articles+ search results

additive manufacturing, PEEK, prosthetic implant, laser beam, and surface treatment

The physicochemical properties of polyether ether ketone (PEEK) allow to use this material for prosthetic restorations applied in implant prosthetics. So far, such attempts have been made in the technology of milling rough material solids of this polymer, but the surface quality was unsatisfactory. Therefore, the production of these materials by additive manufacturing techniques was proposed and an attempt was made to shape their surface using a laser. The possibilities of the method are determined in the paper and preliminary works related to the product surface shaping are presented. The process of making individual prosthetic restorations from the PEEK material by the additive method together with the technology of laser modification of the geometric structure of the material surface for applications in implant prosthetic treatment of patients is innovative and has not been used so far.

połączenia klejowe, metody przygotowania powierzchni, obróbka powierzchniowa, połączenia adhezyjne, adhesive bonding, surface preparation methods, surface treatment, and adhesive-bonded joints

An important part in the process of adhesive bonding is played by the appropriate preparation of surfaces to be subjected to adhesive bonding. The objective of the tests discussed in the article was to identify the effect of various surface preparation methods, including cleaning, grinding, atmospheric plasma treatment and the ATOP method on the strength of adhesive-bonded joints. The tests involved the use of specimens made of aluminium alloy EN AW 5754 as well as specimens made of glass fibre-reinforced epoxy-based plastics. The specimens were subjected to overlap adhesive bonding involving the use of Araldite two-component epoxy adhesive (Huntsman). The article presents results of the static shear test (of the overlap joints) in relation to a given surface preparation method applied before the adhesive bonding process. The highest strength of the adhesive-bonded joints made in the aluminium alloy was obtained in relation to the ATOP method-based treatment. In addition, the above-named method makes it possible to properly prepare a cleaned surface by forming a protective layer ensuring proper surface preparation for several months. In turn, the highest strength of the adhesive-bonded joints made of glass fibre-reinforced plastics was obtained in relation to the surface treatment performed using atmospheric plasma.
W procesie klejenia ważną rolę odgrywa odpowiednie przygotowanie powierzchni klejonych. Celem badań, przedstawionych w artykule, było sprawdzenie wpływu różnych metod przygotowania powierzchni, takich jak: oczyszczanie, szlifowanie, obróbka plazmą atmosferyczną, metoda ATOP na wytrzymałość złączy klejowych. Badania wykonano na próbkach ze stopu aluminium EN AW 5754 oraz próbkach z tworzyw sztucznych wykonanych na osnowie epoksydowej wzmacnianych włóknem szklanym. Próbki klejono na zakładkę klejem epoksydowym dwuskładnikowym - Araldite, firmy Huntsman. Przedstawiono wyniki badań statycznej próby ścinania złączy zakładkowych w zależności od zastosowanej metody przygotowania powierzchni przed klejeniem. Najwyższą wytrzymałości złączy klejowych, dla próbek wykonanych ze stopu aluminium, uzyskano przy obróbce metodą ATOP. Metoda ta pozwala także na odpowiednie zabezpieczenie oczyszczonej powierzchni poprzez wytworzenie warstwy ochronnej, zapewniając prawidłowe przygotowanie powierzchni przez okres kilku miesięcy. Natomiast przy łączeniu tworzyw sztucznych wzmacnianych włóknem szklanym najwyższą wytrzymałość uzyskano przy obróbce powierzchni przed procesem klejenia za pomocą plazmy atmosferycznej.
1. Wersja polska artykułu w wydaniu papierowym s. 37-43.
2. Opracowanie rekordu ze środków MNiSW, umowa Nr 461252 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2020).

surface treatment, product development, vibratory machining, surface roughness, brass, finishing, obróbka powierzchniowa, rozwój produktu, obróbka wibracyjna, chropowatość powierzchni, wykończenie, and mosiądz

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

surface treatment, magnesium alloy, modified surface layer, microstructure, obróbka powierzchniowa, stop magnezu, warstwa powierzchniowa zmodyfikowana, and mikrostruktura

