Effect of Cutting Conditions on the Size of Dust Particles Generated during Milling of Carbon Fibre-Reinforced Composite Materials.

Conventional dry machining (without process media) of carbon fibre composite materials (CFRP) produces tiny chips/dust particles that float in the air and cause health hazards to the machining operator. The present study investigates the effect of cutting conditions (cutting speed, feed per tooth and depth of cut) during CFRP milling on the size, shape and amount of harmful dust particles. For the present study, one type of cutting tool (CVD diamond-coated carbide) was used directly for machining CFRP. The analysis of harmful dust particles was carried out on a Tescan Mira 3 (Tescan, Brno, Czech Republic) scanning electron microscope and a Keyence VK-X 1000 (Keyence, Itasca, IL, USA) confocal microscope. The results show that with the combination of higher feed per tooth (mm) and lower cutting speed, for specific CFRP materials, the size and shape of harmful dust particles is reduced. Particles ranging in size from 2.2 to 99 µm were deposited on the filters. Smaller particles were retained on the tool body (1.7 to 40 µm). Similar particle sizes were deposited on the machine and in the work area.

Elimination of Delamination during the Drilling of Biocomposite Materials with Flax Fibers.

The present study focuses on the elimination of delamination during the drilling of a linen-based biocomposite material in epoxy resin used for the manufacture of sports kayaks, depending on the tool material, cutting conditions, and the use of additional wooden support plates. In the present study, HSS (high-speed steel) and Carbide cutting tools without coatings, with the same geometry and two types of cutting conditions (n = 1500 rpm, fn = 0.05 and 0.1 mm/rev) were used. A Sololite-type wooden backing plate was used to aid in reducing delamination. The results show that the additional support plates significantly reduced delamination by up to 80% both at the material inlet and especially at the drill hole outlet. In this study, the use of a lower feed rate (fn = 0.05 mm/rev) per tooth was shown to have a significant effect on reducing the delamination of biocomposite materials with flax fibers, which are generally known to be difficult to machine. The Carbide cutting tool shows significantly better results both in terms of its wear and in terms of delamination of the biocomposite material. The highest delamination was obtained without the use of a backing board at the tool exit after 50 drilled holes of 3509 µm. With the use of a backing board, this delamination decreased to 693 µm after 50 drilled holes.

Elevated glutathione in researchers exposed to engineered nanoparticles due to potential adaptation to oxidative stress.

Aim: To find a practical biomonitoring method for researchers exposed to nanoparticles causing oxidative stress. Methods: In a continuation of a study in 2016-2018, biological samples (plasma, urine and exhaled breath condensate [EBC]) were collected in 2019-2020 from 43 researchers (13.8 ± 3.0 years of exposure) and 45 controls. Antioxidant status was assessed using glutathione (GSH) and ferric-reducing antioxidant power, while oxidative stress was measured as thiobarbituric acid reactive substances, all using spectrophotometric methods. Researchers' personal nanoparticle exposure was monitored. Results: Plasma GSH was elevated in researchers both before and after exposure (p < 0.01); postexposure plasma GSH correlated with nanoparticle exposure, and GSH in EBC increased. Conclusion: The results suggest adaptation to chronic exposure to nanoparticles, as monitored by plasma and EBC GSH.

What is this study about? Identifying markers of oxidative stress and/or adaptation to oxidation stress could offer tools for monitoring exposure to nanoparticles in exposed researchers. In this study, we question whether these markers correlate with their personal exposure during the shift. What were the results? We found that exposure to nanoparticles correlated with the antioxidant marker glutathione, which is higher in workers who are already pre-exposed. What do the results mean? This study suggests that the researchers have adapted to nanoparticle exposure and are ready to combat oxidative stress. However, the similarity with increased markers of oxidative stress from asbestos and silica exposure, including nucleic acid oxidation, previously found in these researchers highlights the need for further research in this area to better understand and prevent potential future effects.

Destruction of Carbon and Glass Fibers during Chip Machining of Composite Systems.

Composite materials with carbon and glass fibers in an epoxy matrix are widely used systems due to their excellent mechanical parameters, and machining is a standard finishing operation in their manufacture. Previous studies focused exclusively on the characteristics of the fibers released into the air. This work aimed to analyze the nature of the material waste that remains on the work surface after machining. The dust on the work surface is made up of fibers and a polymer matrix, and due to its dimensions and chemical stability, it is a potentially dangerous inhalable material currently treated as regular waste. The smallest sizes of destroyed carbon fibers were generated during drilling and grinding (0.1 µm), and the smallest glass fiber particles were generated during milling (0.05 µm). Due to their nature, carbon fibers break by a tough fracture, and glass fibers by a brittle fracture. In both cases, the rupture of the fibers was perpendicular to or at an angle to the longitudinal axis of the fibers. The average lengths of destroyed carbon fibers from the tested processes ranged from 15 to 20 µm and 30 to 60 µm for glass fibers.

