Metals doi: 10.3390/met14030350
Authors: Songyuan Ai Yifan Li Mujun Long Haohao Zhang Dengfu Chen Huamei Duan Danbin Jia Bingzhi Ren
Exploring the mechanism of the α-ferrite precipitation process on high-temperature properties plays an important guiding role in avoiding slab cracks and effectively regulating quality. In this work, in situ observation of the α-ferrite sustained precipitation behavior for peritectic steel during the austenitic phase transition process has been investigated using high-temperature confocal scanning laser microscopy. Meanwhile, the high-temperature evolution of the phase fractions during the phase transition process was quantitatively analyzed based on the high-temperature expansion experiment using the peak separation method. Furthermore, the high-temperature properties variations of the casting slab during the α-ferrite sustained precipitation process were investigated with the Gleeble thermomechanical simulator. The results show that the film-like ferrite precipitated along the austenite grain boundaries at the initial stage of phase transition, then needle-like ferrite initiates rapid precipitation on film-like ferrite when the average thickness reaches 15~20 μm. Hot ductility reached a minimum at the ferrite phase fraction fα = 10~15%, while high-temperature properties returned to a higher level after fα > 40~45%. The appearance of a considerable amount of needle-like ferrite and grain refinement effectively improves the high-temperature properties with the α-ferrite precipitation process advances.
]]>Metals doi: 10.3390/met14030349
Authors: Zhen Peng Zhang
In this paper, the fluid flow, slag entrainment and solidification process in a slab mold were studied using physical modeling and numerical simulation. The effect of two types of submerged entry nozzles (SENs) was also studied. The results showed that the surface velocity for type A SEN was larger than that using type B SEN. For type A SEN, the maximum surface velocity was 0.63 m/s and 0.56 m/s, and it was 0.20 m/s and 0.18 m/s for type B SEN. The larger shear effect on the top surface made the slag at narrow face impacted to the vicinity of 1/4 wide face, while the slag layer at the top surface was relatively stable for type B SEN. Increasing the immersion depth of SEN decreased the surface velocity and slag entrainment. For type A SEN, the thickness of the solidified shell at the narrow face of the mold outlet was thin (12.3 mm) and there was a risk of breakout. For type B SEN, the liquid steel with high temperature would flow to the meniscus and it was beneficial to the melting of the mold flux. The thickness of the solidified shell at the narrow face of the mold outlet was increased. Furthermore, the surface velocity was also increased and it was not recommended for high casting speed.
]]>Metals doi: 10.3390/met14030348
Authors: Hualin Cai Zhixuan Ma Jiayi Zhang Liang Qi Jinbing Hu Jiayi Zhou
Vacuum electron-beam welding (EBW) was used to join the precipitation-strengthened GH4169 superalloy and a new nickel-based superalloy IC10 to fabricate the turbine blade discs. In this study, a solid solution (1050 °C/2 h for GH4169 and 1150 °C/2 h for IC10) and different heat-exposure temperatures (650 °C, 750 °C, 950 °C and 1050 °C/200 h, respectively) were used to study the high-temperature tensile properties and microstructure evolution of welded joints; meanwhile, the formation and evolution of the second phases of the joints were analyzed. After EBW, the welded joint exhibited a typical nail morphology, and the fusion zone (FZ) consisted of columnar and cellular structures. During the solidification process of the molten pool, Mo elements are enriched in the dendrites and inter-dendrites, and that of Nb and Ti elements was enriched in the dendrites, which lead to forming a non-uniform distribution of Laves eutectic and MC carbides in the FZ. The microhardness of the FZ gradually increased during thermal exposure at 650 °C and reached 300–320 HV, and the γ′ and γ″ phases were gradually precipitated with size of about 50 nm. Meanwhile, the microhardness of the FZ decreased to 260–280 HV at 750 °C, and the higher temperature resulted in the coarsening of the γ″ phase (with a final size of about 100 nm) and the formation of the acicular δ-phase. At 950 °C and 1050 °C, the microhardness of FZ decreased sharply, reaching up to 170~190 HV and 160~180 HV, respectively. Moreover, the Laves eutectic and MC carbides are dissolved to a greater extent without the formation of γ″ and δ phases; as a result, the absent of γ″ and δ phases are attributed to the significant improvement of segregation at higher temperatures.
