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A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

Several applications, where extreme conditions occur, require the use of alloys often containing many critical elements. Due to the ever increasing prices of critical raw materials (CRMs) linked to their high supply risk, and because of their fundamental and large utilization in high tech products and applications, it is extremely important to find viable solutions to save CRMs usage. Apart from increasing processes’ efficiency, substitution, and recycling, one of the alternatives to preserve an alloy and increase its operating lifetime, thus saving the CRMs needed for its manufacturing, is to protect it by a suitable coating or a surface treatment. This review presents the most recent trends in coatings for application in high temperature alloys for aerospace engines. CRMs’ current and future saving scenarios in the alloys and coatings for the aerospace engine are also discussed. The overarching aim of this paper is to raise awareness on the CRMs issue related to the alloys and coating for aerospace, suggesting some mitigation measures without having the ambition nor to give a complete overview of the topic nor a turnkey solution.

High specific strength characteristics make magnesium alloys widely demanded in many industrial applications such as aviation, astronautics, military, automotive, bio-medicine, energy, etc. However, the high chemical reactivity of magnesium alloys significantly limits their applicability in aggressive environments. Therefore, the development of effective technologies for corrosion protection is an urgent task to ensure the use of magnesium-containing structures in various fields of application. The present paper is aimed to provide a short review of recent achievements in corrosion protection of magnesium alloys, both surface treatments and coatings, with particular focus on Mg-Al-Mn-Ce, Mg-Al-Zn-Mn and Mg-Zn-Zr alloys, because of their wide application in the transport industry. Recent progress was made during the last decade in the development of protective coatings (metals, ceramics, organic/polymer, both single layers and multilayer systems) fabricated by different deposition techniques such as anodization, physical vapour deposition, laser processes and plasma electrolytic oxidation.

High Entropy Alloys (HEA) are multi-principal element materials that have been intensively studied over the past decade. In this work, two Al–Fe–Cr–Ni–Cu HEAs were synthesized and processed into thin films by DC magnetron sputtering, and their structural, mechanical and electrochemical properties were systematically evaluated. The coatings exhibited dense, uniform structures with strong adhesion to 304 L stainless steel. Coatings hardness was higher than the substrate material. Electrochemical tests in 3.5 g/L NaCl solution revealed superior corrosion resistance for the I8-10-derived coating, which achieved the lowest corrosion rate (5.54E-05 mm/year) and the highest polarization resistance (5.470.008 Ω), outperforming both the bulk alloys and uncoated substrates.

Halogenated benzaldehydes possess unique chemical properties that render them valuable in pharmaceutical synthesis, pesticide formulation, and dye production. However, thorough thermodynamic data for these compounds remain scarce. This study aims to fill this knowledge gap by investigating key physical properties of several halogenated benzaldehydes, namely 4-chlorobenzaldehyde, 4-bromobenzaldehyde, 2,3-dichlorobenzaldehyde, 2,4-dichlorobenzaldehyde, and 2,6-dichlorobenzaldehyde. The physical properties determined in this study include volatility, phase transitions, and water solubility, all of which are crucial for predicting the environmental fate of these compounds. The vapor pressures of both crystalline and liquid phases were measured using a reliable static method, allowing for the determination of standard molar enthalpies, entropies, and Gibbs energies of sublimation and vaporization, as well as their triple points. The melting temperature and molar enthalpy, along with the isobaric molar heat capacity of the crystalline phase, were assessed using differential scanning calorimetry. Water solubility was evaluated at 25 °C through the saturation shake-flask method, complemented by ultra-violet visible spectroscopy. By combining sublimation and solubility data, additional properties such as Gibbs energies of hydration and Henry’s law constants were derived. The experimental results were integrated into existing databases, enhancing the predictive models for properties including melting temperature, vapor pressure, solubility, Gibbs energy of hydration, and Henry’s constant. These findings significantly improve the environmental modeling capabilities, providing valuable insights into the mobility and fate of halogenated benzaldehydes in various environmental contexts.

