Diamond Coatings Research Articles

Deposition of Diamond Coatings on Ultrathin Microdrills for PCB Board Drilling.

The drilling of State-of-the-Art printed circuit boards (PCBs) often leads to shortened tool lifetime and low drilling accuracy due to improved strength of the PCB composites with nanofillers and higher thickness-to-hole diameter ratio. Diamond coatings have been employed to improve the tool lifetime and drilling accuracy, but the coated microdrills are brittle and suffer from coating delamination. To date, it is still difficult to deposit diamonds on ultrathin microdrills with diameters lower than 0.2 mm. To avoid tool failure, the pretreatment was optimized to afford sufficient fracture strength and enough removal of cobalt. Further, the adhesion of the diamond coating was improved by employing an interlayer comprising SiC/microcrystalline diamond, which mitigates stress accumulation at the interface. By these means, microdrills with diameters of 0.8 and 0.125 mm were coated with adherent diamonds. In this context, the composite coating with the diamond/SiC interlayer and a nanodiamond top layer featured enhanced adhesion compared to single nano- or microdiamond coatings on the WC-Co microdrills. The composite diamond-coated WC-Co microdrills featured improved wear resistance, resistance to delamination of the diamond coating, and improved performance for drilling PCBs compared to micro- and nanodiamond-coated microdrills without interlayer. In addition, a higher hole quality was achieved when the diamond-coated microdrills were used. These results signify that the composite/nanodiamond coating features the highest bonding strength and best drilling performance.

Achieving precise graphenization of diamond coatings below the interfacial thermal stress threshold

Abstract Diamond coatings possess numerous excellent properties, making them desirable materials for high-performance surface applications. However, without a revolutionary surface modification method, the surface roughness and friction behavior of diamond coatings can impede their ability to meet the demanding requirements of advanced engineering surfaces. This study proposed the thermal stress control at coating interfaces and demonstrated a novel process of precise graphenization on conventional diamond coatings surface through laser induction and mechanical cleavage, without causing damage to the metal substrate. Through experiments and simulations, the influence mechanism of surface graphitization and interfacial thermal stress was elucidated, ultimately enabling rapid conversion of the diamond coating surface to graphene while controlling the coating’s thickness and roughness. Compared to the original diamond coatings, the obtained surfaces exhibited a 63%–72% reduction in friction coefficients, all of which were below 0.1, with a minimum of 0.06, and a 59%–67% decrease in specific wear rates. Moreover, adhesive wear in the friction counterpart was significantly inhibited, resulting in a reduction in wear by 49%–83%. This demonstrated a significant improvement in lubrication and inhibition of mechanochemical wear properties. This study provides an effective and cost-efficient avenue to overcome the application bottleneck of engineered diamond surfaces, with the potential to significantly enhance the performance and expand the application range of diamond-coated components.

Air Oxidation Behavior of Sanicro-25 with Different Surface Finishes

AbstractSanicro-25 is a high-temperature material used as the structural material for steam superheaters and reheaters in advanced ultra-supercritical power plants. The air oxidation behavior of Sanicro-25 with various surface roughnesses is being assessed at 650 °C for about 1000 h. Different surface-roughened samples were studied, namely polishing the sample up to diamond finish, grinding up to (80-grit finish and 600-grit finish) and grit blasted. The diamond finish sample showed more weight gain than others, and higher weight gain was observed in the initial oxidation stage. Attributed to different surface preparations leads to defects at different levels, which further alters the diffusion of various elements. The diamond finish sample showed the presence of Cr-rich oxides, and other samples showed the presence of Fe-rich oxides. Smooth surfaces promoted the formation of thick protective oxide scales.

Property Research on Nano-Micro Crystalline Diamond Coated Tools Lapping Sapphire Wafer

Diamond coating were deposited on serrated blade by hot filament chemical vapor deposition (HFCVD) method. The lapping experiments of sapphire wafer were carried out by using diamond coated tools. The diamond coatings and machined surface of the sapphire wafer were characterized by scanning electron microscopy (SEM), laser confocal microscope and Raman spectrum. The results show that the lapped sapphire chips are small irregular chips and long thread-like debris. During the lapping process, there is graphitization of diamond crystal. A low surface roughness can be obtained using a spherical grain diamond coated tool.

