Material Processing Techniques Research Articles

Innovative techniques for joining and processing of some aluminum alloys used in the aircraft industry

The continuous development of various cutting-edge fields of science and technology, including the aerospace industry, is advancing at an accelerated pace. To meet current technical, economic, and environmental demands, new ecological and efficient material joining and processing techniques have been developed, aiming to replace some of the commonly used industrial procedures. For aluminum alloys, friction-based joining and processing methods with a rotating tool element are presented in this paper, with potential applications in the aerospace industry. Data is provided on Friction Stir Welding (FSW), known for its ability to produce high-quality joints without compromising the structural integrity of materials, highlighting its advantages over traditional welding methods. The diversity of metallic materials, their characteristics and properties, as well as the technical requirements of different applications, have led to the development of variants of the friction stir welding process, one of which is Submerged (underwater) Friction Stir Welding (SFSW). Data on FSW and SFSW welding as well as several aluminum alloys that can be used in the aerospace industry are included in the paper. The paper also discusses ISIM's approaches in the FSW/SFSW domain for aluminum alloys EN AW 6082 and EN AW 7075 that are applicable to the aerospace industry because of their relevance and interest. The positive outcomes show that FSW and SFSW welding can be developed for a variety of metallic materials. The goal of ISIM’s current and future research is to apply the principles of the FSW/SFSW process to the FSP/SFSP processing of non-ferrous alloys, which can be used in a variety of industries.

Cinnabar for Roman Ephesus: Material quality, processing and provenance

Ephesus was an important harbor city that flourished during the Roman period and ancient texts mention Almadén in Spain and the Cilbian fields of Ephesus as important cinnabar sources in antiquity. This work investigates whether imported cinnabar was used and whether this could be related to changes in painting activities over time. Microscopic analysis indicates a consistent preparation of cinnabar, hinting at a uniform source material quality or processing technique. However, the use of cinnabar varies among the architectural structures studied, indicating a plurality of painting techniques. A few of the analyzed cinnabar samples overlap with Turkish- and Balkan reference Pb isotope ratios; three samples from tabernas, however, deviate from this. The Hg isotope ratios reveal that cinnabar from carbonate-hosted deposits was likely used, and that processing of cinnabar included heating as suggested by ancient texts. Most notably, a correlation exists between the geochemical data and the painting technique – shifts in sourcing and cinnabar usage are potentially assignable to building chronology and/or usage. Through the lens of material provenance and processing, Ephesian cinnabar brings the organization of pigment trade into focus.

Bridging high resolution sub-cellular imaging with physiologically relevant engineered tissues

While high-resolution microscopic techniques are crucial for studying cellular structures in cell biology, obtaining such images from thick 3D engineered tissues remains challenging. In this review, we explore advancements in fluorescence microscopy, alongside the use of various fluorescent probes and material processing techniques to address these challenges. We navigate through the diverse array of imaging options available in tissue engineering field, from wide field to super-resolution microscopy, so researchers can make more informed decisions based on the specific tissue and cellular structures of interest. Finally, we provide some recent examples of how traditional limitations on obtaining high-resolution images on sub-cellular architecture within 3D tissues have been overcome by combining imaging advancements with innovative tissue engineering approaches.

Investigating Anode Structural Characteristics with Multistage Data Quantification: Influence of Extrinsic Properties of Anodes for Oxidation Evolution Reaction in Alkaline Water Electrolysis