]]>Metals doi: 10.3390/met14030347
Authors: Laura Kreinest Johannes Schüssler Onur Özaydin Sujith Kochuthundil Subhash Edgar Willenborg Andreas Bührig-Polaczek
Laser remelting is being explored as a viable technique for obtaining a graphite-free, defect-free surface layer on cast iron EN GJS 400-15. The goal is to obtain a large remelted layer along with a low surface roughness to enable a subsequent manual high-gloss surface finish. The impact of the laser remelting process parameters is evaluated by using samples with three different cooling rates, resulting in different graphite microstructures. By utilizing four passes and a laser power of 300 W, the smallest roughness and largest remelting depth are achieved. The remelted layer is mostly devoid of graphite particles. Subsequent manual polishing is performed to evaluate the potential for achieving a high-gloss finish with a roughness of Sa < 0.05 µm. Laser remelting alone does not improve visual appearance or reduce roughness. However, after manual polishing, the roughness of the laser-remelted surfaces with Sa = 0.018 µm is one order of magnitude smaller than the manually polished initial state. Graphite removal during laser remelting therefore makes it possible to achieve a conventional and high-gloss polish, overcoming the previous limitations of GJS materials.
]]>Metals doi: 10.3390/met14030346
Authors: Tomohiko Hojo Akihiko Nagasaka Junya Kobayashi Yuki Shibayama Eiji Akiyama
The effects of hydrogen on the tensile properties, fatigue life, and tensile and fatigue fracture morphologies of nitrogen-added ultrahigh-strength transformation-induced plasticity (TRIP)-aided martensitic (TM) steels were investigated. The total elongation and number of cycles to failure (Nf) of the hydrogen-charged TM steels decreased with the addition of nitrogen; in particular, adding 100 ppm of nitrogen decreased the total elongation and Nf of the TM steels. The quasi-cleavage cracking around the AlN occurred near the sample surface, which is the crack propagation region, although dimples appeared at the center of the fracture surface in the tensile samples. The initial fatigue crack initiated at the AlN precipitate or matrix/AlN interface, located at the notch root. During crack propagation, new cracks were initiated at the AlN precipitates or matrix/AlN interfaces, while quasi-cleavage crack regions were observed around the AlN precipitates. The decrease in the total elongation and Nf of the hydrogen-charged TM steel with 100 ppm of added nitrogen might be attributable to the crack initiation around the AlN precipitates formed by a large amount of hydrogen trapped at the AlN precipitates and matrix/AlN interfaces, and to the dense distribution of AlN, which promoted crack linkage.
]]>Metals doi: 10.3390/met14030345
Authors: Xiaoqin Wang Zhulin Zhou Xuting Si Youcai Lu Qingchao Liu
In order to overcome the interface emulsification problem of TBP-FeCl3 systems and the instability of β-diketone systems in high-concentration alkaline medium, it is necessary to design and synthesize some new extractants. By introducing amino groups into a phosphorus extractant, a new 2-ethylhexyl hydrogen {[bis(2-ethylhexyl)amino]methyl} phosphonate acid (HA) extractant was synthesized. In this study, an efficient method of recovering lithium from the effluent of spent lithium-ion batteries (LIBs) is proposed. Experiments were conducted to assess the influential factors in lithium recovery, including the solution pH, saponification degree, extractant concentration, and phase ratio. Over 95% of lithium in the effluent was extracted into the organic phase, and nearly all lithium in the organic phase could be stripped into the aqueous phase using a 3 mol/L HCl solution. There was no significant decrease in extraction capacity after 10 cycles. The experimental results indicated that the extraction mechanism was a cation exchange process, and the extractive complex was proposed as LiA. Importantly, after three months of stable operation, the process demonstrated excellent stability and extraction efficiency, with rapid phase separation and a clear interface. This study offers an efficient, cost-effective, and environmentally friendly method for lithium extraction from the effluent of spent LIBs.
