Plasma Carburizing Research Articles

Effect of Low-Temperature Plasma Carburization on Fretting Wear Behavior of AISI 316L Stainless Steel

AISI 316L stainless steel has received considerable attention as a common material for key ball valve components; however, its properties cannot be improved through traditional phase transformation, and fretting wears the contact interface between valve parts. A carburized layer was prepared on the surface of AISI 316L stainless steel by using double-glow low-temperature plasma carburization technology. This study reveals the effect of double-glow low-temperature plasma carburization technology on the fretting wear mechanism of AISI 316L steel under different normal loads and displacements. The fretting wear behavior and energy dissipation of the AISI 316L steel and the carburized layer were studied on an SRV-V fretting friction and wear machine with ball–plane contact. The wear mark morphology was analyzed by using scanning electron microscopy (SEM), the phase structure of the carburized layer was characterized with X-ray diffractometry (XRD), and the wear profile and wear volume were evaluated with laser confocal microscopy. The carburized layer contains a single Sc phase, a uniform and dense structure, and a metallurgically combined matrix. After plasma carburizing, the sample exhibited a maximum surface hardness of 897 ± 18 HV0.2, which is approximately four times higher than that of the matrix (273 ± 33 HV0.2). Moreover, the surface roughness was approximately doubled. The wear depth, wear rate, and frictional dissipation energy coefficient of the carburized layer were significantly reduced by up to approximately an order of magnitude compared with the matrix, while the wear resistance and fretting wear stability of the carburized layer were significantly improved. Under different load conditions, the wear mechanism of the AISI 316L steel changed from adhesive wear and abrasive wear to adhesive wear, fatigue delamination, and abrasive wear. Meanwhile, the wear mechanism of the carburized layer changed from adhesive wear to adhesive wear and fatigue delamination, accompanied by a furrowing effect. Under variable displacement conditions, both the AISI 316L steel and carburized layer mainly exhibited adhesive wear and fatigue peeling. Oxygen elements accumulated in the wear marks of the AISI 316L steel and carburized layer, indicating oxidative wear. The fretting wear properties of the AISI 316L steel and carburized layer were determined using the coupled competition between mechanical factors and thermochemical factors. Low-temperature plasma carburization technology improved the stability of the fretting wear process and changed the fretting regime of the AISI 316L steel and could be considered as anti-wearing coatings of ball valves.

Slurry and liquid impingement erosion behavior of low-temperature plasma carburized AISI 420 martensitic stainless steel

The impact of plasma carburizing treatment on the erosion wear resistance of AISI 420 martensitic stainless steel (MSS) was studied. Experiments were carried out varying a broad spectrum of erosion parameters, including impact velocity, impact angle, and exposure duration. Both slurry and liquid impingement erosion were employed in the experiments, with testing conducted using both distilled water and saline solutions to assess the combined effects of corrosion and erosion wear. Compared to untreated samples, a significant improvement in the erosion wear resistance of AISI 420 MSS due to low-temperature plasma carburizing treatment was observed for all tested conditions. The observed performance enhancement can be attributed to the formation of the carburized layer, constituted of the α'C and Fe3C phases. Results also highlighted that the severity of the tribosystem was significantly influenced by the test solution characteristics. A marginal increase in severity was observed upon introducing the saline solution, while a more substantial severity increase occurred with the addition of solid particles in the test fluid. The specimens' mass loss was increased by increasing impact velocity, following a simple potential relationship, and with impact angle, following a first-degree linear equation. In the case of the exposure time, the mass loss curves depended on the test environment. For solutions containing quartz particles, an additional final stabilization stage was observed in addition to the acceleration stage observed in the absence of abrasive component. This phenomenon was attributed to surface work hardening induced by the impact of solid particles. Regarding wear mechanisms, samples tested only with distilled water displayed erosion flow marks. Those containing distilled water and NaCl exhibited not only flow marks but also pits. Lastly, solutions containing solid particles additionally presented features of plastic deformation, lip formation, craters, indentations, and extruded material.

