Surface Modification Process Research Articles

Comprehensive review of PEO coatings on titanium alloys for biomedical implants

Titanium and its alloys are commonly utilized in the biomedical field for fabricating orthopedic and dental implants due to their favorable mechanical, chemical, and biological properties. However, titanium alloys exhibit limited or no bioactivity, necessitating the application of surface functionalization techniques to enhance their functional characteristics suitable for biomedical applications. Plasma Electrolytic Oxidation (PEO) treatment is a simple and versatile surface modification process for valve metals that can add superior osseointegration and bioactive properties to titanium and its alloys. Therefore, this review aims to summarize the mechanisms involved in obtaining porous coatings on the surface of titanium alloys using the PEO method, as well as to outline some of the physicochemical and biological properties of the resulting surfaces. The article discusses the mechanisms of action of bactericidal agents such as copper, silver, and zinc, commonly incorporated into PEO coatings. Finally, the study concludes by discussing remaining challenges and future perspectives that need to be addressed.

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process.

Hydrophobic Coating on Metal Matrix Composites

Abstract: The combination of traditional aluminum metal matrix composites (MMCs) with innovative reinforcement materials offers promising avenues for enhancing material properties and expanding application domains. In this study, aluminum matrix composites reinforced with ZrB2 (zirconium diboride) particles were fabricated using a stir casting technique. The addition of ZrB2 to the aluminum matrix aimed to improve mechanical strength, wear resistance, and thermal stability. Following fabrication, the resulting composite specimens were subjected to a surface modification process involving the application of a superhydrophobic coating. The superhydrophobic coating, characterized by its extreme water repellency and self-cleaning properties, was applied to the surface of the aluminum-ZrB2 composites using a spray-coating method. The coating material consisted of a hydrophobic compound integrated with nanostructured particles, engineered to achieve a hierarchical surface morphology that mimics natural superhydrophobic surfaces. The coated specimens were evaluated for their water repellency, contact angle measurements, and durability under various environmental conditions. The results of this study demonstrated that the combination of aluminum metal matrix composites with ZrB2 reinforcement, coupled with the application of a superhydrophobic coating, yielded surfaces with exceptional water-repellent properties. The coated composites exhibited high contact angles and low water adhesion, indicative of their superhydrophobic nature. Furthermore, the durability tests revealed the robustness of the coating against mechanical abrasion and environmental exposure. Overall, the integration of aluminum-ZrB2 composites with a superhydrophobic coating holds significant promise for applications requiring water-resistant surfaces, suchas aerospace components, marine structures, and outdoor equipment. This researchcontributes to advancing the development of multifunctional materials with tailoredsurface properties, paving the way for improved performance and longevity in diverse engineering applications

Post‐combustion carbon dioxide adsorption of concurrent activated and surface modified palm kernel shell‐derived activated carbon

AbstractThis research applied a concurrent activation and surface modification (CAM) process to synthesize palm kernel shell‐derived activated carbon (PKSdAC) to obtain CO2 affinity surface functionalization. The CAM process is a simplified activated carbon activation process that is cost‐effective. The CAM process used in this study integrates sulphuric acid activation and barium chloride functionalization. The formation of barium sulphate is targeted to incorporate barium through a reduction process with carbon‐containing material at elevated temperatures into PKSdAC to obtain basic metal surfaces functional group for chemical adsorption. The optimal temperature for CAM‐PKSdAC CO2 adsorption performance was at 40–60 °C, established through temperature‐programmed desorption of CO2 (TPD‐CO2) analysis. The CAM‐PKSdAC adsorption performance was tested using a lab‐scale adsorption system. The bed CO2 content was determined using gas chromatography coupled with a thermal conductivity detector (GC‐TCD) by manual syringe injection. CAM‐PKSdAC exhibited a high CO2 adsorption capacity of 0.89 mmol g−1 from TPD‐CO2, and 1.91 mmol g−1 from GC‐TCD at 40 °C and 1 bar. It showed comparable CO2 adsorption capacity to conventional surface modified‐activated PKSdAC (1.96 mmol g−1) while higher than commercial and modified ACs (1.14–1.60 mmol g−1), but lower than potassium hydroxide modified ACs (1.81–2.10 mmol g−1) at 40 °C and 1 bar. Barium promoted chemisorption of CO2 as supplementary reaction, which increases adsorption capacity. The non‐linear Dubinin Radushkevich model strongly correlates with the experimental adsorption data for CAM‐PKSdAC adsorption, indicating the physisorption process via micropore filling on CAM‐PKSdAC. CAM‐PKSdAC showed moderate reusability with negligible variation in adsorption capacity after 10 adsorption–desorption cycles. © 2024 Society of Chemical Industry and John Wiley & Sons, Ltd.