Protection against microbiologically influenced corrosion (MIC) is critical for materials used in aquatic environments, as MIC accelerates material degradation and leads to faster structural failure. Copper (Cu) has the potential to substantially improve the MIC resistance in alloys. In this study, high-entropy alloy (HEA) coatings containing Cu were deposited using DC (Direct Current) magnetron sputtering to enhance the corrosion resistance and mechanical properties of various substrates. Two CuCrFeMnNi HEA compositions in the form of bulk alloys and PVD (Physical Vapor Deposition) coatings, with 5% and 10% Cu, were analyzed for their microstructural, mechanical, and anticorrosive characteristics. Deposition parameters were varied to select the optimal values. Microstructural evaluations using SEM-EDS (scanning electron microscopy and energy dispersive X-ray spectroscopy), XRD (X-ray diffraction), and AFM (atomic force microscopy) revealed uniform, dense coatings with good adhesion composed of dendritic and interdendritic BCC (body-centered cubic) and FCC (face centered cubic) structures, respectively. Microhardness tests indicated improved mechanical properties for the samples coated with developed HEAs. The coatings exhibited improved corrosion resistance in NaCl solution, the 10% Cu composition displaying the highest polarization resistance and lowest corrosion rate. These findings suggest that Cu-containing HEA coatings are promising candidates for applications requiring enhanced corrosion protection.

The structure and magnetic properties of epitaxial Heusler alloy films (Co2FeGe) deposited on MgO (100) substrates were investigated. Films of 60 nm thickness were prepared by magnetron co-sputtering at different substrate temperatures (TS), and those deposited at room temperature were later annealed at various temperatures (Ta). X-ray diffraction confirmed (001) [110] Co2FeGe || (001) [100] MgO epitaxial growth. A slight tetragonal distortion of the film cubic structure was found in all samples due to the tensile stress induced by the mismatch of the lattice parameters between Co2FeGe and the substrate. Improved quality of epitaxy and the formation of an atomically ordered L21 structure were observed for films processed at elevated temperatures. The values of magnetization increased with increasing TS and Ta. Ferromagnetic resonance (FMR) studies revealed 45° in-plane rotation of the easy anisotropy axis direction depending on the degree of the tetragonal distortion. The film annealed at Ta = 573 K possesses the minimal FMR linewidth and magnetic damping, while both these parameters increase for another TS and Ta. Overall, this study underscores the crucial role of thermal treatment in optimizing the magnetic properties of Co2FeGe films for potential spintronic and magnonic applications.

Thin polycrystalline Co2FeGe films with composition close to stoichiometry have been fabricated using magnetron co-sputtering technique. Effects of substrate temperature (TS) and post-deposition annealing (Ta) on structure, static and dynamic magnetic properties were systematically studied. It is shown that elevated TS (Ta) promote formation of ordered L21 crystal structure. Variation of TS (Ta) allow modification of magnetic properties in a broad range. Saturation magnetization ~920 emu/cm3 and low magnetization damping parameter α ~ 0.004 were achieved for TS = 573 K. This in combination with soft ferromagnetic properties (coercivity below 6 Oe) makes the films attractive candidates for spin-transfer torque and magnonic devices.

The heterostructures of five monolayers B1-Ti x Zr 1−x N(111), x = 1.0, 0.6, 0.4 and 0.0 (where B1 is a NaCl-type structure) with one monolayer of a Si 3 N 4 -like Si 2 N 3 interfacial layer were investigated by means of first-principles quantum molecular dynamics and a structure optimization procedure using the Quantum ESPRESSO code. Slabs consisting of stoichiometric TiN and ZrN and random, as well as segregated, B1-Ti x Zr 1−x N(111) solutions were considered. The calculations of the B1-Ti x Zr 1−x N solid solutions, as well as of the heterostructures, showed that the pseudo-binary TiN-ZrN system exhibits a miscibility gap. The segregated heterostructures in which Zr atoms surround the Si y N z interface were found to be the most stable. For the Zr-rich heterostructures, the total energy of the random solid solution was lower compared to that of the segregated one, whereas for the Ti-rich heterostructures the opposite tendency was observed. Hard and super hard Zr-Ti-Si-N coatings with thicknesses from 2.8 to 3.5 μm were obtained using a vacuum arc source with high frequency stimulation. The samples were annealed in a vacuum and in air at 1200 °C. Experimental investigations of Zr-Ti-N, Zr-Ti-Si-N and Ti-Si-N coatings with different Zr, Ti and Si concentrations were carried out for comparison with results obtained from Ti x Zr 1−x N(111)/SiN y systems. During annealing, the hardness of the best series samples was increased from (39.6 ± 1.4) to 53.6 GPa, which seemed to indicate that a spinodal segregation along grain interfaces was finished. A maximum hardness of 40.8 GPa before and 55 GPa after annealing in air at 500 °C was observed for coatings with a concentration of elements of Si  (7-8) at.%, Ti  22 at.% and Zr  70 at.%.