Surface Roughness Research Articles

Effect of the deposition sequence of Ti and W on the Ni-based Ohmic contacts to n-type 4H-SiC

The paper investigated the deposition sequence-dependent behavior of Ni (50 nm)/Ti (60 nm)/W (60 nm) and Ni (50 nm)/W (60 nm)/Ti (60 nm) Ohmic contacts on n-type 4H-SiC after annealing at 1050 °C for 3 min in Ar atmosphere by in-depth electrical and physical characterization. The contact resistivity of the Ni/Ti/W structure (∼ 8.43 × 10−6 Ω·cm2) was found to be lower than that of the Ni/W/Ti structure (∼ 21.9 × 10−6 Ω·cm2). For the Ni/W/Ti structure, the W layer closer to the contact interface led to an increase in the preferred orientation degree of the δ-Ni2Si (220) plane at the interface, favoring a lower contact resistivity according to previous studies. However, the content and interfacial coverage of δ-Ni2Si is reduced by the WxNiyC phase and the interfacial strain/stress is greatly increased by the WxNiyC phase as well, which ultimately leads to an increase in the contact resistivity. The larger interfacial strain/stress in the Ni/W/Ti structure also results in a rough surface morphology with more microcracks and a large area of delamination. In addition, the shearing strength of Al wire bonding points on the Ni/W/Ti surface is slightly weaker than that on the Ni/Ti/W surface due to the higher surface roughness. The above experimental findings can provide a guideline for further structural optimization of the 4H-SiC Ohmic contacts.

The effect of whitening toothpastes on the color stability and surface roughness of stained resin composite

BackgroundThis study aimed to investigate the effect of whitening toothpastes on the color stability and surface roughness of resin composites stained with coffee and cigarette smoke.MethodsSeventy-two disk-shaped specimens (6 × 2 mm) of suprananohybrid resin composite were randomly divided into two groups and exposed to coffee and cigarette smoke (n = 36). After staining, the samples randomly divided into four groups according to whitening toothpastes and were brushed for 4 min: Opalescence Whitening (OW); Colgate Optic White (COW); Curaprox Black is White (CPX) and, distilled water (control) (n = 9). Color was measured with spectrophotometer at the initial, after staining, and after brushing, and surface roughness was measured with profilometer at the initial and after brushing. A surface morphology analysis was examined using scanning electron microscopy and atomic force microscopy. The obtained data were statistically analyzed. (p < 0.05).ResultsCigarette smoke caused a significantly higher color change than coffee in the resin composite (p < 0.05). Brushing with hydrogen peroxide and silica-containing whitening toothpaste showed significant differences in color change (p < 0.05). The lowest whitening effect was found in activated charcoal-containing toothpaste. While all toothpastes increased the degree of surface roughness of resin composites, the highest roughness was caused by whitening toothpastes containing activated charcoal. (p < 0.05).ConclusionsThe color stability and surface properties of resin composites can be affected by brushing them with whitening toothpaste. The utilization of whitening toothpaste containing hydrogen peroxide can be considered a safe method for increasing the whiteness of discolored resin composites.

Grinding performance of MgF2 ceramics using biomimetic shark fin grinding wheels with different structure parameters

In the field of precision machining, with the popularity of brittle and hard materials such as infrared windows, it has become difficult for conventional diamond grinding wheels to effectively perform high-quality machining. The structuring of traditional diamond grinding wheels using a pulsed laser is a key technology to effectively improve the grinding quality of grinding wheels. In this paper, three new shark fin diamond grinding wheels (SFSGW) with different slot widths are designed based on the excellent drag-reducing and channelizing properties of shark dorsal fins. The grinding performance of traditional grinding wheels (USGW) and SFSGW on magnesium fluoride ceramics was compared. The effects of SFSGW on the surface quality, surface roughness and wheel damage of the workpiece were investigated. The results showed that the surface roughness of ceramics after grinding by SFSGW was reduced by 22.15 % compared with USGW, and the surface quality was better. Proper construction increases the material removal rate of the wheel and improves the wear resistance and service life of the wheel.