Tackling climate change demands the deployment of sustainable technologies, among which alkaline water electrolysis (AWE) emerges as one of the pivotal solutions. In AWE, anode morphology plays a critical role in facilitating the oxygen evolution reaction (OER), which is a key step in splitting water molecules into oxygen and hydrogen gas. OER performance can be enhanced by fine-tuning the morphology of the anodes [1, 2]. Therefore, there is a critical need to quantitatively comprehend surface morphology or coating quality quantitatively and define the relationships between these surface features and the activity of anodes.We have observed that conducting a quantitative analysis of the nanoscale structure of anodes produced via ultrasonic spray coating provides a reliable metric, serving as a descriptor to evaluate the quality of particle-based catalyst coatings [3, 4]. For this quantitative analysis, it is crucial to characterize the structure with high resolution. However, high-resolution techniques commonly employed such as atomic force microscopy (AFM) have a significant limitation. They cover only a small measurement area that may not represent the entire surface area. In response to this need, we have introduced multistage data quantification (MSDQ) technique as a full-scale surface extrapolation method. The MSDQ technique is a statistical approach that facilitates an impartial characterization of surfaces by optimizing the process of region selection (ROS) and feature extraction, as exemplified in Figure 1.We validated MSDQ through the characterization of anodes produced utilizing different spray coating processing parameters. AFM was employed to capture surface morphology. Through MSDQ, the following surface characteristics are extracted: the surface roughness indicates the variations of surface texture, measuring the peaks and valleys on the surface, the roughness factor refers to the total area covered by the electrode surface to the projected area, and the homogeneity score quantifies the uniformity of the surface structure, essential for assessing the consistency of catalyst coatings were extracted.For validation, in a first proof of principle, extrinsic surface features were correlated to electrocatalytic activity for the oxygen evolution reaction (OER), as quantified through scanning droplet cell (SDC) measurements. The anode that showed a consistent surface topography yielded uniform electrochemical activity, while the anode that displayed irregular surface characteristics also lead to a more wide-spread electrochemical activity. To validate the reliability of the MSDQ technique, we conducted independent ROS measurements and found that the measured features were consistent with the ranges previously predicted by MSDQ. This consistency underscores the effectiveness of MSDQ in accurately characterizing surface features of anode, further establishing its credibility as a robust tool for surface analysis.Taken together, the developed strategy exhibits high potential for adaptability across diverse electrochemical systems and their components. Moreover, it acts as a powerful approach for linking statistically backed-up surface characteristics, also beyond AFM, with electrochemical activity. This capability enhances our understanding of how surface nuances influence the overall electrochemical performance, offering valuable insights into optimizing material compositions and processing techniques for improved functionality.

(Invited) Recent Advances in Protonic Ceramic Electrochemical Cells at KAIST

Protonic ceramic electrochemical cells (PCECs) offer a promising pathway for sustainable energy conversion and storage, operating at temperatures below 600°C. However, several challenges, including sluggish kinetics at the oxygen electrode and the formation of secondary phases within perovskite electrolyte materials, have hindered their widespread adoption. In this presentation, we highlight recent results aimed at overcoming these hurdles and advancing the performance of PCECs at KAIST. Firstly, we present an innovative approach to mitigate processing-related issues in PCECs. By employing a microwave-assisted sintering process (MW-PCEC), we significantly reduce sintering times while suppressing undesirable cation diffusion and grain growth. This results in PCECs with stoichiometric electrolytes and nanostructured fuel electrodes, leading to substantial enhancements in electrochemical performance. Secondly, we tackle the challenge of developing efficient and stable proton-conducting electrolytes. We introduce a novel high entropy perovskite oxide (HEPO) material, with superior conductivity and chemical stability, even in the presence of contaminants like CO2. Utilizing this electrolyte, we fabricate reversible PCECs (R-PCECs) with unprecedented performance, setting new benchmarks in power density and current density. Furthermore, we address the issue of sluggish reaction kinetics at the oxygen electrode by introducing bifunctional oxygen electrodes based on bimetal-doped BaCoO3-𝛿 (BCO). Through doping, we transform BCO into cubic perovskite, enhancing water uptake and hydration abilities, thereby improving proton transport properties. PCECs incorporating these electrodes exhibit record-high power densities, showcasing the potential of rational electrode design for achieving high performance. Overall, our research represents a comprehensive approach to advancing the performance of PCECs through innovative materials design and processing techniques. By addressing critical challenges and pushing the boundaries of current capabilities, we would like to pave the way for the widespread implementation of PCECs as efficient and sustainable energy conversion devices.

Sixty Years of Mechanical Alloying—Past Achievements, Current Challenges, and Future Prospects

Mechanical alloying (MA), a completely solid‐state high‐energy powder processing method, was initially used to develop Ni‐based and Fe‐based superalloys containing oxide dispersions for applications at high temperatures and requiring high strength. MA is currently an established materials process to synthesize a variety of nonequilibrium alloys with unique microstructures and properties. Supersaturated solid solutions, metastable intermediate phases, amorphous alloys, quasicrystalline alloys, nanostructures, and nanocomposites, and high‐entropy alloys are some of the materials developed using MA. These advanced structural and functional materials exhibit great potential with widespread applications. Several new and novel applications have also been recently developed. A major concern in using this technique to produce advanced materials is the inherent contamination experienced by the milled powder. In the present article, the past achievements during the last 60 years and current challenges are described in brief. Methods to decrease powder contamination and ways to reduce the cost of powders produced are also discussed. It is also shown that while the MA concept is straightforward, the outcome of the process can be stochastic, depending on many variables which must be experimentally determined since no comprehensive process model exists. The article concludes with the future prospects of this materials processing technique.

