Surface Finish Research Articles

Designing bipolar anodizing towards white anodic aluminum oxide (AAO)

Obtaining white anodic aluminum oxide (AAO) is a major challenge in the surface finishing industry. The present work presents a cost-effective route to design light-scattering morphologies through submicrometric hollows homogeneously dispersed in the depth of the oxide layer, created by localized hydrogen evolution. To this end, cathodic steps are added in alternance with anodic steps in a bipolar pulse anodizing process performed in 2 M sulfuric acid. The mechanisms of nucleation and growth of the targeted hollows within the AAO are highlighted by combining in situ electrochemical measurements and high magnification SEM observations. The aesthetic performances in terms of white color, evaluated by reflectance spectroscopy in comparison with a white reference, are directly related to the size, shape and distribution of the hollows, controlled by both the parameters of the cathodic step and the thickness of the unit anodic oxide layers.

Evaluation of Colour Changes in Nanocomposite-Based Bulk-Fill and Universal Composite Using Different Polishing Systems.

Resins composites are widely used in modern dentistry because of their aesthetic and physical properties. However, discoloration of anterior tooth restorations is a common complaint. Understanding the factors affecting the colour stability of resin composites can lead to longer-lasting repairs. This study aimed to evaluate and compare the colour changes of nanocomposite-based bulk-fill and universal resin composites after immersion in coffee using various polishing systems. A total of 160 samples were prepared using four different composite groups, with 40 pieces for each combined group. Based on the finishing procedure, the samples were divided into four subgroups for each composite group. Three different polishing procedures were applied to the samples according to the manufacturer's instructions. The control group was not subjected to any treatment. Initial colour measurements were performed using a VITA Easyshade V spectrophotometer. After the initial measurements, the samples were immersed in a Nescafe coffee solution for seven days, followed by colour measurements. Data were analysed using the Kolmogorov-Smirnov test and two-way analysis of variance. Tukey's honest significant difference (HSD) test was used to determine differences between subgroups. The results indicate that bulk-fill resins exhibit more discolouration than universal composites; however, this difference was not statistically significant. The resin group with the smallest discolouration was Ceram X, and the most effective polishing method was Twist polishing. Final surface polishing significantly reduced the composites' discolouration. These findings support the selection of appropriate materials and polishing techniques to achieve aesthetic outcomes and colour stability in dental restorations.

Fabrication of FeCoNi alloy film via friction-assisted selective area electrodeposition

Nowadays, carbon neutrality target has been receiving a growing attention in academia and industry. In many industry applications, the wear and fatigue damages of bearing components are the frequent failures affecting machine operation. The maintenance and replacement of damaged bearings cause enormous cost in the aspects of consumptions of energy and materials. In this study, a novel technique of friction-assisted electrodeposition (FAED) is firstly demonstrated for surface remanufacturing of worn bearing races. By using the FAED technique, FeCoNi alloys with nanocrystalline were successfully deposited on the selective surface zone. The surface morphology, microstructure feature as well as mechanical properties of the deposited FeCoNi film were quantitatively characterized. The results have indicated that friction load and electrodeposition time have a remarkable effect on the microstructure of the film and its surface finish. The cross-section exhibited a uniform distribution of Fe, Co and Ni. Meanwhile, typical amorphous and polycrystalline features were observed within the deposited film. Additionally, the as-deposited layer shows desired mechanical properties, including hardness, complex modulus and friction coefficient, matching with those of the GCr15 substrate. Scratch test results showed that a good bonding strength between the coating and the bearing steel was achieved. Moreover, the role of friction in the electrodeposition process has been analyzed. This work provides a new route to achieve selective area electrodeposition of alloy films on bearing steel, which can be further developed for metal surface repairing.

A data-driven underground gas storage production system string failure prediction model for time-varying reliability analysis

In underground gas storage (UGS) systems, the production tubing string system undergoes complex thermo-mechanical loading conditions, leading to fatigue damage accumulation and potential failure risks. To accurately assess the fatigue reliability and mitigate risks, it is crucial to develop a data-driven physics-informed uncertainty modeling approach that captures the coupled thermo-mechanical effects and accounts for various uncertainties. This study proposes a data-driven physics-informed modeling method based on thermo-mechanical coupling for fatigue reliability assessment and risk mitigation in critical UGS systems. A quantitative analysis method is introduced, which relies on small-scale multi-stage loading experiments and combines the stochastic degradation process with time-series reliability theory. To analyze the fatigue life of joints under complex loading conditions, a modified S-N curve model is developed. This model takes into account the influences of the dimension coefficient, stress concentration factors, surface finish coefficients, and thermal load. It considers the uncertainties associated with different temperature loads and surface finish on fatigue life. By integrating physics-informed modeling, uncertainty quantification, and fatigue damage accumulation analysis, this approach provides a comprehensive framework for fatigue reliability assessment and risk mitigation in critical UGS systems. It enables informed decision-making for safe and reliable operations, as well as optimized maintenance strategies, ultimately enhancing the overall system performance and mitigating potential failures.