Insight into the effective electrocatalytic sulfide removal from aqueous solutions using surface oxidized stainless-steel anode and its desulfurization mechanism

The electrochemical oxidation of hydrogen sulfide (H2S) has shown its potential for the real application of H2S emission control in wastewater treatment. In this study, a surface corrosion treatment of stainless steel (SS) was optimized by regulate Ni content in the oxide film on the SS AISI 304 surface for sulfide removal. The X-ray photoelectron spectroscopy and linear sweeping voltammetry results indicated a higher Ni content in the oxide film of surface-oxidized stainless steel (SOSS) attributed to a higher sulfide removal potential. Sulfide removal experiment results showed that SS-150 (with 150 s anodic pretreatment) anodes achieved the highest Ni content of 69% with the best sulfide removal efficiency, i.e., 97% within 48 h, which increased by 20% compared to the untreated SS. This study also demonstrated a strategy for in situ removal of deposited sulfur on the anodes by cathodic treatment at −0.38 V vs. RHE to alleviate the common issue of sulfur passivation. Density functional theory (DFT) calculation revealed that NiOOH was the major active species in SS-150 oxide film for a faster sulfide removal rate. The study developed a SS surface modification process for Ni content regulation that contributed to better sulfide removal efficiency.

Novel surface modification strategies for enhanced CeO2 nanoparticle dispersion and suspension stability

This work aims to modify the surface characteristics of cerium oxide (ceria, CeO2) nanoparticles using different surface modification strategies for improved CeO2 nanoparticle dispersion and suspension stability. Analysis and discussion were conducted on the two surface modification processes used by a cationic surfactant like hexadecyl cetyltrimethylammonium bromide (CTAB) and a silane agent like tetraethyl orthosilicate (TEOS). Untreated CeO2 was used as reference material. The dispersion effect of surface-modified CeO2 nanoparticles at different pHs was determined by zeta potential measurements. Fourier transform infrared spectroscopy (FT-IR), X-ray photoelectron spectroscopy (XPS), Particle size analysis (PSA), Thermogravimetric analysis (TGA), Scanning electron microscope (SEM), Brunauer–Emmett–Teller analysis (BET), and X-ray diffraction (XRD) were used to confirm the efficacy of the surface modification of CeO2 nanoparticles. First, the results obtained in this experimental work demonstrate that both advanced modifications greatly enhance the dispersion and suspension stability of surface-modified CeO2 nanoparticles in comparison with untreated CeO2 nanoparticles. Second, it is also shown that the surface-modified CeO2 nanoparticles obtained through a silanization surface process with TEOS silane agent had a better dispersion effect and dispersion stability than the surface-modified CeO2 nanoparticles obtained by surface modification with CTAB cationic surfactant. These results can help better understand how advanced surface modifications can assist the application of well-dispersed CeO2 nanoparticles in technological applications.

Porous titanium alloys for medical application: Progress in preparation process and surface modification research

Excellent mechanical properties and biocompatibility are the most sought-after attributes in biomedical materials for the regeneration of damaged tissues. However, conventional dense titanium alloys possess a modulus significantly higher than that of human tissues, leading to potential stress-shielding effects. Medical porous titanium alloys can reduce the elastic modulus of the material, promote tissue fixation and vascular regeneration, and improve the suitability for human tissue properties. With the continuous development of technology, the preparation process of porous titanium alloys has undergone a series of multifaceted transformations and improvements in the aspects of powder sintering, fiber preparation, and additive manufacturing processes, and its structural characteristics and mechanical properties are constantly evolving in a controllable direction. Alongside the enhancement of the material’s mechanical properties through porous design, optimization of the properties at the implant-tissue interface also leads to improved antimicrobial and osteogenic properties of porous titanium. Due to the complex internal structure of porous titanium alloys, surface modification is mainly carried out in fluid media, which is realized by morphological modification and the introduction of functional substances. Over time, the surface modification of porous titanium alloys for medical applications has progressed from morphological modification and introduction of chemical composition to the loading of bioactive substances. This evolution aims to enhance safety and efficiency in the use of these materials. This paper reviews the preparation and surface modification processes of porous titanium alloys for medical use and summarizes the advantages, disadvantages, and influencing factors among different processes, with a view to providing new ideas for the development of porous implants for medical use.

