Yes / The mass production of polymeric parts with functional surfaces requires economically viable manufacturing routes. Injection moulding is a very attractive option however wear and surface damage can be detrimental to the lifespan of replication masters. In this research, the replication of superhydrophobic surfaces is investigated by employing a process chain that integrates surface hardening, laser texturing and injection moulding. Austenitic stainless steel inserts were hardened by low temperature plasma carburising and three different micro and nano scale surface textures were laser fabricated, i.e. submicron triangular LaserInduced Periodic Surface Structures (LIPSS), micro grooves and Lotus-leaf like topographies. Then, a commonly available talc-loaded polypropylene was used to produce 5000 replicas to investigate the evolution of surface textures on both inserts and replicas together with their functional response. Any wear orsurface damage progressively built up on the inserts during the injection moulding process had a clear impact on surface roughness and peak-to-peak topographies of the replicas. In general, the polymer replicas produced with the carburised inserts retained the wetting properties of their textured surfaces for longer periods compared with those produced with untreated replication masters. / European Union’s H2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No. 675063 (www.laser4fun.eu). The work was also supported by three other H2020 projects, i.e. “HighImpact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA, No. 766871), “Process Fingerprint for Zero-defect Net-shape Micromanufacturing” (MICROMAN, No. 674801) and “Modular laser based additive manufacturing platform for large scale industrial applications” (MAESTRO, No. 723826). Further support was provided by the UKIERI DST programme “Surface functionalisation for 18/20 Accepted in the journal Tribology – Materials, Surfaces & Interfaces. food, packaging, and healthcare applications”

A comprehensive, transient three-dimensional model of a single-pass laser surface alloying process has been developed and used to examine the heat, momentum and species transport phenomena. A numerical study is performed in a co-ordinate system moving with the laser at a constant scanning speed. In this model a fixed grid enthalpy-porosity approach is used, which predicts the evolutionary pool development. In this model two extreme cases of alloying element and base metal combinations are considered based on their relative melting points. One extreme case is for an alloying element with its melting point much lower than that of the base metal. In this case the alloying element melts almost instantaneously. Hence it is assumed that the alloying element introduced on the melt pool surface is in the molten state. Thus, while solving the species conservation equation a species flux condition is used on the entire melt pool surface. This case is analysed for aluminium alloying element on iron base metal. The final species distribution in the melt pool as well as in the solidified alloy is predicted. The other extreme case is studied for an alloying element with its melting point relatively higher than that of the base metal. In this case all the alloying element particles on the melt pool surface will not melt. Only those particles which fall in the region on the melt pool surface where the local temperature is higher than the melting point of the alloying element will melt. The particles which fall away from this region are advected into the melt pool, due to a strong Marangoni convection on the melt pool surface. If a particle is advected into the inner region in the melt pool (where the temperature is higher than its melting point), it starts melting and thus the molten species mass gets distributed. Hence, the species flux condition at the entire surface of the melt pool is not valid. The particles are tracked in the melt pool by assuming the alloying particles to be spherical in shape and moving without any relative velocity with the surrounding fluid. Simultaneously, the temperature field inside the spherical particle is solved by assuming its surface temperature to be the local temperature in the melt pool. The amount of particle mass that fuses as it passes through a particular control volume is noted. The same procedure is repeated for a large number of particles initiated at various locations on the pool surface, and a statistical distribution of the species mass source in the entire pool is obtained. This species mass source distribution is then used to solve the species conservation equation. Nickel alloying element on aluminium base metal is used to illustrate this case. The numerical results obtained from the two cases are compared with the available experimental results. A qualitative matching is found between the numerical and experimental results.