Tribological performance of low-temperature plasma carburized AISI 420 martensitic stainless steel

Plasma carburizing has emerged as a potent technique for improving the wear resistance of stainless steels, and sustaining or improving corrosion resistance through a suitable choice of process parameters. This study evaluated the impact of plasma carburizing time and temperature on the tribological behavior of AISI 420 martensitic stainless steel through dry-sliding wear tests in a ball-on-disk configuration. Two different treatment sets were conducted to assess the impact of carburizing time and temperature on the wear performance of the treated AISI 420 steel. The first group encompassed treatments at temperatures spanning from 350 to 500 °C, with fixed treatment times of 8 and 12 h. The second group involved treatments at a temperature of 400 °C for durations spanning 12 to 48 h and at temperature of 450 °C for durations between 4 and 16 h. To facilitate the discussion of wear test results, microstructural analysis was performed using metallographic analysis, X-ray diffraction, and microscale hardness measurements. Microstructural characterization results revealed that the carburized surface consists of an outer layer followed by a diffusion layer. The diffusion layer is primarily composed of the α′C phase, while the outer layer contains α′C and Fe3C (for low-temperature and short-time treatments) and Cr/Fe-carbides primarily formed due to the α′C decomposition into Fe–α phase (for the studied higher-temperature and longer-time treatments). Wear test results suggest that the surface structure and composition of the treated material exert substantial influence on its tribological behavior. Carburized layers free from Cr-carbide precipitation exhibit lower wear and friction coefficients. The decomposition of α′C into Fe-α and Cr/Fe-carbides leads to an elevation of friction and wear coefficients. Finally, carbon enrichment does not alter the wear mechanism, as both uncarburized and carburized samples exhibited microabrasion and oxidative wear.

Effect of frictional treatment and low temperature plasma carburizing on the microhardness and electromagnetic characteristics of metastable austenitic steel

Microhardness and electromagnetic characteristics of corrosion-resistant chromium-nickel (wt. %: 16.80 Cr; 8.44 Ni) austenitic steel subjected to electron beam plasma carburizing at temperatures of 350 and 500°C, frictional treatment with a sliding indenter and combined treatments, including frictional treatment and plasma carburizing have been investigated. It has been found that plasma carburizing increases the microhardness of the steel surface from 200 to 1100 HV0.025. The total hardening depth was 25 microns after carburizing at T = 350°C and 300 microns after carburizing at T = 500°C. Frictional treatment increases the microhardness of the steel to 600 HV0.025 with a total hardening depth of 500 microns. It has been shown that the diffusion-active layer with a dispersed structure formed during preliminary frictional treatment contributes to additional hardening of the steel (up to 1275 HV0.025) during subsequent low-temperature (350°C) carburizing. Combined treatment with carburizing at a temperature of 500 °C increases the microhardness of the steel to 820 HV0.025, and the total hardening depth is 500 microns for both combined treatments. It has also been found that plasma carburizing of the steel leads to a decrease in the eddy-current readings compared to the quenched steel and their growth compared to the steel subjected to frictional treatment, which can be used to develop quality control techniques for such treatments.

The Influence of Frictional Treatment and Low-Temperature Plasma Carburizing on the Microhardness and Electromagnetic Properties of Metastable Austenitic Steel

The Influence of Frictional Treatment and Low-Temperature Plasma Carburizing on the Microhardness and Electromagnetic Properties of Metastable Austenitic Steel

Effects of Solid-Solution Carbon and Eutectic Carbides in AISI 316L Steel-Based Tungsten Carbide Composites on Plasma Carburizing and Nitriding

AISI 316L stainless-steel-based tungsten carbide composite layers fabricated via laser metal deposition are used for additive manufacturing. Heat treatment practices such as low-temperature plasma carburizing and nitriding improve the hardness and corrosion resistance of austenitic stainless steels via the formation of expanded austenite, known as the S phase. In the present study, practices to enhance the hardness and corrosion resistances of the stainless-steel parts in the composite layers have been investigated, including single plasma carburizing for 4 h and continuous plasma nitriding for 3.5 h following carburizing for 0.5 h at 400 and 450 °C. The as-deposited composite layers contain solid-solution carbon and eutectic carbides owing to the thermal decomposition of tungsten carbide during the laser metal deposition. The eutectic carbides inhibit carbon diffusion, whereas the original solid-solution carbon contributes to the formation of the S phase, resulting in a thick S phase layer. Both the single carburizing and continuous processes are effective in improving the Vickers surface hardness and corrosion resistance of the composite layers despite containing the solid-solution carbon and eutectic carbides.