Deep Learning and Image data-based surface cracks recognition of laser nitrided Titanium alloy

Laser nitriding, a high-precision surface modification process, enhances the hardness, wear resistance and corrosion resistance of the materials. However, laser nitriding process is prone to appearance of cracks when the process is performed at high laser energy levels. Traditional techniques to detect the cracks are time consuming, costly and lack standardization. Thus, this research aims to put forth deep learning-based crack recognition for the laser nitriding of Ti–6Al–4V alloy. The process of laser nitriding has been performed by varying duty cycles, and other process parameters. The laser nitrided sample has then been processed through optical 3D surface measurements (Alicona Infinite Focus G5), creating high resolution images. The images were then pre-processed which included 2D conversion, patchification, image augmentation and subsequent removal of anomalies. After preprocessing, the investigation focused on employing robust binary classification method based on CNN models and its variants, including ResNet-50, VGG-19, VGG-16, GoogLeNet (Inception V3), and DenseNet-121, to recognize surface cracks. The performance of these models has been optimized by fine tuning different hyper parameters and it is found that CNN base model along with models having less trainable parameters like VGG-19, VGG-16 exhibit better performance with accuracy of more than 98% to recognize cracks. Through the achieved results, it is found that VGG-19 is the most preferable model for this crack recognition problem to effectively recognize the surface cracks on laser nitrided Ti–6Al–4V material, owing to its best accuracy and lesser parameters compared to complex models like ResNet-50 and Inception-V3.

Effect of temperature on oxidation during boriding of Ni-Hard 4

Abstract Ni-Hard 4, also known as white cast iron, is widely used in many applications that demand high mechanical strength. This material is recognized for its ability to withstand challenging conditions. In this study, surface modification processes, particularly boriding, were carried out on the material. Boriding is considered an effective process for enhancing the mechanical strength of a surface. While there are various methods for performing boriding, the pack-boriding method was chosen for this study. This method was applied in a typical heat treatment furnace. Ni-Hard 4 specimens were subjected to different combinations of temperature (1000–1200 °C) and 4 h duration, resulting in a total of three distinct samples. Subsequently, the microstructure, hardness, and chemical composition of the boride layers formed on the material’s surface were meticulously examined. As a result of the detailed analysis, it was determined that if the boriding process was carried out in a furnace without controlled atmosphere, high temperature oxidation started on the surface of Ni-Hard 4, and in this case it increased in parallel with the increase in temperature.

In-depth characterization of FSP-enhanced aluminum metal matrix: A study in materials modeling and computational techniques

The production of aluminum metal-matrix composites (AMM) involves reinforcing aluminum and its alloys with various powders, with the addition of ceramic reinforcements expected to enhance the mechanical properties, corrosion resistance, and the wear resistance behaviour. However, suboptimal production techniques often result in reduced ductility and toughness when incorporating non-deformable ceramic reinforcements. To address this, friction stir processing (FSP) was employed as a novel surface modification process, using Ti–6Al–4V particles to reinforce 1100 Aluminum Alloy. Microstructures of the composites were analyzed through Scanning Electron Microscopy (SEM), revealing a mean particle size of 2.69 × 103μm for a one-pass FSP at X155 magnification. Notably, the two-pass sample with a particle size of 2.69 × 103μm displayed fewer spherical structures and more irregular structures, indicating a change in the flow mechanism. The three-pass sample exhibited a mean particle size of 1.36 × 103μm, indicating a more uniform distribution and significant size reduction compared to one and two passes.Additionally, a torque-based predicted heat-input analysis indicated that higher temperatures resulting from increased heat production rate and power input led to a decrease in the torque with rising rotational speed. The threaded taper tool generated more heat, potentially facilitating plastic deformation. Finite Element Analysis (FEA) using ABAQUS predicted how this heat affected composite quality, closely aligning with experimental data, with less than a 10 °C difference between processing temperatures in experimental and simulated data. The peak temperature increased as the tool rotated at various tool speeds in line with the projected temperature history of FSP. This study is a significant contribution to enhancing aluminium metal matrix composite through the FSP technology.

