316L stainless steel is a common biomedical material. Currently, biomedical parts are produced through powder injection molding (PIM). Carbon control is the most critical in PIM. Improper debinding can significantly change the properties of the final product. In this work, thermal debinding and sintering were performed in two different furnaces (i.e. laboratory and commercially available furnaces) to study the mechanical properties and corrosion resistance. Debounded samples were sintered in different atmospheres. The samples sintered in inert gas showed enhanced mechanical properties compared with wrought 316L stainless steel and higher corrosion rate than those sintered in the vacuum furnace. The densification and tensile strength of the hydrogen sintered samples increased up to 3% and 51%, respectively, compared with those of the vacuum-sintered samples. However, the samples sintered in inert gas also exhibited reduced ductility and corrosion resistance. This finding is attributed to the presence of residual carbon in debonded samples during debinding.
Metallic foams are a new class of materials that have a great potential to be used in various functional and structural applications. Due to their competitive price compared to aluminium, metallic foams are anticipated to become an alternative material for light-weight structures. In this study, stainless steel foams are fabricated using a powder space holder method. The materials used include stainless steel powder, a novel space holder glycine and binders consisting of palm stearin and of polyethylene (PE). The stainless steel foams are sintered at 1100o C, 1200o C and 1300o C with sintering times of 1, 2 and 3 h, respectively, to investigate the effects of the sintering parameters on the compressive yield strength of the stainless steel foams. The results showed that all of the stainless steel foams produced exhibit the general behaviours of metal foams. The sintering time is the most significant parameter that influences the compressive yield strength of stainless steel foams. Increasing the sintering temperature and sintering time will increase the compressive yield strength. The interaction between the sintering temperature and sintering time is found to be not statistically significant.
FERMSOSTAT is a developed laboratory scale solid state fermenter. It is a horizontal stirrer drum bioreactor with about 70 L capacities. The fermenter is made of stainless steel which is anti-corrosive and non-toxic to the process organism. The fermenter is equipped with sets of control systems for temperature, agitation, aeration and also outlets for substrate sampling as well as inlets for inoculation and substrate additions. The uniqueness of this FERMSOSTAT system is its ability to carry out in situ substrate sterilization and extraction of enzymes at the end of SSF process. Moreover, the mixing system provided by FERMSOSTAT can be performed either full or half mixing as well as forward or reverse mixing. Furthermore, the mixing can be programmed to run at certain agitation rate and time interval during the fermentation process to prevent or reduce damage to the fungus mycelia. FERMSOSTAT is a developed SSF bioreactor and not an improvement of any existing one. The performances of FERMSOSTAT have been evaluated. Under optimum solid state fermentation conditions, about 63.4, 397 and 3.21 U/g of CMCase, xylanase and FPase activities were detected, which were higher compared to the tray system.
The current work is an attempt to reduce friction coefficient of the treated betelnut fibre reinforced polyester (T-BFRP) composites by aging them in twelve different solutions with different kinematic viscosities. The test will be performed on a pin on disc (POD) wear test rig using different applied loads (5⁻30 N), different sliding distances (0⁻6.72 km) at sliding speed of 2.8 m/s subjected to a smooth stainless steel counterface (AISI-304). Different orientations of the fibre mats such as anti-parallel (AP) and parallel (P) orientations subjected to the rotating counterface will be considered. The worn surfaces were examined through optical microscopy imaging and it was found that the aged specimens had significantly lower damages as compared to neat polyester (NP) and the unaged samples. Besides, P-O samples revealed lower friction coefficients as compared to AP-O, i.e., reduction was about 24.71%. Interestingly, aging solutions with lower kinematic viscosities revealed lower friction coefficients of the aged T-BFRP composites when compared to the ones aged in higher kinematic viscosities.
The combination of metallic bio-inert material, stainless-steel 316L (SS316L) and a bio-active material, hydroxyapatite (HA) can produce a composite which has superior properties for orthopaedic applications. The main objective of this study is to investigate the effects of sintering temperature and holding time on the physical and mechanical properties of the sintered part. 50wt.% SS316L and 50wt.% HA were mixed with a binder system of palm stearin (PS) and polyethylene (PE) at 61 vol.% powder loading. Rheological properties show a pseudo-plastic behaviour of the feedstock, where viscosity decreases with increasing shear rate. The feedstock was injection moulded into a tensile bar shape while thermal debinding was carried out at 320°C and 500°C. The brown parts were sintered at 1000, 1100, 1200 and 1300°C, with three different sintering times of 1, 3 and 5 hours in the furnace. It was found that the highest sintered density measured was 95.61% of the theoretical density. In addition, the highest hardness and Young's modulus measured were 150.45 HV and 52.61 GPa respectively, which are higher than those of human bone. The lowest percentage of carbon content was 0.022wt.% given by the sample sintered at 1300°C for 1 hour. Therefore, SS316L/HA composite with good mechanical and physical properties was successfully produced through the PIM process.
