Surface Quality Research Articles

Tensile testing in high-pressure gaseous hydrogen using the hollow specimen method

Metallic materials, predominantly steels, are the most common structural materials in the various components along the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a key factor in the ramp-up of the hydrogen economy. This requires extensive materials qualification, however, most of the accepted; and standardized test methods for determining the influence of gaseous hydrogen on metallic materials describe complex and costly procedures that are only available to a very limited extent worldwide. The hollow specimen technique is a simple, rapid, and economical method designed to overcome the limitations of the current methods for the qualification of metallic materials under high-pressure hydrogen gas. However, this technique is not yet standardized. The TransHyDE-H2Hohlzug project is presented in this article, along with the main steps required to optimize the hollow specimen technique. This includes closing knowledge gaps related to the specimen geometry, surface quality, and gas purity in dedicated working packages, thus contributing to a comprehensive standardization of the technique for tests in high-pressure hydrogen gas.Impact statementThe hydrogen economy is considered a key solution for achieving climate neutrality in Europe, as it plays a crucial role in the decarbonization of sectors such as transport, industry, power, etc. Ensuring the safety and reliability of infrastructure is crucial for the ramp-up of the hydrogen economy. Therefore, it is necessary to meticulously study the materials and components used for infrastructure under conditions that closely resemble in-service conditions. The currently standardized methods are limited as they do not precisely replicate in-service conditions, and when they do, they are often complex, costly, and not easily accessible. This article presents the hollow specimen technique, a simple, and economical method developed to address the limitations of current standardized methods. The results from this work will contribute to the standardization of this technique for tests in high-pressure hydrogen gas. This will enable a faster evaluation of materials for hydrogen applications by industry and academia, thereby contributing to the growth of the hydrogen economy.Graphical abstract

Optimization of laser-tool distance and laser power in laser-assisted milling under material softening and surface quality constraints

Optimization of laser-tool distance and laser power in laser-assisted milling under material softening and surface quality constraints

Surface Evolution and Optimizing Strategy for Polishing Natural Heterogeneous Marble Using Sol-Gel Diamond Pad

Inefficiency and poor quality are the main problems in polishing natural heterogeneous marbles using sol-gel (SG) diamond pads. A strategy was proposed to address these issues by establishing a natural heterogeneous marble polishing model based on the optimal polishing time. The surface evolution and optimal time for polishing natural heterogeneous marble were systematically investigated. Six different types of marbles were polished by the sol-gel diamond pads. The surface glossiness, roughness, peak–valley value, and surface morphology of the marbles were measured and analyzed after different polishing times. The optimal polishing time for each marble was revealed using sol-gel diamond pads. The experimental results show that the standard deviation of the hardness distribution of marble tile significantly affects the material removal inconsistency and evolution of the surface during polishing, resulting in different optimal polishing times for different kinds of marble. The larger the standard deviation of the hardness of the marble is, the more difficult it is to obtain better surface quality, and the orange peel effect is more likely to occur. Furthermore, the optimal polishing time has a good logarithmic relationship with the standard deviation of the hardness distribution. Finally, a curve model of the optimal polishing time for each marble was established. The determination of the optimal polishing time can effectively optimize the polishing process, simplify the processing flow, improve production efficiency, and reduce production costs. The proposed method and obtained results in this paper can provide a theoretical basis and reference for polishing other types of heterogeneous stone materials.

Experimental investigation on performance of bubble-bursting atomization methods for minimum quantity lubrication in face milling tool steel

The metal cutting industry faces challenges in machining hard materials due to high forces and temperatures. This paper introduces bubble-bursting atomization minimum quantity lubrication (BBA-MQL), a novel MQL technique that generates fine biodegradable oil mists for cooling and lubrication. Although the initial results of BBA-MQL are promising, there has not been a comprehensive investigation into its use in machining hard materials, specifically tool steels. Therefore, this study focused on the applicability of BBA-MQL in face milling of AISI P20 + Ni tool steel in comparison with dry cutting and conventional MQL using commercial and vegetable oil. The machining tests were performed at three cutting speeds (50, 80, and 110 m/min), fixed cutting depth (0.2 mm), and feed rate (0.15 mm/tooth). The performance is evaluated by measuring the cutting force, surface quality, cutting temperature, and tool wear. It was found that BBA-MQL decreased cutting force and surface roughness considerably, with the average reductions being 23.2 % and 49.8 % compared with the conventional minimum quantity lubrication. The highest cutting speed of 110 m/min was preferred for achieving the lowest roughness value and cutting force when milling tool steel P20 + Ni. Furthermore, BBA-MQL with castor oil proved more effective compared to conventional MQL in reducing cutting force, showing improved surface finish, reduced cutting temperature, and delayed tool wear.

