Using cutting fluid in the machining process for Aluminum Alloy 1050 is advantageous as it helps mitigate the effects of temperature generated during cutting. It can shorten tool life and impair the quality of machine parts. Despite its benefits, cutting fluids has several disadvantages, such as high expenses, potential environmental harm, and user health risks. This research evaluates the effects of green cutting conditions, particularly nozzle types, on the metallurgical properties of the material. Their impacts on tool wear, X-Ray Diffractometer (XRD) pattern, Full Width at Half Maximum (FWHM), crystallite size, and hardness during the drilling process were investigated. The findings indicate that using chilled air with dual nozzles for cooling and lubrication is highly effective, resulting in less tool wear and a relatively purer crystalline structure of the material compared to other conditions. These results emphasize the importance of controlling cutting conditions, especially nozzle types, to produce high-quality parts with improved metallurgical properties.

An approach for improving the strength of the structure made of two different strength steel plates joining by the dissimilar metal weld (DMW) was perfomed to enhanced the strength of the joint. A stainless steel (AISI 304) and mild steel (AISI 1018) plates were joined by the Metal Inert Gas (MIG) welding process using a stainless steel ER 308LSi welding wire Different weld bead path, i.e. straight, angle and lap weld bead paths were designed to investigate their effects on the strength of the joint of the steel plates. The different weld bead path designs of the DMW of stainless steel (AISI 304) and mild steel (AISI 1018) plates were subjected to the tensile test to study the corresponding mechanical strength properties under a certain load. The strength of the sample joining with angle bead weld path was highest as compared to the other two weld bead path design. The joining part subject to the tensile test shows that the strength of weld joint was affected by the total weld area and the total length the path of the weld. The rupture of the dissimilar metal weld sample during the tensile test were also affected by the weld bead path designs.

Trimming the scrap portion of ultra-high strength steel (UHSS) components poses a significant challenge due to the inherent high strength and hardness characteristics of the material. For UHSS components with a higher geometric complexity such consisting of inclined and curved sections, sharp tilt, and small bend radius, the large trimming load results in poor sheared quality and shape defects, which commonly happen in these areas. This research investigated the effects of applying a small inclination angle to the punch in the trimming of the UHSS parts having an inclined and curved shape. The inclined punch was modified to four sets of different degrees of inclination i.e., 1°, 3°, 5°, and 10°. A comparative analysis of the trimming load, trimming energy, sheared edge quality and shape defects was conducted between these modified punches and the normal punch for their effectiveness in the trimming operation. Results showed that the application of inclination angle significantly decreased the trimming load, reduced the trimming energy, and improved the sheared edge surface quality, as well as prevented the shape defects at the inclined and curved zones as compared to the outcomes produced when trimming using the normal punch. The study suggested that the change to the punch geometry is an effective option to improve the performance of the process as well as the quality of the part, particularly in trimming the high-strength components having complex shapes.

Successive forging is a multi-stage process for tailoring ultra-high strength steel (UHSS) sheets thickness which normally done using rolling or welding process. Long transition zone and degrading of mechanical properties among the main problem when tailoring or reducing the steel thickness using these two processes. This study investigates the geometrical change and deformation at the transition zone at the thickness reduction area after the successive forging process. A 1.6 mm in thickness JSC1180YN UHSS sheet was subjected to a successive forging process using a 1500-kN servo press, aiming at achieving a thickness reduction of 0.8 mm. 20 forging steps were set with a constant feed rate of 5 mm. The punch was designed with chamfered edges to promote uniform strain distribution while the lower die is set to be flat. The results show that the process achieved a precise and consistent thickness reduction to about 0.8 mm with only a slight increase in width and length. The geometric control was followed by a great improvement in mechanical properties, where there was an increase in Vickers hardness from 415 HV to a stable 442 HV due to strain hardening. Successive forging can shorten the transition zone length with minimal impact on shape changes. Overall, successive forging proves to be a process which is well-controlled that can effectively modify both the geometry and mechanical properties of UHSS, providing many important data for predicting the characteristics of the final forged components.

Cu2O stands out as a promising semiconductor material for solar energy conversion, primarily due to its exceptional light-absorbing qualities and its widespread availability. However, its efficiency is somewhat hindered by its relatively low carrier mobility and a limited absorption band for carriers. The introduction of magnesium (Mg) doping into Cu2O has emerged as a potential means to enhance its morphology, optical characteristics, and electrical properties, making it an intriguing avenue for exploration. To fabricate the Mg-doped Cu2O layers, an electrodeposition process was employed on an Indium Tin Oxide (ITO) substrate. The resulting films were then subjected to characterization using Field Emission Scanning Electron Microscopy (FESEM), Ultraviolet-Visible Spectroscopy (UV-Vis), and HALL Effect Measurement, focusing on their morphology, optical properties, and electrical behaviors. Notably, the concentration of magnesium played a significant role in shaping the properties of the Cu2O layer. The fabrication process extended up to a dopant concentration of 0.3 M for both undoped Cu2O and Mg-doped Cu2O layers, leading to morphological alterations. Specifically, the grain size increased with varying dopant concentrations, but it became smaller and more compact after doping with 0.3 M Mg. The average absorbance of visible light for both undoped and Mg-doped Cu2O layers fell within the range of 1~2 au. Intriguingly, a doping level of 0.3 M Mg led to the simultaneous achievement of high carrier mobility (29.98 cm2/Vs), low bulk carrier concentration (2.3.928 x 1021 cm-3), and high resistivity (5.3 x 10-5 Ω cm) in the Cu2O material. Additionally, Cu2O/ITO thin films exhibiting rectifying characteristics were successfully fabricated, confirming the semiconductor nature of the deposited p-type Cu2O layer. The primary objective of this study was to synthesize Cu2O layers doped with varying concentrations of Mg and thoroughly characterize their morphology, optical attributes, and electrical behaviors through the electrodeposition method. The study findings and implications were extensively discussed.

Adhesion strength, toughness, and resistance to frictional heating are critical characteristics for suppressing premature coating delamination and protecting the substrate from plastic deformation. This study investigates the synergistic role of intermediate adhesion-promoting layers on the mechanical and tribological performance of diamond-like carbon (DLC) coatings deposited on tool steel substrates via high-power impulse magnetron sputtering (HiPIMS). Nanoindentation and micro-scratch testing were conducted to evaluate single-layer TiAlN, single-layer DLC, and multilayer DLC/TiAlN coating architectures. Owing to the TiAlN interlayer beneath the DLC topcoat, the multilayer DLC/TiAlN system demonstrated superior composite hardness and interfacial adhesion strength. Microstructural characterization via SEM-EDS and Raman spectroscopy confirmed that a dense, columnar TiAlN interlayer with a high aluminum concentration provided vital load-bearing capacity for the overlying DLC film. During dry CNC turning tests on aluminum and steel alloys, the multilayer DLC/TiAlN coating exhibited the lowest cutting forces, cutting temperatures, and surface roughness. The architecture effectively suppressed flank and crater wear, which reduced the chip compression ratio and mitigated plastic shear strain at the tool–chip interface. This synergistic interaction within the DLC/TiAlN coating system minimizes tribological degradation, demonstrating high potential for demanding machining applications.