathematical statistics. The log-normal and the two-parameter Weibull distributions were used to fit the probability distribution of impact resistance of the SFEPSC and EPSC specimens. Finally, both types of specimens’ destruction modes and mechanisms were analyzed. The mechanism of the EPS particles and the SFs dissipating impact load energy was analyzed from the energy point of view.     

Chunky Graphite in Low and High Silicon Spheroidal Graphite Cast Irons–Occurrence,Control and Effect on Mechanical Properties

Chunky graphite appears easily in heavy-section spheroidal graphite cast irons and is known to affect their mechanical properties. A dedicated experiment has been developed to study the effect of the most important chemical variables reported to change the amount of chunky graphite, namely the content in silicon and in rare earths. Quite unexpectedly, controlled rare earths contents appear beneficial for decreasing chunky graphite when using standard charge materials. Tin is shown to decrease chunky graphite appearance and it is evidenced that this effect is not related to rare earths. Finally, the effect of tin and antimony are compared and it is noticed that both suppress chunky graphite but also lead to some spiky graphite when no rare earth is added. Chunky graphite negatively affects the room temperature mechanical properties, though much more in the case of low silicon spheroidal graphite cast irons than in high silicon ones. Spiky graphite has been found to be much more detrimental and should thus be avoided.     

The Influence of Expanded Glass and Expanded Clay on Lightweight Aggregate Shotcrete Properties

In the construction industry, the selection of sustainable materials leads to a movement towards more sustainable construction. In this study, lightweight aggregate shotcrete based on expanded glass (EG) and expanded clay (EC) is investigated. The goal of the study is to determine the influence of EG and EC inclusion on the properties of shotcrete. Ordinary Portland cement (OPC) powder with supplementary cementitious materials, such as silica fume and ground glass waste, are used as binders. The mechanical, physical and morphological properties, as well as the mineral and oxygen compositions, are obtained through compressive and flexural strength tests, thermal conductivity measurements, scanning electron microscopy with energy dispersive X-ray spectrometry (SEM–EDX), X-ray diffraction (XRD) and X-ray fluorescence (XRF) analysis. In this study, the mechanical, physical and thermal properties and waste utilization as cement supplementary materials are balanced. The shotcrete samples show that a density of 790 kg/m³ had a good thermal performance (thermal conductivity coefficient of 0.174 W/(m·K)) with the sufficient compressive strength of 6.26 MPa.     

Formation of Nanocones on Highly Oriented Pyrolytic Graphite by Oxygen Plasma

Improvement in hemocompatibility of highly oriented pyrolytic graphite (HOPG) by formation of nanostructured surface by oxygen plasma treatment is reported. We have showed that by appropriate fine tuning of plasma and discharge parameters we are able to create nanostructured surface which is densely covered with nanocones. The size of the nanocones strongly depended on treatment time. The optimal results in terms of material hemocompatibility were obtained after treatment with oxygen plasma for 15 s, when both the nanotopography and wettability were the most favorable, since marked reduction in adhesion and activation of platelets was observed on this surface. At prolonged treatment times, the rich surface topography was lost and thus also its antithrombogenic properties. Chemical composition of the surface was always more or less the same, regardless of its morphology and height of the nanocones. Namely, on all plasma treated samples, only a few atomic percent of oxygen was found, meaning that plasma caused mostly etching, leading to changes in the surface morphology. This indicates that the main preventing mechanism against platelets adhesion was the right surface morphology.     

Effect of Boron Doping on the Interlayer Spacing of Graphite

Boron-doped graphite was prepared by the heat treatment of coke using B₄C powder as a graphitization catalyst to investigate the effects of the substitutional boron atoms on the interlayer spacing of graphite. Boron atoms can be successfully incorporated into the lattice of graphite by heat treatment, resulting in a reduction in the interlayer spacing of graphite to a value close to that of ideal graphite (0.3354 nm). With an increase in the catalyst mass ratio, the content of substituted boron in the samples increased significantly, causing a decrease in the interlayer spacing of the boron-doped graphite. Density functional theory calculations suggested that the effects of the substitutional boron atoms on the interlayer spacing of the graphite may be attributed to the transfer of Π electrons between layers, the increase in the electrostatic surface potential of the carbon layer due to the electron-deficient nature of boron atoms, and Poisson contraction along the c-axis.     