]]>Metals doi: 10.3390/met14030344
Authors: Junqing Guo Bo Wang Shizhong An
The morphology of phases in magnesium alloys is vitally important for their performance. It is found that improved discharge performance is achieved in AZ72-0.05La alloy via a refining Mg17Al12 phase by means of hot rolling. Before rolling, as-cast AZ72-0.05La alloy has a relatively coarse and strip-like Mg17Al12 phase. After rolling, the Mg17Al12 phase becomes much finer, showing a granulated shape. Due to the refinement of the Mg17Al12 phase, the discharge voltage and energy density of an Mg-air battery with as-rolled AZ72-0.05La alloy as the anode increases by 6% and 3% under a discharge current density of 20 mA·cm−2 in a 3.5% NaCl solution, respectively. The corrosion rate of the as-rolled AZ72-0.05La alloy is slightly larger than the as-cast AZ72-0.05La alloy, but still much lower than as-cast AZ72 alloy. The as-rolled AZ72-0.05La alloy possesses a discharge voltage of 0.74 V and an energy density of 918 mWh·g−1 under a discharge current density of 20 mA·cm−2, and a relatively low corrosion rate of 0.51 mg·cm−2·h−1, demonstrating good overall discharge performance. This work provides a method for improving the discharge performance of Mg-air batteries.
]]>Metals doi: 10.3390/met14030343
Authors: Gengliang Liu Jiaxuan Yang Tianren Shan Huaimei Li Dianlong Wang Lipo Yang
In response to the challenging difficult-to-deform of magnesium foils, a high-efficiency and high-precision electro-rolling temperature field coupled model is established. This model is designed to simulate the non-annealing electric rolling (NAER) process of Mg foils under conditions of high current density, rapid temperature rise rates, and large temperature gradients. Firstly, a coupled temperature field difference model for the guide roller, roll, and Mg foil is established, based on the equipment for NAER and the electrification conditions. The Joule heat, distortion heat, and friction heat in the electric rolling process were precisely considered. Secondly, considering the peculiarity of the heat source and the heat transfer mechanism during NAER, the influence of the dynamic boundary conditions on the instantaneous temperature of the Mg foil was analyzed, which was closer to the actual situation. The experimental results show that the original model can accurately simulate the transient temperature change in Mg foils during NAER, and the error between the predicted value and the measured value is within 7.1%. According to the calculation of the model, the microstructure of completely recrystallized magnesium foil with a grain size of 4.61 μm and a texture strength of 11.3 can be obtained at an inlet temperature of 250 °C.
]]>Metals doi: 10.3390/met14030342
Authors: Mohammed Abdelmaola Brian Thurston Boyd Panton Anupam Vivek Glenn Daehn
This study demonstrates that the thickness of the target and its backing condition have a powerful effect on the development of a wave structure in impact welds. Conventional theories and experiments related to impact welds show that the impact angle and speed of the flyer have a controlling influence on the development of wave structure and jetting. These results imply that control of reflected stress waves can be effectively used to optimize welding conditions and expand the range of acceptable collision angle and speed for good welding. Impact welding and laser impact welding are a class of processes that can create solid-state welds, permitting the formation of strong and tough welds without the creation of significant heat affected zones, and can avoid the gross formation of intermetallic in dissimilar metal pairs. This study examined small-scale impact using a consistent launch condition for a 127 µm commercially pure titanium flyer impacted against commercially pure copper target with thicknesses between 127 µm and 1000 µm. Steel and acrylic backing layers were placed behind the target to change wave reflection characteristics. The launch conditions produced normal collision at about 900 m/s at the weld center, with decreasing impact speed and increasing angle moving toward the outer perimeter. The target thickness had a large effect on wave morphology, with the wave amplitude increasing with target thickness in both cases, peaking when target thickness is about twice flyer thickness, and then falling. The acrylic backing showed a consistently smaller unwelded central zone, indicating that impact welding is possible at a smaller angle in that case. Strength was measured in destructive tensile testing. Failure was controlled by the breakdown of the weaker of the two base metals over all thicknesses and backings. This demonstrates that laser impact welding is a robust method for joining dissimilar metals over a range of thicknesses.
