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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 433 records · Page 24

Development of Remote Laser Decontamination System - 18183

A cleaning method using a laser ablation technology is widely used in various industries such as automobile, aviation, and semiconductor industries. Recently, applying this technology to decontamination works has been receiving attention as a useful and effective decontamination method. The laser decontamination method allows for decreasing a generation of secondary radioactive waste because materials like abrasive and water are not required. This is one of big advantages in use for decontamination works. Additionally, the system is compact and requires less than 100 W electric power. These features provide a low running cost. Remote operation obviously plays an important role in terms of a dose reduction in highly-radioactive and contaminated environment. The laser decontamination method is also suitable for remote works using manipulators as the laser head is light and compact, and a reaction force during operation is small, compared to the other types of decontamination tools. This paper provides an outline and a capability of the remote laser decontamination system developed by IHI Corporation (IHI) with some results of component tests for this system. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Erosion-Corrosion Detection in Carbon Steel Pipe Loops using SRNLs Thickness and Mass Loss Measurement Coupons - 20464

Structural health of waste transfer infrastructure is of utmost importance to DOE and communities surrounding their active sites. A Fitness-for-Service (FFS) program for the Waste Transfer System has been implemented by the US Department of Energy (DOE) for the purposes of evaluating and quantifying the degradation of critical components. Currently, the method of approach is to section and evaluate pipelines that have been removed at end service. In order to augment data collection methods applied to making lifespan estimates of waste transfer system components, Florida International University (FIU) has been investigating new-technology based strategies for quantifying the rate of degradation. Present research considers the option of a coupon system installed on a section of pipe at points of interest that will provide easy access to high resolution measurements of erosion/corrosion rates during operation. Researchers at Savannah River National Laboratory (SRNL) have developed this novel solution for in situ erosion and corrosion measurements in many applicable locations such as tanks, pipes, ducts, and injection points. The coupons are approximately 12.7 mm (1/2 inch) in diameter and 25.4 mm (1 inch) in length and can be placed in the pipe sections using Swagelok compression fittings. The coupon design allows for monitoring of the total degradation resulting from corrosion and erosion. High-resolution Ultrasonic Thickness (UT) testing allows in-situ monitoring of both degradation mechanisms. When removed from the system mass loss resulting from corrosion and erosion may also be evaluated. Experimental testing at FIU implemented the SRNL coupon system in a 6.10 meter (20 foot) pipe loop system comprised of 50.8 mm (2 inch) and 76.2 mm (3 inch) pipe sections in order to replicate expected use cases at the sites. Operational conditions were emulated by pumping abrasive materials through the pipeline at full capacity and collecting measurements from the SRNL coupons. Initial testing was conducted by circulating water followed by a mixture of sand and water for uniform wear rates. Thickness changes and mass loss were measured, and the surface exposed to the process fluid was observed for visual evidence of characteristic wear patterns resulting from an erosive environment. The test matrix consisted of several hours of operation and using fine, medium and coarse grain sands. Test results were analyzed to check for all three parameters (mass loss/gain, thickness change and surface patters) which could provide estimates of the remaining useful life of the pipe sections. Thus, the research presents the findings of this evaluation of the SRNL coupons as a means for conducting high accuracy, cost effective in-situ analysis of pipeline and waste transfer systems for erosion and corrosion susceptibility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Graphite Dust Deposition on HTGR Steam Generator: Effect of Particle-wall Impact - 18520

Generated by abrasion of fuel spheres, graphite dust is an important issue for the operation and maintenance of high-temperature gas-cooled reactor (HTGR), since the transport of fission product is closely coupled with graphite dusts. AVR experiments on dust specific radioactivity indicate that graphite dust deposition on steam generator (SG) should be of special interest. Most previous simulations on graphite dust deposition assume a hit-and-stick nature for particles, which may overestimate the deposition rate. In this work we uses a critical velocity model to account for particle-wall interaction. Combined with computational fluid dynamics simulation and discrete phase method, the deposition of graphite dust in the upper 22 layers of SG tubes was studied with particle-wall interaction considered. The result shows that the deposition rate is highly overestimated if hit-and-stick is assumed. For particles larger than 5 {mu}m, the difference can be as large as 3 times. Particle deposition rate reaches maximum at about 3 {mu}m. As for the spatial distribution, few particles deposit on the first layer of tubes due to relative low Stokes number while more depositions occur after entering bundle zone, which indicates that the unsteady wake among tubes could be a major mechanism for the deposition. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Fragmentation Modeling for Space Applications: Charge Dispersion Effects - Paper 136