Magnesiumwerkstoffe sind aufgrund ihrer geringen Dichte und hohen spezifischen Festigkeit für den Leichtbau prädestiniert. Ziel der vorgelegten Arbeit ist es, durch die gleichzeitige Verbesserung des Korrosions- und Verschleißverhaltens neue Anwendungsfelder für Magnesiumlegierungen zu erschließen. Anhand der Magnesiumlegierung AZ91D wurden die Möglichkeiten einer lokalen beanspruchungsgerechten Modifikation von Struktur und Gefüge im oberflächennahen Bereich durch eine Elektronenstrahl(EB)-Flüssigphasen-Randschichtbehandlung ohne Zusatzstoff (EB-Umschmelzen) und unter Verwendung von Al-Si-Zusatzstoffen (EB-Umschmelzlegieren) aufgezeigt. Die mittels verschiedener hochfrequenter Strahlablenktechniken erzeugten Schichten weisen eine deutliche Gefügefeinung, neue Gefügemorphologien sowie eine veränderte Phasenverteilung und/oder -neubildung auf, sind riss- und porenfrei und haben eine ausgezeichnete schmelzmetallurgische Anbindung an den Grundwerkstoff. Anhand von Tauchversuchen und potentiodynamischen Polarisationsmessungen in verschieden konzentrierten NaCl-Lösungen konnte eine signifikante Verbesserung des Korrosionsverhaltens der generierten Schichten im Vergleich zum Ausgangszustand nachgewiesen werden. EB-umschmelzlegierte Schichten weisen im Ergebnis von Trockenverschleißtests (Stift-Scheibe) eine deutliche Reduzierung des spezifischen Verschleißkoeffizienten auf.

In the present investigation, surface coatings employing laser surface alloying (LSA) and plasma electrolytic oxidation (PEO) processes have been prepared on Mg alloys. The coatings have been investigated for corrosion and wear behaviour. Two important Mg alloys based on Mg–Al system were selected namely, MRI 230D and AM50 as substrates. LSA coatings have been prepared employing Al and Al2O3 as precursors using different laser scan speeds. PEO coatings were prepared in standard silicate and phosphate based electrolytes employing unipolar, pulsed DC. Hybrid coatings using a combination of the two processes were also produced and investigated for corrosion and wear behaviour. Hybrid coatings of LSA followed by PEO (LSA+PEO) were investigated for effectiveness of sealing the cracks in the LSA coatings by subsequent PEO process and consequent improvement in the corrosion resistance. Hybrid coatings of PEO followed by LSA (PEO+LSA) were prepared with an objective of sealing the pores in the PEO coating LSA treatment. In an attempt to produce more compact PEO coatings, electrolyte containing montmorillonite clay additives was employed for the PEO process of AM50 Mg alloy. The coatings were produced employing different current densities and the effect of current density on the microstructure and corrosion behaviour of coating was investigated. Electrochemical corrosion tests of uncoated and coated alloys were carried out in 3.5 wt.% (0.6M)NaCl, neutral pH, solution with an exposed area of 0.5 cm2 for a time duration of 18.5 h. For the PEO coatings with clay additives, corrosion tests were conducted additionally in 0.5 wt.% (0.08 M) NaCl, neutral pH, solution for a time duration of 226.1 h. Wear behaviour of LSA coatings was analyzed by employing a pin on disc tribo–tester conforming to ASTM G–99 standard at ambient conditions with ground EN32 steel disc of hardness Rc 58 as the counterface. Tests were conducted under dry sliding conditions for a sliding distance of 1.0 km at a sliding velocity of 0.837 m/s employing normal loads of 10, 20, 30 and 40 N. Friction and wear behavior of PEO and PEO+LSA coatings were analyzed at ambient conditions by employing a ball−on−flat linearly oscillating tribometer conforming to ASTM G–133 standard. AISI 52100 steel ball of diameter 6 mm was employed as the friction partner. Wear tests were conducted under dry sliding conditions for a total sliding distance of 100 m at normal loads of 2 N and 5 N with oscillating amplitude of 10 mm and mean sliding speed of 5 mm/s. LSA coatings could not improve the corrosion resistance of MRI 230D Mg alloy. This was attributed to the presence of cracks in the LSA coating, which resulted in the accelerated galvanic corrosion of the substrate. LSA coatings improved the wear resistance at all loads. The improved wear resistance was attributed to β (Mg17Al12) phase and Al2O3 particles in the coating which increased the hardness of the LSA layer. No trend in corrosion and wear resistance with laser scan speed was observed for LSA coatings. PEO coatings improved the corrosion resistance of the MRI 230D Mg alloy significantly. The