This paper presents an effective approach for the optimization of an in-feed centreless cylindrical grindingof EN52 austenitic grade steel (DIN: X45CrSi93) with multiple performance characteristics based on thegrey relational analysis. To study the effect of the entire space of the input variables, nine experimentalruns, based on the Taguchi method of L9 orthogonal arrays, were performed to determine the best factorlevel condition. The response table and response graph for each level of the machining parameters wereobtained from the grey relational grade. In this study, the in-feed centreless cylindrical grinding processparameters, such as dressing feed, grinding feed, dwell time and cycle time, were optimized by takinginto consideration the multiple-performance characteristics like surface roughness and out of cylindricity.By analyzing the grey relational grade, it was observed that dressing feed, grinding feed and cycle timehad significant effect on the responses. The optimal multiple performance characteristics were achievedwith dressing feed at level 1 (5 mm/min), grinding feed at level 2 (6 mm/min), dwell time at level 2(2.5 s), and cycle time at level 2 (11 s). It is clearly shown that the above performance characteristics inthe in-feed Centreless cylindrical grinding process can be improved effectively through this approach.
This study focuses on the effect of boronizing medium on the boride layer thickness of pack boronized 304 stainless steel after surface modification. Pack boronizing treatment was conducted in temperature of 900oC for a duration of eight hours. The treatment was performed using two different boronizing mediums which are powder and paste inside a tight box in an induction furnace. The characteristics of the samples were then observed using optical microscopy and XRD analyser. The thickness of boride layer was then measured using MPS digital image analysis software. The results showed that boronizing medium significantly affected the thickness of boride layer as paste boronized samples exhibited thicker boride layer thickness. The enhancement was mainly due to the size of boron particle in the paste medium which was smaller than powder medium that enabled better diffusion. It is expected that the enhancement of the boride layer thickness would result in further improvement of the mechanical and wear properties of this material.
With the trend for green technology, the study focused on utilizing a forgotten herb to produce an eco-friendly coating. Andrographis paniculata or the kalmegh leaves extract (KLE) has been investigated for its abilities in retarding the corrosion process due to its excellent anti-oxidative and antimicrobial properties. Here, KLE was employed as a novel additive in coatings and formulations were made by varying its wt%: 0, 3, 6, 9, and 12. These were applied to stainless steel 316L immersed in seawater for up to 50 days. The samples were characterized and analyzed to measure effectiveness of inhibition of corrosion and microbial growth. The best concentration was revealed to be 6 wt% KLE; it exhibited the highest performance in improving the ionic resistance of the coating and reducing the growth of bacteria.
Microbial electrosynthesis is a new approach to converting C1 carbon (CO2) to more complex carbon-based products. In the present study, CO2, a potential greenhouse gas, was used as a sole carbon source and reduced to value-added chemicals (acetate, ethanol) with the help of bioelectrochemical reduction in microbial electrosynthesis systems (MES). The performance of MES was studied with varying electrode materials (carbon felt, stainless steel, and cobalt electrodeposited carbon felt). The MES performance was assessed in terms of acetic acid and ethanol production with the help of gas chromatography (GC). The electrochemical characterization of the system was analyzed with chronoamperometry and cyclic voltammetry. The study revealed that the MES operated with hybrid cobalt electrodeposited carbon felt electrode yielded the highest acetic acid (4.4 g/L) concentration followed by carbon felt/stainless steel (3.7 g/L), plain carbon felt (2.2 g/L), and stainless steel (1.87 g/L). The alcohol concentration was also observed to be highest for the hybrid electrode (carbon felt/stainless steel/cobalt oxide is 0.352 g/L) as compared to the bare electrodes (carbon felt is 0.22 g/L) tested, which was found to be in correspondence with the pH changes in the system. Electrochemical analysis revealed improved electrotrophy in the hybrid electrode, as confirmed by the increased redox current for the hybrid electrode as compared to plain electrodes. Cyclic voltammetry analysis also confirmed the role of the biocatalyst developed on the electrode in CO2 sequestration.