Impact of Toolpath Pitch Distance on Cutting Tool Nose Radius Deviation and Surface Quality of AISI D3 Steel Using Precision Measurement Techniques.

The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the workpiece, extend tool life, reduce overall cost, and improve productivity. This work aims to establish the performance of end milling process parameters and the impact of trochoidal toolpath parameters on the surface finish of AISI D3 steel. It especially focuses on the effect of the tool tip nose radius deviation on the surface quality using precision measurement techniques. The experimental design was carried out in a systematic manner using a face-centered central composite design (FCCD) within the framework of response surface methodology (RSM). Twenty different experiment trials were conducted by changing the independent variables, such as cutting speed, feed rate, and trochoidal pitch distance. The main effects and the interactions of these parameters were determined using analysis of variance (ANOVA). The optimal conditions were identified using a multiple objective optimization method based on desirability function analysis (DFA). The developed empirical models showed statistical significance with the best process parameters, which include a feed rate of 0.05 m/tooth, a trochoidal pitch distance of 1.8 mm, and a cutting speed of 78 m/min. Further, as the trochoidal pitch distance increased, variations in the tool tip cutting edge were observed on the machined surface due to peeling off of the coating layer. The flaws on the tool tip, which alter the edge micro-geometry after machining, resulted in up to 33.83% variation in the initial nose radius. Deviations of 4.25% and 5.31% were noted between actual and predicted values of surface roughness and the nose radius, respectively.

Regulating emulsion properties through tannin acid-mediated gelatin/cellulose nanocrystal complexes: From low-oil emulsion to high internal phase emulsion gel for 3D printing

In this study, a stabilized low-oil emulsion and high internal phase emulsion gels (HIPE gels) integrated preparation method is proposed. Highly stable low-oil emulsions, prepared using tight ternary complexes formed by incorporating tannic acid (TA) into gelatin/cellulose nanocrystals (GLT/CNC) complexes mainly through strengthening hydrogen-bonding interaction. The subsequent heating-centrifugation process was used to enable the conversion of GLT/CNC/TA stabilized low-oil emulsions to stabilized HIPE gels, and systematically investigated the regulation of emulsion properties by TA concentrations. The ternary complexes formed by appropriate concentration of TA (0.6 %) can form stable low-oil emulsions with smallest average particle (36.1 ± 0.25 μm) size and best rheological properties, while the rheological properties of HIPE gels were similarly regulated by the TA concentration (0 %, 0.2 %, 0.6 %, 1.0 %, 1.2 %). Heating induced flocculation of low-oil emulsions without causing demulsification, allowed for the subsequent centrifugation to yield stable HIPE gels, significantly superior to the GLT/CNC/TA-stabilized HIPE gels prepared by conventional methods that typically exhibit thermal instability. TA effectively promoted the interfacial adsorption of GLT/CNC and tight stacking of oil droplets to build a more stable network structure in the continuous phase. HIPE gels with 0.6 % TA demonstrated excellent 3D printability with optimal dimensional resolution and surface quality, presenting a novel strategy for HIPE gel preparation and versatile emulsion applications.