Study on stability and characterization of high internal phase water-in-oil compound collector emulsion

To address the high consumption and poor environmental performance associated with traditional coal slime flotation oils, we have developed a high internal phase water-in-oil (HIP W/O) emulsion using methyl oleate and methyl laurate as collectors. This study examines the factors influencing emulsion stability and water dispersion. Comparative flotation tests were performed, and the emulsion’s microstructure and rheological properties were assessed using freeze-scanning electron microscopy and a rheometer. The optimal emulsion formulation contained 5.56 vol% of a compound collector, 4.44 vol% Span 80, and 90 vol% of a sodium chloride and gelatin water solution. The incorporation of gelatin into the water phase established a three-dimensional gel network within the emulsion droplets, significantly enhancing both viscosity and stability. This emulsion reduced compound collector consumption by approximately 84 % while maintaining comparable flotation performance. Its fine particle distribution and effective coal surface adsorption highlight its potential as an environmentally friendly option for fine coal flotation, thus promoting cleaner and more efficient coal utilization.

Comparative evaluation of vat photopolymerization and steel tool molds on the performance of injection molded and overmolded tensile specimens

AbstractThis study explores the use of vat polymerization stereolithography (SLA) for fabricating mold tooling, subsequently utilized in injection molding (IM) and overmolding of tensile specimens and directly compared to those produced using metal molds. The results first find the manufacturing time for an SLA‐fabricated mold is remarkably short, approximately 6 h, presenting a substantial improvement over traditional methods. Mechanical testing revealed that the tensile specimens from the SLA‐fabricated molds exhibited the highest tensile strength among all overmolding batches. This performance was consistent with the tensile bars produced using metal molds, demonstrating the viability of SLA‐fabricated molds for overmolding applications and highlighting the potential of FDM to customize the properties of final products. However, variations in mold types impacted the dimensional tolerance and tensile strength of the final specimens. Metal mold‐fabricated tensile bars exhibited superior dimensional accuracy and maximum tensile strength (50.6–61.7 MPa) compared to those produced with SLA‐fabricated molds (46.9–55.9 MPa). These differences are attributed to the rougher surface finish inherent to the layer‐by‐layer construction of SLA and the internal stresses and defects resulting from lower thermal conductivity and uneven cooling. In conclusion, this study underscores the promising future applications of SLA‐fabricated molds in overmolding, offering reduced manufacturing costs and enhanced design freedom. The findings support the potential of SLA to revolutionize mold fabrication, thereby extending its utility and optimizing the production of polymer components with customized properties.Highlights SLA molds compared to metal molds for direct injection molding and overmolding. FFF preforms with varied geometries were overmolded to finalize the specimens. Joint configurations in overmolding improved tensile performance. Overmolding showed better dimensional accuracy than FFF specimens. SLA mold preparation significantly reduced manufacturing costs.

Tribological Performance of Additive Manufactured PLA-Based Parts.

Polymer additive manufacturing has advanced from prototyping to producing essential parts with improved precision and versatility. Despite challenges like surface finish and wear resistance, new materials and metallic reinforcements in polymers have expanded its applications, enabling stronger, more durable parts for demanding industries like aerospace and structural engineering. This research investigates the tribological behaviour of FFF surfaces by integrating copper and aluminium reinforcement particles into a PLA (polylactic acid) matrix. Pin-on-disc tests were conducted to evaluate friction coefficients and wear rates. Statistical analysis was performed to study the correlation of the main process variables. The results confirmed that reinforced materials offer interesting characteristics despite their complex use, with the roughness of the fabricated parts increasing by more than 300%. This leads to an increase in the coefficient of friction, which is related to the variation in the material's mechanical properties, as the hardness increases by more than 75% for materials reinforced with Al. Despite this, their performance is more stable, and the volume of material lost due to wear is reduced by half. These results highlight the potential of reinforced polymers to improve the performance and durability of components manufactured through additive processes.