Growth of Fe3C-VACNT surfaces by metal dusting under plasma carburizing: Fractional factorial study and correlation with morphological and structural aspects

This study investigates the development of surfaces that combine wear-resistance and solid lubrication properties using single low-temperature plasma carburizing treatments associated with the metal dusting phenomenon. The surfaces consisted of a regular cementite (Fe3C) layer and a film composed by vertically aligned carbon nanotubes (VACNT) grown over the carburized layer. For that, specimens of AISI 1005 steel were used as a substrate. A fractional factorial design of experiments was conducted to identify the best processing conditions to achieve the required Fe3C-VACNT surfaces. Morphological and structural aspects of the surfaces were assessed by scanning and transmission electron microscopy, X-ray diffraction, and Raman spectroscopy. The results show that the carburizing performed between 600 and 700 °C and with plasma power densities ≥0.30 W/cm2 were effective for developing the bilayer surfaces. A signature of that process was a temporal increase of the plasma current. According to a created statistical model, the most influential experimental parameters in the average power plasma density were output voltage, %CH4 in the gas mixture, and duty cycle. The surfaces were able to reduce the friction coefficient to values down to 0.08 and decrease the wear rate by 25 to 70 %, depending on their characteristics.

The Influence of Frictional Treatment and Low-Temperature Plasma Carburizing on the Structure and Phase Composition of Metastable Austenitic Steel

The features of the structure and phase composition of corrosion-resistant austenitic chromium–nickel steel (16.80 wt % Cr, 8.44 wt % Ni) subjected to carburizing in electron beam plasma at temperatures of 350 and 500°C, frictional treatment with a sliding indenter, and a combination of frictional treatment and plasma carburizing have been considered. It has been established that plasma carburizing results in the formation of a modified surface layer consisting of carbon-saturated austenite and carbides (Cr23C6, Fe3C); in this case, the formation of γC-phase occurs only at a temperature of 350°C. The depth of a modified layer increases with an increase in the carburizing temperature. It has been shown that it is useful to perform combined frictional treatment and plasma carburizing at a carburizing temperature of 350°C, since in this case the deformation-induced structure formed as a result of frictional treatment is preserved, and the precipitated carbides remain highly dispersed. In this case, frictional treatment should provide the formation of the deepest possible diffusion-active layer with a dispersed structure.

The Influence of Frictional Treatment and Low-Temperature Plasma Carburizing on the Structure and Phase Composition of Metastable Austenitic Steel

The features of the structure and phase composition of corrosion-resistant austenitic chromium–nickel steel (16.80 wt % Cr, 8.44 wt % Ni) subjected to carburizing in electron beam plasma at temperatures of 350 and 500°C, frictional treatment with a sliding indenter, and a combination of frictional treatment and plasma carburizing have been considered. It has been established that plasma carburizing results in the formation of a modified surface layer consisting of carbon-saturated austenite and carbides (Cr23C6, Fe3C); in this case, the formation of γC-phase occurs only at a temperature of 350°C. The depth of a modified layer increases with an increase in the carburizing temperature. It has been shown that it is useful to perform combined frictional treatment and plasma carburizing at a carburizing temperature of 350°C, since in this case the deformation-induced structure formed as a result of frictional treatment is preserved, and the precipitated carbides remain highly dispersed. In this case, frictional treatment should provide the formation of the deepestpossible diffusion-active layer with a dispersed structure.

Galling-Free Fine Blanking of Titanium Plates Using Carbon-Supersaturated High-Speed Steel Punch

A carbon-supersaturated (CS-) high-speed steel punch was prepared using low-temperature plasma carburizing for fine blanking of pure titanium plates. The bare high-speed steel punch was also prepared as a reference to describe the adhesion and abrasive galling in the fine blanking of the titanium plates, even in a single shot. The CS-punch was free from severe chemical galling, even after repeatedly fine-blanking the pure titanium plates. A microstructure analysis, element mapping and a chemical composition analysis demonstrated that titanium debris fragments slightly deposited at the CS-punch edges in the presence of agglomerated free-carbon film due to the CS-punch. This galling-free fine-blanking behavior came from the in situ formation of free carbon tribofilms. This in situ lubrication resulted in the completely burnished surfaces of pure titanium blanks.