Fragmenting of high-energy heavy ions in nuclear collisions is an important process in space radiation transport, shielding and risk assessment since the secondary particles produced by these collisions have ranges greater than their parent nucleus, and are damaging to humans and spacecraft components. This work uses a quantum-mechanical optical potential abrasion-ablation collision-modeling concept in which nucleons in both the projectile and target are removed by a combination of knockout and evaporation processes in these collisions. In the knockout stage, the collision results in some of the struck projectile nucleons exiting the nucleus and leaving an excited pre-fragment, which then deexcites by a emitting photons, nucleons and light ions by a cascade-evaporation process. The main thrust of this work is to investigate differences in isotope and element production cross sections as a result of utilizing two very different models of charge-to mass ratios for the projectile pre-fragments produced by the abrasion/knockout process. (authors)

61 RADIATION PROTECTION AND DOSIMETRY↗

Superhard Materials: Advances in the Search and Synthesis of New Materials

Materials with superior hardness can be categorized as ultrahard (Vickers hardness, H v ≥ 80 GPa) and superhard (H v ≥ 40 GPa). These materials are commonly used as cutting tools and abrasives in the machining and manufacturing industries. With its extreme hardness, diamond is the best known and most used ultrahard material for industrial applications. However, it is ineffective at cutting and drilling ferrous alloys due to diamond's high reactivity with iron and poor thermal stability in air. Additionally, the synthesis of diamond requires both high pressure (HP) and high temperature, making it an expensive process. These limitations have driven the search for alternative superhard materials that are capable of cutting steels and other materials at lower costs. This article reviews the concept of hardness and summarizes advancements in the synthesis and mechanical properties of hard materials. It begins with a review of methods to measure hardness, adding HP diffraction methods to more conventional hardness measurements. It then considers new ultrahard materials that exist within the B–C–N ternary system, with hardness approaching diamond but improved chemical stability. Finally, it surveys superhard nitrides, oxides, and borides as potential alternative materials, focusing on transition metal boride systems where the synthesis can be readily achieved at ambient pressure and scaled for industrial applications. We hope that this article serves as an overview of hard materials and guide for the comparison of data reported in the literature.

36 MATERIALS SCIENCE↗

Magneto-Acoustic Mixing Technology: A Novel Method of Processing Metal-Matrix Nanocomposites

In recent decades, nanoparticles have received substantial scientific attention due to their novel behavior and industrial applications, from quantum dots to catalysis.Synthesis of nanoparticles is often challenging, since they exist far from equilibrium with a high surface to volume ratio. This work investigates a novel nanoparticle fabrication methodology: combined reaction and acoustic cavitation abrasion of a solid in contact with a liquid. A mechanism is proposed by which particles are generated more effectively by the combination of reaction and cavitation than by either independently. In the current study, a novel method known as Magneto-Acoustic Mixing Technology (MAMT)[3] is used to produce nanometer to micron sized particles by chemical and acoustic mechanisms between diamond particles and a stainless steel surface in the presence of a metallic liquid, in this application Mg. This method demonstrates a number of advantages, including fabrication of novel chemistries and continuous particle production. This methodology is also easily adaptable to an in-situ nanoparticle generation mechanism for the production of metal matrix nanocomposites (MMnCs). In-situ particle generation methods like MAMT inherently limit particle agglomeration and improve the safety of nanocomposite fabrication by eliminating environmental contamination. In the current study, particle size, volume fraction, and chemistry are investigated, as well as the interaction of sonic power and chemical reaction.