Impact of photochemical aging on high‐performance fabrics used in firefighters' protective clothing

AbstractHigh‐performance fabrics used in the outer shell of firefighters' protective clothing protect the wearer from severe conditions. These fabrics are exposed to ultraviolet (UV) radiation during service and storage, which may eventually reduce their performance. This study explored the effect of accelerated photochemical aging on three fabrics used in the outer shell of firefighters' protective clothing; they corresponded to aramid copolymer/polybenzoxazole, para‐aramid/meta‐aramid, and para‐aramid/polybenzimidazole fiber blends. The fabric specimens were subjected to irradiances between 0.35 and 1.35 W/m2 at temperatures between 40°C and 80°C for up to 600 hours. They were tested for breaking force and apparent water contact angle. Complementary microscopy, chemical, and physicochemical analysis were also performed. The UV‐aged para‐aramid/polybenzimidazole fabric demonstrated a better breaking force retention compared to the aramid copolymer/polybenzoxazole and para‐aramid/meta‐aramid fabrics. The considerable reduction in strength observed in the two latter fabrics was associated with fiber breakage. Furthermore, the apparent water contact angle significantly decreased following UV exposure, indicating the potential degradation of the fabric surface finish. On the other hand, no significant changes in the crystallinity index were detected whereas potential decreases in the peak intensity of some chemical functional groups were observed after photochemical aging. These results highlight the significance of material selection in enhancing the long‐term performance of fire‐protective fabrics and offer insightful information on the photochemical aging of high‐performance fabrics.

Effects of stress-relief and natural aging on the geometric tolerances and functional requirements of ferritic nitrocarburized gray cast iron brake rotors

Gray cast iron (GCI) brake rotors are prone to corrosion, particularly in electric vehicles (EVs), owing to their regenerative braking systems. Ferritic nitrocarburizing (FNC) heat treatment has been used to improve the corrosion resistance and cleanability of GCI rotors. However, pre-existing residual stresses in the rotors can lead to distortion after FNC processing, thereby affecting the functional and tolerance requirements. This study investigated the effects of stress-relief (SR) heat treatment and natural aging (NA) on the natural frequency, damping properties, surface roughness, and geometric tolerances of GCI brake rotors before and after FNC treatment. The GCI brake rotors were subjected to SR and NA processes, followed by FNC treatment. The natural frequency, damping Q-factor, surface roughness, and geometric tolerances were measured and analyzed using two-way ANOVA at a 95% confidence level (α = 0.05). The results showed that SR heat treatment significantly reduced the effect of residual stresses and improved geometric tolerances compared to NA. The FNC treatment increased the surface roughness and slightly improved the damping properties but had an insignificant effect on the natural frequency. The combination of SR and FNC treatments provided the best overall performance in terms of quality, geometric tolerance, and surface finish. This study highlights the importance of SR heat treatment for optimizing the manufacturing process of FNC-treated GCI brake rotors for EVs.

Fine particulate matter and ozone variability with regional and local meteorology in Beijing, China

Fine particulate matter (PM2.5) and surface ozone air pollution have severe health consequences. Since China implemented the nationwide Air Pollution Prevention and Control Action Plan (APPCAP) in 2013, annual average PM2.5 concentrations have decreased while O3 concentration have increased in Beijing. It is unclear, however, to the extent that short-term meteorological variability has influenced these trends. To separate the influence of meteorology from long-term emissions-induced changes, we quantify the portion of the long-term PM2.5 and O3 concentration signals associated with short-term meteorological variability. Building off recent literature highlighting the regional nature of pollutant variability, we incorporate both locally observed meteorology and average regional reanalysis. We isolated sub-seasonal variability using the Kolmogorov-Zurbenko filter. Next, we trained and compared the utility of three statistical models of varying complexity (a linear model, a general additive model with splines, and a random forest) in their ability to predict out-of-sample daily concentrations. The random forest model yields the best predictive capability in holdout tests and predicts changing meteorological contributions to PM2.5 and ozone concurrent with changing concentrations across the study period. Results show an overall decrease in meteorology induced PM2.5 concentration variability at daily scales since 2013, but variability from meteorology has increased relative to mean PM2.5 concentrations. In contrast, O3 shows the opposite trend, with increasing meteorology-induced variability (meteorology-induced variability normalized by mean observed O3 has decreased). Our results show the importance of including regional meteorology in explaining local PM2.5 and O3 variability and quantify links between long-term policy implementation and short-term meteorological contributions to pollutant concentrations.