The thermochemical treatment applied to improve the surface properties of AZ91 consisted in heating the material in contact with AlSi10Mg powder at 445 oC for 30 min. During heat treatment process the powder was held under pressure to facilitate the diffusion of the alloying elements to the substrate and, accordingly, the formation of a modified layer. Two pressures, 1 MPa and 5 MPa, were tested. The resultant layers, containing hard Mg2Si and Mg17Al12 phases, were examined using an optical microscope and a scanning electron microscope equipped with an energy-dispersive X-ray spectrometer (EDS). The experimental data show that the layer microstructure was dependent on the pressure applied. A thicker, three-zone layer (about 200 μm) was obtained at 1 MPa. At the top, there were Mg2Si phase particles distributed over the Mg17Al12 intermetallic phase matrix. The next zone was a eutectic (Mg17Al12 and a solid solution of Al in Mg) with Mg2Si phase particles embedded in it. Finally, the area closest to the AZ91 substrate was a eutectic not including the Mg2Si phase particles. By contrast, the layer produced at a pressure of 5 MPa had lower thickness of approx. 150 μm and a two-zone structure. Mg2Si phase particles were present in both zones. In the upper zone, Mg2Si phase particles were regularly distributed over the Mg17Al12 intermetallic phase matrix. The lower zone, adjacent to the AZ91, was characterized by a higher volume fraction of Mg2Si phase particles distributed over the matrix composed mainly of Mg17Al12. The alloyed layers enriched with Al and Si had much higher hardness than the AZ91 substrate.

surface treatment, quality management, automation in foundry, robotics in foundry, abrasive water jet cutting, castings, obróbka powierzchniowa, zarządzanie jakością, automatyzacja w odlewni, robotyka w odlewni, cięcie strumieniem wody, and odlewy

This article proposes to use abrasive waterjet cutting (AWJ) for deflashing, deburring and similar finishing operations in casting. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The experiments focused on the removal of external flash from elements made of EN-GJL-150 cast iron. The method employed for finishing was abrasive waterjet cutting. The tests were carried out using an APW 2010BB waterjet cutting machine. The form profiles before and after flash removal were determined with a Taylor Hobson PGI 1200 contact profiler. A Nikon AZ100 optical microscope was applied to observe and measure the changes in the flash height and width. The casting surface after finishing was smooth, without characteristic sharp, rough edges that occur in the cutting of objects with a considerable thickness. It should be emphasized that this method does not replace precise cutting operations. Yet, it can be successfully used to finish castings for which lower surface quality is required. An undoubted advantage of waterjet cutting is no effect of high temperature as is the case with plasma, laser or conventional cutting. This process is also easy to automate; one tool is needed to perform different finishing operations in order to obtain the desired dimensions, both internal and external.

FFF (Fused Filament Fabrication), polylactide (PLA), acrylonitrile-butadiene-styrene (ABS), surface treatment, surface roughness, polilaktyd (PLA), kopolimer akrylonitrylo-butadieno-styrenowy (ABS), obróbka powierzchniowa, and chropowatość powierzchni

The aim of the conducted research was to examine the possibility of using chemical and physical methods of surface treatment of elements printed on a 3D printer. Elements were printed from polylactide (PLA) and acrylonitrile-butadiene-styrene (ABS) – materials most commonly used in fused filament fabrication (FFF) technology. Roughness measurements were made to assess the quality of individual methods. The best surface smoothness results were obtained during abrasive paper processing and after applying epoxy resin. The intended effect was also obtained after processing samples from PLA in chloroform fumes, and ABS samples in acetone vapors.

carbon fibers, surface treatment, desizing, mechanical properties, włókna węglowe, obróbka powierzchniowa, odklejenie, and właściwości mechaniczne

