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The incompatibility of natural fibers with polymer matrices is one of the key obstacles restricting their use in polymer composites. The interfacial connection between the fibers and the matrix was weak resulting in a lack of mechanical properties in the composites. Chemical treatments are often used to change the surface features of plant fibers, yet these treatments have significant drawbacks such as using substantial amounts of liquid and chemicals. Plasma modification has recently become very popular as a viable option as it is easy, dry, ecologically friendly, time-saving and reduces energy consumption. This paper aims to explore plasma treatment for improving the surface adhesion characteristics of sisal fibers (SFs) without compromising the mechanical attributes of the fiber.

A cold glow discharge plasma (CGDP) modification using N₂ gas at varied power densities of 80 W and 120 W for 0.5 h was conducted to improve the surface morphology and interfacial compatibility of SF. The mechanical characteristics of unmodified and CGDP-modified SF-reinforced epoxy composite (SFREC) were examined as per the American Society for Testing and Materials standards.

The cold glow discharge nitrogen plasma treatment of SF at 120 W (30 min) enhanced the SFREC by nearly 122.75% superior interlaminar shear strength, 71.09% greater flexural strength, 84.22% higher tensile strength and 109.74% higher elongation. The combination of improved surface roughness and more effective lignocellulosic exposure has been responsible for the increase in the mechanical characteristics of treated composites. The development of hydrophobicity in the SF had been induced by CGDP N₂ modification and enhanced the size of crystals and crystalline structure by removing some unwanted constituents of the SF and etching the smooth lignin-rich surface layer of the SF particularly revealed via FTIR and XRD.

Chemical and physical treatments have been identified as the most efficient ways of treating the fiber surface. However, the huge amounts of liquids and chemicals needed in chemical methods and their exorbitant performance in terms of energy expenditure have limited their applicability in the past decades. The use of appropriate cohesion in addition to stimulating the biopolymer texture without changing its bulk polymer properties leads to the formation and establishment of plasma surface treatments that offer a unified, repeatable, cost-effective and environmentally benign replacement.

The authors are sure that this technology will be adopted by the polymer industry, aerospace, automotive and related sectors in the future.

This experimental study aims to deal with the improvement of process performance of electric discharge drilling (EDD) for fabricating true blind holes in titanium alloy Ti6Al4V. Micro EDD was performed on Ti6Al4V and blind holes were drilled into the workpiece.

The effects of input parameters (i.e. voltage, capacitance and spindle speed) on responses (i.e. material removal rate, tool wear rate and surface roughness [SR]) were evaluated through response surface methodology. The data was analyzed using analysis of variance and multi-optimization was performed for the optimized set of parameters. The optimized process parameters were then used to drill deeper blind holes.

Blind holes have few characteristics such as SR, taper angle and corner radius. The value of corner radius reflects the quality of the hole produced as well as the amount of tool roundness. The optimized process parameters suggested by the current experimental study lower down the response values (i.e. SR, taper angle and corner radius). The process is found very effective in producing finished blind holes.

This experimental study establishes EDD as a feasible process for the fabrication of truly blind holes in Ti6Al4V.

The purpose of this study is to explore the machining characteristics of electrical discharge machining (EDM) when a tool is fabricated using powder metallurgy. Because pure Cu tools obtained using conventional machining pose problems of high tool wear rate, tool oxidation causes loss of characteristics in tool shape.

The research investigation carried out experiments planned through Taguchi’s robust design of experiments and used analysis of variance (ANOVA) to carry out statistical analysis.

It has been found that copper and chromium electrodes give less metal removal rate as compared to the pure Cu tool. Analytical outcomes of ANOVA demonstrated that MRR is notably affected by the variable’s polarity, peak current, pulse on time and electrode type in the machining of EN9 steel with EDM, whereas the variables pulse on time, gap voltage and electrode type have a significant influence on EWR. Furthermore, the process also showed that the use of powder metallurgy tool effectively reduces the value of SR of the machined surface as well as the tool wear rate. The investigation exhibited the possibility of the use of powder metallurgy electrodes to upgrade the machining efficiency of EDM process.

There is no major limitation or implication of this study. However, the composition of the powders used in powder metallurgy for the fabrication of tools needs to be precisely controlled with careful control of process variables during subsequent fabrication of electrodes.