Evaluating Benchtop Additive Manufacturing Processes Considering Latest Enhancements in Operational Factors

With the evolution of additive manufacturing technologies, concerning their material processing techniques, range of material choices and deposition speed, 3D printers are extensively employed in academia and industry for a number of purposes. It is no longer uncommon to have a portable, desktop 3D printer and build specific designs in a matter of minutes or hours. The functionality, costs, materials and applications of desktop 3D printers differ. Among the several desktop 3D printers with a variety of characteristics, it might be challenging to choose which one is optimal for the intended applications and uses. In this study, a variety of commercially available thermoplastic and photopolymer resin desktop 3D printers are presented and compared for user selection. This article intends to provide end-users of desktop 3D printers with fundamental information and guidelines via a comparison of desktop 3D-printing technologies and their technical characteristics, enabling them to assess and select appropriate desktop 3D printers for a variety of applications.

3D Binder-Free Mo@CoO Electrodes Directly Manufactured in One Step via Electric Discharge Machining for In-Plane Microsupercapacitor Application.

Cobalt oxide-based in-plane microsupercapacitors (IPMSCs) stand out as a favorable choice for various applications in energy sources for the Internet of Things (IoT) and other microelectronic devices due to their abundant natural resources and high theoretical specific capacitance. However, the low electronic conductivity of cobalt oxide greatly hinders its further application in energy storage devices. Herein, a new manufacturing method of electric discharging machining (EDM), which is simple, safe, efficient, and environment-friendly, has been developed for synthesizing Mo-doped and oxygen-vacancy-enriched Co-CoO (Mo@Co-CoO) integrated microelectrodes for efficiently constructing Mo@Co-CoO IPMSCs with customized structures in a single step for the first time. The Mo@Co-CoO IPMSCs with three loops (IPMSCs3) exhibited a maximum areal capacitance of 30.4 mF cm-2 at 2 mV s-1. Moreover, the Mo@Co-CoO IPMSCs3 showed good capacitive behavior at a super-high scanning rate of 100 V s-1, which is around 500-1000 times higher than most reported CoO-based electrodes. It is important to note that the IPMSCs were fabricated using a one-step EDM process without any assistance of other material processing techniques, toxic chemicals, low conductivity binders, exceptional current collectors, and conductive fillers. This novel fabrication method developed in this research opens a new avenue to simplify material synthesis, providing a novel way for realizing intelligent, digital, and green manufacturing of various metal oxide materials, microelectrodes, and microdevices.

Heterogeneous microstructure of γ-irradiated pre-oxidized PAN fiber revealed by microfocus SR-SAXS reconstruction and molecular simulation.

The microstructure plays a crucial role in the manufacturing and application of polyacrylonitrile fibers, which serve as precursors for carbon fibers. Synchrotron radiation small angle x-ray scattering (SR-SAXS) is a non-destructive and precise technique for analyzing fiber structures. This study employed one-dimensional SR-SAXS mapping to extract key structural parameters such as periodicity, lamellae thickness, and the extent of amorphous regions, as well as the directional orientation in γ-irradiated, pre-oxidized polyacrylonitrile fibers. The analysis revealed a three-layered structure comprising a surface skin, a transitional layer, and a central core. Notably, the lamellar thickness exhibits a "U"-shaped distribution, while the long-period structures, amorphous regions, and orientational properties demonstrate a "wave-like" pattern. Within this structure, the skin exhibits a higher level of orientation, with the orientation decreasing progressively from the skin toward the core layer. The structure of the layered crystal was further corroborated by the morphological analysis. In addition, molecular simulations were performed to propose the mechanisms underlying the formation of this layered structure. This comprehensive investigation using SR-SAXS and one-dimensional mapping provides detailed insights into the microstructural and morphological characteristics of polyacrylonitrile fibers, which can inform future advancements in material processing and refinement techniques for the production of advanced fibers.