In this work, the influence of carbon fiber surface treatment on mechanical properties of unsaturated polyester was investigated. Two approaches have been used in the surface treatment; the first is the desizing of the carbon fiber by the release of the epoxy layer. The second is with the release of epoxy layer and etching the fibers. It was concluded that both methods give good results on adhesion between the matrix and the fibers. It is found that the treatment of carbon fibers is effcient and greatly improves the CFRP handress. The tensile strength of composite materials increases by 30% for etched carbon fibers compared to untreated carbon fibers.SEM images confirm the results obtained.

obróbka powierzchniowa, kulkowanie, wzmocnienie, modelowanie, surface treatment, shot-peening, strengthening, and modelling

Purpose: of this paper is developing the mathematical models of shot-peening, in which is reflected moving shot-peening head or machine parts surfaces during treating that will achieve uniformity of treatment machine parts. Design/methodology/approach: The main methods used for the theoretical research are mathematical modelling, integral calculus, fundamentals of analytic geometry, probability theory. It is used approved enough and well known numerical methods for calculations after mathematical models. Findings: Method of mathematical modeling for shot-peening is developed based on the energy conception. Mathematical model in which is reflected moving shot-peened head or machine parts surfaces during treating is created. It allows forecasting the characteristics of surface quality depending on the technological modes of treatment. Research limitations/implications: It is planned developing and improving the methods of shot-peening mathematical modeling in future research by extending theirs for the curvilinear treated surfaces, which has movement relative to the nozzle of shot-peening head after the different laws of motion, and for different kinds of materials, especially for metal joint endoprosthesis biomaterials. Practical implications: has the applied software, elaborated on the basis of the models, that allows providing for automation of calculations of the characteristics of surface quality depending on the technological modes of treatment. Originality/value: It is pioneered receiving functional dependences in which is reflected moving shot-peened head or machine parts surfaces during treating. Created functional dependences takes into account the distribution of characteristics of working medium (mass and velocity) all along the cross-sections of shot blast.

wygładzarki pojemnikowe, obróbka powierzchni, stal nierdzewna, warstwa wierzchnia, obróbka ścierna, smoothing container machine, surface treatment, stainless steel, surface layer, and abrasive finishing

Przedstawiono wyniki pomiarów struktury geometrycznej powierzchni próbek wykonanych ze stali nierdzewnej, poddanych procesowi wygładzania w wygładzarce pojemnikowej. Zaprezentowano analizy efektów obróbki oraz możliwości stosowania obróbki pojemnikowej w szeroko pojętym wzornictwie przemysłowym. Badania zrealizowano na wygładzarce rotacyjno-kaskadowej z użyciem żywicznych i ceramicznych kształtek ściernych. Przeprowadzono próbę wdrożenia robota przemysłowego do intensyfikacji procesu obróbkowego z wykorzystaniem wygładzarki rotacyjnej.

Vickers indentation, residual stress, FEM analysis, material property, and surface treatment

Residual stress has a great influence on the metal, but it is difficult to measure at small area using a general method. Residual stress calculations using the Vickers indentation can solve this problem. In this paper, a numerical simulation has been made for the residual stress measurement method of metal material deformed by high-speed impact. Then, the stress-strain curve at the high-speed deformation was confirmed through actual experiments, and the residual stresses generated thereafter were calculated by the Vickers indenter method. A Vickers indentation analysis under the same conditions was performed at the position where a residual stress of about 169.39 MPa was generated. Experiments were carried out and high speed impact was applied to the specimen to generate residual stress. The obtained results indicate that it is possible to identify residual stresses in various metals with various shapes through Vickers indentation measurements, and to use them for process and quality control.

obróbka powierzchniowa, stop tytanu, obróbka laserowa, mikrostruktura, skład fazowy, surface treatment, titanium alloy, laser treatment, microstructure, and phase composition