improved corrosion resistance was attributed to the enhanced barrier protection provided by dense barrier layer formed at the substrate/coating interface and to the insoluble phase constituents in the coatings. PEO coating was effective in improving the wear resistance at low loads/contact pressures. At higher loads, the coating underwent micro–fracture as a result of the porosity in the coatings. Hybrid coatings of LSA followed by PEO (LSA+PEO) in silicate based electrolyte improved the corrosion resistance of LSA coatings. However, the corrosion resistance was not improved to the extent of PEO coatings on as–cast alloy as a result of cracks in the primary coatings, which were not fully sealed by the plasma conversion products. No trend in corrosion resistance with laser scan speed was observed for LSA+PEOcoatings. In hybrid coatings of PEO followed by LSA (PEO+LSA), primary PEO coating was completely melted and mixed with applied precursor to form a single composite LSA layer. The corrosion resistance of the hybrid coatings was observed to be lower than that of the as–cast alloy. The presence of solidification cracks reduced the barrier properties and resulted in the accelerated galvanic corrosion of the substrate similar to LSA coatings. Hybrid (PEO+LSA) coatings exhibited improved wear resistance as compared to as–cast alloy at lower loads as a result of increase in the hardness due to β (Mg17Al12) phase and oxide/ceramic particles in the hybrid layer. At higher loads, hybrid coatings exhibited higher wear rate as compared to as–cast alloy and PEO coatings. This was attributed to three–body abrasive wear as a result of dislodged hard oxide/ceramic particles in the wear tracks. No trend in corrosion and wear resistance with laser scan speed was observed for PEO+LSA coatings. PEO coatings on AM50 Mg alloy by employing clay additives in the electrolyte resulted in the reactive uptake of clay particles producing a predominantly amorphous coating at low current density. Clay additives were effective in improving the compactness of the coating at lower current density. At higher current densities, the porosity of the coatings increased. The clay particles got re–constituted producing increasing amount of crystalline phases with increase in current density. Long term impedance measurements showed that clay addition as well as increased current density employed for the PEO process was not effective in improving the corrosion resistance of the coatings. At low current density, even though the coating with clay additives was more compact, it was deficient in MgO and consisted predominantly of an amorphous phase, which underwent fast dissolution in electrolyte thereby resulting in an early loss of barrier properties. At higher current densities, even though the coatings consisted of increased amount of MgO and crystalline phases, which resist dissolution in the electrolyte, the increased porosity and defective barrier layer resulted in easy permeation of the electrolyte into the substrate/coating interface, which resulted in much earlier loss of barrier properties and inferior corrosion resistance.

Magnesiumwerkstoffe sind aufgrund ihrer geringen Dichte und hohen spezifischen Festigkeit für den Leichtbau prädestiniert. Ziel der vorgelegten Arbeit ist es, durch die gleichzeitige Verbesserung des Korrosions- und Verschleißverhaltens neue Anwendungsfelder für Magnesiumlegierungen zu erschließen. Anhand der Magnesiumlegierung AZ91D wurden die Möglichkeiten einer lokalen beanspruchungsgerechten Modifikation von Struktur und Gefüge im oberflächennahen Bereich durch eine Elektronenstrahl(EB)-Flüssigphasen-Randschichtbehandlung ohne Zusatzstoff (EB-Umschmelzen) und unter Verwendung von Al-Si-Zusatzstoffen (EB-Umschmelzlegieren) aufgezeigt. Die mittels verschiedener hochfrequenter Strahlablenktechniken erzeugten Schichten weisen eine deutliche Gefügefeinung, neue Gefügemorphologien sowie eine veränderte Phasenverteilung und/oder -neubildung auf, sind riss- und porenfrei und haben eine ausgezeichnete schmelzmetallurgische Anbindung an den Grundwerkstoff. Anhand von Tauchversuchen und potentiodynamischen Polarisationsmessungen in verschieden konzentrierten NaCl-Lösungen konnte eine signifikante Verbesserung des Korrosionsverhaltens der generierten Schichten im Vergleich zum Ausgangszustand nachgewiesen werden. EB-umschmelzlegierte Schichten weisen im Ergebnis von Trockenverschleißtests (Stift-Scheibe) eine deutliche Reduzierung des spezifischen Verschleißkoeffizienten auf.

