The article presents the results of research on abrasive and tribocorrosion wear of boron steel. This type of steel is used in the automotive and agricultural industries for the production of tools working in soil. The main goal of the article is the evaluation of tribocorrosion and abrasive wear for hot-formed 22MnCrB5 steel and a comparison of the obtained results with test results for steel in a cold-formed state. The spinning bowl method to determine the wear of samples working in the abrasive mass was used. Furthermore, a stand developed based on the ball-on-plate system allows to determine the wear during the interaction of friction and corrosion. After the hot-forming process, 22MnCrB5 steel was three times more resistant for the abrasive wear than steel without this treatment. The average wear intensity for 22MnCrB5 untreated steel was 0.00046 g per km, while for 22MnCrB5 hot-formed steel it was 0.00014 g per km. The tribocorrosion tests show that the wear trace of hot-formed 22MnCrB5 steel was about 7.03 µm, and for cold-formed 22MnCrB5 steel a 12.11 µm trace was noticed. The hot-forming method allows to obtain the desired shape of the machine element and improves the anti-wear and anti-corrosion properties for boron steel.

This research focuses on the production process of soft magnetic composites in the form of 3D bulk compacts made from insulated powder particles using different milling parameters, aiming to enhance their magnetic properties and to study an innovative method of the powder surface “smoothing” technique. A structure analysis using scanning electron microscopy (SEM), EDS, and optical microscopy is also included. We found out that the samples made by the innovative method have lower density values. This can be caused by a more consistent SiO₂ insulation layer on highly pure iron powder particles. A correlation between the mechanical smoothing method and better insulation of powder particles can help to provide eco-friendlier solutions for the preparation of soft magnetic composites, such as less usage of reagents and more consistent coverage of powder particles with lower final insulation thickness. The magnetic properties of these compacts are evaluated by coercive field, permeability, and loss measurements. The particle-level smoothing technique in some cases can reduce the value of coercivity up to 20%. For some samples, the ball-to-powder ratio has a bigger impact on magnetic properties than surface treatment, which can be caused by an increased amount of insulation in the SMC compacts.

Inseparable joints are widely used in machine and vehicle construction. Hybrid joints include bonding with sheet metal clinching. This combination reduces costs as well as the time of production compared to welded joints. Tests on the samples made of DC01 sheets were carried out. A case study was conducted on four research series. For each series, the shear forces of the joint were measured. The first series consisted of adhesive bonding, and the second and third series consisted of hybrid bonding, during which the sheet metal clinching joint was developed immediately after the completion of adhesive application and after full joint formation. The last test series only includes sheet metal clinching. In the series where bonding was used, the homogeneity of the prepared joints was analysed using the ultrasonic echo technique. The shear strength of the bonded joints was 476 N, whereas the shear strength of sheet metal clinching was 965 N. For the hybrid joint, the average forces were 1085 N (for the specimens in which the lap joint was made after the joint was fully cured) and 1486 N (for the specimens in which the lap joints were made immediately after the adhesive was applied). It was discovered that the clinching of the steel sheets significantly increases the strength of the joint. The stabilisation of the joint causes better crosslinking conditions. This results in an increase in the strength of the hybrid joint.

The paper presents the scope of applicability and the usefulness of the method of predicting crystalline structure of castings using a commercially available system called Calcosoft CAFE. The influence of individual values of the parameters of the thermal model and the model predicting the structure (phenomenon of nucleation and crystal growth), and the method of interpretation of the results were identified. In simulation studies, it is important to use reliable and validated material database, under appropriate conditions. It is necessary to predict the properties of castings with a comprehensive, new and practical approach to modelling the formation of phase components of structure in terms of both macroscale and microscale phenomena (Multiscale and Multiphysics). Therefore, in this paper, the experimental-simulation validation of the CAFE code was undertaken. The tests were carried out on castings solidifying under various heat transfer conditions controlled by mould materials such as: a homogenous mould made of moulding sand, moulding sand with chill, and mould made of insulating mass with chill. These conditions directly influence the structure formation. The method of validation of the structure was determined in terms of its three parameters, i.e., the degree of refinement of the crystals, the location of the columnar-to-equiaxed transition zone—CET and the angle of the crystals. The above tests enabled to extend the content of databases, which often lack the necessary values of parameters used in modelling, e.g., crystallization of a specific alloy under given conditions (sand casting, chills or laser surface treatment). On this basis, the basics of correlating the simulation results on a micro- and macroscale were generalized, the limits of the application of individual parameters (mould, alloy materials) and their impact on the structure formation were determined. It resulted in the extension of the database for simulation calculations.

The paper presents the investigations of mechanical properties and microstructure of materials formed by thermal drilling process (Flow drill). The aim of this study was to determine the microstructure of the surface layers produced using galvanic method on the low-carbon steel after formed this layer using thermal drilling technology. The coatings of copper and nickel thicknesses of 5, 10 and 15 μm were applied. Microstructure, chemical composition and microhardness was study. It was found the possibility of forming galvanic coatings using thermal drilling technology and change in chemical composition of treated material.

The paper presents the investigations of selected chemical and mechanical properties as well as macro- and microstructure of materials formed using thermal drilling process (Flow drill). The aim of this study was to determine the microstructure of the coatings produced using laser cladding with powder technology. The coatings were produced on the low-carbon steel using 1 kW disc laser. After modification of surface, the thermal drilling process was applied. To produce all coatings, the pure copper powder was used. In this study the laser power equal of 500, 700 and 900 W were used. The microstructure, chemical composition (EDS) and microhardness were investigation. It was found that the surface modification of low carbon steel and next conducted thermal drilling process caused change the surface properties on the hole flange. It was found that surface modification of steel using laser cladding with cooper powder and next Flow drill process contributes to the change in microhardness and chemical composition on hole flange.