Effects of Minor Zn Dopants in Sn-10Bi Solder on Interfacial Reaction and Shear Properties of Solder on Ni/Au Surface Finish.

Sn-10Bi low-bismuth-content solder alloy provides a potential alternative to the currently used Sn-Ag-Cu series due to its lower cost, excellent ductility, and strengthening resulting from the Bi solid solution and precipitation. This study primarily investigates the interfacial evolution and shear strength characteristics of Sn-10Bi joints on a Ni/Au surface finish during the as-soldered and subsequent isothermal aging processes. To improve the joint performance, a 0.2 or 0.5 wt.% dopant of Zn was incorporated into Sn-10Bi solder. The findings demonstrated that a 0.2 or 0.5 wt.% Zn dopant altered the composition of the intermetallic compound (IMC) formed at the interface between the solder and Ni/Au surface finish from Ni3Sn4 to Ni3(Sn, Zn)4. The occurrence of this transformation is attributed to the diffusion of Zn atoms into the Ni3Sn4 lattice, resulting in the substitution of a portion of the Sn atoms by Zn atoms, thereby forming the Ni3(Sn, Zn)4 IMC during the soldering process, which was also verified by calculations based on first principles. Furthermore, a 0.2 or 0.5 wt.% Zn dopant in Sn-10Bi significantly inhibited the Ni3(Sn, Zn)4 growth after both the soldering and thermal aging processes. Zn addition can enhance the shear strength of solder joints irrespective of the as-soldered or aging condition. The fracture mode was determined by the aging durations-with the brittle mode occurring for as-soldered joints, the ductile mode occurring for aged joints after 10 days, and again the brittle mode for joints after 40 days of aging.

Influence of ultrasonic-assisted abrasive peening treatment on Ti-6Al-4V and OFHC Cu alloys

Numerous peening techniques exist can effectively modify the sample surface, although at the expense of severe surface damage and high capital investment. Ultrasonic-assisted abrasive peening (UAP) is a superior option that can peen the surface with minimal deterioration using a basic probe sonicator. In this paper, the influence of UAP parameters (i.e., beaker size and fluid volume, power, abrasive concentration, and time) on the surface integrity of Ti-6Al-4V and OFHC Cu was studied experimentally. The process is capable of inducing significant compressive residual stress at around 84 % and 280 % of yield strength in Ti-6Al-4V and OFHC Cu, respectively. The study examined the change in surface roughness (ΔRa), ΔRa = roughness before - roughness after peening. As peening intensities increase, ΔRa reaches +7 nm, showing a surface finish in Ti-6Al-4V. The dislocations density calculated from the Williamson-Hall equation exhibited a 20 and 4.5-fold augmentation in peened Ti-6Al-4V and OFHC Cu in comparison to their un-peened state. EBSD analysis revealed a 28 % and 40 % reduction in grain size in Ti-6Al-4V and OFHC Cu after peening. This work validates the efficacy of the proposed UAP technique and supports the selection of optimized UAP process parameters.

Assessment on the influence of FDM process parameters on the mechanical properties of PLA samples

Abstract The manufacturing of functional parts from the fused deposition modeling 3D printer is limited due to poor mechanical properties, low surface finish, and huge production time. During 3D printing of prototypes, the time consumption of printing and mechanical properties of the model is directly proportional. The fused deposition modeling process parameters significantly impact the quality of printed parts. The prime objective of this research is to optimize the process parameters of a 3D printing machine (wall thickness, infill percentage, infill pattern, and infill speed) using polylactic acid material to enhance the mechanical properties with less printing time of the 3D printing model. The ultimate tensile strength and elongation of the 3D printed samples are used to evaluate the mechanical properties of the various slicing process parameters as per the standards. From the results, it is evident that the mechanical properties of the 3D printed materials increased significantly. The magnitude of ultimate tensile strength is reported as 39.972 MPa with a printing time of 28 min. From close observation, it is evident that lower infill speeds with gyroid infill pattern produce the highest ultimate tensile strength of all combinations. Also, optimal results are derived at higher wall thickness and higher infill percentage. In addition to that, finite element analysis was carried out for different infill percentages of the specimen to validate the actual result.