Purpose: The purpose of this paper is modification of the Ti-6Al-4V titanium alloy surface layer properties through laser alloying technology. Design/methodology/approach: Laser treatment was performed on the samples coated by graphite and BN powders in stream of nitrogen. Thopography of the surface of laser melted layer was investigated. Microstructure,fracture surface and chemical composition analysis were made by using Epiphot 300 optical microscope and Novascan 30 scanning electron microscope equipped with EDS X-ray detector. Phase composition was determined using X-ray diffractometry (Philips) with CuKα radiation. The Vickers hardness under load of 1.96 N and thermo-electric power was measured on the surface of cross-sections. Findings: Laser treatment has produced a surface layer which consists of hard ceramic TiC, TiN and TiB particles spaced in ductile martensitic matrix. Under the layer, the heat affected zone containing martensitic Tiα’ phase is present. The hardness obtained on cross-sectioned layer increases clearly in comparison with the base material. The high hardness level (HV 920 - 570) can be attributed to the formation of TiN, TiC and TiB phases. The thermoelectric power decreases noticeably with hardness increase and enables alloying process evaluation. Research limitations/implications: Research range was limited to investigation of microstructure, phase composition and hardness effects of laser alloying process. In order to estimate the influence of the laser alloying technology on durability of the layer, supplementary wear resistance tests will be performed in future research. Practical implications: The surface alloying by laser irradiation is investigated as a process capable to produce coatings composed of metallic matrix reinforced by ceramic particles and this can increase durability of elements made of titanium alloys. Originality/value: The wide range of investigations contained microstructure, phase and chemical composition analysis as well as fractographic and thermo-electric power estimation enables in-depth analysis of alloying process efficiency.

surface treatment, water treatment, coagulation, uzdatnianie wody, koagulacja, and uzdatnianie powierzchni

Coagulation is a process commonly used in water treatment, especially for surface water. This process aims to effectively remove organic matter [1, 2] especially precursors of oxidation and disinfection by-products [3–5], whose creation potential is related to absorption values at 254 nm (UV254) [6] Due to a very large variability in surface water composition over the course of the year and different contamination levels dependent on water source location, it is important to optimally choose coagulant type and dosage. Such optimization is difficult due to the presence of a large number of coagulants on the market. Świderska-Bróż and Rak [7] and Lee et al. [8] have shown that prehydrolyzed coagulants are less sensitive to changes in temperature and pH of the input water than classic ones. Lin et al. [9] suggest however that the effectiveness of coagulation mainly depends on the type and structure of organic matters present in waters, and to a much lesser degree on pH and temperature.

odpad przemysłowy, tworzywo sztuczne, właściwości mechaniczne, kompozyt cementowy, obróbka powierzchniowa, industrial waste, plastic, mechanical properties, cement composite, and surface treatment

W pracy omówiono wyniki badań możliwości wykorzystania odpadów z polipropylenu (PP), polietylenu (PE) i poliamidu (PA), uzyskanych z zakładu przetwarzania odpadów, jako wzmocnienie zapraw. Jednym z głównych problemów związanych z wykorzystywaniem odpadów z tworzyw sztucznych w kompozytach cementowych jest hydrofobowość powierzchni tworzywa sztucznego, która uniemożliwia adhezję zaczynu cementowego. W badaniach zastosowano rozcieńczony roztwór izopropanolu do obróbki powierzchniowej tworzyw sztucznych. Przy projektowaniu mieszanin uwzględniono trzy zmienne; rodzaj tworzywa sztucznego (PP, PE, PA), ich dodatek oraz ich obróbkę powierzchniową. Przeprowadzono badania wytrzymałości na zginanie i ściskanie. 1,5% dodatek PP i PE zwiększył wytrzymałość na zginanie zaprawy, natomiast obróbka powierzchniowa nie wpłynęła na tę wytrzymałość. Wraz ze zwiększaniem dodatku tworzyw sztucznych zwiększała się energia pękania zapraw z tymi tworzywami. Dla stosunku objętościowego 1,5% zwiększeniu uległa energia pękania w odniesieniu do mieszaniny wzorcowej, przy czym największy wpływ miał odpad PP. W przypadku niepoddanych obróbce powierzchniowej odpadów stwierdzono znaczne zwiększenie energii pękania, przy równoczesnym zmniejszeniu wytrzymałości na ściskanie i energii pękania przy ściskaniu, jednak ten wpływ uległ zwiększeniu po obróbce powierzchniowej odpadów. Odpadowe tworzywa sztuczne mogą być stosowane w zaprawach lub w betonach, w celu poprawy ciągliwości i udarności. Równocześnie wykorzystanie tych odpadów eliminuje zanieczyszczenie środowiska.

