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In recent years, reduced graphene oxide (rGO) received considerable interest as a lubricant nano-additive for enhancing sliding and rolling contacts. This paper investigates the tribological and dynamic behavior of ball bearings lubricated by lithium grease at different weight percentages of rGO. Full bearing tests were conducted for experimental modal analysis, vibration analysis, ultrasonic analysis, and infrared thermography. Modal analysis indicated considerable improvements of the damping ratio values up to 50% for the bearings with rGO nano-additives. These findings were confirmed by the corresponding reductions in vibrations and ultrasound levels. The steady-state temperatures of bearings running with lithium grease reached 64 °C, whereas the temperature of bearings lubricated by grease with 2 wt.% rGO measured only 27 °C. A Timken Load test was conducted on grease samples with and without rGO additives. Grease samples having 2, 3.5, and 5 wt.% rGO showed the highest OK load with an increase of 25%, 50%, and 100% as compared to values of lithium grease. For comparison, all tests were conducted on samples of the same grease blended with graphite and MWCNTs’ nano-additives. The results proved the superiority of graphene in enhancing the load-carrying capacity and damping of grease in rolling bearings.

The widespread use of mineral cutting fluids in metalworking poses challenges due to their poor wettability, toxicity, and non-biodegradability. This study explores cactus oil-based nanofluids as sustainable alternatives for metal cutting applications. Samples of cactus oil are prepared in plain form and with 0.025 wt.%, 0.05 wt.%, and 0.1 wt.% activated carbon nanoparticles (ACNPs) from recycled plastic waste. Plain cactus oil exhibited a 34% improvement in wettability over commercial soluble oil, further enhanced by 60% with 0.05 wt.% ACNPs. Cactus oil displayed consistent Newtonian behavior with a high viscosity index (283), outperforming mineral-based cutting fluid in thermal stability. The addition of ACNPs enhanced the dynamic viscosity by 108–130% across the temperature range of 40–100 °C. The presence of nano-additives reduced the friction coefficient in the boundary lubrication zone by a maximum reduction of 32% for CO2 compared to plain cactus oil. The physical and rheological results translated directly to the observed improvements in surface finish and tool wear during machining operations on H13 steel. Cactus oil with 0.05 wt.% ACNP outperformed conventional fluids, reducing surface roughness by 35% and flank wear by 57% compared to dry. This work establishes cactus oil-based nanofluids as a sustainable alternative, combining recycled waste-derived additives and non-edible feedstock for greener manufacturing.

A worldwide growing trend is dedicated towards reducing carbon dioxide emissions from mechanical systems in different industries. One key factor under focus of research is to decrease energy losses in rotating machinery during operation by improving lubrication performance. This paper presents a novel grease nano-additive using activated carbon (AC) as a byproduct from recycled polymer waste. Five different concentrations of AC nanoparticles (ACNPs) are added to lithium grease to obtain blends containing 0.025 wt.%, 0.05 wt.%, 0.1 wt.%, 0.5 wt.%, and 1 wt.%. The tribological assessment of blends has been performed using a four-ball wear test and load carrying capacity test. The obtained results for blends are compared to samples of base grease and to blends with 2 wt.% reduced graphene oxide (rGO). Test results showed a remarkable enhancement of load carrying capacity of AC samples by 20–30% as compared to base grease. By observing wear scar in rolling elements, the ACNPs lowered the average wear scar diameter (WSD) for all samples by 30–36%. Base grease samples showed the highest coefficient of friction (COF) values between 0.15 and 0.17. These values are reduced to 0.03 and 0.06 for grease with ACNPs reaching their minimum in the case of 1 wt.% AC. These outcomes are found consistent with the enhancements in driving power saving values. The results proved the competitiveness and suitability of the AC as a recycled waste and nano-additive for improving the tribological performance of grease lubrication.