36 MATERIALS SCIENCE↗

Material-Dependent Antagonistic Effects between Soot and ZDDP

While soot in engine oil is known to accelerate the wear of diesel and gasoline direct-injection compression-ignition engines, there is a lack of consensus on the wear mechanism though various hypotheses have been proposed in the literature. Particularly, some recently observed antagonistic effects between soot and a common lubricant antiwear additive, zinc dialkyldithiophosphate (ZDDP), while others did not. The discrepancy is, in part, explained by the strong alloy dependence of such antagonism discovered in this study. Specifically, four alloys, 52100 steel and M2, M50, and A2 tool steels, are tested in lubricants containing carbon black (CB, a soot surrogate) with and without ZDDP present. Adding the CB alone to the oil increases the wear rate for all steel alloys as expected. However, distinct wear performance is observed for the four steel alloys when ZDDP is introduced to the CB-containing oil: while the 52100 steel has notable wear reduction, the three tool steels suffer significant wear increase. Comprehensive tribofilm characterization suggests that the Mo content in the steel alloy and the sulfur from ZDDP strongly influence wear behavior. The combination of CB/Mo-catalyzed sulfidation and CB-accelerated abrasion is hypothesized to be responsible for the high wear of the Mo-alloyed tool steels.

36 MATERIALS SCIENCE↗

Effect of Nano-Y{sub 2}O{sub 3} on Microstructure and Crack Formation in Laser Direct-Deposited In Situ Particle-Reinforced Fe-Based Coatings

In situ hard-particle-reinforced Fe-based composite coatings were prepared on Q235 steel substrates by direct laser deposition using Fe-based alloy powders containing 2 wt.% B, 3 wt.% Si and 1-3 wt.% nano-Y{sub 2}O{sub 3}. The microstructures, phase compositions, hardnesses and wear resistances of the deposited coatings with different nano-Y{sub 2}O{sub 3} contents were studied using metallographic microscopy, scanning electron microscopy, x-ray diffraction, transmission electron microscopy, microhardness tests and pin-on-disk abrasion tests (MMW-1A), respectively. The results showed that the appropriate addition of Y{sub 2}O{sub 3} played a role in grain refinement and in decreasing the number of brittle phases and impurity elements in the grain boundaries. Consequently, the number of cracks in the laser-deposited coating also decreased. The Fe-based composite coatings were mainly composed of α-Fe, γ-Fe and in situ-produced reinforced particle phases, such as Cr{sub 23}C{sub 6}, Cr{sub 7}C{sub 3}, (Cr, Fe){sub 7}C{sub 3}, Fe{sub 2}B, and CrFeB. When the content of nano-Y{sub 2}O{sub 3} was 2 wt.%, a Fe-based composite coating with a thickness of 4 mm that was free of cracks was obtained, and its surface hardness reached 650HV. Moreover, the wear resistance of the coating with 2 wt.% nano-Y{sub 2}O{sub 3} was the best among the samples studied. The presence of nano-Y{sub 2}O{sub 3} increased the solubility of Cr and Si in the solid solution, which eliminated the residual austenite region, and as a result, the phase transformation from γ-Fe to α-Fe was restrained and the transformation stress was also limited, thereby decreasing the probability of cracks in the coatings.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Comparative Analysis of the Microstructural Features of 28 wt.% Cr Cast Iron Fabricated by Pulsed Plasma Deposition and Conventional Casting

The effect of pulsed plasma deposition (by an electrothermal axial plasma accelerator) followed by post-heat treatment on the structure and microhardness of a 28 wt.% Cr white cast iron is analyzed and discussed with respect to the microstructure of the conventionally cast monolithic counterpart. The cast iron (as deposited on a 14 wt.% Cr cast iron substrate) had a microhardness of 630-750 HV{sub 0.05}; it had layered light contrast/dark contrast structure where dark contrast layers contain fine carbide network. Pulsed plasma deposition followed by heat treatment resulted in a substantial refinement of the microstructure: eutectic M{sub 7}C{sub 3} coarse acicular plates in the conventional cast iron were replaced by fine M{sub 7}C{sub 3}, M{sub 3}C{sub 2}, M{sub 3}C particles (Cr depleted in favor of Fe), while the initial carbide particle of 2-3 μm was reduced to 0.6 μm. Secondary dendrite arm spacing decreased from 15 to 1.3 μm, accordingly. The carbide volume fraction in the post-heat-treated coating remarkably increased with respect to the conventional counterpart resulting in a substantial increase in the coating hardness (1300-1750 HV{sub 0.05}). The heat-treated coating displayed higher resistance to three-body abrasion than the as-deposited coating and similar resistance with that of the conventionally cast iron.