Study on CO2 based thermal plasma torch and its effective utilization for material processing in atmospheric pressure

Reuse of greenhouse gases is one of the promising approaches towards controlling global warming to some extent. As a part of that, an attempt has been made to utilize CO2 gas as one of the primary gases to form a thermal plasma jet for material processing. For that purpose, a unique direct current (DC) non-transferred arc thermal plasma torch was designed and its current-voltage characteristics and electro-thermal efficiency with different discharge currents and gas compositions were studied. The torch is made of rod type cathode and a nozzle type anode, which can produce a stable thermal plasma jet under different gas compositions. CH4 was used as a secondary mixing gas in an Ar-CO2 gas composition to produce a carbon-rich thermal plasma with high electro-thermal efficiency. The maximum electro-thermal efficiency of 73 % were reached while the torch operated at 100 A current with 6 slpm of CH4 flow along with 15 and 20 slpm of Ar and CO2 gas flow, respectively. Torch efficiency decreased to 12 % with increase in discharge current from 100 A to 200 A. Optical emission spectrum of the plasma jet was recorded at the exit of the torch nozzle to understand the emission characteristics of the plasma and estimate temperature and electron density. Temperature of the plasma increased from 13,400 to 17,800 K with respect to the discharge current. Thermodynamical studies were carried out for the given experimental conditions to understand the thermal decomposition of CO2-CH4 gas mixture and select the suitable condition for the material processing. Under the selective conditions, plasma torch was utilized for the spheroidization of tungsten metal powder and carburization of the AISI 316 L stainless-steel coupons in atmospheric pressure without using any shielding gases. Results showed that around 85 % of the metal powders were spheroidized perfectly at 15 kW input power. Plasma carburization results showed that the microhardness of the steel surface reached 605 HV with a short processing time of 3 min which was 4 times higher than the untreated steel surface. This work provides useful insight for the utilization of CO2 as primary plasma forming gas to generate thermal plasma for material processing.

Experimental Study of Diamond-like Carbon Film on Aermet100 Steel and First-Principles Calculation of Interfacial Adhesion.

Three different types of surface-modified layers of N, C, and N+C are successfully prepared on AerMet100 steel by plasma-assisted thermochemical treatment, and diamond-like carbon (DLC) films are formed on the top surfaces of the latter two. The results show that the DLC films produced by prenitriding and then carburizing (N+C) exhibit a smoother and finer morphology and higher sp3 content than that without prenitriding (C). In addition, the wear resistance of the N+C specimen with a high hardness nitrided layer as the support for the outermost DLC films is superior to that of the C specimen. In view of the catalytic effect of the Fe3C phase on the growth of DLC films, the interfacial properties of Fe3C(001)/diamond(111) are investigated using first-principles calculations. On the basis of the most preferred Fe-terminated HCP site model, the effects of alloyed cementite (Fe2MC) on interfacial adhesion of Fe2MC(001)/diamond(111) are also investigated. Furthermore, the mechanisms of interfacial adhesion for two representative dopings (Zr weakened and V enhanced) are revealed in detail. These results are expected to provide a potential promising means for future experimental works on the preparation of high-performance DLC films on alloy steel surfaces by plasma carburizing.

Near-Net Forging of Titanium and Titanium Alloys by the Plasma Carburized SKD11 Dies

The carbon supersaturated SKD11 punch and core-die were prepared by the plasma carburizing at 673 K for 14.4 ks. The upsetting experiment was performed by using this punch to describe the plastic flow of pure titanium and β-titanium works in higher reduction of thickness than 50%. The measured load – stroke relationship was utilized to describe the frictional behavior on the contact interface of punch to work materials and their work hardening process. The contact interface of carbon supersaturated punch to work was analyzed to investigate the formation of isolated carbon tribofilms from punch material and to describe the in situ solid lubrication on the contact interface. The micro-hardness mapping technique was also utilized to investigate how to suppress the work-hardening behavior by this in-situ solid lubrication. Free near-net forging experiments were performed to shape the circular β-titanium alloy wires to triangular bars.