In recent years, bio-lubricants have received a growing interest for industrial applications. Still, a full-scale implementation in machinery lubrication requires a thorough evaluation of their performance through tribological and operational tests to stand upon their performance. Additionally, the promising outcomes achieved by nanoadditives in improving the performance of synthetic lubricants have prompted research efforts to identify suitable nanoadditives for bio-grease. This paper introduces a bio-grease from a hybrid vegetable oil and glycerol monostearate as a thickener for the lubrication of rolling bearings. Activated carbon nanoparticles (ACNPs) as nanoadditives were synthesized, characterized, and incorporated into the bio-grease at concentrations of 0.5, 1, and 2% by weight. Tribo-tests were conducted on these bio-grease blends, and running tests were carried out using 6006 ball bearings on a custom test rig. Throughout a 30-min test run under a radial load of 10% of the bearing’s dynamic load rating, mechanical vibrations and power consumption were measured and analyzed for each bearing. The bio-grease with ACNPs exhibited a substantial reduction in wear scar diameter (WSD) and coefficient of friction (COF), achieving improvements of up to 73.6 and 65%, respectively, in comparison to lithium grease. Furthermore, the load carrying capacity was enhanced by 200%. The study revealed a strong correlation between measured vibration amplitudes and the viscosity of the bio-grease. The absence of high frequency resonant bands in vibration spectra indicated that the test grease samples satisfied the conditions of elastohydrodynamic lubrication, and these findings were corroborated through calculations of the minimum oil film thickness.

The role of industrial lubricants in machinery is to reduce friction and wear between moving components. Due to the United Nations’ tendency to reduce dependency on fossil fuel, a general awareness is strongly driven towards developing more eco-friendly lubricants. Palm oil possesses promising properties, which promote it to be a competitive alternative to the hostile mineral oils. Still, marginal oxidation stability, viscosity, and tribological properties remain critical issues for performance improvement. This paper presents an improved palm grease using reduced graphene oxide (rGO) and zinc oxide (ZnO) nano-additives at different concentrations. Oil and grease samples were tested for viscosity, oxidation stability, pour point, penetration, roll stability, dropping point, churned grease-oil release, copper corrosion, friction, and wear. ZnO additives enhanced the oxidation stability by 60% and shifted the pour point to 6 °C. Adding ZnO and rGO to the palm grease increased the load-carrying capacity between 30% and 60%, respectively, and reduced the friction coefficient by up to 60%. From the wear scar morphologies, it is believed that graphene 2D nanoparticles formed absorption layers which contributed to the increase in load-carrying capacity, while ZnO chemically reacted with the metallic surface layer, forming zinc compounds that resulted in a protective boundary lubricating film.

This paper presents a novel grease from jojoba oil and activated carbon nanoparticles (ACNPs) extracted from banana peel waste. The raw jojoba oil and ACNPs are first characterized for structural properties. Samples of jojoba grease blended with 0.5 and 1.5 wt. % ACNPs are prepared and tested for physicochemical and tribological properties as compared to plain jojoba grease. Adding ACNPs to jojoba grease improves corrosion resistance from grade 2c to 1a while increasing the dropping point from 100 to 109 °C. ACNPs enhanced the viscosity of jojoba oil by up to 33% for testing temperature range of 40–100 °C. The load-carrying capacity of jojoba grease is increased by about 60% when blended with 1.5 wt.% ACNPs. The same blending decreased both the coefficient of friction and the wear scar diameter by 38% and 24%, respectively. A customized test rig is used to test the effectiveness of the grease samples in rolling bearing lubrication in terms of vibration levels and power consumption. The novel jojoba grease proved to show exceptional reductions power consumption reaching 25%. The vibration spectra show the absence of resonant peaks at high frequencies suggesting the capability of jojoba grease to form a stable full film lubrication.