Investigation of the media tightness of a microform-fitted plastic/light metal composite

Plastic/metal hybrid components made of amorphous thermoplastics such as polycarbonate and light metals such as aluminum offer potential to be used in modern automotive headlights to meet the high requirements for tolerances and surface quality. A microform-fit joining approach is used to join plastics and metals, which combines the advantages of material-fit and form-fit joining processes while at the same time avoiding some of the disadvantages of the respective joining approaches, such as stress peaks or the use of additional chemicals. For this purpose, the light metal component is microstructured through laser ablation. To ensure the functional safety of electrical components, the media tightness of the hybrid component is tested with a pressure drop test. An influence of the structure arrangement, the structure spacing and the molding compound on the media tightness can be determined. The highest media tightness can be achieved with a ring-shaped structural arrangement in which the microstructures are orientated orthogonally to the outlet direction of the test medium. The media permeability of a ring-shaped structure arrangement with a structure spacing of 500 µm is 0.42 cm3/s for test specimens made of aluminum and polycarbonate. As the value is below the threshold value of 12 cm3/s, watertightness up to an overpressure of at least 0.5 bar can be concluded.

Influences of fiber orientation and process parameters on diamond wire sawn surface characteristics of 2.5D Cf/SiC composites

2.5D Cf/SiC composite materials are widely used in aerospace high-temperature components, optical system structural components and other fields due to their excellent performance. For the cutting of 2.5D Cf/SiC composites, diamond wire saw cutting process has great potential for application. In this study, experiments were conducted on cutting 2.5D Cf/SiC composites with diamond wire saw along different fiber orientations (P0°, P90°, V90°) and different process parameters. The effects of fiber orientation, feed speed, and wire speed on the surface morphology, surface waviness profile, and roughness of the as-sawn surface were analyzed. The results show that fiber orientation significantly affects the fiber damage mode and surface quality of the as-sawn surface, with the surface quality of the slices ranked as V90°>P0°>P0°. The surface morphology and surface roughness improves with decreasing feed speed and increasing wire speed. However, surface waviness profile peak-valley (PV) values increases with increasing the feed speed and wire speed. The study provides experimental references for process optimization and quality improvement in diamond wire saw cutting of 2.5D Cf/SiC composite materials.

Processing of Layered Composite Products Manufactured on the Basis of Bioresin Reinforced with Flax Fabric Using Milling Technology.

In this work, a laminate based on bioresin and natural fibers was produced. Flax fabric was selected as the natural fiber. The biocomposite was subjected to strength tests. Stress-strain characteristics and strength indicators were determined. The workability of the laminate produced was also tested using milling technology. The tests were carried out using five carbide shank cutters for different purposes. The cutters with the geometry used in the processing of polymer materials and composites, general purpose cutters, and cutters with the geometry for aluminum and with different numbers of blades were analyzed. In order to obtain information on the workability of the prepared material, machining tests with different configurations of technological parameters were carried out. For each cutter, the effect of cutting speed and feed rate on the quality of the machined surface was tested. Due to the small thickness of the laminate, the machining was carried out in one pass, as a result of which the cutting depth in each case was constant. Changes in cutting speed and feed were evenly distributed over five levels. The quality of machining was assessed in two stages. The first stage included a visual assessment of the machined surface, involving a preliminary qualification of the machining parameters. The criterion was the amount of chips, frays, burrs, etc., remaining after machining that adhered to the surface. The next stage was the measurement of the geometric structure of the surface, during which the roughness parameters were analyzed using an optical microscope with a roughness analysis attachment. Quantitative analysis was performed for the best quality composite surfaces from each measurement series. The studies showed a dependence of the quality of machining on the technological parameters used. High tool speed, regardless of the type, especially at low feed, led to the sticking of chips, which had a very delicate form. In turn, low tool speed and high feed, due to the chip thickness, favored the formation of burrs. Machining with different types of tools showed that the process progresses better for tools with sharp blade geometry. Machining with a regular and polished cutter did not show any differences in the scope of the process progress.

Surface Topography Analysis of BK7 with Different Roughness Nozzles Using an Abrasive Water Jet.