Research on laser brazing diamond coating process based on temperature field finite element simulation and machine learning

The temperature of laser brazing diamond seriously affects the quality and service life of diamond tools. In this study, a finite element model of laser brazing diamond was established to achieve digital control of the temperature field during the brazing process. It was determined that the main energy of diamond warming comes from the heat conduction of the molten pool. The maximum temperature value within the brazing layer was proposed as an important indicator of the quality of diamond coating formation. The correlation and local sensitivity of each process parameter to the maximum value of temperature were calculated by a neural network-based machine learning method, and the influence of process parameters on the temperature field was explored. The result of the theoretical analys was finally verified by the coating wear-resistance experiments, and the wear-resistance of the diamond coatings was significantly better than that of other cases when the maximum temperature value in the brazing process was in the range of 1100 °C–1130 °C.

STUDY ON THE PROPERTIES OF DIAMOND FILMS ON CEMENTED CARBIDE SUBSTRATES BY SURFACE IMPLANTATION PRETREATMENT PROCESS

The deposition of diamond films on tungsten carbide-based tools can greatly improve the life and performance of cutting tools. However, the deposition of diamond coatings on cemented carbide (WC-Co) suffers from poor film-base bond strength. In this paper, diamond coatings were deposited of phytocrystalline metal micropowders (pure, Nb, Ti, Ta) pretreatment method and the properties of diamond films were analyzed by energy spectrometry (EDS), scanning electron microscopy (SEM), Raman spectroscopy and bonding strength test of diamond films. The results show that through the experiment of the pretreatment process of surface implanted crystal metal micropowder, the best implanted crystal metal micropowder was obtained, the surface quality of implanted crystal titanium (Ti) coating was improved, the diamond Raman peaks were sharp and the indentation cracks had a crack diameter of 389 [Formula: see text]m, which is small and has the highest bond strength. The pretreatment process of phytocrystalline diamond micropowder can deposit high-performance diamond coatings and improve the bonding strength between the coating and the substrate film base.

Research on the Fixed-Abrasive Lapping Process of Polycrystalline Aluminum Nitride

Due to the characteristics of hard brittleness and strengthening inertia, the high-efficiency and ultra-precision machining of the third generation semiconductor materials has become an urgent problem, with low processing efficiency and poor surface quality. The aggregate fixed-abrasive (FA) lapping pad was used to lap polycrystalline aluminum nitride (AlN) substrates, which provided practical experience for efficient precision machining of hard and brittle semiconductor substrates. The results indicated that: the effect of aggregate particle initial size and applied load on MRR and Ra during rough lapping and fine lapping were most significant. In the rough and fine lapping stage, W5-7 and W3-5 Al-Si binder aggregate diamond lapping pads were adopted, respectively, with an applied load of 2.0 psi. The optimized process can reduce the Ra value of the AlN blank to <70 nm within 1 h.

Ti6Al4V alloy with diamond particle-reinforced Cu-based coatings: Microstructure and tribological performance

To enhance the surface wear resistance of the Ti6Al4V alloy, diamond particles-reinforced Cu-based composite coatings (D500/D1000/D2000 coating: 500/1000/2000 mesh diamond: Cu-based alloy powder = 1:30 (wt%)) were fabricated by vacuum cladding. Cu-based alloys with liquid phase temperatures lower than the phase transition temperature of Ti6Al4V alloys were employed as cladding materials to avoid performance deterioration of Ti6Al4V substrates. The microstructure, mechanical properties, and dry-sliding tribological properties of the Cu-based composite coatings have been investigated systematically. The Cu-based composite coatings are composed of the ductile intermetallic compounds Ti3Sn and SnTi2 as the metal matrix, the hard and brittle intermetallic compounds CuTi, CuTi2, Ti(Cu, Al)2 and CuSn3Ti5, in situ generated TiC and the directly introduced diamond particle as the reinforced phases. In addition, a TiC hard phase protective layer was formed around the diamond particles, which retained the original properties of the diamond. The hardness of diamond particles-reinforced Cu-based composite coatings is much higher than that of the Ti6Al4V. Among them, the D2000 coating possesses the highest microhardness. The average Vickers hardness (HV0.5) on the coating surface and nanoindentation hardness (H) on the coating cross-section (the middle part without diamond particles) of the D2000 coating are 1329.8 HV0.5 and 16.87 GPa), which are 4–5 times higher than that of the Ti6Al4V substrate (333 HV0.5 and 3.37 GPa). Nevertheless, the D2000 coating (wear rate of 50.75 ×10−5 mm3/Nm) demonstrates slightly inferior tribological performance compared to the D500 coating. The wear rate of the latter is approximately 13.37 × 10−5 mm3/Nm, which is only 1/5.6 of the substrate (75.67 ×10−5 mm3/Nm). The larger the diamond particle size, the more the diamond serves as a bearing capacity support point to prevent the hard WC ball from further ploughing into the composite coating, and the better the wear resistance of the coating. Notably, D500 coating with excellent wear resistance has the potential for application in various fields of the machinery industry, marine engineering, and aerospace.

