In this work, diamond-like carbon (DLC) thin film coatings are deposited on silicon substrates by using plasma-enhanced chemical vapour deposition (PECVD) technique. By varying the hydrogen (H2) flow rate, CH4−Argon (Ar) flow rate and deposition temperature (Td) as per a Box-Behnken experimental design (BBD), 15 DLC deposition experiments are carried out. The Young’s modulus (E) and the coefficient of friction (COF) for the DLCs are measured. By using a second-order polynomial regression approach, two metamodels are built for E and COF, that establish them as functions of H2 flow rate, CH4-Ar flow rate and Td. A non-dominated sorting genetic algorithm (NSGA-III) is used to obtain a set of Pareto solutions for the multi-objective optimization of E maximization and COF minimization. According to various practical scenarios, evaluation based on distance from average solution (EDAS) approach is used to identify the most feasible solutions out of the Pareto solution set. Confirmation experiments are conducted which shows the efficacy of the polynomial regression—NSGA-III—EDAS hybrid approach. The surface morphology of the DLCs deposited as per the optimal predictions is also studied by using atomic force microscopy.

This paper investigated the fretting failure of axial thrust steel bearings as per ASTM 4170 in the presence of anti-fretting pastes used in process industries. The pastes were differentiated based on the content of additives in them. The results indicated that the paste containing the additive package of copper, molybdenum disulfide, and graphite exhibited excellent anti-fretting properties (75–80% less bearing race mass loss) as compared with other lubricating pastes that contained only graphite/molybdenum disulfide and nickel as primary additives. There was less surface damage to the bearing races in the lubricating paste containing copper, graphite, and molybdenum disulfide. The machine vision images of the false brinelling indicated that the average area of false brinelling on the bearing races with the paste containing copper, molybdenum disulfide, and graphite was 2.537 ± 0.623 mm², while that of the other pastes containing graphite/molybdenum disulfide and nickel as primary additives were 4.504 ± 0.566 mm² and 4.914 ± 0.621 mm², respectively, indicating 50% less false brinelling area in the paste containing copper, molybdenum disulfide, and graphite as compared with the paste containing graphite/molybdenum disulfide and nickel. An asymmetric wear pattern was also observed in the thrust bearings used during the tribo test. Surface characterizations indicated the formation of wear debris, plastic deformations, and surface cracks during the tribo tests. The physico-chemical properties of the lubricating pastes such as the viscosity and work penetration properties played an important role in controlling the failure of the bearings due to fretting.

The modern industrial landscape stands at the confluence of macroscopic manufacturing processes and microscopic fabrication techniques, representing a dynamic interplay that significantly impacts the environment and sustainability. This chapter explores the complex relationship between these two realms and delves into their environmental implications, as well as the innovative solutions that promise a more sustainable future. The initial sections provide a comprehensive overview of macroscopic manufacturing processes and microscopic fabrication techniques, shedding light on their respective environmental footprints. The environmental challenges arising from these two domains are discussed, highlighting the need for sustainable approaches in manufacturing and fabrication. In response to these challenges, the chapter explores a range of sustainable practices, including materials management, resource efficiency, and eco-friendly technologies. It engages us with discussions toward the horizon, for the future directions. It explores emerging technologies and innovative approaches that hold promise for a more environmentally friendly and sustainable manufacturing landscape. In conclusion, the chapter emphasizes the critical importance of balancing industrial progress with environmental responsibility. Recommendations for both industry stakeholders and policymakers, providing a roadmap for a more sustainable and environmentally conscious future in the field of macroscopic manufacturing and microscopic fabrication, have also been established for the reader.