Anatomically precontoured plates are commonly used to treat periarticular fractures. A well-fitting plate can be used as a tool for anatomical reduction of the fractured bone. Recent studies highlighted that some plates fit poorly for many patients due to considerable shape variations between bones of the same anatomical site. While it is impossible to design one shape that fits all, it is also burdensome for the manufacturers and hospitals to produce, store and manage multiple plate shapes without the certainty of utilization by a patient population. In this study, we investigated the number of shapes required for maximum fit within a given dataset, and if they could be obtained by manually deforming the original plate. A distal medial tibial plate was automatically positioned on 45 individual tibiae, and the optimal deformation was determined iteratively using finite element analysis simulation. Within the studied dataset, we found that: (i) 89% fit could be achieved with four shapes, (ii) 100% fit was impossible through mechanical deformation, and (iii) the deformations required to obtain the four plate shapes were safe for the stainless steel plate for further clinical use. The proposed framework is easily transferable to other orthopaedic plates.
Hydroxyapatite (HA) coated implant is more susceptible to bacterial infection as the micro-structure surface which is beneficial for osseointegration, could also become a reservoir for bacterial colonisation. The aim of this study was to introduce the antibacterial effect of silver (Ag) to the biomineralised HA by utilising a polydopamine film as an intermediate layer for Ag and HA immobilisation. Sufficient catechol groups in polydopamine were required to bind chemically stainless steel 316 L, Ag and HA elements. Different amounts of Ag nanoparticles were metallised on the polydopamine grafted stainless steel by varying the immersion time in silver nitrate solution from 12 to 24 h. Another polydopamine layer was then formed on the metallised film, followed by surface biomineralisation in 1.5 Simulated Body Fluid (SBF) solution for 3 days. Several characterisation techniques including X-Ray Photoelectron Spectroscopy, Atomic Force Microscopy, Scanning Electron Microscopy and Contact Angle showed that Ag nanoparticles and HA agglomerations were successfully immobilised on the polydopamine film through an element reduction process. The Ag metallisation at 24 h has killed the viable bacteria with 97.88% of bactericidal ratio. The Ag was ionised up to 7 days which is crucial to prevent bacterial infection during the first stage of implant restoration. The aged functionalised films were considered stable due to less alteration of its chemical composition, surface roughness and wettability properties. The ability of the functionalised film to coat complex and micro scale metal make it suitable for dental and orthopaedic implants application.
Corrosion prevention in biomaterials has become crucial particularly to overcome inflammation and allergic reactions caused by the biomaterials' implants towards the human body. When these metal implants contacted with fluidic environments such as bloodstream and tissue of the body, most of them became mutually highly antagonistic and subsequently promotes corrosion. Biocompatible implants are typically made up of metallic, ceramic, composite and polymers. The present paper specifically focuses on biocompatible metals which favorably used as implants such as 316L stainless steel, cobalt-chromium-molybdenum, pure titanium and titanium-based alloys. This article also takes a close look at the effect of corrosion towards the implant and human body and the mechanism to improve it. Due to this corrosion delinquent, several surface modification techniques have been used to improve the corrosion behavior of biocompatible metals such as deposition of the coating, development of passivation oxide layer and ion beam surface modification. Apart from that, surface texturing methods such as plasma spraying, chemical etching, blasting, electropolishing, and laser treatment which used to improve corrosion behavior are also discussed in detail. Introduction of surface modifications to biocompatible metals is considered as a "best solution" so far to enhanced corrosion resistance performance; besides achieving superior biocompatibility and promoting osseointegration of biocompatible metals and alloys.