surface treatment, casting defect, tungsten inert gas, chromium cast iron, nodular cast iron, obróbka powierzchniowa, wada odlewu, metoda TIG, żeliwo chromowe, and żeliwo sferoidalne

Repair of cast iron elements realize in order to cut out a superficial casting defects. Defects decrease a usability of castings for constructional application and increase a manufacturing costs. The paper presents research results of use of TIG - Tungsten Inert Gas also known as GTA - Gas Tungsten Are surfacing by welding on cold and half-hot to repair chromium cast iron EN-GJN-XCrl5 with chromium content about 15% and nodular (with ferritic-pearlitic matrix) cast iron EN-GJS-500-7. The result of investigations show possibility of castings repair by put on defects a good quality padding welds, which have comparable or better properties than base material.

shot peening, double shot peening, surface treatment, residual stresses, roughness, kulkowanie, podwójne kulkowanie, obróbka powierzchniowa, naprężenia szczątkowe, and chropowatość

The bead blasting process is widespread in both the automotive and aerospace industry and is performed in order to improve the fatigue strength of various components. Bead blasting is a cold plastic forming process during which the surface of the material processed is hit by small, hard particles consisting of steel pellets, bearing balls or glass beads. It increases the hardness of the outer layer and establishes compression stresses inside it, which is why this processing is often used to improve fatigue strength. Contrary to other peening methods, bead blasting does not result in a reduction in the height of the processed surface’s unevenness in most cases. Shot peening changes the residual tensile stresses into residual compression stresses, thanks to which, the lifetime of the parts processed is extended and their carrying capacity is increased. The double shot peening process proposed by the authors consists in a two-stage bead blasting process. The first stage consists in blasting with round cast steel pellets, pellets cut from wire or cast iron pellets. During the second stage the same samples underwent glass bead blasting. The tests conducted on the RSA-501 aluminum alloy indicate that as a result of the processing medium’s impact in the form of glass beads or pellets of different diameter and shape, a permanent plastic deformation of the material surface occurs. On the basis of the obtained results it is possible to infer that the choice of parameters of both conventional shot peening and the double shot peening determine the impact thereof on the material’s mechanical properties. Thanks to the application of the double shot peening process there is a noticeable decrease in value of the Ra parameter, by about 40% on average. When analyzing the compressive stress results it is possible to state that after the first blasting process the value of stress was increasing when moving deeply into the sample from its surface, while after the glass bead blasting the value of compressive stress was significantly higher already near the surface. Double shot peening results in an increase in the value of compressive stresses by 40-50% when compared to conventional blasting.

obróbka powierzchniowa, stal narzędziowa, stopowanie, obróbka laserowa, surface treatment, tool steel, alloying, and laser treatment

Purpose: The objective of the present work was to study the modification of the microstructure of hot-work tool steel X40CrMoV5-1 during the surface modifying by means of laser technology. Design/methodology/approach: The initial experiments consisting in alloying the hot work tool steel indicate to the clear influence of the laser power on the run face shape and its depth. Findings: The structure of material solidifying after laser remelting is characteristic of the diversified morphology connected with the repeated changes of the crystals’ growth direction, from the small dendrites, whose principal axes are oriented in accordance with the heat removal direction sat the boundary between the solid and liquid phases, clusters of carbides arranged in accordance with the swirls caused by the metallic liquid convection motion, and partially non-remelted WC conglomerates as the alloying material in the central area of the remelted zone, to the fine equiaxial grains in the subsurface zone. Research limitations/implications: Laser remelting and alloying with the tungsten carbide results in refinement of the structure in the entire laser power range and in diversification of the grain size in the particular surface layer zones. Practical implications: Laser alloying has the important cognitive significance and gives grounds to the practical employment of these technologies for forming the surfaces of new tools and regeneration of the used ones. Originality/value: The fine grained, dendritic structure occurs in the remelted and alloyed zone with the crystallization direction connected with the dynamical heat abstraction from the laser beam influence zone. The fine grained martensite structure is responsible for hardness increase of the alloyed layer.