The Influence of the Chemical Composition of Flax and Hemp Fibers on the Value of Surface Free Energy.

The article presents the exploration of flax and hemp fibers' surface free energy depending on the chemical composition of the fiber, which is closely related to the plant variety and the method of extracting the fiber. For this purpose, tests of the surface free energy (SFE), evaluation of the percentage content of individual fiber components and FTIR analyses were conducted. The research was carried out with the use of fibrous materials prepared in three different ways: 1. To analyze the effect of subsequent stages of flax fibers refining process on chemical composition and SFE, 2. to explore the dependence of fiber SFE on hemp variety, the water-retting hemp fibers were used, 3. To evaluate the influence of the retting method of hemp fibers BIAŁOBRZESKIE variety on SFE, the fibers extracted with the use of dew and water retting were used as the research material. The study confirmed that the content of individual components in the fiber influenced its sorption capacity and therefore determined its hydrophilic properties. The values of Pearson's linear correlation coefficients determined in the statistical analysis proved that the surface free energy was strongly correlated with the content of individual components in the fibers. Understanding the wettability characteristics of bast fibers will allow modeling the properties of products made of these fibers and designing surface modification processes in order to obtain specific functionality of textile products, depending on their intended utilization.

Surface Modification of Nanopores in an Anodic Aluminum Oxide Membrane through Dopamine-Assisted Codeposition with a Zwitterionic Polymer.

Surface modification through dopamine-assisted codeposition with functional zwitterionic polymers can provide a simple and one-step functionalization under ambient conditions with robust and stable dopamine-surface interactions to improve the hydrophilicity of nanoporous membranes, thereby expanding their applicability to nanofiltration, ion transport, and blood purification. However, a significant knowledge gap remains in our comprehension of the mechanisms underlying the formation and deposition of dopamine/polymer aggregated coatings within nanoscale confinement. This study explores a feasible method for membrane modification through the codeposition of dopamine hydrochloride (DA) and poly(sulfobetaine methacrylate) (PSBMA) on nanopores of anodic aluminum oxide (AAO) membranes. Our findings demonstrate that the aggregated coatings of DA and PSBMA nanocomposites can effectively deposit on the surfaces within cylindrical AAO nanopores, significantly enhancing the hydrophilicity of the nanoporous membranes. The morphology and homogeneity of the nanocomposite coatings within the nanopores are further investigated by varying PSBMA molecular weights and AAO pore sizes, revealing that higher molecular weights result in more uniform deposition. This work sheds light on understanding the codeposition of DA and zwitterionic polymers in nanoscale environments, highlighting a straightforward and stable surface modification process of nanoporous membranes involving functional polymers.

Surface integrity and fatigue behavior of AISI 4340 steel after hybrid laser-ultrasonic assisted ball burnishing process

The final surface modification processes enhance the fatigue strength, wear resistance, and corrosion resistance of the workpiece by improving the surface quality, enhancing the microhardness, generating compressive residual stresses on the surface, and creating favorable changes in the microstructure. In this regard, using processes with different mechanisms is regarded as an optimal method to increase the efficiency of the final surface modification processes. This research seeks to experimentally investigate the hybrid laser-ultrasonic assisted ball burnishing (LUAB) process and its effect on the surface integrity and fatigue strength of 4340 alloy steel. The effect of the process on the sample’s microstructure was evaluated by the images obtained from the optical microscope and SEM. Further, the parameters of mean surface roughness and microhardness, as well as the results of the uniaxial tensile test and fatigue test of the workpiece were evaluated. In the case of using appropriate parameters in the process, the results indicated a 93.38% reduction in mean surface roughness and an increase of surface microhardness by 3.4 times compared to the initial sample. Additionally, the investigation of microstructure revealed the accessibility of homogeneous and refinement martensitic structures without surface melting. The results of uniaxial tensile and fatigue tests indicated a 6.29% increase in tensile strength and a 20.71% increase in the endurance limit of the treated sample (LUAB) compared to the initial sample. Finally, the results also showed a change in the fracture mode in the uniaxial tensile test and a reduction in the final fracture area in the fatigue test.