36 MATERIALS SCIENCE↗

On Development and Wear Behavior of Microwave-Processed Functionally Graded Ni-SiC Clads on SS-304 Substrate

In this study, the functionally graded Ni-SiC claddings with gradual change in SiC contents were deposited on SS-304 substrate using microwave hybrid heating technique. Experimental trials were carried out inside a multimode domestic microwave device at 2.45 GHz and 900 W. The optimal exposure time of 900 W microwave power was varied with compositional gradient, and it was from 300 to 360 s. The developed functionally graded clad (FGC) was characterized by SEM/EDS, XRD and Vicker’s micro-hardness. Microstructural analysis results revealed that the FGC of approximately 2 mm thickness was developed and was free from any type of interfacial cracks and visible porosity. The maximum micro-hardness was at the top FGC layer, and its value was 1025 ± 30 HV. Three types of single-layer claddings were also developed to compare the tribological behavior of FGC. FGC exhibited 32 and 1.2 times more wear resistance than SS-304 substrate and Ni + 30% SiC layer, respectively. In the case of FGC, wear mainly occurs due to debonding of carbide particles from the matrix, while plastic deformation and strong abrasion are responsible for material loss in the case of the SS-304 substrate.

36 MATERIALS SCIENCE↗

Investigation of the Effect of Residual Stress Gradient on the Wear Behavior of PVD Thin Films

The control of residual stresses has been seldom investigated in multilayer coatings dedicated to improvement of wear behavior. Here, we report the preparation and characterization of superposed structures composed of Cr, CrN and CrAlN layers. Nano-multilayers CrN/CrAlN and Cr/CrN/CrAlN were deposited by Physical Vapor Deposition (PVD) onto Si (100) and AISI4140 steel substrates. The Cr, CrN and CrAlN monolayers were developed with an innovative approach in PVD coatings technologies corresponding to deposition with different residual stresses levels. Composition and wear tracks morphologies of the coatings were characterized by scanning electron microscopy, high-resolution transmission electron microscopy, atomic force microscopy, x-ray photoelectron spectroscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction and 3D-surface analyzer. The mechanical properties (hardness, residual stresses and wear) were investigated by nanoindentation, interferometry and micro-tribometry (fretting-wear tests). Observations suggest that multilayer coatings are composed mostly of nanocrystalline. The residual stresses level in the films has practically affected all the physicochemical and mechanical properties as well as the wear behavior. Consequently, it is demonstrated that the coating containing moderate stresses has a better wear behavior compared to the coating developed with higher residual stresses. The friction contact between coated samples and alumina balls shows also a large variety of wear mechanisms. In particular, the abrasive wear of the coatings was a combination of plastic deformation, fine microcracking and microspallation. The application of these multilayers will be wood machining of green wood.

36 MATERIALS SCIENCE↗

Wear Behavior of AZ31/Al{sub 2}O{sub 3} Magnesium Matrix Surface Nanocomposite Fabricated via Friction Stir Processing

The aim of this study was to produce magnesium-based surface nanocomposites via friction stir processing and to investigate the effect of tool rotational speed on the microstructure, hardness and wear behavior. The surface of the nanocomposites was characterized using optical and scanning electron microscopes, as well as through microhardness and wear tests. The results indicated that with the increase in rotational speed, the grain size of the surface nanocomposites increased, but its hardness decreased despite the improved distribution of Al{sub 2}O{sub 3} nanoparticles. It was also found that the wear resistance has a direct relation to the distribution of the Al{sub 2}O{sub 3} nanoparticles. Furthermore, the addition of nano-Al{sub 2}O{sub 3} changed the wear mechanism from the adhesive mode in the as-received AZ31 to the abrasive mode in the nanocomposite specimens. The rotational speed of 1400 rpm was an optimum parameter to achieve a suitable composite layer with the highest wear resistance.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Wear Mechanisms in Contacts Involving Slippers in Axial Piston Pumps: A Multi-Technical Analysis

