This paper presents a comprehensive review of recent advancements in surface engineering of metals, encompassing techniques, characterization methods and applications. The study emphasizes the significance of surface engineering in enhancing the performance and functionality of metallic materials in various industries. The paper discusses the different techniques employed in surface engineering, including physical techniques such as thermal spray coatings and chemical techniques such as electroplating. It also explores characterization methods used to assess the microstructural, topographical, and mechanical properties of engineered surfaces. Furthermore, the paper highlights recent advancements in the field, focusing on nanostructured coatings, surface modification for corrosion protection, biomedical applications, and energy-related surface functionalization. It discusses the improved mechanical and tribological properties of nanostructured coatings, as well as the development of corrosion-resistant coatings and bioactive surface treatments for medical implants. The applications of surface engineering in industries such as aerospace, automotive, electronics, and healthcare are presented, showcasing the use of surface engineering techniques to enhance components, provide wear resistance, and improve corrosion protection. The paper concludes by discussing the challenges and future directions in surface engineering, highlighting the need for further research and development to address limitations and exploit emerging trends. The findings of this review contribute to advancing the understanding of surface engineering and its applications in various sectors, paving the way for future innovations and advancements.

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

Selective laser melting has a great potential to manufacture biocompatible metal alloy scaffolds or implants with a regulated porosity structure. This study uses five face-centered cubic (FCC) lattice structures, including FCC, FCC-Z, S-FCC, S-FCC-Z, and FCC-XYZ. Specimens with different lattice structures are fabricated using two laser energy densities, 71 J/mm³ and 125 J/mm³. Density, tensile, compressive and flexural test results exhibit the effect of laser parameters and lattice structure geometries on mechanical properties. The higher laser energy density of 125 J/mm³ results in higher properties such as density, strength, and Young’s modulus than the laser energy density of 71 J/mm³. The S-FCC lattice has the lowest density among all lattices. The mechanical tests result show specimen with FCC-XYZ lattice structures fabricated using a laser energy density of 125 J/mm³ meet the tensile properties requirement for human ribs. This structure also meets the requirement in flexural strength performance, but its stiffness is over that of human ribs. The compression test results of lattices are still incomparable due to unavailable compression data of the human ribs. In short, The FCC-XYZ lattice design fabricated by the 125 J/mm³ laser energy density parameter can be used to manufacture customized rib implants.

The aims of this study were to examine the effect of implant neck design and cortical bone thickness using 3D finite element analysis and to analyse the stability of clinical evidence based on micromotion and principal stress. Four commercial dental implants for a type IV bone and maxillary segments were created. Various parameters were considered, including the osseointegration condition, loading direction and cortical bone thickness. Micromotion and principal stresses were used to evaluate the failure of osseointegration and bone overloading, respectively. It was found that the maximum stress of the peri-implant bone decreased as cortical bone thickness increased. The micromotion level in full osseointegration is less than that in non-osseointegration and it also decreases as cortical bone thickness increases. The cortical bone thickness should be measured before surgery to help select a proper implant. In the early stage of implantation, the horizontal loading component induces stress concentration in bone around the implant neck more easily than does the vertical loading component, and this may result in crestal bone loss.

This review paper provides a comprehensive overview of the phenomenon of superlubricity, its associated material characteristics, and its potential applications. Superlubricity, the state of near-zero friction between two surfaces, presents significant potential for enhancing the efficiency of mechanical systems, thus attracting significant attention in both academic and industrial realms. We explore the atomic/molecular structures that enable this characteristic and discuss notable superlubric materials, including graphite, diamond-like carbon, and advanced engineering composites. The review further elaborates on the methods of achieving superlubricity at both nanoscale and macroscale levels, highlighting the influence of environmental conditions. We also discuss superlubricity’s applications, ranging from mechanical systems to energy conservation and biomedical applications. Despite the promising potential, the realization of superlubricity is laden with challenges. We address these technical difficulties, specifically those related to achieving and maintaining superlubricity, and the issues encountered in scaling up for industrial applications. The paper also underscores the sustainability concerns associated with superlubricity and proposes potential solutions. We conclude with a discussion of the possible future research directions and the impact of technological innovations in this field. This review thus provides a valuable resource for researchers and industry professionals engaged in the development and application of superlubric materials.

The aim of this study is to develop a micro-V-bending testing system and to investigate the grain size effect of 99.5% Ferrum sheet plate in the micro-V-bending process. In this study, two experiments have been conducted. They attempt to explain the characteristic of thickness variation at a constant average grain size of 29.93 µm with a standard deviation (SD) of 2.4 and the different average grain sizes at a constant mean thickness of 490.63 µm with a SD of 11.3. A laser displacement sensor is employed to monitor the real position of punch movement and to verify the effective stroke. In the micro-V-bending test, the thickness/average grain size (T/D) ratio is used to discuss material behavior such as punch force, springback, and spring-forward. According to the results, the conventional concept of V-bending deformation cannot be applied to different average grain sizes at a constant thickness in the micro-V-bending test particularly when the T/D ratio is less than 2.