This study investigated the effect of abrasive water jet (AWJ) kinematic parameters, such as jet traverse speed and water pressure, abrasive mass flow rate, and standoff distance on the surface of BK7. Nozzle A reinforced with a 100 nm particle-sized coating of titanium alloy has more wear resistance compared to Nozzle B coated with nothing. Through analysis of variance and measurement of BK7 surface quality, it is concluded that the grooving and plowing caused by abrasive particles and irregularities in the abrasive water jet machined surface with respect to traverse speed (3, 7.2, 7.8, and 9 mm/min), abrasive flow rate (7 L/min and 10 L/min, 80 mesh) and water pressure (2 and 3 MPa) were investigated using surface topography measurements. The surface roughness (15.734 nm) of BK7 results show that a nozzle coated with titanium alloy has more hardness, which protects BK7 undamaged and super-smooth. The values of selected surface roughness profile parameters-average roughness (Ra) and maximum height of PV (maximum depth of peak and valleys)-reveal a comparatively smooth BK7 surface in composites reinforced with 2% titanium alloy in the nozzle weight at a traverse speed of 7.8 mm/min. Moreover, abrasive water jet machining at high water pressure (3 MPa) produced better surface quality due to material removal and effective cleaning of lens fragmentation and abrasive particles from the polishing zone compared to a lower water pressure (2 MPa), low traverse speed (5 mm/min), and low abrasive mass flow rate (200 g/min).

Моделирование и оптимизация процесса накатывания роликом AL6061-T6 для достижения минимального отклонения от круглости, минимальной шероховатости поверхности и повышения ее микротвердости

Introduction. Roller burnishing is one of the most common methods of improving the surface quality of parts, wear resistance, microhardness, and corrosion resistance. The process involves compressing and smoothing the workpiece using the pressure of a hardened roller. It is often used to improve part performance and lifespan in sectors including automotive, aerospace, and medical equipment manufacturing. The literature reviewed shows that the roller burnishing process effectively improves the overall surface quality and hardness of the workpiece. In addition, roller burnishing is considered as an affordable method to enhance the functionality and robustness of machined parts by reducing the likelihood of surface defects such as like scratches and cracks. However, very few studies have been reported on the modeling and optimization of roller burnishing of Al6061-T6 for minimum surface roughness, better microhardness, and roundness. The methods of investigation. In the current work, roller burnishing of Al6061-T6 is modeled and optimized for superior microhardness, roundness, and minimal surface roughness. Under dry-cutting conditions, the performance of roller burnishing of Al6061 specimens is assessed in terms of process factors such as cutting speed, feed, and number of passes. Mathematical models to predict the surface roughness, microhardness, and deviation in roundness are developed based on the experimental results. Results and Discussion. The coefficient of correlation for the developed models is found to be close to 0.9, which indicates that it can be reliably used to predict and optimize the roller burnishing of the Al6061-T6. According to this study, the use of the following cutting parameters leads to the lowest variation in roundness (4.282 µm), the better microhardness (119.2 Hv), and the lowest surface roughness (0.802 µm): cutting speed 344 rpm, feed 0.25 mm/rpm and four passes. Further, the study reveals that increasing the number of passes (beyond four) does not significantly improve the surface roughness or microhardness. However, it does lead to a slight increase in the roundness deviation. Therefore, in order to achieve optimal results, it is recommended to use a maximum of four passes during roller burnishing of Al6061 specimens under dry cutting conditions. These results imply that roller burnishing can effectively improve the overall quality and hardness of the workpiece surface. In addition, roller burnishing is considered as an affordable method to increase the functionality and robustness of machined parts by reducing the likelihood of surface defects like scratches and cracks.

Magnetic field assisted blasting erosion arc machining (M-BEAM): A novel efficient and quality improved machining method for Inconel 718

Electrical Arc Machining (EAM) presents an efficient technique for processing difficult-to-cut materials such as Inconel 718. However, despite its extremely high machining efficiency, the high energy density in machining makes it difficult to achieve a desirable surface quality that can be compatible with the subsequent cutting process. To solve this issue, this study explores the application of a magnetic field to enhance the performance of Blasting Erosion Arc Machining (BEAM), namely Magnetic Field assisted BEAM (M-BEAM). It leads to an increased Material Removal Rate (MRR) and reductions in both the Tool Wear Ratio (TWR) and the Surface Roughness (represented by Sa) with the increasing magnetic field strength, attributed to the improvements of the arc deflection and molten metal expelling. Moreover, the electromagnetic force is positively correlated with the discharge energy, which can further improve the machining performance of BEAM, especially when the hydrodynamic force is hard to act at large discharge energy. The MRR and Sa are enhanced and reduced by 14.52 % and 41.86 % respectively due to the stronger control effect at large energy. After multi-objective optimization, the optimized MRR in M-BEAM achieves a 9.22 % enhancement and Sa also decreases by 25.96 % and 60.61 % in the roughing and finishing process. This advancement also elevates machining precision as well as mitigates defects such as debris adhesion, overburning, and cracks. Moreover, the recast layer is significantly reduced by 88.59 % and 89.96 %. Consequently, M-BEAM promises extensive applications in aerospace industries for machining Inconel 718 and even for other difficult-to-cut materials with high efficiency and quality.