Revolutionizing healthcare materials: Innovations in processing, advancements, and challenges for enhanced medical device integration and performance

Cutting-edge materials have transformed the fabrication of medical devices and implants. However, the processing used to create these materials impacts their mechanical, physical, and biological characteristics, preventing effective integration. This study is intended to provide a detailed analysis of healthcare materials processing techniques, stressing healthcare-specific material requirements, such as biocompatibility, mechanical strength, corrosion resistance, stabilizability, and bioactivity, followed by classifying these processing methods as “ordinary” and “edge-cutting” methods. The consequences of each processing on the material, as well as the benefits, drawbacks, and recent developments of each technique, are also aimed to be concluded. The study also aimed to explore how process factors affect product qualities. The articles are collected from the Scopus and Web of Science databases using the search strings “Advance Material,” “Material Processing,” “Healthcare,” and “HealthCare Application.” The assessment of the selected literature has been done in accordance with the objectives. The assessment emphasizes quality assurance and regulatory compliance by stressing the need for quality assurance, characterization, and testing for medical devices and implants. Processes such as polishing, etching, and coatings improve biocompatibility and reduce infection risk, according to the findings. It was also concluded that cutting-edge processing methods such as additive manufacturing (3D printing) and electrospinning provide exact control over material composition, structure, and porosity, making them ideal for many clinical applications.

(Invited) Polarization Stability Improvement for Hf0.5Zr0.5O2-Based Ferroelectric Capacitor

The instability in polarization during the endurance test of Hf0.5Zr0.5O2 (HZO) ferroelectrics thin films including the wake-up and the fatigue are still major challenges for the development of HZO-based ferroelectric memories. In this work, we will review the proposed mechanisms of the instabilities in polarization including wake-up and fatigue of the HZO-based metal-ferroelectric-metal (MFM) capacitors. Then, the material processing techniques to address the issues of instabilities are provided. The in-situ deposition of electrode and ferroelectric layers by atomic layer deposition (ALD) attracted considerable attention as a promising solution. Owing to the improved interface quality, both the endurance characteristics and remanent polarization were enhanced. We have also developed a HfO2/ZrO2 superlattice structure to further enhance the ferroelectric endurance of the MFM capacitors. The superlattice MFM capacitors show wake-up free characteristics with excellent endurance. The device performances and endurance characteristics of ferroelectric thin film transistor will also be presented.

Large-area magnetic skin for multi-point and multi-scale tactile sensing with super-resolution

The advancements in tactile sensor technology have found wide-ranging applications in robotic fields, resulting in remarkable achievements in object manipulation and overall human-machine interactions. However, the widespread availability of high-resolution tactile skins remains limited, due to the challenges of incorporating large-sized, robust sensing units and increased wiring complexity. One approach to achieve high-resolution and robust tactile skins is to integrate a limited number of sensor units (taxels) into a flexible surface material and leverage signal processing techniques to achieve super-resolution sensing. Here, we present a magnetic skin consisting of multi-direction magnetized flexible films and a contactless Hall sensor array. The key features of the proposed sensor include the specific magnetization arrangement, K-Nearest Neighbors (KNN) clustering algorithm and convolutional neural network (CNN) model for signal processing. Using only an array of 4*4 taxels, our magnetic skin is capable of achieving super-resolution perception over an area of 48400 mm2, with an average localization error of 1.2 mm. By employing neural network algorithms to decouple the multi-dimensional signals, the skin can achieve multi-point and multi-scale perception. We also demonstrate the promising potentials of the proposed sensor in intelligent control, by simultaneously controlling two vehicles with trajectory mapping on the magnetic skin.

Green power solutions: Advancements in eco‐friendly cellulose‐derived composite battery separators—Material properties and processing techniques

AbstractBatteries play a crucial role in our daily lives, with separators being a key component influencing their functionality. The separators based on petrochemical for example polythene and polypropylene have been long favored for their chemical and thermal stability, their drawbacks in terms of sustainability, eco‐efficiency, and associated environmental risks are undeniable. In pursuit of sustainable development, there is a growing demand for biopolymer composite separators that offer a compelling combination of low cost, high mechanical and thermal stability, biodegradability, and renewability. Among these alternatives, cellulose‐derived separators have garnered significant attention from the scientific community. This review delivers a brief overview of cellulose's chemical structure, their types, delving into the intricate interplay of various electrodes and electrolytic solutions. The focus is then directed towards exploring diverse preparatory methods for cellulose‐derived separators, along with highlighting the promising factors associated with their adoption. Special attention is given to cellulose composite separators and the challenges they present.Highlights Cellulose‐based composite separators in LIB/SIB batteries are discussed. Preparatory methods for eco‐friendly cellulose‐derived composite battery separators. Prominent affecting factors of separator performance have been elaborated. Special attention to the challenges cellulose composite separators present.