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling.

This study aimed to investigate the effect of the clearance angle of the milling tool on wear, cutting forces, machined edge roughness, and delamination during non-contiguous milling of carbon-fiber-reinforced plastic (CFRP) composite panels with a twill weave and 90° fiber orientation. To achieve the objective of the study, it was first necessary to design suitable tools (6 mm diameter sintered carbide shank milling cutters) with a variety of clearance angles (8.4°, 12.4°, and 16.4°) and all the machinery and measuring equipment for the research to be carried out. Furthermore, measurement and evaluation methods for cutting tool wear, cutting forces, machined edge roughness, and delamination were developed. Last but not least, the results obtained during the research were summarized and evaluated. From the experiments conducted in this study, it was found that the tool clearance angle has a significant effect on tool wear, roughness of the machined surface, and delamination of the carbon fiber composite board. The tool with a clearance angle of 8.4° wore faster than the tool with a clearance angle of 16.4°. The same trend was observed for cutting force, machined surface roughness, and delamination. In this context, it was also shown that the cutting force increased as the tool wear increased, which in turn increased surface roughness and delamination. These results are of practical significance, not only in terms of the quality of the machined surface but also in terms of time, cost, and energy savings when machining CFRP composite materials.

Formation of Nanostructure during Replication of a Hierarchical Plant Surface.

Plant and animal surfaces have become a model for preparing special synthetic surfaces with low wettability, reflectivity, or antibacterial properties. Processes that lead to the creation of replicas of natural character use two-step imprinting methods. This article describes a technique of synthetic polymer surface preparation by the process of two-stage imprinting. The laboratory-prepared structure copies the original natural pattern at the micrometer and sub-micrometer levels, supplemented by a new substructure. The new substructure identified by the scanning electron microscope is created at the nanometer level during the technological process. The nanostructure is formed only under the conditions that a hierarchical structure forms the surface of the natural replicated pattern, the replication mold is from a soft elastomeric material, and the material for producing the synthetic surface is a polymer capable of crystallizing. A new nanometer substructure formation occurs when the polymer cools to standard laboratory temperature and atmospheric pressure.

Individual DNA Methylation Pattern Shifts in Nanoparticles-Exposed Workers Analyzed in Four Consecutive Years.

A DNA methylation pattern represents an original plan of the function settings of individual cells and tissues. The basic strategies of its development and changes during the human lifetime are known, but the details related to its modification over the years on an individual basis have not yet been studied. Moreover, current evidence shows that environmental exposure could generate changes in DNA methylation settings and, subsequently, the function of genes. In this study, we analyzed the effect of chronic exposure to nanoparticles (NP) in occupationally exposed workers repeatedly sampled in four consecutive years (2016-2019). A detailed methylation pattern analysis of 14 persons (10 exposed and 4 controls) was performed on an individual basis. A microarray-based approach using chips, allowing the assessment of more than 850 K CpG loci, was used. Individual DNA methylation patterns were compared by principal component analysis (PCA). The results show the shift in DNA methylation patterns in individual years in all the exposed and control subjects. The overall range of differences varied between the years in individual persons. The differences between the first and last year of examination (a three-year time period) seem to be consistently greater in the NP-exposed subjects in comparison with the controls. The selected 14 most differently methylated cg loci were relatively stable in the chronically exposed subjects. In summary, the specific type of long-term exposure can contribute to the fixing of relevant epigenetic changes related to a specific environment as, e.g., NP inhalation.

Three-Year Study of Markers of Oxidative Stress in Exhaled Breath Condensate in Workers Producing Nanocomposites, Extended by Plasma and Urine Analysis in Last Two Years.

Human data concerning exposure to nanoparticles are very limited, and biomarkers for monitoring exposure are urgently needed. In a follow-up of a 2016 study in a nanocomposites plant, in which only exhaled breath condensate (EBC) was examined, eight markers of oxidative stress were analyzed in three bodily fluids, i.e., EBC, plasma and urine, in both pre-shift and post-shift samples in 2017 and 2018. Aerosol exposures were monitored. Mass concentration in 2017 was 0.351 mg/m3 during machining, and 0.179 and 0.217 mg/m3 during machining and welding, respectively, in 2018. In number concentrations, nanoparticles formed 96%, 90% and 59%, respectively. In both years, pre-shift elevations of 50.0% in EBC, 37.5% in plasma and 6.25% in urine biomarkers were observed. Post-shift elevation reached 62.5% in EBC, 68.8% in plasma and 18.8% in urine samples. The same trend was observed in all biological fluids. Individual factors were responsible for the elevation of control subjects' afternoon vs. morning markers in 2018; all were significantly lower compared to those of workers. Malondialdehyde levels were always acutely shifted, and 8-hydroxy-2-deoxyguanosine levels best showed chronic exposure effect. EBC and plasma analysis appear to be the ideal fluids for bio-monitoring of oxidative stress arising from engineered nanomaterials. Potential late effects need to be targeted and prevented, as there is a similarity of EBC findings in patients with silicosis and asbestosis.