obróbka mechaniczna, odtłuszczanie, przygotowanie powierzchni, połączenie klejowe, klej epoksydowy, wytrzymałość, mechanical treatment, degreasing, surface treatment, adhesive joint, epoxy adhesive, and strength

Celem pracy było określenie wpływu wybranych sposobów przygotowania powierzchni na wytrzymałość połączeń klejowych blach stalowych ocynkowanych metodą zanurzeniową, wykonanych za pomocą kleju epoksydowego Epidian 53/Z-1/100:10. Przygotowanie powierzchni łączonych elementów zostało zrealizowano, w następujących wariantach: wariant A, obejmujący obróbkę mechaniczną papierami ściernymi o różnej gradacji bez odtłuszczania oraz wariant B składający się z obróbki mechanicznej i odtłuszczania rozcieńczalnikiem ekstrakcyjnym powierzchni próbek blach przeznaczonych do klejenia. Ocenę wpływu przygotowania powierzchni dokonano na podstawie badań wytrzymałościowych jednozakładowych połączeń klejowych na maszynie wytrzymałościowej Zwick/Roell 150, zgodnie z normą DIN EN 1465. W badaniach przeprowadzono także pomiary wybranych parametrów chropowatości powierzchni w celu oceny struktury geometrycznej po obróbce mechanicznej papierami ściernymi o różnej gradacji. Na podstawie wyników badań zauważono, że zastosowanie podczas przygotowywania powierzchni do klejenia odtłuszczacza, jakim był rozcieńczalnik ekstrakcyjny, wpłynęło korzystnie na wzrost wytrzymałości na ścinanie połączeń klejowych, w porównaniu do wytrzymałości połączeń, w których zastosowano jedynie obróbkę mechaniczną.

microwave plasma, plasma sheet, surface treatment, plazma mikrofalowa, płaszczyzna plazmowa, and obróbka powierzchni

Currently, plasma systems for plastic, metal, glass and composite surface modifications are of high interest from industry point of view. In addition, attention is paid to the reduction of investment as well as operating costs of the process. According to this, to meet industry expectations a novel compact microwave plasma device for surface treatment was designed, built and tested. The major advantage of the device is a unique shape of the generated plasma having a form of a plasma sheet suitable for surface treatment.

obróbka wykończeniowa, obróbka powierzchni, docieranie powierzchni, szlifowanie powierzchni, szlifierki, obrabiarki, czas wykonania, czasochłonność, finishing treatment, surface treatment, lapping of surface, surface grinding, grinders, machine tools, execution time, and time consumption

Docierania i szlifowanie należy do podstawowych metod obróbki wykończeniowej. Technologie te stosowane są obecnie zarówno w obróbce elementów metalowych, jak i niemetalowych. Przeanalizowano czas, jaki jest potrzebny do wykonania tych operacji.

surface treatment, temperature field, phase transformations, welding, surfacing, obróbka powierzchniowa, przemiany fazowe, pole temperatury, spawanie, and napawanie

In this work, a model of phase transformations during multipass weld surfaced steel casts is presented. In the temperature field calculation algorithm, the influence of the heat of overlaying beads and a self-cooling of previously overlayed beads have been taken into account. The fusion area, full and part transformation zones, by solidus, A1and A3and A A1temperatures has been determined, respectively. The temperatures of the beginning and the end of the phase changes during cooling were determined on the basis of the time-temperature-transformation welding diagram. In the phase change kinetic description, the JMAK law and KM formula were used. Theoretical considerations are illustrated by example of volume share calculations of particular structural components during the weld surfaced 230-450 W steel cast. The results of computation in the graphical forms are presented: welding thermal cycle diagrams and structural share change histories at selected points, as well as temperature and the phase share distributions in cross section.