Surgical site infection associated with surgical instruments has always been a factor in delaying post-operative recovery of patients. The evolution in surface modification of surgical instruments can be a potential choice to overcome the nosocomial infection mainly caused by bacterial populations such as Staphylococcus aureus, Pseudomonas aeruginosa, and Escherichia coli. A study was, therefore, conducted characterising the morphology, hydrophobicity, adhesion strength, phase, Nano-hardness, surface chemistry, antimicrobial and biocompatibility of SS 316L steel deposited with a Nano-composite layer of Silver (Ag) and Tantalum oxide (Ta2O5) using physical vapour deposition magnetron sputtering. The adhesion strength of Ag/AgTa2O5 coating on SS 316L and treated at 250-850 °C of thermal treatment was evaluated using micro-scratch. The Ag/Ag-Ta2O5-400 °C was shown a 154% improvement in adhesion strength on SS 316L when compared with as-sputtered layer or Ag/Ag-Ta2O5-250, 550, 700 and 850 °C. The FESEM, XPS, and XRD indicated the segregation of Ag on the surface of SS 316L after the crystallization. Wettability and Nano-indentation tests demonstrated an increase in hydrophobicity (77.3 ± 0.3°) and Nano-hardness (1.12 ± 0.43 GPa) when compared with as-sputtered layer, after the 400 °C of thermal treatment. The antibacterial performance on Ag/Ag-Ta2O5-400 °C indicated a significant zone of inhibition to Staphylococcus aureus (A-axis: 16.33 ± 0.58 mm; B-axis: 25.67 ± 0.58 mm, p
Stainless steels are increasingly used in construction today, especially in harsh environments, in which steel corrosion commonly occurs. Cold-formed stainless steel structures are currently increasing in popularity because of its efficiency in load-bearing capacity and its appealing architectural appearance. Cold-rolling and press-braking are the cold-working processes used in the forming of stainless steel sections. Press braking can produce large cross-sections from thin to thick-walled sections compared to cold-rolling. Cold-forming in press-braked sections significantly affect member behaviour and joints; therefore, they have attained great attention from many researchers to initiate investigations on those effects. This paper examines the behaviour of residual stress distribution of stainless steel press-braked sections by implementing three-dimensional finite element (3D-FE) technique. The study proposed a full finite element procedure to predict the residual stresses starting from coiling-uncoiling to press-braking. This work considered material anisotropy to examine its effect on the residual stress distribution. The technique adopted was compared with different finite element techniques in the literature. This study also provided a parametric study for three corner radius-to-thickness ratios looking at the through-thickness residual stress distribution of four stainless steels (i.e., ferritic, austenitic, duplex, lean duplex) in which have their own chemical composition. In conclusion, the comparison showed that the adopted technique provides a detailed prediction of residual stress distribution. The influence of geometrical aspects is more pronounced than the material properties. Neglecting the material anisotropy shows higher shifting in the neutral axis. The parametric study showed that all stainless steel types have the same stress through-thickness distribution. Moreover, R/t ratios' effect is insignificant in all transverse residual stress distributions, but a slight change to R/t ratios can affect the longitudinal residual stress distribution.
Welding parameters obviously determine the joint quality during the resistance spot welding process. This study aimed to investigate the effect of welding current and electrode force on the heat input and the physical and mechanical properties of a SS316L and Ti6Al4V joint with an aluminum interlayer. The weld current values used in this study were 11, 12, and 13 kA, while the electrode force values were 3, 4, and 5 kN. Welding time and holding time remained constant at 30 cycles. The study revealed that, as the welding current and electrode force increased, the generated heat input increased significantly. The highest tensile-shear load was recorded at 8.71 kN using 11 kA of weld current and 3 kN of electrode force. The physical properties examined the formation of a brittle fracture and several weld defects on the high current welded joint. The increase in weld current also increased the weld diameter. The microstructure analysis revealed no phase transformation on the SS316L interface; instead, the significant grain growth occurred. The phase transformation has occurred on the Ti6Al4V interface. The intermetallic compound layer was also investigated in detail using the EDX (Energy Dispersive X-Ray) and XRD (X-Ray Diffraction) analyses. It was also found that both stainless steel and titanium alloy have their own fusion zone, which is indicated by the highest microhardness value.
Laser-assisted high speed milling is a subtractive machining method that employs a laser to thermally soften a difficult-to-cut material's surface in order to enhance machinability at a high material removal rate with improved surface finish and tool life. However, this machining with high speed leads to high friction between workpiece and tool, and can result in high temperatures, impairing the surface quality. Use of conventional cutting fluid may not effectively control the heat generation. Besides, vegetable-based cutting fluids are invariably a major source of food insecurity of edible oils which is traditionally used as a staple food in many countries. Thus, the primary objective of this study is to experimentally investigate the effects of water-soluble sago starch-based cutting fluid on surface roughness and tool's flank wear using response surface methodology (RSM) while machining of 316 stainless steel. In order to observe the comparison, the experiments with same machining parameters are conducted with conventional cutting fluid. The prepared water-soluble sago starch based cutting fluid showed excellent cooling and lubricating performance. Therefore, in comparison to the machining using conventional cutting fluid, a decrease of 48.23% in surface roughness and 38.41% in flank wear were noted using presented approach. Furthermore, using the extreme learning machine (ELM), the obtained data is modeled to predict surface roughness and flank wear and showed good agreement between observations and predictions.