3D visualization microscope of TENG contact interface based on astigmatic imaging

The triboelectric nanogenerator (TENG) is a mechanical device that can collect mechanical energy from the contact and separation of different materials. Due to the short distance of charge transfer, the characterization of the micro-contact state under localized stress has become an urgent issue in the study of TENG’s contact electrification mechanism. Most of the contact surfaces of TENG are curved surfaces, and there is a lack of effective means to characterize the contact state of curved surfaces. In this article, a technique based on astigmatic imaging principle is provided to visualize the three-dimensional contact interface of TENG, using polydimethylsiloxane (PDMS) and butyronitrile film with rough surface as TENG. Through this technique, the three-dimensional deformation of its contact interface was observed and the three-dimensional effective contact area was calculated. The comparison of current density generated at different pressing pressures verified that larger contact area leads to higher current density, which applies to the law in 3D contact interfaces as well. Visualizing conformal contact interfaces for TENG provide a powerful tool for analyzing the charge transfer-contact separation phase coordination mechanism, providing a new route approaching larger output efficiency. In addition, this technology offers possibility for characterization of TENG with both-side deformable, which abandons the requirements of the rigid contact surface in the total reflection scheme and is much more applicable for organic TENG.

In-situ SANS study on spatial evolution of coal nanoporosity during pyrolysis at elevated temperatures

The nanopore evolution in coal during pyrolysis is vital for optimizing heat and mass transfer in coal conversion processes. Therefore, small-angle neutron scattering (SANS) was utilized to examine the in-situ changes in the nanopore structures of two subbituminous Chinese coal samples during pyrolysis. The nanopore structures were examined in terms of average pore size, pore volume distribution, fractal dimension by SANS at elevated temperatures. Throughout the pyrolysis process, a consistent enlargement of the average size of nanoscale pores was noted as temperatures escalated, with an expansion ranging from 5.3 to 8.2 nm. Particularly during the devolatilization phase (300–500 °C), there was a marked surge in the volume of large pores, exhibiting a growth rate of about 88.1–150.5%. High-temperature (600–800 °C) conditions facilitated the formation of new and smaller pores. While the surface roughness of nanopores experienced a slight reduction throughout the pyrolysis, the directional growth of the pores maintained an isotropic distribution.

Hard X-ray HfO2/Al2O3 multilayers fabricated by atomic layer deposition

Multilayer is a widely used X-ray optics that can be designed and optimized for specific X-ray application. Atomic layer deposition (ALD) has unique advantage in coating homogeneous ultra-thin film on both flat and curved substrates, which shows great potential in the fabrication of X-ray multilayer with small period. In this paper, hard X-ray HfO2/Al2O3 multilayers on Si substrate prepared by ALD were investigated. The X-ray (0.154 nm) reflectivity of HfO2/Al2O3 multilayer with 3.44 nm period, 60 bilayers is 24 %. Atomic force microscope results show that surface roughness of HfO2/Al2O3 multilayer with total thickness more than 200 nm is slightly larger than that of the substrate. High resolution transmission electron microscope images reveal that amorphous HfO2/Al2O3 material pair forms multilayer with sharp interfaces even for 1.69 nm period. Further study indicates that lowering substrate roughness can reduce the deviation between actual and theoretical X-ray reflectivity. These results demonstrate that for multilayer-based hard X-ray optics, ALD-grown HfO2/Al2O3 is a promising candidate.

ERRATUM (An erratum has been prepared for the following articles in the 33rd volume and 2nd issue of Current Research in Dental Sciences in 2023.)

Erratum An erratum has been prepared for the following articles in the 33rd volume and 2nd issue of Current Research in Dental Sciences in 2023. - In the article titled "Özyurt E, Kurt A. Effect of Different Teas on Surface Roughness of Conventional and Bulk-Fill Composite Resins Beverage Effect on Composite Resins. Curr Res Dent Sci. 2023; 33(2): 84-89", a patient consent draft was added inadvertently, even though there was no participant. - In the article titled "Keleş ZH, Ozan G. Effect of preheating on the microhard- ness and depth of cure of two composite resins with and without BIS-GMA. Curr Res Dent Sci. 2023; 33(2): 79-83", a patient consent draft was added inadvertently, even though there was no participant. - In the article titled “Yamalı AY, Turhan Bal B. Properties and clinical applications of lithium disilicate ceramics. Curr Res Dent Sci. 2023; 33(2): 122-130” although the article titled is a compilation, a patient consent draft was mistakenly included. - In the article titled "Eriş Derkuş F, Yılmaz UN. Demographic Analysis, Diagnosis, and Treatment Methods of Maxillofacial Trauma Cases in the Southeastern Anatolia Region of Turkey: Retrospective and Comparative Analysis. Curr Res Dent Sci. 2023; 33(2): 103-107", it was forgotten to write Dicle University in the sections left as XXX in the Methods section for the sake of article blindness. - Since the study titled “Yıldızer Keriş E. Comparison of Articular Eminence Steepness in Patients With Temporomandibular Joint Disc Disorders. Curr Res Dent Sci. 2023; 33(2): 117-121” was retrospective, patient consent could not be obtained and this information was forgotten to be added. - In the article titled “Şener E, Baksı Şen G. 3D Modelling and virtual planning technologies in dentistry. Curr Res Dent Sci. 2023; 33(2): 131-134” although the article titled is a compilation, a patient consent draft was mistakenly included.