The genotoxic effects in the leukocytes of workers handling nanocomposite materials.

The extensive development of nanotechnologies and nanomaterials poses a number of questions to toxicologists about the potential health risks of exposure to nanoparticles (NP). In this study, we analysed DNA damage in the leukocytes of 20 workers who were long-term exposed (18 ± 10 years) to NP in their working environment. Blood samples were collected in September 2016, before and after a shift, to assess (i) the chronic effects of NP on DNA (pre-shift samples) and (ii) the acute effects of exposure during the shift (the difference between pre- and post-shift samples). The samples from matched controls were taken in parallel with workers before the shift. Leukocytes were isolated from heparinised blood on a Ficoll gradient. The enzyme-modified comet assay (DNA formamido-pyrimidine-glycosylase and endonuclease III) demonstrated a considerable increase of both single- and double-strand breaks in DNA (DNA-SB) and oxidised bases when compared with the controls (2.4× and 2×, respectively). Acute exposure induced a further increase of DNA-SB. The welding and smelting of nanocomposites represented a higher genotoxic risk than milling and grinding of nanocomposite surfaces. Obesity appeared to be a factor contributing to an increased risk of oxidative damage to DNA. The data also indicated a higher susceptibility of males vs. females to NP exposure. The study was repeated in September 2017. The results exhibited similar trend, but the levels of DNA damage in the exposed subjects were lower compared to previous year. This was probably associated with lower exposure to NP in consequence of changes in nanomaterial composition and working operations. The further study involving also monitoring of personal exposures to NP is necessary to identify (i) the main aerosol components responsible for genotoxic effects in workers handling nanocomposites and (ii) the primary cause of gender differences in response to NP action.

DNA Methylation Profiles in a Group of Workers Occupationally Exposed to Nanoparticles.

The risk of exposure to nanoparticles (NPs) has rapidly increased during the last decade due to the vast use of nanomaterials (NMs) in many areas of human life. Despite this fact, human biomonitoring studies focused on the effect of NP exposure on DNA alterations are still rare. Furthermore, there are virtually no epigenetic data available. In this study, we investigated global and gene-specific DNA methylation profiles in a group of 20 long-term (mean 14.5 years) exposed, nanocomposite, research workers and in 20 controls. Both groups were sampled twice/day (pre-shift and post-shift) in September 2018. We applied Infinium Methylation Assay, using the Infinium MethylationEPIC BeadChips with more than 850,000 CpG loci, for identification of the DNA methylation pattern in the studied groups. Aerosol exposure monitoring, including two nanosized fractions, was also performed as proof of acute NP exposure. The obtained array data showed significant differences in methylation between the exposed and control groups related to long-term exposure, specifically 341 CpG loci were hypomethylated and 364 hypermethylated. The most significant CpG differences were mainly detected in genes involved in lipid metabolism, the immune system, lung functions, signaling pathways, cancer development and xenobiotic detoxification. In contrast, short-term acute NP exposure was not accompanied by DNA methylation changes. In summary, long-term (years) exposure to NP is associated with DNA epigenetic alterations.

The repeated cytogenetic analysis of subjects occupationally exposed to nanoparticles: a pilot study.

The application of nanomaterials has been rapidly increasing during recent years. Inhalation exposure to nanoparticles (NP) may result in negative toxic effects but there is a critical lack of human studies, especially those related to possible DNA alterations. We analyzed pre-shift and post-shift a group of nanocomposite researchers with a long-term working background (17.8 ± 10.0 years) and matched controls. The study group consisted of 73.2% males and 26.8% females. Aerosol exposure monitoring during a working shift (involving welding, smelting, machining) to assess the differences in exposure to particulate matter (PM) including nanosized fractions <25-100 nm, and their chemical analysis, was carried out. A micronucleus assay using Human Pan Centromeric probes, was applied to distinguish between the frequency of centromere positive (CEN+) and centromere negative (CEN-) micronuclei (MN) in the binucleated cells. This approach allowed recognition of the types of chromosomal damage: losses and breaks. The monitoring data revealed differences in the exposure to NP related to individual working processes, and in the chemical composition of nanofraction. The cytogenetic results of this pilot study demonstrated a lack of effect of long-term (years) exposure to NP (total frequency of MN, P = 0.743), although this exposure may be responsible for DNA damage pattern changes (12% increase of chromosomal breaks-clastogenic effect). Moreover, short-term (daily shift) exposure could be a reason for the increase of chromosomal breaks in a subgroup of researchers involved in welding and smelting processes (clastogenic effect, P = 0.037). The gender and/or gender ratio of the study participants was also an important factor for the interpretation of the results. As this type of human study is unique, further research is needed to understand the effects of long-term and short-term exposure to NP.