Mass production and cutting performance of diamond coated cutting tools for machining titanium alloys

Diamond coated cutting tools are applied for machining difficult-to-machine materials of titanium alloys. However, the temperature field uniformity needs to be further improved for the mass production of diamond coated tools using the hot filament chemical vapor deposition (HFCVD) method. In this paper, the tools temperature distribution is simulated by the finite volume method (FVM) during the deposition of diamond coatings. An optimization method of deposition setting with fine filaments in dense arrangement (FFDA) is proposed, and the temperature distributions of the tools under the coarse filament in sparse arrangement (CFSA) and FFDA are simulated to systematically elucidate the effects of fine filament densification. Subsequently, the different hot filament arrangements are adopted to mass production experiment for deposition of micro/nano composite diamond (MCD/NCD) coatings on WC-6%Co cutting tools. In addition, the cutting experiments on titanium alloys are conducted using diamond coated tools, and the cutting performance of tools at different locations is evaluated. The results indicate that the FFDA method can improve the temperature field uniformity of mass-produced diamond coated cutting tools, and the cutting tools have better consistency in surface morphology, thickness, chemical composition, surface roughness and cutting performance.

Diamond coatings on copper surfaces through interface engineering

To address the challenges posed by the significant thermal stress and limited affinity of diamond coatings on copper (Cu) substrates, we developed a method combining femtosecond (fs) laser texturing with the application of a nickel (Ni) interlayer. This technique was utilized for adhesion enhancement of diamond coatings on Cu. By varying the deposition duration and microgrid depth through multiple fs laser scanning passes, it is possible to attain well-adhered diamond coatings on Cu substrates. These coatings demonstrate an outstanding quality factor of 93.4% and an average grain size of 5.5 μm. The enhanced adhesion results from the synergistic reinforcement of the mechanical interlock and anchoring mechanisms facilitated by the textured surface, further bolstered by the presence of the Ni interlayer. Moreover, the shape of the texture significantly influences the deposition outcome. Single-crystal diamonds with an average grain size of 10 μm were achieved on sharp microgrids at a substrate temperature of 550 °C. This work is expected to offer a general approach for deposition of diamond coatings on metallic materials with enhanced adhesion.

Tuning the adhesion of diamond/copper interfaces through surface chemical modifications and reconstruction

Diamond and diamond-like carbon (DLC) coatings are well-known for their exceptional combination of tribological and mechanical properties, such as low friction coefficients and wear rates, together with high hardness and elastic modulus. A significant limitation in their employment concerns their spallation from the substrate; it is thus interesting to explore how DLCs adhesion can be tuned through chemical modifications of its surfaces. We employ ab initio simulations to study the effect of surface reconstruction and chemical species intercalation (B, P, O, F, N, S, H) on the adhesion of non-reconstructed and Pandey-reconstructed C(111)/Cu(111) interfaces. We found that the increment of graphitization at the diamond surface decreases the adhesion. Moreover, when a high degree of surface graphitization is present the best way to increase adhesion is to select atoms able to act as chemical bridges (e.g., B and N), compensating for the lack of interaction between the surfaces. Conversely, adhesion reduction of ∼100% can be achieved, regardless of the degree of surface graphitization, by intercalating an atomic species that does not bond with the countersurface and prevents the interaction between the slabs, i.e. F and S.

Enhanced precision lapping techniques for fused quartz optical elements: Synergistic integration of mechanical and mechanochemical processes