Impact of Silica Sand on Mechanical Properties of Epoxy Resin Composites and Their Application in CFRP–Concrete Bonding

Premature debonding between carbon fiber-reinforced polymer (CFRP) and concrete is a critical issue in structural reinforcement applications, often leading to a significant reduction in the load-carrying capacity of the system. This failure mode is typically initiated by inadequate adhesion at the interface, compromising the effectiveness of CFRP in enhancing the structural performance of concrete elements. To address these issues, this study explores the impact of silica sand on the mechanical and adhesion properties of epoxy resin composites. Initially, this paper investigates the physical and mechanical properties of epoxy resin composites by varying the ratios of silica sand from 0% to 15% by volume. Subsequently, it examines the effectiveness of these composites as sealing materials to enhance the bond strength between CFRP and concrete. Incorporating a 10% silica content improves the mechanical properties of the epoxy resin, with the tensile strength increasing from 29.47 MPa to 35.52 MPa and an elastic modulus from 4.38 GPa to 5.83 GPa. Furthermore, silica sand enhances the adhesion strength between CFRP and concrete, as confirmed by the increase in the pull-out force from 14.21 kN to 18.79 kN. Silica particles improve surface roughness and interlocking, contributing to a better load distribution and stress transfer at the interface. Therefore, silica-filled epoxy resin is an efficient material for CFRP–concrete bonding applications.

Characterization of alane (AlH3) thin films grown by atomic layer deposition for hydrogen storage applications

Alane (AlH3) is an increasingly favored material for hydrogen and energy storage. It has demonstrated its potential in various applications, including rocket fuel, explosives, reducing agents, and serving as a viable source of hydrogen for portable fuel cells. In this study, we present the fabrication, morphology and elemental characterization of an AlH3 thin film grown through atomic layer deposition using a dimethylethylamine alane (DMEAA; AlH3N(CH3)2(CH2CH3)) precursor. The AlH3 thin film exhibited a rough surface with a white-like appearance, forming coarse grains as observed via scanning electron microscopy. X-ray diffraction confirmed the presence of AlH3 and it was compared with an aluminum thin film. Energy-dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy confirmed the presence of pure AlH3 under a very thin aluminum oxide surface layer. Additionally, we propose a dissociation reaction mechanism based on the DMEAA precursor. Our work contributes to the advancement of hydrogen storage materials and energy-related applications that necessitate high hydrogen storage capacity and energy efficiency.

Research on the correlation between roughness parameters and contact stress on tooth surfaces and its dominant characteristics

The contact performance of the tooth surface is a crucial factor affecting the operational lifespan of gears. There is a significant correlation between tooth surface topography and contact stress, as well as fatigue performance. To investigate the influence of different topography parameters on tooth surface contact stress, this paper performs analytical calculations on asperity contacts of rough tooth surfaces based on reconstruction modeling. Through efficient calculations, sufficient correlation analysis data is obtained. The neural network analysis method is used to measure the degree of influence of roughness parameters on tooth surface contact performance. Research on the correlation between micro-topography parameters and maximum contact stress on tooth surfaces, as well as regression analysis, is conducted. The results show that: (1) Considering rough surfaces, the tooth surface contact stress field exhibits two stress peaks in the near-surface layer and sub-surface layer, with a maximum Mises stress increase of up to 30 % compared to a smoother surface. (2) In the case of low roughness (Sa < 0.2 μm), the amplitude of the maximum Mises stress peak in the near-surface layer is close to that in the sub-surface layer. However, as the roughness amplitude increases, the amplitude of the near-surface stress peak increases sharply. (3) Ranking the roughness parameters based on their influence on contact stress, the main parameters characterizing contact performance are identified as Spk, Vmp, and Sq. The peak characteristics of the surface are the decisive factors affecting fatigue extremes, which are stronger than the traditional surface roughness parameter Sq. This paper establishes a direct correlation model between tooth surface topography parameters and contact stress, providing a foundation for simplifying stress calculations considering complex topographies and offering new insights for fatigue-resistant design of tooth surfaces.