In this work, the aqueous Lawsonia inermis extract (LI) is investigated as an economic and green deterioration inhibitive formula for steel alloy 4130 in 3.5 wt.% NaCl solutions. The water-based extraction process is considered as one of the cheapest techniques for preparation of active ingredients of natural products. These ingredients play an important role in corrosion mitigation of steel alloy 4130 in saline media. This extract was subjected to three different parameters: inhibitor concentration, rotation speed, and temperature in 3.5 wt.% NaCl solutions. The electrochemical techniques are used to perceive the corrosion behavior, and the obtained results were dedicated to theoretical explorations to assess the features of corrosion inhibition and the adsorption over the steel substrate in 3.5 wt.% NaCl solutions. Affording to the electrochemical techniques of LI showed very promising results against corrosion depending on the inhibitor concentrations. The inhibition efficiency of LI was additionally appraised at three diverse temperatures, and the results disclosed that the inhibition efficiency is decreased. Additionally, the theoretical aspects illuminated that the main active ingredients of LI have a proclivity to coagulate on the steel substrates allowing these areas to paradigm a protecting layer on the steel surfaces. This behavior is in provision of investigational results. Statistical studies were used to examine the consequence of chief constraints (i.e., inhibitor concentration, temperature, and rotation speed) on the inhibition efficiency and the rate of corrosion of steel alloy 4130. The inhibitive effect of LI in contradiction of the corrosion of steel alloy 4130 surfaces is considered by resources of DFT/6-31G(d) calculations. The quantum chemical parameters interrelated to the inhibition efficiency are considered.

Hydrogen, as a renewable zero-carbon fuel, is an ideal alternative to internal combustion engine fuels. The paper numerically investigates the effect of piston geometry on lean combustion in hydrogen engines, focusing on early and late injection strategies. Two novel piston bowl designs, referred to as the right-concave piston and left-concave piston, were analyzed for their interaction with hydrogen jets during mixture formation and combustion processes. Validation of the numerical outputs were conducted using an experimental testbench. Results reveal that the right-piston had a stronger and larger scale tumble, compared to the flat-top piston, facilitating hydrogen diffusion. However, due to their early injection timing, mixture distribution at ignition timing was relatively uniform, resulting in comparable indicated thermal efficiency (ITE) and NOx emissions. Conversely, the left-concave piston demonstrated inferior ITE and higher emissions under single injection but achieved superior performance with an optimized dual injection strategy. This strategy improved mixture stratification increased thermal efficiency, and significantly reduced NOx emissions. The key findings highlight the critical role of piston geometry and injection strategy in optimizing hydrogen combustion engines for higher efficiency and lower emissions.

The performance of rolling element bearings is one of the machine quality measures in industry. The fatigue life and performance of rolling element bearings depends mainly on the dynamic characteristics of those bearings. This paper studied the effect of the internal radial clearance on the damping characteristics, natural modes of vibration, and fatigue life of rolling element bearings. Vibration modal analysis was performed on rolling bearings of the same size and type to measure their dynamic characteristics. These dynamic characteristics include the natural frequency of the first mode of vibration, damping, and amplitude of frequency response function at resonance. The internal radial clearances of these bearings were measured. A statistical analysis was performed to study the correlation between the internal radial clearance and the dynamic characteristics of rolling bearings. It was found that the damping ratio of the bearing assembly increased by reducing the internal radial clearance of the bearing. Similarly, rolling bearings that have large internal clearances showed short predicted fatigue life. It is concluded that the dynamic characteristics, and consequently the dynamic performance, of rolling bearings are significantly affected by the internal radial clearance.

The current study focuses on axial ultrasonic vibration-assisted micro-milling as an advanced technique to improve the machining performance of Ti6Al4V, a material whose difficult-to-cut properties present a significant barrier to manufacturing the high-quality micro-components essential for aerospace and biomedical applications. A full factorial design was employed to evaluate the influence of feed-per-tooth (fz), axial depth-of-cut (ap), and ultrasonic vibration on cutting forces, surface roughness, burr formation, and tool wear. Experimental results demonstrate that ultrasonic assistance significantly reduces cutting forces by 20.09% and tool wear by promoting periodic tool–workpiece separation and improving chip evacuation. However, it increases surface roughness due to the formation of uniform micro-dimples, which may enhance tribological properties. Burr dimensions were primarily governed by feed-per-tooth, with higher feeds minimizing burr size. The study provides actionable insights into optimizing machining parameters for cutting Ti6Al4V, highlighting the trade-offs between force reduction, surface texture, and burr control. These findings contribute to advancing ultrasonic-assisted micro-milling for industrial applications, namely aerospace and biomedical applications requiring high precision and extended tool life.