Fused silica is a material of great importance in the field of precision optical equipment due to its excellent optical properties, e.g. photolithography, laser fusion devices, etc. However, the material's inherent hardness and brittleness render it a challenging material to process. Therefore, an enhanced precision lapping technique was proposed, i.e., a synergistic integration of mechanical and mechanochemical lapping processes. Firstly, a synergistic lapping tool with an outer layer of porous diamond abrasive and an inner layer of CeO2 abrasive was fabricated by hot press forming method. The reduction of layer thickness due to abrasion and detachment of the porous diamond abrasive layer was analyzed, and the lapping mechanism of porous diamond on fused silica materials was revealed. The surface creation mechanism of the CeO2 abrasive layer on fused silica material was analyzed by molecular dynamics simulation and the results were validated by enhanced precision lapping experiment. The results demonstrated that the surface atoms of fused silica are removed in a ‘remote disordered’ manner by conventional diamond abrasive grains, whereas the surface atoms of fused silica are removed in a ‘proximally ordered’ manner by the fine porous diamond abrasive grains through the micro-multi-flute cutting. Consequently, the grinding of a porous diamond abrasive layer can significantly reduce the processing damage, with the surface roughness of the lapping Ra reaching 199 nm. The lapping of CeO2 induces the formation of an oxygen bridge on the surface of fused silica, which then produces bending vibration. This is followed by the adsorption and diffusion of oxygen atoms, which form the -Ce-O-Si intermediate with the oxygen atoms shared with the fused silica. This process results in the formation of CeSiO3 and CaSiO3 compounds. The final surface quality with a surface roughness of Ra 21 nm was obtained by mechanochemical lapping of the cerium oxide abrasive layer. The single mechanical-mechanochemical composite ultra-precision lapping process provides technical support for the efficient and low-damage processing of hard and brittle components.

Ultra-precision diamond finishing of reaction-sintered silicon carbide enhanced by vibration-assisted photocatalytic oxidation

RS-SiC faces limitations in surface accuracy with conventional finishing processes due to its high mechanical hardness and multiphase nature. In this study, vibration-assisted photocatalytic oxidation is introduced to enhance the efficiency and precision of RS-SiC diamond polishing. By utilizing the photocatalytic reaction, the hard heterogeneous SiC phase and Si phase on the RS-SiC surface are transformed into a "softer" homogeneous oxide layer that can be removed easily. The introduction of vibration increases the relative velocity between the workpiece and the abrasive and prevents the aggregation of the photocatalyst, thus improving polishing efficiency. By reducing the abrasive size to the nanometer scale, the boundary between the Si phase and SiC phase can be smoothed out to further improve the workpiece surface finish. Using TiO2 as the photocatalyst, H2O2 as the oxidant, 25 nm diamond as the abrasive, and introducing vibration, an ultra-smooth surface with a surface roughness of 0.195 nm in Ra is obtained by the finishing method proposed in this paper. The proposed photocatalysis/vibration-assisted finishing approach offers a novel method for ultra-smooth polishing reaction-sintered silicon carbide.

Unveiling the microstructure and promising electrochemical performance of heavily phosphorus-doped diamond electrodes

The challenge of doping synthetic diamond with phosphorus stems from the atomic size mismatch between phosphorus and carbon atoms, which previously hindered achieving high phosphorus doping levels. This limitation delayed the exploration of phosphorus-doped diamond (PDD) in electrochemical applications, where it holds potential as a novel and appealing electrode material because PDD uniquely combines diamond's exceptional properties with phosphorus atoms inducing n-type conductivity. In this study, heavily doped PDD electrodes were successfully developed using chemical vapour deposition, followed by comprehensive microstructural and electrochemical characterisations. The influence of phosphorus doping, manipulated via high phosphine gas concentration or time-dependant precursor gas flow control, on the PDD properties was thoroughly examined. PDD layers grown at higher phosphine concentrations demonstrated enhanced phosphorus incorporation, leading to a higher prevalence of fine nano-crystalline diamond grains and non-diamond carbon components, while also slowing the growth rate. Notably, a distinct PDD sample produced under dynamic gas flow with lower phosphine concentration revealed larger grain sizes, increased effective deposition rate, and improved phosphorus levels compared to its counterpart synthesized under static conditions. Cyclic voltammetry in a 1 mol L−1 KCl solution revealed a low double-layer capacitance (<11 µF cm−2) in all as-grown PDD electrodes. However, significant differences between the samples emerged during the experiments conducted with redox probes [Ru(NH3)6]3+/2+ and [Fe(CN)6]3−/4−. Particularly, higher phosphorus content promoted well-developed voltammograms, significantly reduced peak-to-peak separation values, faster electron transfer rates, and increased peak currents. Furthermore, the possibility of using heavily P-doped diamond electrodes for the detection of two organic analytes, dopamine and ascorbic acid, was successfully manifested. All in all, the as-grown, highly P-doped diamond electrodes proved their ability, first time ever, to record well-defined signals of both inorganic redox probes and complex organic compounds, unravelling their potential in electroanalysis and sensor development and broadening the scope of PDD utilisation.