Machine learning approaches for predicting mechanical properties in additive manufactured lattice structures

This study examines the mechanical performance of various lattice structures, highlighting the roles of geometric configurations, material properties, and processing conditions. Through advance feature importance analysis and correlation heatmaps, key determinants of mechanical behaviour such as lattice volume, surface roughness, micro-Vickers hardness, and lattice dimensions are identified. The findings reveal that lattice volume and surface roughness are the most significant predictors of displacement, accounting for 24.29 % and 23.71 % of the predictive power, respectively. An inverse relationship between micro-Vickers hardness and displacement emphasizes the need for material hardness optimization in design processes. Scatterplot analyses show complex interactions between surface roughness and micro-Vickers hardness across different conditions. Gyroid and BCC lattices exhibit inverse linear trends, while honeycomb and diamond display distinct linear and horizontal patterns, respectively. These complexities necessitate advanced analytical techniques like machine learning to capture and predict the mechanical behaviours of lattice structures effectively. Machine learning’s ability to handle high-dimensional data and identify non-linear relationships is crucial for accurate predictive models. The study also assesses the impact of post-processing conditions, indicating that stress relief and heat treatment enhances structural integrity and optimizes the material microstructure. This research provides a framework for designing and optimizing lattice structures, guiding informed decisions to meet performance standards.

Assessment of the effect of experimental gel of pregabalin associated with 35% hydrogen peroxide bleaching on bovine dental enamel: an in vitro study.

To assess the effect of bleaching with gel of pregabalin associated with 35% hydrogen peroxide on the mechanical and chemical properties and ultramorphology of dental enamel. Thirty-six (36) specimens of bovine dental incisors were obtained and divided into three groups (n = 12), namely: CG = bleaching with 35% hydrogen peroxide; KFG = bleaching with 5% potassium nitrate and 2% sodium fluoride gel + 35% hydrogen peroxide; and PGG = bleaching with experimental gel of pregabalin + 35% hydrogen peroxide. The specimens were assessed with respect to Knoop microhardness, surface roughness, and colour change, before and after bleaching. They were also assessed using scanning electron microscopy and energy-dispersive spectroscopy after treatments. All groups exhibited an increase in surface roughness and a reduction in Knoop microhardness after the protocols. There was colour change in all groups, with no difference between them. In addition, there were changes in enamel morphology and non-significant loss of calcium and phosphorus. The experimental gel of pregabalin did not influence the action of 35% hydrogen peroxide, yielding results similar to those of the other groups assessed in all the parameters. Therefore, the gel of pregabalin can be an alternative for topical application on the surfaces of the teeth in association with bleaching treatments.

An energy concisions analytical modelling approach with experimental verification for cutting performance assessment in EDM of Ti-based superalloy

Electric discharge machining (EDM) is a stochastic process which is commonly engaged for cutting of Ti-based difficult-to-cut alloys. Experimental investigation in EDM is costly and requires significant amount of time due to the complex nature of the process. Moreover, the energy intensive nature is another criticism associated to this technique. Therefore, this research is focused on developing an energy conscious mathematical model of the process while considering the categorical parameters like type of dielectric, electrode and nano-powder along with pulse time ratio. Taguchi design of experiment (DOE) has been executed for the experimentation. The comprehensive analysis of the findings depicts transformer oil (TO) delivers a remarkable improvement in MRR and SEC in comparison to other dielectric choices. Furthermore, brass electrode stands out for achieving the best surface finish. When it comes to micro-additives, SiC exhibits substantial potential in increasing MRR, and graphite gives a better surface finish. The process has also been effectively modeled which helps to predict material removal rate (MRR), surface roughness (SR) and specific energy consumption with decent precision which is the key contribution of this study. 3D simulation for EDM illustrates that the features of the crater are defined by the liquefied region, whilst the dynamics of the mushy zone play a crucial role in controlling and characterizing the microstructure size progression. The confirmatory experimental results revealed that the use of optimized parametric combinations demonstrate 90.87% improvement in MRR, 52.07% reduction in SR and 96.19% decrease in SEC in contest to the responses’ values obtained at non-optimal settings.

Modulating the Water Contact Angle Using Surface Roughness: Interfacial Properties of Hexagonal Boron Nitride Surfaces.