Study on the fatigue performance and Residual Stress of subsurface fluid flow of 2519a aluminum alloy based on water jet peening

In this study, the influence mechanism of water jet (WJ) strengthening on the surface integrity and fatigue properties of 2519 aluminum alloy was investigated by using finite element software Abaqus 2023 and fatigue analysis software Fe-safe. The effects of jet velocity and transverse velocity on the development of surface roughness and residual stress in different strengthening stages were studied, and the fatigue properties of WJ strengthened samples were analyzed by Fe-safe fatigue software. Finally, the fatigue life and fracture morphology of WJ strengthened specimens were analyzed by fatigue test, and the accuracy of finite element analysis was verified. Results indicate that surface roughness post-WJ enhancement displays a “W” shaped distribution, positively correlated with jet velocity. Conversely, increased roughness negatively correlates with higher traverse speeds, with optimal values recorded between 400 and 600 mm/min at WJ-290 mm/s, ranging from 1.10322 to 1.41167 μm. Additionally, the study reveals that maximum residual compressive stress during the WJ-Ip phase correlates positively with jet velocity, peaking at 302 MPa for WJ-290 mm/s. The research also notes that while higher jet velocities enhance residual compressive stress, they simultaneously elevate surface roughness, potentially introducing damage and increasing the variability of stress magnitudes. The study underscores the necessity of meticulously calibrating WJ parameters to enhance surface quality effectively while minimizing adverse effects. This balance is critical to optimizing the treatment process and achieving desired material properties.

Robotic grinding and polishing of complex aeroengine blades based on new device design and variable impedance control

Owing to the advantages of good flexibility and low cost, robots are gradually replacing manual labor as an effective carrier for the grinding and polishing of aeroengine blades. However, the geometric features of blades are complex and diverse, and the contour accuracy and surface quality requirements are high, making the robotic grinding and polishing of blades still a challenging task. For this reason, this article first designs a new device by integrating different tools, which can achieve full-feature grinding and polishing of blades. Then, in order to improve the accuracy and stability of force tracking during the robotic grinding and polishing processes, a variable impedance control approach with simultaneous changes in stiffness and damping and parameter boundaries is proposed. Finally, the superiority of the proposed variable impedance control method is verified by comparative experiments on surface tracking. In addition, by combining the device with the variable impedance control method in the robotic grinding and polishing experiments of an aeroengine blade, their effectiveness in practical situations is confirmed.

An efficient detector for detecting surface defects on cold-rolled steel strips

Surface-defect inspection is vital in cold-rolled steel-strip manufacturing, given the complexities of production environments and the high speeds involved. Further, the defects on cold-rolled steel strips are often characterized by their small size, diversity of types, and similarities among different types, posing significant challenges in balancing detection accuracy and efficiency. To address the challenges, we designed a detector based on You Only Look Once version 5 (YOLOv5) to achieve precise detection of surface defects on cold-rolled steel strips. First, a dataset containing seven types of defects was curated, named the Cold-Rolled Steel Defect Dataset (CR7-DET). Next, a feature-extraction network based on residual-like connections within a single residual block (Res2net) was developed to enhance the model’s feature-extraction capability, alongside introducing a multi-head attention module to focus on key information features. To reduce the information loss during feature fusion, we established an adaptive feature-fusion Path Aggregation Network (aff-PAN), which was optimized by designing a lightweight adaptive down-sampling module (LAD) to increase the sensory-field implementation of feature fusion. The ghost convolution effectively reduced the number of parameters and increased the speed without affecting the model’s performance. Finally, experiments were conducted on our CR7-DET and a public dataset (GC10-DET). With a reduced parameter count of 6.85 million, our model achieved a mean average precision(mAP) of 87.6% on CR7-DET and 79.7% on GC10-DET. The experimental results demonstrated that our model achieved a balance between detection accuracy and inference efficiency. The model has the potential to reduce scrap rates caused by defects and improve the overall surface quality of cold-rolled steel strips.

