The most time-consuming phase of the injection molding cycle is cooling. Cooling efficiency can be enhanced with the application of conformal cooling systems or high thermal conductivity copper molds. The conformal cooling channels are placed along the geometry of the injection-molded product, and thus they can extract more heat and heat removal is more uniform than in the case of conventional cooling systems. In the case of copper mold inserts, cooling channels are made by drilling and heat removal is facilitated by the high thermal conductivity coefficient of copper, which is several times that of steel. Designing optimal cooling systems is a complex process; a proper design requires injection molding simulations, but the accuracy of calculations depends on how precise the input parameters and boundary conditions are. In this study, three cooling circuit designs and three mold materials (Ampcoloy 940, 1.2311 (P20) steel, and MS1 steel) were used and compared using numerical methods. The effect of different mold designs and materials on cooling efficiency were examined using calculated and measured results. The simulation model was adjusted to the measurement results by considering the joint gap between the mold inserts.

The unusual combination of the fundamentally contradictory properties of high tensile strength and high fracture toughness found in maraging steel makes it well suited for safety-critical applications that require high strength-to-weight materials. In certain instances, additive manufacturing (AM) has produced materials that may be desirable for safety-critical applications where impact toughness is a key property, such as structural parts for the aerospace industry or armor plates for military applications. Understanding the influence of process parameters and defect structure on the properties of maraging steel parts produced via laser powder bed fusion (LPBF) is a fundamental step towards the broader use of AM technologies for more demanding applications. In this research, the impact energy of V-notched specimens made of 1.2709 maraging steel produced by LPBF was determined via Charpy impact testing. Specimens were produced using different processing parameter sets. By combining the process parameters with the porosity values of the parts, we demonstrate that an almost full prediction of the impact properties can be achieved, paving the way for significantly reducing the expenses of destructive testing.

Long-term environmental goals will motivate the automotive industry, component suppliers, and lubricating oil developers to reduce the friction of their tribosystems to improve overall efficiency and wear for increased component lifetime. Nanoscale ceramic particles have been shown to form a protective layer on components’ surface that reduces wear rate with its high hardness and chemical resistance. One such ceramic is yttria (Y₂O₃), which has an excellent anti-wear effect, but due to its rarity it would be extremely expensive to produce engine lubricant made from it. Therefore, part of the yttria is replaced by zirconia (ZrO₂) with similar physical properties. The study presents the result of the experimental tribological investigation of nanosized yttria–zirconia ceramic mixture as an engine lubricant additive. Yttria-stabilized zirconia (YSZ) nanoparticle was used as the basis for the ratio of the ceramic mixture, so that the weight ratio of yttria–zirconia in the resulting mixture was determined to be 11:69. After the evaluation of the ball-on-disc tribological measurements, it can be stated that the optimal concentration was 0.4 wt%, which reduced the wear diameter by 30% and the wear volume by 90% at the same coefficient of friction. High-resolution SEM analysis showed a significant amount of zirconia on the surface, but no yttria was found.

Long-term sustainability and decreasing amount of fossil oil reserves require a partial or complete transformation of traditional lubricating oils. The use of silica nanoparticles as a lubricant additive has a huge tribological potential, which has already been discussed in numerous articles. Nanosized silica shows excellent results in reducing friction and preventing wear, but they quickly aggregate and settle after homogenization in oils. For long-term stable dispersion of lubricating oils containing nanoceramics, the surface of the particles was modified with ethyl oleate. The surface modification, the ethyl oleate applied to the surface of the nanosilica, was confirmed by Fourier-transform infrared spectroscopy. Group III based lubricating oil was prepared using the surface-modified nanosilica. The particle size of the nanoparticles in the lubricating oil dispersion was examined by dynamic light scattering. Oscillating tribometer measurements were performed with different concentrations (0.1; 0.2; 0.3 wt%) of nanolubricants. Based on the tribological results, the friction coefficient of the surface-modified nanosilica is more stable, its wear is 15% lower compared to the reference. There is no significant change in the magnitude of the friction coefficient. It can be concluded that the ethyl oleate surface modification method may be suitable for tribological investigations of the acting mechanisms of nanoparticles.

This work aimed to comprehensively evaluate the influence of different surface modifications on the surface roughness of Ti6Al4V alloys produced by selective laser melting (SLM), casting and wrought. The Ti6Al4V surface was treated using blasting with Al₂O₃ (70–100 µm) and ZrO₂ (50–130 µm) particles, acid etching with 0.017 mol/dm³ hydrofluoric acids (HF) for 120 s, and a combination of blasting and acid etching (SLA). It was found that the optimization of the surface roughness of Ti6Al4V parts produced by SLM differs significantly from those produced by casting or wrought processes. Experimental results showed that Ti6Al4V alloys produced by SLM and blasting with Al₂O₃ followed by HF etching had a higher surface roughness (Ra = 2.043 µm, Rz = 11.742 µm), whereas cast and wrought Ti6Al4V components had surface roughness values of (Ra = 1.466, Rz = 9.428 m) and (Ra = 0.940, Rz = 7.963 m), respectively. For Ti6Al4V parts blasted with ZrO₂ and then etched by HF, the wrought Ti6Al4V parts exhibited higher surface roughness (Ra = 1.631 µm, Rz = 10.953 µm) than the SLM Ti6Al4V parts (Ra = 1.336 µm, Rz = 10.353 µm) and the cast Ti6Al4V parts (Ra = 1.075 µm, Rz = 8.904 µm).

In this study, copper(II) oxide, titanium dioxide and yttrium(III) oxide nanoparticles were added to Group III-type base oil formulated with overbased calcium sulfonate. The nanosized oxides were treated with ethyl oleate surface modification. The tribological properties of the homogenized oil samples were tested on a linear oscillating tribometer. Friction was continuously monitored during the tribological tests. A surface analysis was performed on the worn samples: the amount of wear was determined using a digital optical and confocal microscope. The type of wear was examined with a scanning electron microscope, while the additives adhered to the surface were examined with energy-dispersive X-ray spectroscopy. From the results of the measurements, it can be concluded that the surface-modified nanoparticles worked well with the overbased calcium sulfonate and significantly reduced both wear and friction. In the present tribology system, the optimal concentration of all three oxide ceramic nanoadditives is 0.4 wt%. By using oxide nanoparticles, friction can be reduced by up to 15% and the wear volume by up to 77%. Overbased calcium sulfonate and oxide ceramic nanoparticles together form a lower friction anti-wear boundary layer on the worn surfaces. The results of the tests represent another step toward the applicability of these nanoparticles in commercial engine lubricants. It is advisable to further investigate the possibility of formulating nanoparticles into the oil.