Plasma Carburizing of Laser Powder Bed Fusion Manufactured 316 L Steel for Enhancing the Surface Hardness

Austenitic stainless steels produced by laser powder bed fusion (L-PBF) are quite interesting materials owing to their specific microstructure consisting of dendrite walls built of dislocations pinned by many nano-oxides that involves significant strengthening without loss of ductility. In this work, different plasma treatments were performed to harden the surface of 316 L steel manufactured by L-PBF. The samples were characterized by X-ray diffraction (XRD), Raman spectroscopy (RS), light microscopy (LM) and micro-hardness tests. The experimental results show that all the plasma treatments enhance the hardness of the surface because a C-enriched layer of austenite (S-phase) forms with a thickness up to 25 μm. The plasma gas mixture, consisting of 2.5% (CH4) + 97.5% (H2), resulted in being the most effective and produced a surface hardness (547 ± 27 HV) more than double with respect to that of the untreated material. The treatment temperature was 475 °C, which represents a good compromise between the necessity to avoid the precipitation of M23C6 carbides and the compatibility of treatment time with the industrial practice. Moreover, it has been observed that a 2 μm-thick over-layer of amorphous C forms on the sample surface. The hardness of such over-layer, which depends on the specific treatment and is related to the degree of topological disorder, is generally greater than that of S-phase. The work demonstrates that plasma carburizing is quite effective in hardening the surface of 316 L steel manufactured by L-PBF and further improves its mechanical properties, which are basically superior to those of the same material prepared by conventional processes.

Effect of low-temperature plasma carburizing on surface topography, mechanical and tribological properties of sintered iron and nitrided sintered iron

This study investigated the effect of a low-temperature carburized layer on the topography, mechanical and tribological properties of sintered and nitrided sintered iron. Two nitride layers (γ’-Fe4N and ε-Fe2–3N) were produced by plasma nitriding. Subsequently, low-temperature plasma carburizing was used to develop a cementite layer over the samples. The carburized layer increased H/E* and H3/E*2 of the sintered iron more effectively than the nitride layers. The cementite layer improved the wear resistance of the iron by 45%, statistically similar to the γ ´ nitride layer. Postcarburizing enhanced the mechanical properties of the nitrided iron due to the formation of a duplex layer. However, the presence of pores at the interfacial region of the duplex layers induced a brittle wear mechanism.

The formation of diamond-like carbon structure anchored in the nitrided layer of M50 steel during plasma-assisted thermochemical treatment

Diamond-like carbon (DLC) has excellent performance but cannot be directly applied in gears and bearings due to poor adhesion. A novel gradient composite layer that includes a hardened nitrided layer and a self-lubricating DLC structure at the outermost surface was fabricated on M50 steel via plasma-assisted thermochemical treatment. The structure evolution of the modified layer was comprehensively characterized by optical microscopy, scanning electron microscope (SEM), atomic force microscopy (AFM), transmission electron microscope (TEM), Raman spectroscopy, and X-ray photoelectron spectroscopy (XPS). The results show that the nanoparticles embedded in the DLC structure gradually increase until the nitrided diffusion layer. The DLC structure is like being anchored in the nitrided layer by nanoparticles carbide/nitride. The inner of the pre-nitrided layer is hardly affected during the plasma carburizing process. The gradient structure is verified to endow the treated samples with functionally graded hardness profile and super wear resistance by Vickers hardness tester, Nano-indentation tester, and pin-on-disk tribometer. The composite layer's tribological behavior was discussed through wear scar morphology observation by SEM and chemical structure in tracks with Raman spectroscopy. This method proposes a promising way for self-lubricating layer application in the steel matrix without complex operation and high economic cost.

Formation and Properties of Nitrocarburizing S-Phase on AISI 316L Stainless Steel-Based WC Composite Layers by Low-Temperature Plasma Nitriding

Stainless steel-based WC composite layers fabricated by a laser cladding technique, have strong mechanical strength. However, the wear resistance of WC composite layers is not sufficient for use in severe friction and wear environments, and the corrosion resistance is significantly reduced by the formation of secondary carbides. Low-temperature plasma nitriding and carburizing of austenitic stainless steels, treated at temperatures of less than 450 °C, can produce a supersaturated solid solution of nitrogen or carbon, known as the S-phase. The combined treatment of nitriding and carburizing can form a nitrocarburizing S-phase, which is characterized by a thick layer and superior cross-sectional hardness distribution. During the laser cladding process, free carbon was produced by the decomposition of WC particles. To achieve excellent wear and corrosion resistance, we attempted to use this free carbon to form a nitrocarburizing S-phase on AISI 316 L stainless steel-based WC composite layers by plasma nitriding alone. As a result, the thick nitrocarburizing S-phase was formed. The Vickers hardness of the S-phase ranged from 1200 to 1400 HV, and the hardness depth distribution became smoother. The corrosion resistance was also improved through increasing the pitting resistance equivalent numbers due to the nitrogen that dissolved in the AISI 316 L steel matrix.