Duplex stainless steels (DSSs) are complex materials and they have been widely used in the marine environment and gas industries, primarily offering a better resistance of pitting corrosion and good mechanical properties. In the present work, the effects of heat treatment on duplex stainless steel (DSS) weld overlay samples that were heat treated at three different temperatures, namely 350 °C, 650 °C, and 1050 °C, and followed by air cooling and water quenching were studied. Stress relief temperature at 650 °C had induced sigma phase precipitation in between delta ferrite and austenite (δ/γ) grain boundaries, resulting in the loss of corrosion resistance in the weld metal. Interestingly, post weld heat treatment (PWHT) test samples that were reheated to solution annealing temperature had shown no weight loss. The ferrite count determination in the region of weld metal overlay increased at hydrogen relief and decreased at stress relief temperatures due to slow cooling, which is more favorable to austenite formation. The amount of ferrite in the weld metals was significantly reduced with the increment of solution anneal temperature to 1050 °C because of sufficient time for the formation of austenite and giving optimum equilibrium fraction in the welds.
Automobile, aerospace, and shipbuilding industries are looking for lightweight materials for cost effective manufacturing which demands the welding of dissimilar alloy materials. In this study, the effect of tool rotational speed, welding speed, tilt angle, and pin depth on the weld joint were investigated. Aluminum 5052 and 304 stainless-steel alloys were joined by friction stir welding in a lap configuration. The design of the experiments was based on Taguchi's orthogonal array for conducting the experiments with four factors and three levels for each factor. The microstructural analysis showed tunnel defects, micro voids, and cracks which formed with 0° and 1.5° tilt angles. The defects were eliminated when the tilt angle increased to 2.5° and a mixed stir zone was formed with intermetallic compounds. The presence of the intermetallic compounds increased with the increase in tilt angle and pin depth which further resulted in obtaining a defect-free weld. Hooks were formed on either side of the weld zone creating a mechanical link for the joint. A Vickers hardness value of HV 635.46 was achieved in the mixed stir zone with 1000 rpm, 20 mm/min, and 4.2 mm pin depth with a tilt angle of 2.5°, which increased by three times compared to the hardness of SS 304 steel. The maximum shear strength achieved with 800 rpm, 40 mm/min, and a 4.3 mm pin depth with a tilt angle of 2.5° was 3.18 kN.
Wire ropes undergo a fretting fatigue condition when subjected to axial and bending loads. The fretting behavior of wires are classified as line contact and trellis point of contact. The experimental study on the fatigue of wire ropes indicates that most of the failure occurs due to high localized stresses at trellis point of contact. A continuum damage mechanics approach was previously proposed to estimate the fatigue life estimation of wire ropes. The approach majorly depends on the high value of localized stresses as well as the micro-slippage occurs at the contact region. Finite element approach has been used to study radial and axial distribution of stresses and displacement in order to clearly understand the evolution of stresses and existence of relative displacements between neighboring wires under various loading and frictional conditions. The relative movements of contacting wires are more when friction is not considered. In the presence of friction, the relative movement occurs at the boundaries of the contact region. The location of microslip in the presence of friction is backed by the experimental observation stating the crack is initiated at or the outer boundary of the contact spot. The existence of slip is due to different displacement of outer and central wires.
Waste water treatment reservoirs are contaminated with many hazardous chemicals and acids. Reservoirs typically comprise concrete and reinforcement steel bars, and the main elements responsible for their deterioration are hazardous chemicals, acids, and ozone. Currently, a variety of techniques are being used to protect reservoirs from exposure to these elements. The most widely used techniques are stainless steel plating and polymeric coating. In this study, a technique known as arc thermal spraying was used. It is a more convenient and economical method for protecting both concrete and reinforcement steel bar from deterioration in waste water treatment reservoirs. In this study, 316L stainless steel coating was applied to a concrete surface, and different electrochemical experiments were performed to evaluate the performance of coatings in different acidic pH solutions. The coating generated from the arc thermal spraying process significantly protected the concrete surface from corrosion in acidic pH solutions, owing to the formation of a double layer capacitance-a mixture of Cr3+ enriched with Cr₂O₃ and Cr-hydroxide in inner and Fe3+ oxide on the outer layer of the coating. The formation of this passive film is defective owing to the non-homogeneous 316L stainless steel coating surface. In the pH 5 solution, the growth of a passive film is adequate due to the presence of un-dissociated water molecules in the aqueous sulfuric acid solution. The coated surface is sealed with alkyl epoxide, which acts as a barrier against the penetration of acidic solutions. This coating exhibits higher impedance values among the three studied acidic pH solutions.