Characterization of ultrasonic vibration and polishing force in sapphire ultrasonic vibration-assisted flexible polishing: Insights from in-situ monitoring systems

Sapphire ultrasonic vibration-assisted flexible polishing (UVAFP) is a promising technique for comprehensively improving the surface integrity of machined parts. The technique was performed on an ultra-precision machine tool with the in-situ monitoring systems in this paper, which aims to provide a new perspective for understanding the material removal mechanisms in the sapphire UVAFP process. A Taguchi L9 (43) orthogonal experiment was conducted to investigate the effects of feed distance, spindle speed, ultrasonic vibration (UV), and polishing time on the surface finish and material removal in the process. In addition, the effect of a polyurethane ball tool is not trivial. A single-factor experiment was conducted for exploring it. Based on a laser displacement measurement system and an acoustic emission sensor system, the characteristics of time-dependent ultrasonic amplitude and ultrasonic frequency for the sapphire UVAFP system were analyzed, with the effectiveness of UV demonstrated. Based on a three-component force measurement system, the characteristics of normal force and its relationship with process parameters and tool deformation were analyzed, with macro- and micro-level examined. In conclusion, this paper presents the characterization of UV and polishing force in the sapphire UVAFP process, providing novel insights into understanding the material removal mechanisms of sapphire and even more manufacturing problems.

Interlayer Adhesion of Coating System in Analogue and Digital Printing Technologies Formed on Lightweight Honeycomb Furniture Panels

This article concerns research into the influence of the energy dose distributed by UV lamps on selected parameters of varnish coatings formed during the varnishing process of lightweight cellular panels. The lightweight cellular board used in the study was made according to an innovative solution. The surface finishing of the boards was carried out using the roller method in combination with digital and analogue printing under industrial conditions. Contact angle measurements of the obtained varnish coatings were carried out, from which the surface free energy was calculated. In addition, interlayer adhesion was assessed by pull-off tests. Irrespective of the radiation dose, higher contact angle values (54.3–89.9°) were recorded for the last two applied layers (base coat 2 and base coat 3) than for the other coatings (39.6–64.1°). For all systems tested, the γsp component showed lower values (2.25–28.99 mJ/m2) than γsd (28.66–32.80 mJ/m2). The adhesion test results ranged from 0.5 to 0.9 MPa, although with varying types of delamination. Based on the test results, the most favourable variants from the furniture manufacturer’s point of view were selected that provided the desired level of adhesion, in which cohesive damage located within the substrate (A) predominated.

Study of the influence of cutting parameters on tool wear and the state of the machined surface

This work presents a study of wear on the clearance face of turning tools. This study will contribute to the development of improved machining precision and efficiency while extending tool life and also ensuring the surface quality produced, despite wear and edge deposition phenomena. A tool flank wear model is developed as a function of the cutting conditions, including the cutting speed, depth of cut, feed rate, and machining time. Factors influencing tool clearance face wear are determined through experimental testing. We also investigate the edge phenomenon reported on the tool cutting face by plotting a curve of the edge variation versus the machining time. Tool wear and built-up edge phenomena both affect the quality of the surface finish produced. Additionally, the edge phenomenon degrades the geometric quality of the tool and generates wear on the tool clearance face. Therefore, models are developed to aid in selection of appropriate cutting conditions that ensure the expected surface finish is realized while also providing control over tool wear. Overall, this method combines experimental and theoretical approaches to study and control turning tool wear with the aim of improving both machining quality and efficiency.

Influence of HSS drill coatings on surface finish and cylindricity of AA6061/C/ZrO2 composite in CNC drilling operations under dry conditions

Abstract This study aims to evaluate the effect of HSS drill tool coatings, namely single-layer TiN, single-layer AlCrN, and double-layer AlTiN + TiSiXN (Durana), on the surface roughness and cylindricity of AA6061 (90 wt%)/C (5 wt%)/ZrO2 (5 wt%) hybrid composite material processed by the stir casting method. The fabricated sample was examined for the uniform particle distribution of reinforcements using Scanning Electron Microscope. The drilling operation was carried out on the fabricated in a CNC machining center by setting the spindle speeds of 800, 1200, and 1600 rpm, depths of cut of 0.5, 1, and 1.5 mm, and feeds of 50, 100, and 150 mm/rev. An orthogonal array (L27) designed by Taguchi’s method was used as the design of the experiment for the optimization of the best cutting parameters and coating. Surface roughness and cylindricity errors were determined for the 27 experimental runs. Field emission scanning electron microscopic (FESEM) examination and Energy Dispersive Spectroscopy (EDS) were used to analyze the surface integrity and elemental composition, respectively. The results revealed that Durana had a significant effect on the surface substrate with minimum surface roughness (Ra) of 1.666 μm and obtained the minimum cylindricity error for the parameters of depth of cut 0.5 mm, spindle speed of 1200 and feed of 100 mm rev−1.