Effect of Stress on Irradiation Responses of Highly Oriented Pyrolytic Graphite

The effect of stress on irradiation responses of highly oriented pyrolytic graphite (HOPG) was studied by combing molecular dynamics (MD) simulation, proton irradiation, and Raman characterization. MD simulations of carbon knock-on at energies < 60 eV were used to obtain average threshold displacement energies (E¯d) as a function of strain ranging from 0 to 10%. Simulations at a higher irradiation energy of 2–5 keV were used to study the effect of strain on damage cascade evolution. With increasing tensile strain, E¯d was reduced from 35 eV at 0% strain to 31 eV at 10% strain. The strain-reduced E¯d led to a higher damage peak and more surviving defects (up to 1 ps). Furthermore, high strains induced local cleavage around the cavities, as one additional mechanism of damage enhancement. Experimentally, HOPG film was folded, and the folded region with the maximum tensile stress was irradiated by a 2 MeV proton beam. Raman characterization showed significantly enhanced D to G modes in comparison to the stress-free irradiation. Based on the strain dependence of E¯d and the Kinchin–Pease model, a formula for displacement estimation under different tensile strains is proposed. The stress effects need to be considered in graphite applications in a reactor’s harsh environment where both neutron damage and stress are present.     

Effect of the Sliding Element Surface Topography on the Oil Film Thickness in EHD Lubrication in Non-Conformal Contact

Under hard operating conditions such as high load, low speed and a lack of a sufficient quantity of lubricant, the sliding pairs could suffer serious damage. One of the methods that improves the tribological performance of sliding elements in hard operating conditions is the appropriate surface creation that keeps lubricating substance in cavities. This article presents the results obtained in experimental investigations of the oil film thickness in lubricated non-conformal contact with a different surface topography of the sliding element. The tests were conducted on a ball-on-disc instrument equipped with colorimetric interferometry. Balls of diameter equaled to 19.05 mm were produced from 100 Cr6 steel. To provide hard operating conditions, the glass disc rotated at small speeds in the range of 0.1–0.2 m/s. The tests were carried out at loads of 20 N and 30 N. As a result, in most cases, the highest minimum and average oil film thickness values were obtained when the surface of steel balls was characterized by high negative asymmetry with mainly shallow cavities and some valleys of great depth compared to the height of the peaks. The modified sliding surface that had better performance comprised a comparatively small number of peaks and the curvature of the peaks were large.     

Wettability and Surface Roughness Analysis of Laser Surface Texturing of AISI 430 Stainless Steel

Due to its wide applicability in industry, devising microstructures on the surface of materials can be easily implemented and automated in technological processes. Laser Surface Texturing (LST) is applied to modify the chemical composition, morphology, and roughness of surfaces (wettability), cleaning (remove contaminants), reducing internal stresses of metals (hardening, tempering), surface energy (polymers, metals), increasing the adhesion (hybrid joining, bioengineering) and decreasing the growth of pathogenic bacteria (bioengineering). This paper is a continuation and extension of our previous studies in laser-assisted texturing of surfaces. Three different patterns (crater array-type C, two ellipses at 90° overlapping with its mirror-type B and 3 concentric octagons-type A) were applied with a nanosecond pulsed laser (active medium Nd: Fiber Diode-pumped) on the surface of a ferritic stainless steel (AISI 430). Micro texturing the surface of a material can modify its wettability behavior. A hydrophobic surface (contact angle greater than 90°) was obtained with different variations depending on the parameters. The analysis performed in this research (surface roughness, wettability) is critical for assessing the surface functionality, characteristics and properties of the stainless steel surface after the LST process. The values of the surface roughness and the contact angle are directly proportional to the number of repetitions and inversely proportional to the speed. Recommendations for the use of different texturing pattern designs are also made.     