Effect of Different Conditioning Methods on Shear Bond Strength of Orthodontic Ceramic Brackets Bonded to Porcelain Ceramic Surface

The study aimed to investigate the shear bond strength (SBS) of orthodontic ceramic brackets bonded to porcelain ceramic surfaces that had undergone various conditioning methods. Materials and Methods: Forty ceramic discs were fabricated (vita vmk master®, zahnfabric, Germany) with a diameter of (4*10mm). Ceramic discs were divided into four groups (n = 10) according to ceramic surface conditioning methods, 37% phosphoric acid (PH), 9%hydrofluoric acid (HF), and surface conditioning with a fine diamond bur. Transbond XT light-cure composite was used to bond ceramic brackets. Before bonding, extra samples from each group were chosen to be examined using a scanning electron microscope (SEM) to determine the topography of the ceramic surface. The Shear Bond Strength data were evaluated using one-way analysis of variance (ANOVA) and Tukey HSD tests. Under an optical stereomicroscope, debond surfaces were examined. Results: Surface conditioning with a fine diamond bur + HF acid etching group produced the highest SBS (30.64 ± 7.28 MPa), and the lowest SBS was investigated in the PH acid etching group (14.75 ±3.32 MPa). Conclusions: Different conditioning methods affected the porcelain ceramic surface's shear bond strength (P &lt; 0.05). The highest SBS was found in the fine diamond bur_+ HF acid etching group; however, this had a deleterious effect on the ceramic surface after debonding.

High-temperature tribological properties and wear mechanisms of multilayered cubic-BN/nanocrystalline diamond tool coatings

Wear failure of cutting inserts is the main form of failure that occurs when cutting difficult-to-machine materials at high speeds. To obtain cutting inserts with outstanding tribological properties, multilayered cubic boron nitride (cBN) and nanocrystalline diamond (NCD) coatings (cBN/NCD) were prepared on WC-6 wt% Co tool substrates. The tribological properties of the multilayered cBN/NCD coatings were studied at different temperatures, and the results showed that the coefficient of friction (COF) and wear rate of the coatings were closely interrelated to the temperatures, and the COF gradually decrease and the wear rate gradually increase as the temperature increased from room temperature (25 °C) to 600 °C. The COF and wear rate of the multilayer coatings at 600 °C were ∼0.05 and 8.43 × 10−6 mm3/(N⋅m), respectively. The wear resistance of the cBN/NCD coatings was higher than that of TiAlN coatings and PcBN tool materials by more than 3 and 4.5 times, respectively. The high-temperature wear failure modes of the multilayered cBN/NCD coatings were abrasive wear, diamond graphitization, and BN hydrolysis. Coating wear accelerated when pores were formed on the cBN surface of a multilayered cBN/NCD coating due to the low nucleation density of diamond. These results would guide the application of cBN/NCD-coated cutting tools in high-speed cutting processes.

Improving frictional state at fretting interfaces through the covalent structure of diamond–graphite–graphene

This study proposes a novel approach based on the covalent structure of diamond–graphite–graphene (CDGG) to integrate the outstanding properties of diamond, graphite, and graphene, synergistically improving frictional behavior of fretting interfaces. The results demonstrated that in-situ CDGG significantly reduced the alternating stress at the contact interface, the friction coefficient decreased by 40–62 % over pristine diamond coatings under gross slip regime, accompanied by a shorter running-in period. The counterpart pair wear corresponding to in-situ CDGG was lower, and no delamination caused by metal adhesion. The surface graphene/graphite exhibited good frictional toughness, effectively absorbing the relative displacement at contact interface, enabling CDGG to exhibit partial slip regime under higher loads and smaller displacement amplitudes.

Long-Term Corrosion of Eutectic Gallium, Indium, and Tin (EGaInSn) Interfacing with Diamond.

Thermal transport is of grave importance in many high-value applications. Heat dissipation can be improved by utilizing liquid metals as thermal interface materials. Yet, liquid metals exhibit corrosivity towards many metals used for heat sinks, such as aluminum, and other electrical devices (i.e., copper). The compatibility of the liquid metal with the heat sink or device material as well as its long-term stability are important performance variables for thermal management systems. Herein, the compatibility of the liquid metal Galinstan, a eutectic alloy of gallium, indium, and tin, with diamond coatings and the stability of the liquid metal in this environment are scrutinized. The liquid metal did not penetrate the diamond coating nor corrode it. However, the liquid metal solidified with the progression of time, starting from the second year. After 4 years of aging, the liquid metal on all samples solidified, which cannot be explained by the dissolution of aluminum from the titanium alloy. In contrast, the solidification arose from oxidation by oxygen, followed by hydrolysis to GaOOH due to the humidity in the air. The hydrolysis led to dealloying, where In and Sn remained an alloy while Ga separated as GaOOH. This hydrolysis has implications for many devices based on gallium alloys and should be considered during the design phase of liquid metal-enabled products.