Additive Manufacturing-Enabled Advanced Design and Process Strategies for Multi-Functional Lattice Structures.

The properties of each lattice structure are a function of four basic lattice factors, namely the morphology of the unit cell, its tessellation, relative density, and the material properties. The recent advancements in additive manufacturing (AM) have facilitated the easy manipulation of these factors to obtain desired functionalities. This review attempts to expound on several such strategies to manipulate these lattice factors. Several design-based grading strategies, such as functional grading, with respect to size and density manipulation, multi-morphology, and spatial arrangement strategies, have been discussed and their link to the natural occurrences are highlighted. Furthermore, special emphasis is given to the recently designed tessellation strategies to deliver multi-functional lattice responses. Each tessellation on its own acts as a novel material, thereby tuning the required properties. The subsequent section explores various material processing techniques with respect to multi-material AM to achieve multi-functional properties. The sequential combination of multiple materials generates novel properties that a single material cannot achieve. The last section explores the scope for combining the design and process strategies to obtain unique lattice structures capable of catering to advanced requirements. In addition, the future role of artificial intelligence and machine learning in developing function-specific lattice properties is highlighted.

Utilizing Natural Materials in Electronic Devices: Inching Toward "Herbal Electronics".

Sustainable development is the primary key to address global energy challenges. Though the scientific community is engaged in developing efficient ways to not only maximize energy production from natural resources like sun, wind, water, etc. but also to make all the electronic gadgets power efficient, despite all this, the materials used in most of the electronic devices are largely produced using various materials processing techniques and semiconductors, polymers, dielectrics, etc. which again increases the burden on energy and in turn affects the environment. While addressing these challenges, it is very important to explore the possibility to directly, or with minimum processing, utilize the potential of natural resources in the development of electronic devices. Recent articles are focused on the development of herbal electronic devices that essentially implement natural resources, like plants, leaves, etc., either in their raw or extracted form in the device assembly. This review encompasses the recent research developments around herbal electronic devices. Furthermore, herbal electronics has been discussed for several functional applications including electrochromism, energy storage, memresistor, LED, solar cell, water purification, pressure sensor, etc. Moreover, advantages, disadvantages, and challenges encountered in the realization of "herbal electronics" have been discussed at length.

Physics-informed neural network for velocity prediction in electromagnetic launching manufacturing

Electromagnetic launching manufacturing (EMLM) is a high-speed material processing technique powered by pulsed current. The hammer velocity is a key indicator in EMLM, but it is hard to obtain. A viable approach is to use the circuit response current to help in measuring the hammer velocity, but the different curve patterns and the weak interactions between the parameters are major hindrances. In this paper, response current information was used to develop a physics-informed neural network to indirectly predict the hammer velocity. With the experimental dataset, the proposed model had the lowest root mean squared error (0.95) compared with the traditional models (1.62 from Seq2Seq, 1.98 from LSTM, and 2.18 from Attention). This improvement was achieved through the proposed physics-informed neural network architecture. The proposed loss function incorporated knowledge from physics which enabled the model to obtain implicit physical data in the EMLM process, thus enhancing its generalization ability. A fast convergence of the training process was promoted by the developed 2-stage strategy. The introduced attention mechanism added a global perspective that improved the prediction accuracy of the peak velocities. Consequently, our model achieved state-of-the-art predictions of velocities in real-world industrial EMLM systems.