Hexagonal boron nitride (hBN) exhibits immense potential in H2O-related technologies, but its interaction with H2O, especially on rough surfaces, remains unclear. This study unravels the influence of surface roughness and force field selection on hBN wettability using molecular dynamics (MD) simulations. We leverage quantum mechanical calculations to accurately capture the hBN surface charge distribution and combine it with free energy calculations via MD simulations for the hBN-H2O interfaces. Incorporating surface roughness into the model yields results in close agreement with the experimental contact angle of 66° for H2O using FF-3 force fields, validating the simulation approach. However, this approach can yield an unrealistic water contact angle (WCA) of 0° for FF-2 force fields, highlighting the crucial role of force field selection and realistic surface representations. We further dissect the impact of roughness on the WCA, identifying the individual contributions of electrostatic and Lennard-Jones interactions to the work of adhesion. This research investigates the combined impact of surface roughness and force fields on interfacial properties, providing new possibilities for the advancement and optimization of desalination.

Red and Green Laser Powder Bed Fusion of Pure Copper in Combination with Chemical Post-Processing for RF Cavity Fabrication

Linear particle accelerators (Linacs) are primarily composed of radio frequency cavities (cavities). Compared to traditional manufacturing, Laser Powder Bed Fusion (L-PBF) holds the potential to fabricate cavities in a single piece, enhancing Linac performance and significantly reducing investment costs. However, the question of whether red or green laser PBF yields superior results for pure copper remains a subject of ongoing debate. Eight 4.2 GHz single-cell cavities (SCs) were manufactured from pure copper using both red and green PBF (SCs R and SCs G). Subsequently, the surface roughness of the SCs was reduced through a chemical post-processing method (Hirtisation) and annealed at 460 °C to maximize their quality factor (Q0). The geometric accuracy of the printed SCs was evaluated using optical methods and resonant frequency (fR) measurements. Surface conductivity was determined by measuring the quality factor (Q0) of the SCs. Laser scanning microscopy was utilized for surface roughness characterization. The impact of annealing was quantified using Energy-Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction to evaluate chemical surface properties and grain size. Both the SCs R and SCs G achieved the necessary geometric accuracy and thus fR precision. The SCs R achieved a 95% Q0 after a material removal of 40 µm. The SCs G achieved an approximately 80% Q0 after maximum material removal of 160 µm. Annealing increased the Q0 by an average of about 5%. The additive manufacturing process is at least equivalent to conventional manufacturing for producing cavities in the low-gradient range. The presented cavities justify the first high-gradient tests.

Fiber laser irradiation in chemical solution for micro fabrication: Mechanisms and applications

The laser and electrochemical hybrid machining (LECM) could realize high-efficient and quality processing of difficult-to-cut materials and has become a research topic in microfabrication. However, it was difficult to ensure the stability and efficiency of laser transmission in chemical solutions, and an external voltage and auxiliary cathode should be added. In the present study, a novel fiber laser irradiation in chemical solution (LICS) has been proposed to process microstructures. The surface microstructures and chemical composition of the surfaces processed by LICS, laser irradiation in the ultrapure water, and electrochemical machining were compared. In LICS the materials were removed by laser processing and the following high-temperature gradient induced electrochemical dissolution. The high temperature gradient induced electrochemical dissolution could enhance the MRR and improve the surface quality. LICS can be regarded as a novel LECM process. The machining efficiency of LICS had been improved by 46.2 % compared with that laser irradiation in the ultrapure water, and the proportion of laser-induced electrochemical dissolution was 31.6 % in the LICS process. Further, the effects of laser power, chemical solution concentration, and optical fiber end movement control on the processing of micro grooves were explored, considering the dimension, MRR, and surface roughness. A front gap of smaller than 0.8 mm between the optical fiber end and workpiece was recommended during LICS. The repeated feeding of optical fiber was proposed to improve the depth-to-width ratio of the micro grooves fabricated by LICS. Finally, LICS was used to process microstructures with the controlled profiles on the nickel-based superalloy and titanium alloy workpieces without a recast layer, which holds great potential in surface microfabrication and texturing.

Exploring the effectiveness of polyhydroxy complexing agents in sapphire chemical mechanical polishing: Combining experiments and theoretical calculation

High efficiency and environmentally friendly is the core development in sapphire chemical mechanical polishing (CMP) slurry. Therefore, complexing agents xylitol (XL) and mannitol (MA) were used to enhance the CMP performance of sapphire. The results showed that the addition of 0.2 wt% MA resulted in the optimal MRRs of C-, A- and R-plane sapphire, which are 4.878 µm/h, 2.242 µm/h and 2.731 µm/h, and the surface roughness is 0.274 nm, 0.262 nm and 0.260 nm, respectively. Partical size detection, XPS, FTIR and density functional theory (DFT) calculations results showed that the addition of MA did not alter the mechanical action, but can react with Al(OH)4− to form softer complexes, which improves MRRs and surface quality.