Axial piston pumps are widely used in actuation as power conversion systems, especially in aeronautics. Even though they combine compactness and efficiency, wear of their parts reduces their lifespan. Studies on these pumps often consist in analytic or numerical analyses of lubricated contact between their components. Piston slippers are in tribological contacts with swashplate, pistons and slipper retainer. This study aims to understand wear mechanisms in the contacts involving this central component. An experimental multi-technical analysis of helicopter pumps parts after several functioning times is presented. To determine wear mechanisms, worn surfaces are observed with SEM. 3D surface roughness measurements provide surface topography. Contact conditions and consequently wear severity and mechanisms differ from one contact to another. Detached coarse carbides from the swashplate surface act as an abrading third-body against slippers and swashplate. Debris generated in this contact is carried by the fluid to the other contacts. Although pistons are made of the same steel as swashplate, there is no carbide detachment and wear comes from debris polluting the fluid. Slipper retainer is almost not worn, and debris causes abrasive wear and craters generation in the slippers.

36 MATERIALS SCIENCE↗

Surface Self-nanocrystallization in Copper Electroforming

The coarse columnar grain layer generated on top of electroforming deposits leads to low surface strength and poor global performance of deposits. Here, we introduce a particle abrasive-induced surface self-nanocrystallization process, which is a part of the electroforming process rather than involving complex poststeps using special equipment. It can generate a thickness-controllable surface nanocrystalline layer on top of copper deposits for performance enhancement. In this study, surface nanocrystalline layers of 10, 20, 50 and 120 μm were fabricated on top of 500-μm-thick copper deposits. The tensile strength of copper deposits increases from 234 to 246, 330, 383 and 421 MPa, with a corresponding decrease in elongation from 26 to 25, 24, 15 and 6%, respectively. The moderately thick surface nanocrystalline layer makes the copper deposits exhibit good comprehensive mechanical properties. In addition, the surface self-nanocrystallization also makes the copper deposits show a better corrosion resistance in a neutral aqueous 0.1 M NaCl solution. This study aims to promote a convenient, controllable and reliable surface self-nanocrystallization process in electroforming for improving the global performance of deposits.

36 MATERIALS SCIENCE↗

Parametric Optimization of Erosive Wear Response of TiAlN-Coated Aluminium Alloy Using Taguchi Method

In this research work, high-velocity oxy-fuel thermal spraying is used to develop TiAlN coatings on AA1050 and AA5083 aluminium alloy substrates. Slurry wear behavior of coatings is evaluated using jet-type test rig. Surface studies were carried out to investigate the potential erosion mechanism. The influence of key parameters identified using the Taguchi analysis is also corroborated with a wear model. The potential mechanism identified by wear model is in excellent convergence with that observed experimentally. Mixed ploughing and cutting, formation of platelets, abrasion grooves and cracks are witnessed as primary mechanisms causing loss of coating. Results indicate that impact velocity is recognized as a highly contributing parameter with contribution ratio of 79.24 and 83.75% followed by impingement angle with contribution ratio of 15.81 and 11.58% for AA1050 and AA5083, respectively. The important sequences of the control parameters are recognized to be impact velocity > impingement angle > erodent feed rate > erodent size for AA1050 and impact velocity > impingement angle > erodent size > erodent feed rate for AA5083. The best possible combination of control parameters for AA1050 and AA5083 to achieve minimal wear rate with respect to impact velocity, erodent size, impingement angle and erodent feed rate is 30 m/s, 225 µm, 30°, 160 g/min and 25 m/s, 150 µm, 30°, 160 g/min, respectively.