Μελετήθηκαν με μία σειρά από επιφανειακά ευαίσθητες τεχνικές δύο πρότυπα συστήματα με ενδιαφέρον για την ετερογενή κατάλυση. (Α) Στο διμεταλλικό σύστημα Sn/Ni διερευνήθηκαν οι συνθήκες και ο μηχανισμός κραματοποίησης του Sn στην επιφάνεια Ni(111). Το πλήρες επιφανειακό κράμα με δομή (√3×√3)R30°(από περίθλαση ηλεκτρονίων) σχηματίζεται θερμαίνοντας στους 7000C πάνω από 1,2 μονοστρώματα Sn. Οι διατεταγμένες δομές c(4x2) και c(2x2) αποτελούν ένα ενδιάμεσο στάδιο της κραματοποίησης σε χαμηλότερες θερμοκρασίες. Με θερμοπρογραμματισμένη εκρόφηση CO διαπιστώθηκε η βαθμιαία παρεμπόδιση της ρόφησης κατά το σχηματισμό του κράματος. Η διεπιφανειακή αλληλεπίδραση Sn/Ni(111) διερευνήθηκε τόσο με φασματοσκοπίες φωτοηλεκτρονίων, όσο και με θεωρητικούς υπολογισμούς από πρώτες αρχές. (Β) Μελετήθηκαν με φασματοσκοπίες ηλεκτρονίων και σκέδαση ιόντων He ρεαλιστικά πρόδρομα καταλυτικά συστήματα Ziegler – Natta (ZN), παρασκευάζοντας διάφορες σχετικές διεπιφάνειες με εξάχνωση MgCl2 σε υποστρώματα Si(111)7×7, Ti(0001) και SiO2. Η ασθενής αλληλεπίδραση μεταξύ MgCl2 και Si(111)7×7 γίνεται κυρίως μέσω των ατόμων Mg, τα οποία σε χαμηλές καλύψεις συμμετέχουν στη δημιουργία της υπερδομής (√3×√3)R30°. Η αλληλεπίδραση ενισχύεται μετά από θέρμανση, οπότε παραμένει στην επιφάνεια υπομονοστρωματική ποσότητα Mg. Από την άλλη πλευρά, το MgCl2, ακόμα και σε θερμοκρασία δωματίου αλληλεπιδρά ισχυρά με το Ti(0001), κυρίως μέσω των ατόμων Cl. Μετά από θέρμανση, ποσότητα Cl παραμένει συνδεδεμένη με το Ti ενώ απομακρύνεται από την επιφάνεια το Mg. Ασθενής αλληλεπίδραση παρατηρήθηκε μεταξύ MgCl2 και SiO2, ενώ η θέρμανση άφησε στην επιφάνεια υπομονοστρωματική ποσότητα οξειδωμένου Mg. Τέλος, μεταλλικό Ti που αποτέθηκε σε μικτό υπόστρωμα MgCl2 /SiO2 παρουσιάζει οξειδωτικές καταστάσεις οφειλόμενες στην ύπαρξη ατόμων Cl και O στην επιφάνεια, ενώ η θέρμανση οδηγεί στη δημιουργία επιφανειακών συμπλόκων, τα οποία είναι πιθανόν να προσομοιάζουν αντίστοιχα είδη στους πρακτικούς καταλύτες. / Two model systems, important in heterogeneous catalysis, where investigated using surface sensitive spectroscopies. (A) In the bi-metallic system Sn/Ni, the formation conditions and the mechanism of Sn surface alloying on Ni(111) were initially studied. The epitaxial surface alloy formation with LEED structure(√3×√3)R30°, requires annealing at 7000C of more than 1.2 monolayers Sn. The c(4x2) and c(2x2) structures were found to be an intermediate step of surface alloying. Temperature-programmed desorption showed a gradual blocking of CO adsorption with progressing alloying. The interfacial interactions in Sn /Ni(111) were demonstrated both by electron spectrosopies and via first principle calculations. (B) Surface science compatible model catalysts of the Ziegler-Natta (ZN) system were investigated by electron spectroscopies and He ion scattering on relevant interfaces formed via evaporation of MgCl2 on Si(111)7×7, Ti(0001) and SiO2 and upon evaporation of Ti on a MgCl2 /SiO2 mixed substrate.. The weak interaction between MgCl2 and Si(111)7×7 takes place through the Mg atoms, which at low coverage form a new surface structure, namely (√3×√3)R30°. The interaction was stronger after annealing, whereby a submonolayer coverage of Mg atoms remain on the surface. On the other hand, MgCl2 interacts strongly with the Ti substrate even at room temperature via the Cl atoms. Annealing causes the desorption of MgCl2 followed by decomposition, that leaves on the surface only Cl atoms attached to Ti, while no Mg atoms remain on the surface. Only a weak interaction was observed between MgCl2 and SiO2, while annealing resulted in the desorption and decomposition of MgCl2 leaving on the surface a sub-monolayer coverage of oxidized Mg. Upon Ti metal evaporation on the mixed MgCl2 / SiO2 support at room temperature, Ti appears at higher oxidation states, due to reaction with Cl and O atoms at the surface. Annealing causes the formation of surface complexes, which are very likely similar to species formed on practical ZN catalysts.