ROBOTIC APPLICATION FOR ABRASIVE BELT MACHINING OF COMPLEX AIRCRAFT METAL PARTS

Surface finishing applications are still cumbersome manual tasks, therefore, robotization of the process is of great interest as it allows for automation and increased versatility. However, finishing processes are difficult to automate, mainly because of the variation in material removal. In particular, the variables involved undergo changes that modify the material removal rate. This paper proposes a methodology for modeling material removal automatically based on experimental data. The procedure consists of monitoring the material removed from the parts under study that are in an automated precision measuring system during the finishing process. Based on the experimental models, a control algorithm for continuous material removal is presented. It guarantees a homogeneous surface finish by varying the robot feed rate. Finally, the results of several experimental material removal models under different process conditions and the validation of the proposed control algorithm are presented. The results show that the proposed method achieves a substantial improvement in the homogeneity of the finish.

Advancing laser powder bed fusion with non-spherical powder: Powder-process-structure-property relationships through experimental and analytical studies of fatigue performance

This study investigates the multifaceted interdependencies among powder characteristics (i.e., non-spherical morphology and particle size ranging 50–120 or 75–175 µm), laser powder bed fusion (L-PBF) process condition (i.e., contouring), post-process treatments (i.e., hot isostatic pressing (HIP) and mechanical grinding) on the pore, microstructure, surface finish, and fatigue behavior of additively manufactured Ti-6Al-4V samples. Microstructure analysis shows a phase transformation α′ → α+β microstructure after HIP treatment (at 899±14 °C for 2 h under the applied pressure of 1034±34 bar) of the as-built Ti-6Al-4V parts. The findings from pore analysis using micro-computed tomography (μ-CT) show an increase in sub-surface pores when relatively smaller powders are L-PBF processed including contouring. Surface optical profilometry reveals a decrease in surface roughness when fine powder is L-PBF including contouring. Pore analysis conducted through μ-CT reveals that the presence of lack-of-fusion pores within the L-PBF processed coarse powder is more pronounced when compared to the fine powder. Furthermore, HIP treatment does not eliminate these pores. The fracture failure in as-printed parts occurs at the surface, while the combination of HIP and mechanical grinding alters crack initiation to subsurface pore defects. Fractography reveals that HIP and as-built samples followed the facet formation and pseudo-brittle fracture mechanisms, respectively. Fatigue life assessments, supported by statistical analysis, indicate that mechanical grinding and HIP significantly enhanced fatigue resistance, approaching the benchmarks set by wrought Ti-6Al-4V alloy. A fatigue prediction model which considers the surface roughness as a micro-notch has been used.

Experimental analysis of design, development, mechanical and tribological properties of spark plasma sintered advanced WC-Al2O3 composites reinforced by graphene platelets

Alumina-based tungsten carbide composites reinforced by different weight percentages of graphene platelets (GPLs) were successfully sintered by latest spark plasma sintering (SPS) technique. The WC-Al2O3-GPLs composites were fabricated to design advanced tool materials to acquire an optimum set of mechanical, thermal and anti-wear properties for high-temperature cutting tool applications. This study has the novelty that such composites have not been developed using SPS. The addition of GPLs to composites enhanced the microstructure, however the optimum mechanical and thermal properties were exhibited with the composite having lesser addition of GPLs. At higher levels of GPLs addition, the microstructures and properties of composites were degraded on account of stacking/agglomeration of GPLs. It was observed that SPS delivered better densification and microstructures as compared to other conventional sintering. The mechanical properties were best revealed by the sample with 0.6 wt. % of GPLs with hardness of 20.71 GPa and fracture toughness of 11.84 MPa.m1/2. The improved toughening and strengthening results of WC-Al2O3-GPLs composites were essentially acquired by inhibiting grain growth during sintering, bridging of GPLs between matrix components, and improved dispersion of composite constituents (EPMA/WDS), particle hardening and phase toughening (Al2O3, GPLs). A thermal study was conducted to investigate the thermal stability of sintered composites at higher temperatures while providing the maximum thermal conductivity and thermal diffusivity of 166 Wm−1K−1 and 0.276 × 10−4 m2s−1 at room temperatures. The tribological testing revealed that the composites with lesser GPLs reinforcement attributed lower coefficients of friction, better surface finish and least wear of the materials.