Preparation,Mechanical and Thermal Properties of Cement Board with Expanded Perlite Based Composite Phase Change Material for Improving Buildings Thermal Behavior

Here we demonstrate the mechanical properties, thermal conductivity, and thermal energy storage performance of construction elements made of cement and form-stable PCM-Rubitherm^® RT 28 HC (RT28)/expanded perlite (EP) composite phase change materials (PCMs). The composite PCMs were prepared by adsorbing RT28 into the pores of EP, in which the mass fraction of RT28 should be limited to be no more than 40 wt %. The adsorbed RT28 is observed to be uniformly confined into the pores of EP. The phase change temperatures of the RT28/EP composite PCMs are very close to that of the pure RT28. The apparent density and compression strength of the composite cubes increase linearly with the mass fraction of RT28. Compared with the thermal conductivity of the boards composed of cement and EP, the thermal conductivities of the composite boards containing RT28 increase by 15%–35% with the mass fraction increasing of RT28. The cubic test rooms that consist of six boards were built to evaluate the thermal energy storage performance, it is found that the maximum temperature different between the outside surface of the top board with the indoor temperature using the composite boards is 13.3 °C higher than that of the boards containing no RT28. The thermal mass increase of the built environment due to the application of composite boards can contribute to improving the indoor thermal comfort and reducing the energy consumption in the buildings.     

The Effect of Graphite Additives on Magnetization,Resistivity and Electrical Conductivity of Magnetorheological Plastomer

Common sensors in many applications are in the form of rigid devices that can react according to external stimuli. However, a magnetorheological plastomer (MRP) can offer a new type of sensing capability, as it is flexible in shape, soft, and responsive to an external magnetic field. In this study, graphite (Gr) particles are introduced into an MRP as an additive, to investigate the advantages of its electrical properties in MRPs, such as conductivity, which is absolutely required in a potential sensor. As a first step to achieve this, MRP samples containing carbonyl iron particles (CIPs) and various amounts of of Gr, from 0 to 10 wt.%, are prepared, and their magnetic-field-dependent electrical properties are experimentally evaluated. After the morphological aspect of Gr–MRP is characterized using environmental scanning electron microscopy (ESEM), the magnetic properties of MRP and Gr–MRP are evaluated via a vibrating sample magnetometer (VSM). The resistivities of the Gr–MRP samples are then tested under various applied magnetic flux densities, showing that the resistivity of Gr–MRP decreases with increasing of Gr content up to 10 wt.%. In addition, the electrical conductivity is tested using a test rig, showing that the conductivity increases as the amount of Gr additive increases, up to 10 wt.%. The conductivity of 10 wt.% Gr–MRP is found to be highest, at 178.06% higher than the Gr–MRP with 6 wt.%, for a magnetic flux density of 400 mT. It is observed that with the addition of Gr, the conductivity properties are improved with increases in the magnetic flux density, which could contribute to the potential usefulness of these materials as sensing detection devices.     

Study on Morphology and Chemical States of Surface Active Layer of Th-W Cathode

The surface morphology and chemical states of W-2%ThO₂ thermionic cathode during vacuum high-temperature treatment were investigated in this research. The W-2%ThO₂ thermionic cathode was prepared by a solid-liquid doping method combined with high-temperature sintering. The morphology and distribution of thorium oxide were observed using a transmission electron microscope and scanning electron microscope. The chemical states of elements at different temperatures were analyzed by X-ray photoelectron spectroscopy. Results indicate that the surface morphology and chemical form of the alloy evolve with the increase of temperature. The matrix had a lamellar structure at low temperatures, and the surface was relatively flat. The samples were heated to 500 °C, 1100 °C, and 1300 °C for 1 h. During the heating process, thorium oxide changed from granular to spherical, and the matrix was recrystallized. As the heating temperature rises, diffusion channels appear inside the cathode. As the temperature increases, the high-priced tungsten gradually decreases, and the zero-valent tungsten content increases. The adsorbed oxygen left the cathode surface, and the lattice oxygen increased. The surface oxygen content decreased, and the thorium and tungsten content increased.     

