International Journal of Surface Science and Engineering (4 papers in press)

Regular Issues

• Numerical analysis and experimental investigation on the dynamic performance of groove-textured surfaces  
  by Yaochen Shi, Daohan Wang, Shicheng Zhao, Zhuo Zhang, Yufei Nie, Ning Ding 
  Abstract: This study investigates the influence of groove width on contact characteristics and vibration behaviour in 45 steel-chloroprene rubber friction pairs through numerical simulations and reciprocating friction tests. Results demonstrate that grooves interrupt continuous contact stress distribution via area-loss effects, mitigating stress concentration intensity and vibrational continuity. However, excessive groove width exacerbates over-groove impact phenomena. Numerical analysis reveals that contact stress decreases by 28.6-%49.7% as groove width increases from 400 um to 800 um, with minimal over-groove impact. Conversely, 1,000-2,000 m grooves intensify edge stress concentration and vibration amplitudes due to pronounced over-groove impacts. Experimental measurements confirm 5.9%-11.3% and 17.8%-23.1% increases in absolute average acceleration amplitude and root mean square (RMS) for 1,0002,000 m grooves compared to 800 um, validating the degradation mechanism. The medium groove width (800 m) achieves an optimal balance between interfacial stress optimisation and vibration suppression, significantly improving interfacial contact behaviour.
  Keywords: groove texture; tribological properties; numerical analysis; groove width; contact stress.
  DOI: 10.1504/IJSURFSE.2025.10073682
   
  
• Influence of auto correlation length in mean and actual summit radii based multi asperity Gaussian rough surface contact models  
  by Jayashri N. Nair, Nachimuthu Somasundaram, Annapoorna M. Srinivasa Rao, Gokul Biju, B.S. Hari, Santosh Mani 
  Abstract: Different Gaussian rough surfaces are considered by varying the auto correlation length. Then, mean summit and actual summit radii based multi asperity contact models are developed. The contact parameters of contact load and contact area are calculated using single asperity contact model results. In high ACL/SL case, at extreme interference, the mean summit and actual summit radii based multi asperity contact models showed 48% and 70% difference in contact area ratio and 30% and 49% difference in contact load ratio respectively. A power law expression is developed to relate the contact load and contact area. A dynamism in elastic-plastic contact states of summits is identified which is discussed in detail too.
  Keywords: Gaussian rough surface; summit radius; multi asperity contact; elastic-plastic; auto correlation length.
  DOI: 10.1504/IJSURFSE.2025.10074505
   
  
• Rheological and tribological assessment of bio-enhanced coconut oil-based green cutting fluids  
  by Umair Ashraf, Sheikh Shahid Saleem 
  Abstract: Green cutting fluids (GCFs) offer an eco-friendly alternative to synthetic fluids by replacing mineral constituents with sustainable additives. Formulated with coconut oil as base, CAPB as emulsifier, garlic oil as extreme pressure additive, and almond oil as anti-oxidant, GCFs (B01 to B07) exhibit significantly higher viscosities, transitioning to non-Newtonian flow. Viscosity increases 1627 times at 25 C and 100-121 times at 100 C. B03 and B04 show stable viscosity and excellent high-temperature performance. During tribological tests, B04 reduced friction by 8.6% and wear by 30.17%. Surface-analysis revealed smoother wear-tracks with sulphur-rich layers from garlic oil, confirmed by FESEM/EDAX. Incorporating garlic oil and almond oil resulted in shallow wear scars. For B04, skewness of 0.638 and kurtosis of 3.922 indicate deep valleys with rounder peaks, enhancing lubricant storage and flow GCFs B03 and B04 have shown excellent potential as replacement of mineral cutting fluids ensuring proper heat dissipation and effective wear protection.
  Keywords: green cutting fluids; GCFs; bio-additives; manufacturing; viscosity; tribology.
  DOI: 10.1504/IJSURFSE.2026.10076052
   
  
• Improved mechanical, wear and corrosion behaviour of nano-alumina reinforced electrodeposited Ni-P-Mo alloy coatings on HSLA steel  
  by Rabeeka Ferdous, Humaira Kousar, Nabeel Ahmad, Muhammad Siyar, Malik Adeel Umer, Khuram Shahzad, Rana Abdul Shakoor, Muhammad Irfan 
  Abstract: Nanoparticle reinforced ternary alloy coatings offer significant advancement in surface engineering applications. We hereby report on a unique system comprising alumina nanoparticle reinforced ternary Ni-P-Mo composite coatings electrodeposited onto HSLA steel substrates. Detailed characterisation showed exceptional enhancement of the mechanical, wear and corrosion resistant properties. An optimised alumina nanoparticle addition (0.3 g/L) drastically improved hardness up to 35.5% and reduced wear rate by around 11.52% compared to pure Ni-P-Mo coatings. Moreover, a significant reduction in corrosion rate in Ni-P-Mo/Al2O3 (0.3 mils/yr) was observed compared to Ni-P-Mo (4.8 mils/yr). However, the introduction of Al2O3 nanoparticles at concentrations exceeding 0.3 g/L seemed to have a detrimental effect on the coating morphology, leading to compromised mechanical strength, wear resistance and corrosion resistant properties.
  Keywords: Ni-P-Mo; corrosion; composite coatings; wear; nano-indentation.
  DOI: 10.1504/IJSURFSE.2026.10076163