To the best of the authors’ knowledge, this is the first study that investigates the effectiveness of copper and chromium electrodes/tools fabricated by means of powder metallurgy in EDM of EN9 steel. The effectiveness of the tool is assessed in terms of productivity, as well as accuracy measures of MRR and surface roughness of the components in EDM machining.

This paper aims to investigate the influence of “BroncoCut-X” (copper core-ZnCu50 coating) electrode on the machining of Ti-3Al-2.5V in view of its extensive use in aerospace and medical applications. The machining parameters are selected as Spark-off Time (ST_off), Spark-on Time (ST_on), Wire-speed (S_w), Wire-Tension (WT) and Servo-Voltage (S_v) to explore the machining outcomes. The response characteristics are measured in terms of material removal rate (MRR), average kerf width (KW) and average-surface roughness (SA).

Taguchi’s approach is used to design the experiment. The “AC Progress V2 high precision CNC-WEDM” is used to conduct the experiments with ϕ 0.25 mm diameter wire electrode. The machining performance characteristics are examined using main effect plots and analysis of variance. The grey-relation analysis and fuzzy interference system techniques have been developed to combine (called grey-fuzzy reasoning grade) the experimental response while Rao-Algorithm is used to calculate the optimal performance.

The hybrid optimization result is obtained as ST_off = 50µs, ST_on = 105µs, S_w = 7 m/min, WT = 12N and S_v=20V. Additionally, the result is compared with the firefly algorithm and improved gray-wolf optimizer to check the efficacy of the intended approach. The confirmatory test has been further conducted to verify optimization results and recorded 8.14% overall machinability enhancement. Moreover, the scanning electron microscopy analysis further demonstrated effectiveness in the WEDMed surface with a maximum 4.32 µm recast layer.

The adopted methodology helped to attain the highest machinability level. To the best of the authors’ knowledge, this work is the first investigation within the considered parametric range and adopted optimization technique for Ti-3Al-2.5V using the wire-electro discharge machining.

The author proposed a friction plunge micro-welding (FPMW) method and applied it to column grid array packaging to realize the connection of copper columns without precision molds assisted positioning. The purpose of this paper is to study the flow behavior of the solder undergoing frictional thermo-mechanical action during the FPMW and to determine the source of the solders in the micro-zones with different microstructure characteristics near the solder/Cu column friction interface.

Three kinds of Sn58Bi/SAC305 and SAC305/Pb90Sn composite solder samples were designed to study the flow behavior of the solder during FPMW using Bi and Pb as tracer elements.

The results show that most of the solders in the position occupied by the copper column was softened and plasticized during the welding process and was extruded to side of the copper column, flowing axially, circumferentially and radially along a trajectory similar to a conical spiral line. Under the drive of the tangential friction force and the radial hold-tight force, the extruded out visco-plastic solders fully mixed with the visco-plastic solders on the sides of the copper column, and bonded with the solders that deformed plastically on the periphery, so that a stir zone and a dynamic recrystallization zone finally evolved. The outside plastically deformed solders evolved into a thermo-mechanical affected zone.

The flow behavior of the solder during the FPMW was determined, as well as the source of the solders in micro-zones with different microstructure characteristics.

In the process of conveying the solid–liquid two-phase medium of the centrifugal slurry pump, the wear of the flow-passing parts is an important problem affecting its life and safe operation. Therefore, a numerical investigation on the wear characteristics of the centrifugal slurry pump under different particle conditions was conducted.

A solid-liquid two-phase model based on CFD-DEM coupling is established and used to analyze the flow field and the wear characteristics of the flow-passing parts with different particle densities, volume fractions and sizes.

Particle conditions will affect the pump flow field. To analyze the pump wear characteristics, the wear distribution, wear value and cumulative force laws of flow-passing parts under different particle conditions are obtained. In each flow-passing part, with the increase of particle density, volume fraction and size, the wear area is concentrated and the wear depth increases. Under different particle conditions, the wear is mainly on the volute chamber and the blade pressure surface, and the tangential cumulative force of flow-passing parts is much larger than the normal cumulative force.

An accurate model and a coupled simulation method for predicting the wear of the slurry pump are obtained, and the wear characteristic law can provide a reference for the design of the slurry pump to reduce friction.