Assessment of CVD- and PVD-Coated Carbides and PVD-Coated Cermet Inserts in the Optimization of Surface Roughness in Turning of AISI 1045 Steel

In this study, an experimental and statistic investigation approach based on analysis of variance (ANOVA) and response surface methodology (RSM) techniques was performed to find the significant main effects and two-factor interaction effects and to determine how the controllable factors such as cutting speed, feed rate, depth of cut (DOC), tool nose radius, substrate and coating method of cutting tools influence surface quality in turning of AISI 1045 steel. The first optimal or near-optimal conditions for the quality of the generated surface and the second ones, including maximum material removal rate, were established using the proposed regression equations. The group mean roughness of the turned workpieces was lower from using chemical vapor deposition (CVD)-coated carbide inserts than the group means of other types of inserts; however they could not achieve the specific lowest roughness. The physical vapor deposition (PVD)-coated carbide and cermet inserts achieved the best surface quality when the specific combinations within the range interval of controllable factors were used in the experiment, showing that they may be applied to finish turning processes or even to particular high material removal rate conditions associated with the lowest roughness.     

Magnetic Measurement of Zn Layer Heterogeneity on the Flange of the Steel Road Barrier

This study deals with monitoring of Zn layer heterogeneity on the flange of steel road barriers using magnetic measurements. The Barkhausen noise technique is employed for such purpose, and parameters extracted from Barkhausen noise signals are correlated with the true thickness of the Zn layer. The true values of the Zn layer were obtained from the metallographic images, as well as the thickness gauge CM-8825FN (Guangzhou Landtek Instruments Co. Ltd., Guangzhou, China) device. It was observed that the diffusion region lies below the Zn protective layer, which makes the thickness of the Zn layer obtained from the CM-8825FN device thicker than that measured on the metallographic images. For this reason, the chemical gradient of Zn below the Zn layer can be reported, and it affects Barkhausen noise emission. Barkhausen noise decreases along with increasing thickness of the Zn layer, and Barkhausen noise envelopes are shifted to stronger magnetic fields. The number of strong MBN pulses drops down with the increasing thickness of Zn coating at the expense of the increasing number of the weak MBN pulses. The thickness of Zn coating can be polluted by the solidification of Zn melt after galvanizing. The presence of the diffusion layer dims the contrast between ferromagnetic and paramagnetic phases.     

Formation of Micro- and Nanostructures on the Nanotitanium Surface by Chemical Etching and Deposition of Titania Films by Atomic Layer Deposition (ALD)

In this study, an integrated approach was used for the preparation of a nanotitanium-based bioactive material. The integrated approach included three methods: severe plastic deformation (SPD), chemical etching and atomic layer deposition (ALD). For the first time, it was experimentally shown that the nature of the etching medium (acidic or basic Piranha solutions) and the etching time have a significant qualitative impact on the nanotitanium surface structure both at the nano- and microscale. The etched samples were coated with crystalline biocompatible TiO₂ films with a thickness of 20 nm by Atomic Layer Deposition (ALD). Comparative study of the adhesive and spreading properties of human osteoblasts MG-63 has demonstrated that presence of nano- and microscale structures and crystalline titanium oxide on the surface of nanotitanium improve bioactive properties of the material.     

Influences of Toothbrushing and Different Toothpastes on the Surface Roughness and Color Stability of Interim Prosthodontic Materials

The surface properties and color stability of interim crown materials may vary depending on the toothbrushing procedure. This study aimed to investigate the effects of toothbrushing and different toothpastes on the surface roughness (R_a) and color stability of different interim crown materials. Disc-shaped specimens were prepared from four interim crown materials (Tab 2000 (ChPM), Imident (LaPM), Protemp 4 (ChDM), and Telio-CAD (CadPM)). Specimens were divided into four subgroups for the control group (Cnt) and for simulated toothbrushing with distilled water (Dw) or with two different toothpastes (whitening toothpaste (WTp), activated charcoal toothpaste (ACTp)). The specimens’ R_a values were measured before and after 10,000 cycles of toothbrushing. The color parameters were measured and the color differences (ΔE₀₀) were calculated. Data were statistically analyzed by two-way analysis of variance (ANOVA) and Tukey’s HSD tests. A significant increase in the R_a values was observed after toothbrushing, except for the LaPM_Dw, ChDM_Dw, and all the CadPM specimens (p < 0.05). Toothbrushing with toothpastes increased the ΔE₀₀ values of all ChPM and ChDM interim materials (p < 0.05). Before and after all toothbrushing procedures, the CadPM specimens had smoother and ChPM specimens had rougher surfaces than the other interim materials. The two tested toothpastes had similar effects on the R_a of all interim materials. Non-perceivable color changes were seen only with the CadPM_Dw group.     