Digital twin-driven senseless cutting force monitoring and vibration stability control of a rotary ultrasonic machining system

Rotary ultrasonic machining (RUM) emerges as a superior technique for processing difficult-to-cut materials due to its capacity to improve machining efficiency and surface quality. The tool vibration amplitude and its stability in the machining process are critical to guarantee the performance of RUM. However, due to the lack of a reliable status monitoring and control method, the operator cannot identify and solve the problem of vibration loss in time, greatly restricting the wider industrial application of RUM. This study proposes a digital twin-driven method to monitor and control the status of the RUM system. A twin model of the RUM system is first established, which describes the relationship among the driving electrical variables, the vibration amplitude, and the external load when the system works at the resonant state. A frequency tracking algorithm using the electrical signals is used to make the RUM work at the resonant state, which ensures the twin model is always aligned with the physical RUM system. And the actual vibration amplitude and the external load can be derived in real time. Then, a voltage-adjusting method is proposed to make the actual vibration amplitude approach its idle value and the cutting force is updated. Applying the above route, the cutting force and vibration amplitude can be in-process monitored without extra sensors, and vibration stability can be improved. Finally, loading and drilling experiments are carried out to verify the efficacy of the proposed digital twin-driven method. The experimental results demonstrate that the proposed method can monitor the cutting force accurately (average deviation during the whole drilling process <10 %) without using any additional force sensor like dynamometer, and ensure the stability of vibration amplitudes under load (amplitude variation <10 %), enabling the RUM system to become intelligent.

Finite element analysis and experimental study on the cutting mechanism of SiCp/Al composite in laser ultrasonic elliptic vibration turning

SiCp/Al composites have excellent material properties and are increasingly being used in the aerospace, military, and electronic packaging industries. However, the inhomogeneity and non-conductivity of conventional turning (CT) results in poor material surface quality and high cutting forces, which seriously hinder the application of particlereinforced metal matrix composites. The thermal softening property of laser-assisted turning (LAT) and the intermittent cutting property of two-dimensional (2D) ultrasonic elliptical vibratory turning (UEVT) offer unique advantages in improving material surface quality. Therefore, a novel laser ultrasonic elliptical vibratory turning (LUEVT) machining technique is proposed to improve the machining of SiCp/Al composites with two different volume fractions. The effect of highfrequency intermittent machining on material processing was further investigated by adjusting the pulsed laser power. Finite element modelling was used to predict the machining state, surface roughness, and chip morphology between the workpiece and the PCD tool. The effects of varying the machining parameters during the experiment on the two composites were analysed. The results showed that the LUEVT of 25 % and 45 % SiCp/Al composites were reduced by 39.3 % and 30.7 % respectively compared to the CT cutting forces. The experiments verified the consistency of the surface roughness and chip morphology with the finite element simulation results. The stability of the cutting force during the cutting process is also improved, as the material removal process mainly takes the form of small particle fragmentation and matrix encapsulation.

Corrosion inhibitors in H2O2 system slurry for Ru based barrier layer Cu interconnect chemical mechanical polishing and optimization