Experimental study of micro-prismatic electrode array wear during EDM and application to the preparation of microcylindrical electrode array

The focus of this study is to compare the wear characteristics of different types of micro-prismatic electrode array during EDM, and to propose a method for preparing microcylindrical electrode array based on micro-prismatic electrode array. Firstly, the characteristic of the micro-prismatic electrode that the front cross-section becomes circular after wear during EDM is clarified, and the wear form of the micro-prismatic electrode is analyzed. Then, the laws of the influence of electrode shape (triangle, square, hexagon), electrode material (pure copper, copper-tungsten alloy, pure tungsten), electrode size (200 μm, 300 μm, 400 μm) on the wear characteristics of the micro-prismatic electrode array, including the length of the wear of each part of the electrodes, the length of the area of the front cross-section that becomes rounded, the consistency of the wear of the electrode array, the machining efficiency, and electrode wear rate are summarized. After that, the process of changing the electrode array from square columns to cylinders using the new method is given, which confirms the feasibility of the method. Finally, the effects of peak current and pulse width on the size, machining efficiency, surface roughness, and surface micro-morphology of micro-cylindrical electrode array prepared by the new method are summarized. This study is of great significance for achieving mass production of microcylindrical electrode array.

Multilayered carbon nanotube/adhesive films for human body signal detection sensors

This paper presents the development of multilayered carbon nanotube (CNT)/adhesive (MLCA) films for human body signal detection sensors using a spray-coating method. The chemical composition, adhesion properties, and electrical conductivity of the films were investigated using various adhesives, with the acrylate-based adhesive (ABA) exhibiting superior performance. The surface roughness, thickness, and electrical properties of the films were characterized, and the tunability was demonstrated by adjusting the number of coating layers. Tribological tests were performed to assess the wear resistance and friction behavior of the films. The adhesion stabilities and conformabilities of the films on various substrates were investigated. The films were combined with polydimethylsiloxane (PDMS) and surfactants to create biocompatible and durable sensors. The PDMS-surfactant composite was characterized, and the MLCA film/PDMS-surfactant-based sensor exhibited excellent stability under deformation and biocompatibility. The impedance behavior, temperature, humidity, and strain-sensing capabilities of the sensors were evaluated. The capability of the sensor to detect vital signs was validated by accurately capturing the electrocardiogram (ECG) waveforms. This study provides valuable insights into the design and fabrication of CNT-based conductive films for human body signal-detection sensors, offering a promising approach for the development of flexible and wearable electronic devices.

Analysis and optimization of machining parameters of AZ91 alloy nanocomposite with the Influences of nano ZrO2 through vacuum diecast process

The magnesium alloy composite is a vital material for automotive applications due to its features like high stiffness, superior damping resistance, high strength, and lightweight. Here, the motto of research is to establish the AZ91 alloy nanocomposite with the exposures of 0, 1, 3, and 5 volume percentages (vol%) of nano zirconium dioxide (ZrO2) particles (50nm) through fluid stir metallurgy route associated with 1x105 Pa vacuum die cast process. Exposures on structural morphology, hardness, and impact toughness of composite are analyzed and identified as the nano AZ91 alloy composite enclosed with 5vol% is homogenous particle dispersion, enhanced hardness (97.6HV), and optimum toughness of 21.2J/mm2. However, composite faces machining difficulties due to the hard abrasive particles with higher hardness, resulting in tool wear. This experiment predicts the optimum mill parameters during the end mill operation of magnesium alloy nanocomposite (AZ91/5vol%) by using a tungsten carbide coated end mill cutter to attain the maximum metal removal rate with low surface roughness and tool wear analyzed via the general linear model (GLM) ANOVA approach. The input conditions for end milling operation vary, like feed rate (0.1 -0.4mm/rev), depth of cut (0.05 -0.2mm), and spindle speed (250-1000rpm). During the ANOVA GLM approach, the L16 design experiment is fixed for further interaction analysis. The results predicted by the depth to cut and feed rate were dominant and played a major role in deciding the tool wear, surface roughness, and MRR.