Mask-guided microbial jet machining for functionalized textured interface fabrication

This study innovatively develops a novel Mask-Guided Microbial Jet Machining (MGMJM) technology, successfully achieving the precision fabrication of functional microconfigurations on the contact interface of phosphor copper-tin alloy (ZCuSn10Pb1), which significantly enhances the material’s friction and wear performance. By ingeniously integrating the metabolic activity of Acidithiobacillus ferrooxidans with a directional jetting process of cultured supernatant, this technology establishes an efficient and precise new method for microbial machining of surface texturing. Experimental data demonstrated the outstanding processing efficiency advantages of MGMJM: its Material etching rate is 59.36 times higher than that of traditional immersion methods and 5.27 times higher than shaking methods. More importantly, the micro-dimple elements configurations fabricated by this method exhibited excellent multi-scale morphological consistency. Micro-tribological performance tests confirmed that the friction coefficient of the textured interface processed by MGMJM can be reduced by up to 56.8% compared to smooth surfaces, fully validating the technology’s environmentally friendly characteristics and sustainable manufacturing advantages. This paper systematically reveals the material removal mechanism of MGMJM technology, laying an important theoretical foundation for expanding the engineering applications of microbial machining technologies. The innovative application of this technology in the fields of micro-texturing contact interface and micro-functional component manufacturing not only provides a reliable technical solution for the precision manufacturing of bio-functional textured interfaces but also offers new research insights and practical guidance for the development of green manufacturing technologies.