Low-pressure hollow cathode plasma source carburizing technique at low temperature

A low-pressure hollow cathode plasma source carburizing was developed as a novel surface treatment technique based on the active screen plasma carburizing combined with hollow cathode sources. The cylindric cathodic cage with array holes was made of pure graphite, where the hollow cathode graphite tubes were inlaid on. A pulsed high voltage power with a peak voltage of 800 V and a pulse frequency of 30 kHz was supplied to ignite the hollow cathode discharge inside graphite tubes at a low pressure less than about 300 Pa using a gas mixture of CH 4 + 90%H 2 . The hollow cathode plasma source together with the pulsed high voltage power realized a high biasing current on the carburized samples at low pressure, and produced an enhanced heating except the thermal radiation by the cathodic cage. The graphite cathode as a carbon source besides the gas precursor provided an additional carbon potential. The AISI 304L austenitic stainless steel was carburized at a low temperature of 450 °C for a treatment time of 6 h with a bias of 200 V under the carburizing pressure of 50 Pa and 300 Pa, respectively. It was observed that the carburizing case at 50 Pa was about 13 μm with a higher surface carbon concentration of about 6.5 at.% and a higher hardness of about HV 0.25 N 8.5 GPa compared with that at 300 Pa. The carbon-expanded austenite (γ C ) phase was observed by the x-ray diffraction of both the carburizing cases. The metastable high carbon carbide Fe 5 C 2 only appeared at 50 Pa, which was attributed to high carbon potential at the lower pressure. Therefore, an increased carburizing efficiency at the low temperature was obtained by the low-pressure hollow cathode plasma source carburizing technique using a pulsed high voltage power. • Hollow cathode plasma source is utilized in low temperature plasma carburizing. • Pulsed high voltage is used in graphite hollow cathode discharge at low pressure. • High sample biasing current with enhanced heating is realized by plasma source. • Graphite cathode provides additional carbon potential besides the gas precursor. • Thick carburizing case with metastable carbide and high hardness is obtained.

Sequential low-temperature plasma-assisted thermochemical treatments of the AISI 420 martensitic stainless steel

The application of low-temperature plasma carburizing (C), nitriding (N) and nitrocarburizing (NC) treatments in sequential steps on AISI 420 martensitic stainless steel was investigated through nine different treatments. Experiments were performed at 400 °C, being divided in three (8 h)-single treatments, namely C, N and NC, and six distinct (4 h + 4 h)-sequential treatments, namely C + N, N + C, C + NC, N + NC, NC + N, and NC + C, using appropriate gas mixtures for each treatment step. Sequential treatments promoted the formation of treated layers constituted of iron carbides/nitrides, chromium nitrides, and nitrogen/carbon-expanded martensite phases. Interesting results were obtained for both C + N and C + NC sequential treatments, whose application results in greater hardening depths (~20% thicker) and leads to ~40% increase on the surface hardness, when compared to the obtained for the single C treatment keeping a smooth hardness profile. From the microstructural characterization, no significant sensitization was evidenced in the outer layers obtained for all treatments comprising the carburizing step, an indicative result that the interstitial carbon retards the chromium-rich particles precipitation kinetics. The combination of N + NC treatments produced thicker and harder treated cases compared to those produced by the respective single treatments. In brief, results showed that the appropriate selection of thermochemical treatments' sequence can promote increased treatments efficiency concerning the treated layers thickness or effective surface hardness. This work also contributes to the validation of the presented processing approach, proving its advantages over single thermochemical treatments.

Effects of mould wear on hydrophobic polymer surfaces replicated using plasma-treated and laser-textured stainless steel inserts

ABSTRACT The mass production of polymeric parts with functional surfaces requires economically viable manufacturing routes. Injection moulding is a very attractive option, however, wear and surface damage can be detrimental to the lifespan of replication masters. In this research, austenitic stainless steel inserts were hardened by low temperature plasma carburising and then different micro and nano scale surface textures, inspired by Lotus leaves and Springtail skins, were laser fabricated. A commonly available talc-loaded polypropylene was used to produce 5000 replicas and thus to investigate the evolution of surface textures both on inserts and replicas together with their functional response. The progressive wear or surface damage on the inserts during the injection moulding process had a clear impact on surface roughness and peak-to-peak topographies of the replicas. In general, polymer replicas produced with the carburised inserts retained wetting properties for longer periods compared with those produced with the untreated replication masters.