The Effect of Shot Peening on Residual Stress and Surface Roughness of AMS 5504 Stainless Steel Joints Welded Using the TIG Method

This article presents the influence of the Shot Peening (SP) process on residual stress and surface roughness of AMS 5504 joints welded using the Tungsten Inert Gas (TIG) method. Thin-walled steel structures are widely used in the aviation and automotive industries, among others. Unfortunately, the fatigue properties become worse during the welding process. Samples of 1 mm-thick AMS 5504 steel plates were first prepared using TIG welding and then strengthened by the Shot Peening (SP) process. The technological parameters of the SP process were changed in the range of time t from 2 min to 4 min and of pressure p from 0.4 MPa to 0.6 Mpa. The residual stresses were measured by X-ray diffraction in three zones: fusion zone (FZ), heat-affected zone (HAZ) and base metal (BM). The results showed that SP introduced compressive residual stresses in all of the zones measured, especially in the FZ. The greatest value of compressive residual stresses σ = −609 MPa in the FZ was observed for the maximum parameters of SP (p = 0.6 MPa, t = 4 min). The increase in value of residual stress is about 580% when compared to welding specimens without treatment. As a result of shot peening in the FZ, the mean roughness value Ra decreased in range 63.07% to 77.67% in the FZ, while in the BM increased in range 236.87% to 352.78% in comparison to specimen without treatment. Selected surface roughness parameters in FZ and BM were analyzed using neural networks. In FZ, it was demonstrated that the most correlated parameters with residual stresses are Rt and Rsk. On the other hand, in the BM zone, the most correlated parameters were Rv, Rt and Rq. This enables the estimation of stresses in the welded joint after SP on the basis of selected roughness parameters.     

Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness

The article presents the results and process analysis of the face milling of aluminium alloy 2017A with the CoroMill 490 tool on an AVIA VMC 800 vertical milling centre. The study analysed the effects of the cutting speed, the feed rate, the actual number of teeth involved in the process, the minimum thickness of the cut layer (h_min), and the relative displacement in the tool-workpiece system D(ξ) on the surface roughness parameter Ra. To measure relative displacement, an original bench was used with an XL-80 laser interferometer. The analysis of relative displacement and surface roughness allowed these factors to be correlated with each other. The purpose of this article is to determine the stable operating ranges of the CoroMill 490-050Q22-08M milling head with respect to the value of the generated relative displacement w during the face-milling process and to determine its influence on surface roughness. The research methodology presented in this paper and the cutting tests carried out allowed the determination of the optimum operating parameters of the CoroMill 490-050Q22-08M tool during the face milling of aluminium alloy 2017A, which are v_c 300 m/m and f_z—0.14 mm/tooth. Working with the defined cutting parameters allows all the cutting inserts in the tool body to be involved in shaping the geometrical structure of the surface, while maintaining a low vibration level D(ξ) > 1 µm, a low value of the parameter h_min > 1.5 µm, and the desired value of the parameter Ra > 0.2 µm     

Effect of Temperature on the Deformation Behavior of Copper Nickel Alloys under Sliding

The microstructural evolution in the near-surface regions of a dry sliding interface has considerable influence on its tribological behavior and is driven mainly by mechanical energy and heat. In this work, we use large-scale molecular dynamics simulations to study the effect of temperature on the deformation response of FCC CuNi alloys of several compositions under various normal pressures. The microstructural evolution below the surface, marked by mechanisms spanning grain refinement, grain coarsening, twinning, and shear layer formation, is discussed in depth. The observed results are complemented by a rigorous analysis of the dislocation activity near the sliding interface. Moreover, we define key quantities corresponding to deformation mechanisms and analyze the time-independent differences between 300 K and 600 K for all simulated compositions and normal pressures. Raising the Ni content or reducing the temperature increases the energy barrier to activate dislocation activity or promote plasticity overall, thus increasing the threshold stress required for the transition to the next deformation regime. Repeated distillation of our quantitative analysis and successive elimination of spatial and time dimensions from the data allows us to produce a 3D map of the dominating deformation mechanism regimes for CuNi alloys as a function of composition, normal pressure, and homologous temperature.