Ruthenium (Ru) has the advantages of low resistivity, high thermal stability, and good adhesion and wettability, making it an important solution for breaking through the 14 nm process as a new barrier layer material for multilayer copper interconnect. The purpose of copper (Cu) interconnect Ru-based barrier layer chemical mechanical polishing (CMP) is to obtain a highly flat surface, which not only includes the ideal Ru removal rate and selectivity of the Cu/Ru removal rate, but also inhibition of Cu corrosion. In this article, the corrosion inhibition mechanism of environmentally friendly and highly water-soluble inhibitor 5-methylthio-1 H-tetrazole (MTT) on Cu was studied. The inhibitory effect of MTT on Cu was analyzed through static etching rate testing, electrochemical experiments, and surface characterization. A systematic test was conducted on the planarization performance of the optimized polishing slurry. The corrosion inhibition mechanism of MTT on Cu was revealed through quantum chemical calculations and XPS testing. The experimental results show that the corrosion inhibitor MTT can effectively improve the surface quality of Cu. Quantum chemical calculations and experimental results indicate that MTT can be adsorbed on the surface of Cu through both physical and chemical methods, forming a dense passivation film, thereby inhibiting the corrosion of Cu. The optimized ratio of Ru-based barrier layer CMP polishing slurry was 5 wt% SiO2, 0.15 wt% H2O2, 20 mM ethylenediamine (EDA), 5 mM K4Fe(CN)6, and 2000 ppm MTT, resulted in the Cu/Ru removal rate selectivity of 1:1.18 and the Cu/Ru corrosion potential difference of 3 mV. The average correction values for dishing and erosion on the test pattern wafer of the Ru barrier layer were 355 Å and 280 Å, respectively. The results of this study indicate that MTT is an effective copper corrosion inhibitor in alkaline H2O2-based polishing slurry, providing meaningful references for Ru-based barrier layer copper interconnect CMP.

Use of RSM desirability approach to optimize WEDM of mild steel

Wire Electrical Discharge Machining (WEDM) is a non-traditional material removal process commonly used for precision machining of hard materials such as super alloys, ceramics, carbide, and composite materials. Optimization of process parameters is critical for improving machining efficiency and achieving the desired surface quality. Response Surface Methodology (RSM) systematically optimizes process parameters and investigates their impact on machining performance. WEDM control parameters such as pulse ON Time (TON) (50–60 μs), pulse OFF Time (TOFF) (25–34 μs), gap voltage (VG) (25–250 V), peak current (IP) (1–6 A), and dielectric flow rate (Df) (1–3 LPM) are optimized to reduce surface roughness (SR) and taper angle (TA) while increasing material removal rate (MRR) during the machining of Mild Steel. The optimal parameters are TON as 53 μs, TOFF as 28 μs, IP as 2.65 A, VG as 185 V, and Df as 1.5 LPM. The experimental findings are presented to demonstrate the usefulness of the proposed strategy in optimizing WEDM control parameters. The validation test was conducted under optimal conditions and the results were reported. The manufacturing industries can use RSM optimization in the manufacturing domain.

Evaluation of the Influence of the Tool Set Overhang on the Tool Wear and Surface Quality in the Process of Finish Turning of the Inconel 718 Alloy.

The work deals with the influence of the reach of the applied tool holder on the edge wear, dimensional accuracy and surface quality defined by the topography as well as the roughness of the machined surface. The research has been conducted on specimens made of Inconel 718 in the configuration of sleeves, within the scope of finish turning with constant cutting parameters, vc = 85 m/min; f = 0.14 mm/rev; ap = 0.2 mm. The material under machining has undergone heat treatment procedures such as solution treatment and precipitation hardening, resulting in a hardness of 45 ± 2 HRC. Two kinds of turning holders have been used with the reaches of 120 mm and 700 mm. The tools are intended for turning external and internal surfaces, respectively. The tests have been conducted using V-shaped cutting inserts manufactured by different producers, made of fine-grained carbide with coatings applied by the PVD (Physical Vapour Deposition) and CVD (Chemical Vapour Deposition) methods. The edge wear has been evaluated. The value of the achieved diameter dimensions has also been assessed in relation to the set ones, as well as the recorded values of surface roughness and the surface topography parameters have also been assessed. It has been determined that the quality of the manufactured surface evaluated by the 2D and 3D roughness parameters, as well as the dimensional quality are influenced by the kind of the applied tool holder. The influence is also visible considering the edge wear. The smallest values of the deviations from the nominal dimensions have been obtained for the coated inserts of the range of higher abrasion resistance (taking into account information from the producers). The obtained results show that in predicting the dimensional accuracy in the process of turning Inconel 718 alloy with long-overhang tools, one should consider the necessity of correction of the tool path. Taking into account the achieved surface roughness, it should be pointed out that not only the kind of the tool coating but also the character of its wear has a great influence, particularly, when a long cutting distance is required.