Facile Preparation of β-Cyclodextrin-Modified Polysulfone Membrane for Low-Density Lipoprotein Adsorption via Dopamine Self-Assembly and Schiff Base Reaction.

A facile method for the immobilization of β-cyclodextrin on polysulfone membranes with the aim of selectively adsorbing low-density lipoprotein (LDL) was established, which is based on the self-assembly of dopamine on the membrane followed by the Schiff base reaction with mono-(6-ethanediamine-6-deoxy)-β-cyclodextrin. The surface modification processes were validated using X-ray photoelectron spectroscopy and attenuated total reflectance Fourier-transform infrared spectroscopy. Surface wettability and surface charge of the membranes were investigated through the water contact angle and zeta potential analysis. The cyclodextrin-modified polysulfone membrane (PSF-CD) showed good resistance to protein solutions, as shown by the measurement of BSA adsorption. The assessment of BSA adsorption revealed that the cyclodextrin-modified polysulfone membrane (PSF-CD) exhibited excellent resistance to protein solutions. To investigate the adsorption and desorption behaviors of the membranes in single-protein or binary-protein solutions, an enzyme-linked immunosorbent assay was employed. The results revealed that the PSF-CD possessed remarkable adsorption capacity and higher affinity for LDL in both single-protein and binary-protein solutions, rendering it a suitable material for LDL apheresis.

Development and Performance Evolution of Medium-Pressure He/SF6/O2-Based Plasma and Wet Chemical Etching Process for Surface Modification of Fused Silica

Development and Performance Evolution of Medium-Pressure He/SF6/O2-Based Plasma and Wet Chemical Etching Process for Surface Modification of Fused Silica

Enhanced mechanical properties and environmental stability of polymer-bonded magnets using three-step surface wet chemical modifications of Nd–Fe–B magnetic powder

This research focuses on the surface modification of Nd–Fe–B magnetic powder to enhance its thermal and oxidation resistance without compromising magnetic properties and to improve adhesion to the polymer binder for enhanced mechanical properties. A three-step surface modification process involving phosphatization treatment, tetraethyl orthosilicate (TEOS) application, and 3-aminopropyltriethoxysilane (APTES) grafting, was applied to the powder, which was then compounded with polyamide 12 and injection-moulded into cylinders and dog-bone-shaped tubes. The resulting magnets exhibited remanence (Br) of 487.6 mT, coercivity (Hci) of 727.7 kA/m, and energy product (BHmax) of 39.3 kJ/m3. The modified magnets demonstrated exceptional corrosion resistance and thermal stability, with less than 5% irreversible flux loss after exposure to hot water, temperature shock, and pressurised steam. Furthermore, the modified magnets displayed significantly higher tensile strength, elongation at break, and elastic modulus with improvements of 62%, 16.7%, and 19.9%, respectively, compared to the non-modified batch. Additionally, the modified batch showed a notable 52% increase in flexural stress during flexural testing. These findings underscore the potential of silane surface modifications in producing injection-moulded permanent magnets based on Nd–Fe–B alloy, extending their shelf life and enhancing their overall performance.

A universal strategy for rapid and scalable surface modification of ultra high molecular weight polyethylene fiber

The high performance UHMWPE fiber usually demonstrates extremely poor surface adhesion with resin matrix. Therefore, improving the interfacial adhesion property becomes one of the toughest challenges faced by UHMWPE fibers. In this study, a simple and universal surface welding strategy is promoted to effectively modifying UHMWPE fiber with improved surface adhesion in a short time. The surface welding manufacturing approach is realized by the controllable Joule heating generated from the high contact resistance and rapid thermal response of the conductive nano-material layer coated on UHMWPE surface, which can locally melt the UHMWPE fiber surface and weld the nano materials on UHMWE with a strong and robust mechanical bonding. Since the whole welding process is simple and lasts only for a few seconds, it can be easily applied to the current industrial UHMWPE fiber and fabric manufacturing, enabling a continuous, fast, efficiency and scalable roll-to-roll UHMWPE surface modification process.

