Low weight and high strength are significant factors in the current decade’s spread of composite sandwich materials. Previous studies have proven that forming stiffening ribs in these materials through the Single Point Incremental Forming (SPIF) process is possible and gives encouraging results. On the other hand, knowledge of residual stress (RS) values that form during the manufacturing process is essential, as they may affect the structural integrity of manufactured elements, whether in compression or tension. The investigation of the RS in the composite materials formed by the SPIF process using the XRD method was very limited in the previous studies, so this research aims to apply the X-ray diffraction (XRD) method to determine RS on the part of the LITECOR^® sandwich material formed using SPIF. LITECOR^® consists of a plastic core between two layers of steel. In this study, three types of LITECOR^® were used with differing plastic core thicknesses of 0.8, 1.25, and 1.6 mm, while the steel layers’ thickness remained the same at 0.3 mm. The axial and traverse RSs were measured in five positions on both sides of the formed part. It was found that the achieved RSs varied from tensile to compressive along the formed regions. It was found that the residual stress values in both directions were inversely proportional to the thickness of the plastic core. It was noted that the highest RS values were in the unformed base metal, after which the RS was reduced on both sides of the SPIF-formed region, followed by a rise in the RS at the concave of the SPIF-formed region. The maximum measured RS for X-axes was 1041 MPa, whereas, for Y-axes, it was 1260 MPa, both of which were recorded on the back side at a thickness of t = 0.8 mm.

In the present work, it is shown that the surface preparation method used on two Ni-based superalloys prior to aluminizing chemical vapor deposition (CVD) is one of the most important factors determining the oxidation resistance of aluminized Ni-based superalloys. It was found that grit-blasting the substrate surface negatively affects the oxidation resistance of the aluminized coatings. For grit-blasted and aluminized IN 625, a thicker outer NiAl coating was formed compared to that of IN 738. In contrast, no effect on NiAl coating thickness was found for grit-blasted and aluminized IN 738. However, a thicker interdiffusion zone (IDZ) was observed. It was shown that the systems with grit-blasted surfaces reveal worse oxidation resistance during thermal shock tests—namely, a higher mass loss was observed for both grit-blasted and aluminized alloys, as compared to ground and aluminized alloys. A possible reason for this effect of remaining alumina particles originating from surface grit-blasting on the diffusion processes and stress distribution at the coating/substrate is proposed.

The influence of cooling conditions and surface topography after finish turning of Ti6Al4V titanium alloy on corrosion resistance and surface bioactivity was analyzed. The samples were machined under dry and minimum quantity lubrication (MQL) conditions to obtain different surface roughness. The surface topographies of the processed samples were assessed and measured using an optical profilometer. The produced samples were subjected to electrochemical impedance spectroscopy (EIS) and corrosion potential tests (E_corr) in the presence of simulated body fluid (SBF). The surface bioactivity of the samples was assessed on the basis of images from scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis. The inspection of the surfaces of samples after turning under dry and MQL conditions revealed unevenly distributed precipitation of hydroxyapatite compounds (Ca/P) with a molar ratio in the range of 1.73–1.97. Regardless of the cutting conditions and surface roughness, the highest values of E_corr ~0 mV were recorded on day 7 of immersion in the SBF solution. The impedance characteristics showed that, compared to the MQL conditions, surfaces machined under dry conditions were characterized by greater resistance and the presence of a passive layer on the processed surface. The main novelty of the paper is the study of the effect of ecological machining conditions, namely, dry and MQL cutting on the corrosion resistance and surface bioactivity of Ti6Al4V titanium alloy after finish turning. The obtained research results have practical significance. They can be used by engineers during the development of technological processes for medical devices made of Ti6Al4V alloy to obtain favorable functional properties of these devices.

In the present article the doping of aluminide coatings by Pt/Pd as well as Hf or Pd using industrial processes was developed. The different combinations of doping elements were tested as well as their influence on chemical composition of coatings was initially investigated. The Pt and Pd and both Pt + Pd was electroplated on the surface of the MAR M247 nickel superalloy. The Zr or Hf was doped during low activity CVD aluminizing process using industrial Bernex BPX Pro 325S system. The conducted research showed that Pt and Pd formed the (Ni, Pd, Pt) Al solid solution in the outer additive layer. The higher concentration of palladium in the near surface and in the whole additive layer was detected. The platinum was presented below the surface of aluminide coating. The Zr or Hf was detected mainly in the diffusion zone. The low concentration of Zr (about 0.1 wt.%) in the outer zone was observed. The hafnium was detected mainly in the diffusion zone but in the outer additive layer a small concentration of this element was measured. The obtained results showed that formation of three elements (Pd, Pt) + Zr or Hf modified aluminide coating using proposed technology is possible. The structure of all obtained aluminide coatings was typical for a low-activity, high temperature (LAHT) formation process mainly by outward diffusion of Ni from base material.

The influence of surface roughness on its high temperature oxidation for an Ni-base superalloy was studied using laser profilometry, atomic force microscopy, mass change measurements, glow-discharge optical emission spectrometry, scanning electron microscopy, X-ray diffraction, and positron annihilation methods. The isothermal and cyclic air oxidation tests were performed at 1000 °C and showed dependence of oxidation behavior on surface roughness. Smoother surfaces oxidation resulted in the formation of a multilayered oxide scale consisting of NiO, Cr₂O₃, and internally oxidized Al₂O₃ while a rougher surface formed protective Al₂O₃ scale. The factors responsible for different oxidation behaviors were determined as higher concentration of vacancies and increased residual stresses in the near-surface region of studied alloys.

The article presents the results of an analysis of the surface roughness parameters, microhardness, and the stresses of the surface layer ofFSW butt joints subjected to the burnishing process with a diamond tip. This can be useful in selecting the optimal parameters of the burnishing process, ensuring the best properties of the surface layer of the FSW joint. Burnishing force and feed rate influence were analyzed according to the two-factor three-level full factorial statistical completed plan PS/DC 3². The tested material was 2024-T3 aluminum alloy sheets with a thickness of 2 mm. The results show that burnishing significantly reduced the surface roughness from Sa = 6.46 μm to Sa in the range of 0.33 μm–1.7 μm. This treatment provides high compressive residual stresses ${\sigma }_x$ from −86 to −130 MPa and ${\sigma }_y$ from −158 to −242 MPa. Microhardness increased from 84.19% to 174.53% compared to butt joints. Based on the obtained results, multi-criteria optimization was carried out. This optimization allows us to obtain a compromise solution ensuring compressive stresses in the surface layer (${\sigma }_x=-123\mathrm{MPa}$ and ${\sigma }_y=-202\mathrm{MPa}$) and microhardness $H_V=362.56\mathrm{mm}/{\mathrm{mm}}^2$ with the roughness of the weld surface Sa = 0.28 µm, Sku = 3.93 and Spc = 35.88 1/mm.