Leukocyte telomere length is not affected by long-term occupational exposure to nano metal oxides.

The aim of this study was to ascertain whether long-term occupational exposure to nanoparticles would affect relative leukocyte telomere length (LrTL). We analysed occupational exposure to size-resolved aerosol particles, with special emphasis on nanoparticles at two workshops: i/ the production of nanocomposites containing metal oxides; ii/ laboratory to test experimental exposure of nano-CuO to rodents. Thirty five exposed researchers (age 39.5 ± 12.6 yr; exposure duration 6.0 ± 3.7 yr) and 43 controls (40.4 ± 10.5 yr) were examined. LrTL did not significantly (p=0.14) differ between the exposed researchers (0.92 ± 0.13) and controls (0.86 ± 0.15). In addition, no significant correlation (r=-0.22, p=0.22) was detected between the duration of occupational exposure and LrTL. The results remained non-significant after multiple adjustments for age, sex and smoking status. Our pilot results suggest that relative leukocyte telomere length is not affected by occupational exposure to nanoparticles.

Deep Airway Inflammation and Respiratory Disorders in Nanocomposite Workers.

Thousands of researchers and workers worldwide are employed in nanocomposites manufacturing, yet little is known about their respiratory health. Aerosol exposures were characterized using real time and integrated instruments. Aerosol mass concentration ranged from 0.120 mg/m³ to 1.840 mg/m³ during nanocomposite machining processes; median particle number concentration ranged from 4.8 × 104 to 5.4 × 105 particles/cm³. The proportion of nanoparticles varied by process from 40 to 95%. Twenty employees, working in nanocomposite materials research were examined pre-shift and post-shift using spirometry and fractional exhaled nitric oxide (FeNO) in parallel with 21 controls. Pro-inflammatory leukotrienes (LT) type B4, C4, D4, and E4; tumor necrosis factor (TNF); interleukins; and anti-inflammatory lipoxins (LXA4 and LXB4) were analyzed in their exhaled breath condensate (EBC). Chronic bronchitis was present in 20% of researchers, but not in controls. A significant decrease in forced expiratory volume in 1 s (FEV1) and FEV1/forced vital capacity (FVC) was found in researchers post-shift (p ˂ 0.05). Post-shift EBC samples were higher for TNF (p ˂ 0.001), LTB4 (p ˂ 0.001), and LTE4 (p ˂ 0.01) compared with controls. Nanocomposites production was associated with LTB4 (p ˂ 0.001), LTE4 (p ˂ 0.05), and TNF (p ˂ 0.001), in addition to pre-shift LTD4 and LXB4 (both p ˂ 0.05). Spirometry documented minor, but significant, post-shift lung impairment. TNF and LTB4 were the most robust markers of biological effects. Proper ventilation and respiratory protection are required during nanocomposites processing.

Markers of Oxidative Stress in the Exhaled Breath Condensate of Workers Handling Nanocomposites.

Researchers in nanocomposite processing may inhale a variety of chemical agents, including nanoparticles. This study investigated airway oxidative stress status in the exhaled breath condensate (EBC). Nineteen employees (42.4 ± 11.4 y/o), working in nanocomposites research for 18.0 ± 10.3 years were examined pre-shift and post-shift on a random workday, together with nineteen controls (45.5 ± 11.7 y/o). Panels of oxidative stress biomarkers derived from lipids, nucleic acids, and proteins were analyzed in the EBC. Aerosol exposures were monitored during three major nanoparticle generation operations: smelting and welding (workshop 1) and nanocomposite machining (workshop 2) using a suite of real-time and integrated instruments. Mass concentrations during these operations were 0.120, 1.840, and 0.804 mg/m³, respectively. Median particle number concentrations were 4.8 × 104, 1.3 × 105, and 5.4 × 105 particles/cm³, respectively. Nanoparticles accounted for 95, 40, and 61%, respectively, with prevailing Fe and Mn. All markers of nucleic acid and protein oxidation, malondialdehyde, and aldehydes C6⁻C13 were elevated, already in the pre-shift samples relative to controls in both workshops. Significant post-shift elevations were documented in lipid oxidation markers. Significant associations were found between working in nanocomposite synthesis and EBC biomarkers. More research is needed to understand the contribution of nanoparticles from nanocomposite processing in inducing oxidative stress, relative to other co-exposures generated during welding, smelting, and secondary oxidation processes, in these workshops.