Safety and efficacy of a temperature-controlled ablation system for ventricular tachycardia: first results from the TRAC-VT study

Abstract Background Catheter ablation using radiofrequency (RF) energy, is a well-recognized treatment option for patients with ventricular arrhythmias. However, procedural complications may be high, and efficacy is often suboptimal with high recurrence rates. Purpose The TRAC-VT study evaluated safety and efficacy of the DiamondTemp Ablation (DTA) System for the treatment of patients with ventricular arrhythmias by catheter ablation. Methods A temperature-controlled, irrigated RF catheter (with six thermocouples and an internal network of diamond coatings) was utilized to treat subjects with either sustained monomorphic ventricular tachycardia (VT) and structural heart disease or with frequent monomorphic symptomatic ventricular premature beats (VPBs) and normal hearts. Patients were enrolled at five hospital centers in five European countries and were followed for 6 months. Ablation was performed in temperature-control mode with an irrigation flow of 8 mL/min for all power deliveries. The target temperature was set to 55 or 60 °C with a power output limited to 50 Watts. RF energy was applied for a maximum of 45 seconds per target site, depending on impedance drop and electrogram abatement. Results The study enrolled 49 subjects (age 67±12 years, 80% male) in total (38 with sustained monomorphic VT and structural heart disease and 11 with symptomatic VPBs). In all cases, mapping and navigation was used with EnSite systems (Abbott). The average ablation time (defined as time from the insertion of the DTA catheter until removal from body) was 87 ± 44 minutes. During this time, RF energy was applied for an average of 28.2 ± 10.2 seconds with a power of 44.0 ± 7.0 W and a temperature of 50.9 ± 3.9 °C during 35.0 ± 23.2 applications. Acute procedural success was 100% (93%-100%), and it was defined as the elimination of VPBs or non-inducibility for sustained VT (using solely the DTA catheter). The primary safety procedure-related endpoint was an evaluation of cardiovascular-related death, stroke / TIA, cardiac tamponade/perforation, bleeding complication, myocardial infarction, thromboembolism, and pulmonary edema. In total review of the primary safety endpoint, one subject had a confirmation of a stroke / TIA event. Regarding longer term procedural efficacy, the 6-month follow-up was completed in 92% of subjects. For the whole study population chronic success from recurrence of ventricular arrhythmia (faster than 100 beats/min after 6 months) was 73.4% (58.6%-83.6%) for non-sustained ventricular arrhythmias (≥3 beats) and 87.7% (74.7%-94.3%) for sustained ventricular arrhythmias (≥30 sec). Conclusions VT/VPBs ablation using a temperature-controlled irrigated RF catheter was safe and effective with low VT recurrence at 6 months of follow-up.

The Effect of Mechanical Alteration on Repair Bond Strength of S-PRG-Filler-Based Resin Composite Materials.

This study investigates the impact of mechanical alteration on resin composite surfaces and its subsequent effect on repair bond strength. A total of 100 resin composite disks were prepared and were allocated for 24 h or 1 year of artificial aging. Specimens were embedded in epoxy resin, and the composite surfaces were mechanically altered using either diamond burs or air abrasion with aluminum oxide or glass beads. A universal bonding material was applied and a 2 mm circular and 3 mm high repair composite cylinder were prepared using a Teflon mold. Then, the specimens were tested for their shear bond strength, and the de-bonded specimens were observed under a scanning electron microscope to determine the failure pattern. SPSS 26.0 statistical software was used to analyze the data. Two-way ANOVA showed a statistically significant effect of mechanical alteration and aging on the shear bond strength of S-PRG-filler-based resin composite (p < 0.05). Surface modification with a fine diamond bur showed a significantly higher bond strength in both 24-h- and 1-year-aged specimens. Surface modification with alumina significantly increased the bond strength of 1-year-aged specimens; however, it was statistically insignificant for 24 h-aged specimens. Mechanical alteration with a fine diamond bur and 50-micron alumina can improve the repair bond strength of the composite.