Enhanced Electrostatic Safety and Thermal Compatibility of Special Powders Based on Surface Modification.

Electrostatic accumulation is associated with almost all powder-conveying processes which could bring about electrostatic discharges. In most cases of industrial accidents, electrostatic discharge is proven to be the primary source of ignition and explosion. Herein, a surface modification process of polyaniline (PANI) is proposed to construct highly exothermic special powders, namely, HMX@PANI energetic composites, with low charge accumulation for improving powder electrostatic safety. Pure HMX are encapsulated within the PANI-conductive polymer layer through simple hydrogen bonding. Simulation results demonstrate that the forming process of HMX/aniline structure is a spontaneously thermodynamical process. The resultant inclusion complex exhibits excellent thermal stability, remarkable compatibility and intensive heat release. Importantly, PANI possesses superior electrostatic mobility characteristics because of the π-conjugated ligand, which can significantly reduce the accumulated charges on the surface of energetic powders. Moreover, the modified explosive has a narrower energy gap, which will improve the electron transition by reducing the energy barrier. The electrostatic accumulation test demonstrates that HMX@PANI composites possess a trace electrostatic accumulation of 34 nC/kg, which is two orders of magnitude lower than that of pure HMX (-6600 nC/kg) and might indicate a higher electrostatic safety. In conclusion, this surface modification process shows great promise for potential applications and could be extensively used in the establishment of high electrostatic safety for special powders.

Nanometrology based control: taming radical grafting reactions with attoliter precision.

Precisely controlled micropatterning with organic moieties is a promising route for designing smart surfaces, enabling the development of microsensors and actuators with optimal usage of reactants. Such applications require fine control over the surface modification process, which in turn demands detailed knowledge about the surface modification process. As complex surface kinetics often emerge as a result of even slight modifications of the grafting entity, non-invasive, sensitive and precise closed loop control strategies are highly desirable. In this paper we demonstrate that a nanometrology approach based on quantitative phase imaging (QPI) fulfill all these requirements. We first use the technique to monitor surface photografting kinetics of aryl radicals, comprehensively analyzing the effect of substituents on surface addition reactions. We demonstrate that several aspects of the grafting process are affected in complex ways, rendering open-loop strategies impossible to implement precisely. Then, we show that the operando optical phase signal can be used as a direct feedback, guiding the grafting reaction process. Using relatively simple instrumentation, we demonstrate that general and precise control strategies can be designed and used to control the volume of the grafting material with attoliter precision, in spite of radically different surface modification kinetics spanning several orders of magnitude.

UPGRADING AND SURFACE COATING OF EGYPTIAN WHITE SAND WITH POLYMERS AND SILANES

Egypt is endowed with huge reserves of filler minerals, such as silica sand which form approximately 95% of the Earth's crust. The silica sand industry is used in many fields, such as pharmaceutical practices, chemicals, glass, ceramics, electronics, and photovoltaic industries. The aim of this study is to remove impurities from silica sand and apply surface modification processes to enhance its value for various industrial manufacturing applications. Various processing techniques, including classification, attrition scrubbing, magnetic separation, ultra-fine grinding and surface modification, were conducted throughout the study. The results indicated that attrition scrubbing to the classified size fraction of -0.6 + 0.1 mm was capable of reducing the iron concentration from 0.068% to 0.045%. Utilizing the Box-Behnken design, the optimal conditions for magnetic separation were identified, resulting in a decrease in iron content down to 0.012%. Simultaneously, the silica content increased from 99.05% to 99.76%. The results of ultrafine grinding using an attritor mill revealed that a grinding time of 2 hours is sufficient to reach a size suitable for the coating process. Surface modification of the produced ultrafine sand was conducted using polymers and silanes. The treated sand was characterized using SEM, zeta potential, adsorption density, and FTIR measurements. Notably, hydrophobicity increased, accompanied by an increase in particle size. Simultaneously, the surface becomes flatter, indicating the formation of a thin layer. Consequently, the coated sand proved to be a satisfactory material that met the criteria to be used as a filler in coating and paints.