Electrical characteristics of transformer oil (TO) have been studied during normal and thermal aging conditions. In this paper, breakdown voltage (BDV), partial discharge (PD), heat transfer results and the physical mechanisms considering the impact of varying the diameter of Al₂O₃ nanoparticles (NPs) have been investigated. Different quantities of the two sizes of Al₂O₃ were added to the oil using a two-step method to determine the positive effect of NPs on the electrical and thermal properties of TO. Finally, the physical mechanisms related to the obtained experimental results have been performed.

The implementation of nanoparticles in this paper was provided by US Research Nanomaterials, Inc., USA. The provided Al₂O₃ NPs have an average particle size of 20–80 nm and a specific surface area of 138 and 58 m²/g, respectively, which have a purity of over 99%. Thermal aging has been done. The IEC 60156 standard has been implemented to calculate the BDV, and a 500-mL volume test cell (Apar TO 1020) has been used. PD test is performed according to Standard IEC 60343, and a JDEVS-PDMA 300 device was used for this test.

BDV tests indicate that 20 nm Al₂O₃ is more effective at improving BDV than 80 nm Al₂O₃, with an improvement of 113% compared to 99% for the latter. The analysis of Weibull probability at BDV indicates that 20 nm Al₂O₃ performs better, with improvements of 141%, 125% and 112% at probabilities of 1, 10 and 50%, respectively. The results of the PD tests using the PDPR pattern also show that 20 nm Al₂O₃ is superior. For the heat transfer test, 0.05 g/L of both diameters were used to ensure fair conditions, and again, the advantage was with 20 nm Al₂O₃ (23% vs 18%).

The effect of Al₂O₃ NP diameter (20 and 80 nm) on various properties of virgin and aged TO has been investigated experimentally in this paper to examine the effect of proposed NP on electrical improvement of TO.

The purpose of this paper is to enhance the characteristics of TiO₂ nanoparticles (NPs). Because these NPs stick together easily and are difficult to distribute evenly, they cannot be used extensively in lubricating oils. Altering TiO₂ was recommended as an alternate way for making NPs simpler to disperse.

Through dielectric barrier discharge plasma (DBDP)-assisted ball mill diagnostics and modeling of molecular dynamics, TiO₂@PEG-400 NPs were produced using the DBDP-assisted ball mill. The NPs’ microstructure was examined using FESEM, TEM, XRD, FT-IR and TG-DSC. Using the CFT-1 reciprocating friction tester, the tribological properties of TiO₂@PEG-400 NPs as base oil additives were studied. EDS and XPS were used to examine the surface wear of the friction pair.

Tribological properties of the modified NPs are vastly superior to those of the original NPs, and the lipophilicity value of TiO₂ NPs was improved by 200%. It was determined through tribological testing that TiO₂@PEG-400’s exceptional performance might be attributable to a chemical reaction film made up of TiO₂, Fe₂O₃, iron oxide and other organic chemicals.

This work describes an approach for preventing the aggregation of TiO₂ NPs by coating their surface with PEG-400. In addition, the prepared NPs can enhance the tribological performance of lubricating oil. This low-cost, high-performance lubricant additive has tremendous promise for usage in marine engines to minimize operating costs while preserving navigational safety.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

The electric discharge machining (EDM) involves electrons discharged from the electrode and machining progresses due to the removal of the material from the component. This a thermal-based machining process primarily used for hard to machine components with conventional methods. This process is used to make intricate cavities and contours. The fabricated part is the replica of the tool material with high surface finish and good dimensional accuracy. This study aims to evaluate the comprehensive effect of process parameters on electric discharge machining of maraging steel.

Multiple criteria Decision making (MCDM) techniques are used to select the best parameters by comparing several responses to achieve the desired goal. There are different MCDM techniques available for optimization of machining parameters. In the current investigation, multi-objective optimization by data envelopment analysis based ranking (DEAR) approach was used for machining Maraging C300 grade steel.

The Taguchi L9 runs were planned with process parameters such as current (Amp), Tool diameter (mm) and Dielectric pressure (MPa). The effect of process parameters on the responses, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were evaluated. High MRR is found at 15 A current, 14 mm tool diameter and dielectric pressure of 0.2 MPa. Optimum process parameters experiment showed reduced crack density.

An effort was made successfully to enhance the responses using the DEAR method and establish the decision making of selecting the optimal parameters by comparing the results obtained by machining maraging steel C300 grade.