Porous metal structures have emerged as a promising solution in repairing and replacing damaged bone in biomedical applications. With the advent of additive manufacturing technology, fabrication of porous scaffold architecture of different unit cell types with desired parameters can replicate the biomechanical properties of the natural bone, thereby overcoming the issues, such as stress shielding effect, to avoid implant failure. The purpose of this research was to investigate the influence of cube and gyroid unit cell types, with pore size ranging from 300 to 600 µm, on porosity and mechanical behavior of titanium alloy (Ti6Al4V) scaffolds. Scaffold samples were modeled and analyzed using finite element analysis (FEA) following the ISO standard (ISO 13314). Selective laser melting (SLM) process was used to manufacture five samples of each type. Morphological characterization of samples was performed through micro CT Scan system and the samples were later subjected to compression testing to assess the mechanical behavior of scaffolds. Numerical and experimental analysis of samples show porosity greater than 50% for all types, which is in agreement with desired porosity range of natural bone. Mechanical properties of samples depict that values of elastic modulus and yield strength decreases with increase in porosity, with elastic modulus reduced up to 3 GPa and yield strength decreased to 7 MPa. However, while comparing with natural bone properties, only cube and gyroid structure with pore size 300 µm falls under the category of giving similar properties to that of natural bone. Analysis of porous scaffolds show promising results for application in orthopedic implants. Application of optimum scaffold structures to implants can reduce the premature failure of implants and increase the reliability of prosthetics.

In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted.

Determination of the thermal characteristics and temperature-dependent rheological properties of the magnetorheological elastomers (MREs) is of paramount importance particularly with regards to MRE applications. Hitherto, a paucity of temperature dependent analysis has been conducted by MRE researchers. In this study, an investigation on the thermal and rheological properties of epoxidized natural rubber (ENR)-based MREs was performed. Various percentages of carbonyl iron particles (CIPs) were blended with the ENR compound using a two roll-mill for the preparation of the ENR-based MRE samples. The morphological, elemental, and thermal analyses were performed before the rheological test. Several characterizations, as well as the effects of the strain amplitude, temperature, and magnetic field on the rheological properties of ENR-based MRE samples, were evaluated. The micrographs and elemental results were well-correlated regarding the CIP and Fe contents, and a uniform distribution of CIPs was achieved. The results of the thermal test indicated that the incorporation of CIPs enhanced the thermal stability of the ENR-based MREs. Based on the rheological analysis, the storage modulus and loss factor were dependent on the CIP content and strain amplitude. The effect of temperature on the rheological properties revealed that the stiffness of the ENR-based MREs was considered stable, and they were appropriate to be employed in the MRE devices exposed to high temperatures above 45 °C.

Cobalt particles have been introduced as a filler due to the advantages of embedding their magnetic and electrical properties in magnetorheological elastomer (MRE). In the present research, the rheology and resistance of MRE are experimentally evaluated. Isotropic and anisotropic MRE samples containing silicone rubber and cobalt particles were fabricated. The magnetic properties of MRE are conducted using a vibrating sample magnetometer (VSM). The morphological aspects of MRE are observed by using field emission scanning electron microscopy (FESEM) and characterized by energy-dispersive X-ray spectroscopy (EDX). Rheological properties under various magnetic field strengths were measured for the magnetic field, strain amplitude, and frequency sweep test by using a parallel-plate rheometer. Subsequently, the resistance of MRE is tested under different applied forces and magnetic fields. The MRE storage modulus depicted an enhancement in field-dependent modulus across all the applied magnetic fields. The electrical resistance generated from the sample can be manipulated by external magnetic fields and mechanical loads. The conductivity of MRE is due to the existence of cobalt arrangements observed by FESEM. By introducing cobalt as filler and obtaining satisfactory results, the study might open new avenues for cobalt to be used as filler in MRE fabrication for future sensing applications.

The use of highly viscous grease as a medium in magnetorheological grease (MRG) provides the benefit of avoiding sedimentation from occurring. However, it limits the expansion of yield stress in the on-state condition, thus reducing the application performance during operation. Therefore, in this study, the improvement in the rheological properties of MRG was investigated through the introduction of graphite as an additive. MRG with 10 wt % graphite (GMRG) was fabricated, and its properties were compared to a reference MRG sample. The microstructure of GMRG was characterized using an environmental scanning electron microscope (ESEM). The rheological properties of both samples, including apparent viscosity, yield stress, and viscoelasticity, were examined using a shear rheometer in rotational and oscillatory modes. The results demonstrated a slight increase in the apparent viscosity in GMRG and a significant improvement in yield stress by 38.8% at 3 A with growth about 32.7% higher compared to MRG from 0 to 3 A. An expansion of the linear viscoelastic region (LVE) from 0.01% to 0.1% was observed for the GMRG, credited to the domination of the elastic properties on the sample. These obtained results were confirmed based on ESEM, which described the contribution of graphite to constructing a more stable chain structure in the GMRG. In conclusion, the findings highlight the influence of the addition of graphite on improving the rheological properties of MRG. Hence, the addition of graphite in MRG shows the potential to be applied in many applications in the near future.

Temperature is one of the most influential factors affecting the performance of elastomer matrix in magnetorheological elastomer (MRE). Previous studies have utilized silica as a reinforcing filler in polymer composite and as a coating material in MRE to improve the thermal stability of the base material. However, the usage of silica as an additive in the thermal stability of MRE has not been explored. Thus, in this study, the effect of silica as an additive on the temperature-dependent mechanical and rheological properties of ethylene propylene diene monomer (EPDM)-based MREs was investigated by using 30 wt.% carbonyl iron particles (CIPs) as the main filler, with different contents of silica nanoparticles (0 to 11 wt.%). The microstructure analysis was examined by using field-emission scanning electron microscopy (FESEM), while the thermal characterizations were studied by using a thermogravimetric analyzer and differential scanning calorimetry. The tensile properties were conducted by using Instron Universal Testing Machine in the absence of magnetic field at various temperatures. Meanwhile, the rheological properties were analyzed under oscillatory loadings in the influence of magnetic field, using a rotational rheometer at 25 to 65 °C. The results revealed that the temperature has diminished the interfacial interactions between filler and matrix, thus affecting the properties of MRE, where the tensile properties and MR effect decrease with increasing temperature. However, the presence of silica capable improved the thermal stability of EPDM-based MRE by enhancing the interactions between filler and matrix, thus reducing the interfacial defects when under the influence of temperature. Consequently, the incorporation of silica nanoparticles as an additive in EPDM-based MRE requires more exploration, since it has the potential to sustain the properties of MRE devices in a variety of temperature conditions. Thus, the study on the temperature-dependent mechanical and rheological properties of MRE is necessary, particularly regarding its practical applications.