The paper describes processes of metal parts edges deburring and surface of metal samples polishing with ceramic tools based on fibre aluminium oxide. It presents the construction of basic types of tools and their practical industrial applications, and evaluates the influence of machining parameters on surface roughness. An important advantage of the used tools is the possibility of deburring and machining of external flat and shaped surfaces as well as internal surfaces and even deep drilled holes. These tools can be practically used for machining all construction materials. The results of machining of selected engineering materials, such as aluminium 5052 and 2017A, Inconel 718, non-alloy steel, in various variants of machining parameters are presented. The influence of machining parameters on machined surface roughness was described.

The paper presents an experimental evaluation of deformation of flat samples during uniaxial tensile testing, including uniform deformation and post-necking phases. The authors recommend a specially designed vision extensometer and simplified image processing method for analytical correction of triaxial test results for extended stress–strain curve estimation. A modified correction model is proposed, based on the application of Gaussian functions, to determine the neck geometry of the tested sample. The vision extensometer can monitor a specimen’s elongation using two fibre-optic gauges inserted into the material. Measurements taken from the vision extensometer are compared with readings from analogue gauges within the range of uniform deformation. The analytical correction model’s ability to correctly assess the extended true stress–strain curve in the post-necking phase was investigated. Image processing forms the basis of an efficient method for identifying the contour of the specimen’s neck. Digital image correlation (DIC) was used to verify the proposed solutions and assess the results obtained for the uniform and post-neck deformation phases. The change in thickness of the sample was experimentally measured throughout the tensile test with a digital gauge sensor and compared with the results of the digital image correlation.

Although, the friction method is well known for metals surface modification, the novelty of the article is based on the new idea of ceramics surface treatment with metal. The paper describes AlN ceramic metallization process by titanium coating deposition, obtained in friction surfacing method, which has been developed by the authors. The friction energy is directly transformed into heat and delivered in a specified amount precisely to the joint being formed between the metallic layer and the ceramics substrate material. The stress and temperature fields (as factors promoting the formation of diffusion joints) induced in the joint during the metallization process were qualitatively determined with the finite element method analysis and these results were verified experimentally. Finally, obtained structures of the metallic coatings were investigated and the results are discussed in the paper. As a novelty it was found, that the conditions of frictional metallization can favour the formation of a coating-substrate bond based on diffusion phenomena and atomic bonds of the coating components with the components of the substrate, despite the fact that it happens for metal–ceramics pairs. This type of connection is usually associated with long-term heating/annealing in chamber furnaces, because for diffusion in a solid state the most effective factor is time and temperature. It was shown that other components of the chemical potential gradient, such as temperature gradient, gradient and stress level, load periodicity and configuration of pairs of elements with high chemical affinity may play an important role in friction metallization. As a result, the relatively short time of operation (friction) is compensated.