Nonlinear radiative thermal analysis of magneto-micropolar fluid over a bidirectionally extending sheet with varied thermal conditions

Thermal fluid flow analysis occasioned by stretching surfaces offers practical industrial and engineering applications, such as extrusion and drawing processes and materials experiencing heating and cooling conditions. Thus, this study explores magnetohydrodynamic micropolar fluid flow under varied thermal conditions and nonlinear thermal radiation over a dually stretched sheet subject to surface mass flux and an internal heat source. The study thus provides insight into the dynamics of heat transfer mechanisms for improving material processing techniques in many engineering processes. The flow dynamics with the thermal analysis are evaluated by applying two thermal conditions in the heat equation: the prescribed surface temperature (PST) and the prescribed heat flux (PHF). The formulated partial derivative equations that describe the current problem are changed into ordinary derivatives using some similarity quantities, while the converted equations are tackled with the combined techniques of shooting and Runge–Kutta Fehlberg. Consequently, diverse tables and figures are displayed to deliberate on the impacts of the physical terms on the dynamics of flow and heat transmission processes. The consequence of the analysis reveals a higher heat gradient in the prescribed surface temperature case than the uniform temperature distribution, as the Prandtl number magnifies. The micropolar material term reduces the surface frictional factor and depletes heat transmission, but the magnetic field term raises the skin friction coefficient.

Developments and prospects of additive manufacturing for thermoelectric materials and technologies

In view of the increased demand for electricity and the associated environmental and financial concerns, there is an urgent need to develop technological solutions that can improve the efficiency of engineering systems and processes. Thermoelectric (TE) technologies, with their capability of direct conversion of thermal energy into electrical energy, are promising technologies for green power generation through using them as energy harvesting devices for waste heat recovery in industrial processes and power generation systems.To date, TE technologies are still not commercialized on a large scale due to various economic and technical obstacles. The majority of previous research on TE technologies concentrated on improving the TE properties, such as electronic transport and figure-of-merit, while limited attempts were made to identify the best material processing techniques or reduce the cost of manufacturing. Conventional Manufacturing (CM) of TE materials and devices is multi-stage, complex, labour-intensive, time-consuming, and has high energy requirements. Thus, manufacturing challenges are considered key contributors toward limited industrial adoption of TE technologies.The rapid advent of advanced Additive Manufacturing (AM) processes, in recent years, caused dramatic changes in engineering design thinking and created opportunities to solve manufacturing challenges. With its significant capabilities, AM can be the route to address the shortcomings of CM of the thermoelectric technologies. In this regard, this paper presents an in-depth review of the literature studies on using AM technologies, such as selective laser melting, fused deposition modelling, direct ink writing, stereo lithography, etc., for manufacturing TE materials and devices. The benefits and challenges of each AM technology are discussed to identify their merits and the required future research. This paper demonstrates the role of AM in advancing green materials and technologies for solving some of the outstanding energy and environmental issues.

Ultralow-Noise MoS2/Type II Superlattice Mixed-Dimensional van der Waals Barrier Long-Wave Infrared Detector.

Low-noise, high-performance long-wave infrared detectors play a crucial role in diverse applications, including in the industrial, security, and medical fields. However, the current performance of long-wave detectors is constrained by the noise associated with narrow bandgaps. Therefore, exploring novel heterostructures for long-wavelength infrared detection is advantageous for the development of compact and high-performance infrared sensing. In this investigation, we present a MoS2/type II superlattice mixed-dimensional van der Waals barrier long-wave infrared detector (Mixed-vdWH). Through the design of the valence band barrier, substantial suppression of device dark noise is achieved, resulting in 2 orders of magnitude reduction in dark current. The device exhibits outstanding performance, with D* reaching 4 × 1010 Jones. This integration approach synergizes the distinctive properties of two-dimensional layered materials (2DLM) with the well-established processing techniques of traditional three-dimensional semiconductor materials, offering a compelling avenue for the large-scale integration of 2DLM.

Energy Consumption and Tool Condition in Friction Stir Processing of Aluminum Alloys

AbstractFriction Stir Welding (FSW) and Friction Stir Processing (FSP) are solid-state joining and material processing techniques that have garnered considerable attention for their versatility and industrial applicability. In the present work, FSP was performed on AA 6056 T4, dealing with the issue of monitoring tool wear and assessing its impact on the process. The impact of tool wear on power requirements was analyzed, and it was expanded the understanding of tool behavior and its implications for the overall process performance. Specifically, variations in energy consumption, temperatures, and vibrations are observed with changing tool conditions. Further insights are provided by analyzing the microhardness and the pin volume ratio, which show distinct trends as the tool wears. Two tool maintenance ways are proposed, that are cleaning the tool with a sodium hydroxide solution and increasing the tool’s rotational speed. Both the strategies exhibit the potential to partially restore the tool’s initial characteristics. This study highlights the critical importance of assessing tool condition, energy consumption, and process sustainability, particularly in industrial settings where material processing requires efficiency and quality assurance.