36 MATERIALS SCIENCE↗

Effect of Oxygen Content on Wear and Cutting Performance of AlCrON Coatings

In this work, AlCrON coatings with various oxygen contents were deposited by multi-arc-ion plating technology. The effects of oxygen content on the microstructure, mechanical properties, wear and cutting performance of AlCrON coatings were investigated. The result showed that the O contents in the AlCrON coatings increased from 0 to 8.8 wt.% by changing the O{sub 2}/N{sub 2} flow ratios during the deposition process. The AlCrON coatings mainly included fcc-CrN and fcc-AlN phases, and the Al{sub 2}O{sub 3} and Cr{sub 2}O{sub 3} were also confirmed by the XPS results. Addition of oxygen improved the adhesion strength of AlCrON coatings. The AlCrON coating with 4.0 wt.% oxygen content showed the low surface roughness, low friction coefficient and the minimum wear rate. Cutting results also showed that addition of oxygen improved the service life of AlCrON coatings under various cutting conditions. The service life of AlCrON coatings increased firstly and then decreased with increasing oxygen contents, and the AlCrON coating with 4.0 wt.% oxygen content had the maximum cutting length under various cutting conditions, which might be due to the decrease of surface roughness, increase of adhesion strength and hardness. The wear mechanism involved in cutting process included abrasive wear, adhesive wear and oxidation wear.

36 MATERIALS SCIENCE↗

Effects of Co{sub 3}O{sub 4} Addition on Friction and Dry Sliding Wear Characteristics of 8 mol% Yttria-Stabilized Cubic Zirconia

The aim of the present study was to investigate the influence of Co{sub 3}O{sub 4} additive on the microstructure, wear, and tribological properties of 8 mol% yttria-stabilized cubic zirconia (8YSZ) using a pin-on-disk tribometer, surface profilometer, hardness tester, and a scanning electron microscopy system. Specimens were produced by doping 1-15 wt.% Co{sub 3}O{sub 4} in 8YSZ using a colloidal process, sintering at 1500 °C for 1 h, and subsequent annealing at 1500 °C for 10 and 50 h. Microstructural analysis showed that Co{sub 3}O{sub 4} dissolved partially in 8YSZ, with the undissolved Co{sub 3}O{sub 4} precipitating as a secondary phase at the grain boundaries. Further, the addition of Co{sub 3}O{sub 4} enhanced the grain size. Wear tests were carried out using an Al{sub 2}O{sub 3} ball as the counterface against ceramic disk under dry sliding friction conditions at room temperature (24 °C). The wear volume of 8YSZ decreased from 0.30 to 0.11 mm{sup 3} as a result of the addition of 15 wt.% Co{sub 3}O{sub 4}. Additionally, friction coefficient of the 8YSZ significantly reduced from 0.55 to 0.17 at the beginning stage of the sliding after the addition of 15 wt.% Co{sub 3}O{sub 4}. This was because Co{sub 3}O{sub 4} creates a thin lubricating layer on the friction surface. In addition, the undoped and Co{sub 3}O{sub 4}-doped 8YSZ specimens exhibited abrasive wear under the dry sliding friction conditions, owing to the formation and propagation of microcracks, which resulted in the removal of material from the surface. The specific wear rate of 8YSZ decreased with increasing the Co{sub 3}O{sub 4} content. Thus, the addition of Co{sub 3}O{sub 4} to 8YSZ improves its wear resistance and surface topography.

36 MATERIALS SCIENCE↗

Processing, As-Cast Microstructure and Wear Characteristics of a Monotectic Al-Bi-Cu Alloy

Ternary Al-based monotectic alloys have a good combination of wear resistance and mechanical strength. While self-lubricating soft elements guarantee an adequate wear resistance, the modification with third elements can increase the ability to support load. In the present investigation, a collection of microstructures is generated through transient directional solidification of the Al-3.2wt.%Bi-3.0wt.%Cu alloy. Samples with different Bi spacing have been subjected to micro-adhesive wear ball tests. A relationship linking the wear volume, V, the microstructural spacing and the test time is proposed for Bi spacing higher than 16 μm, according to which V decreases with the decrease in Bi spacing. It is observed that wider and deeper grooves emerged on the surface of the samples related to more refined Bi and Al{sub 2}Cu phases, that is, associated with Bi spacing and Bi diameter lower than 16 and 2.4 μm, respectively. A reverse trend is noted for these finer microstructures, for which V increases with further decrease in Bi spacing. This can be caused by the detachment of the very fine and less cohesive Al{sub 2}Cu lamellas as the Al{sub 2}O{sub 3} oxide breaks up forming debris, with the presence of these lamellas as loose debris at the interface acting as third-body abrasives.

36 MATERIALS SCIENCE↗