]]>Metals doi: 10.3390/met14030341
Authors: Facundo Almeraya-Calderon Miguel Villegas-Tovar Erick Maldonado-Bandala Maria Lara-Banda Miguel Angel Baltazar-Zamora Griselda Santiago-Hurtado Demetrio Nieves-Mendoza Luis Daimir Lopez-Leon Jesus Manuel Jaquez-Muñoz Francisco Estupiñán-López Citlalli Gaona-Tiburcio
Precipitation-hardening stainless steels, like AM 350 and Custom 450, are extensively utilized in various aerospace applications. The latter steel is utilized for applications needing great strength and corrosion resistance. In contrast, the former steel has a good corrosion resistance and moderate strength. The purpose of this study was to analyze transient frequencies in the electrochemical noise of Custom 450 and AM 350 stainless steels that had been passivated for 60 and 90 min at 25 and 49 °C using baths of citric and nitric acid and then immersed in solutions containing 1% sulfuric acid (H2SO4) and 5% sodium chloride (NaCl). The potentiodynamic polychromatic curves employed electrochemical techniques and noise (EN) based on the ASTM-G5 and G199 standards. Two methods of data analysis were applied concerning EN: the domain of frequencies (power spectral density, PSD) and the time–frequency domain (Hilbert-Huang Transform). The PHSS passivated in citric acid indicated current densities in the H2SO4 solution between 10−2 and 10−3 mA/cm2, while those in the NaCl solution were recorded around 10−4 and 10−5 mA/cm2. The citric acid functions as a passivating agent. The results of the electrochemical noise analysis show that the PHSS passivated in nitric acid displayed a greater corrosion resistance. Moreover, there is a tendency for PHSS to be passivated in nitric acid to corrode locally.
]]>Metals doi: 10.3390/met14030340
Authors: Ruifeng Dong Jian Li Zishuai Chen Wei Zhang Xing Zhou
The primary objective of this paper is to investigate the influence of deformation degree on the microstructure and properties of a Ni-based superalloy. An upsetting experiment was conducted using a free-forging hammer to achieve a deformation degree ranging from 60% to 80%. The impact of the forging deformation degree on the hardness and high-temperature erosion performance was evaluated using the Rockwell hardness tester (HRC) and high-temperature erosion tester, respectively. The experimental results indicate that as the deformation degree increased, the hardness of the forged material progressively increased while the rate of high-temperature erosion gradually decreased. In order to comprehensively study the mechanism behind the variations in forging performance, optical microscopy (OM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) were employed. The findings reveal that as the deformation degree increased, the presence of small-angle grain boundaries and an increase in grain boundary area contributed to enhanced hardness in the alloy forgings. Furthermore, it was discovered that grain boundaries with twin orientation promoted dynamic recrystallization during deformation, specifically through a discontinuous dynamic recrystallization mechanism. Additionally, the precipitated γ′ phase in the alloy exhibited particle sizes ranging from 40 to 100 nm. This particle size range resulted in a higher critical shear stress value and a more pronounced strengthening effect on the alloy.
]]>Metals doi: 10.3390/met14030339
Authors: Mojtaba Karamimoghadam Mohammad Rezayat Mahmoud Moradi Antonio Mateo Giuseppe Casalino
This article discusses recent advancements in the Laser Surface Transformation Hardening (LSTH) process applied to industrial metals. It focuses on examining the microstructure of the metal surface layer and explores different methods of performing LSTH to evaluate mechanical and surface properties. The study also investigates the utilization of various industrial lasers and simulation software for the LSTH process. The careful analysis of heat transfer and temperature control during LSTH aims to prevent the generation of surface defects like micro-cracks and surface melting. Finite element method (FEM) software effectively simulates the LSTH process. The research provides a comprehensive overview of recent developments in LSTH, categorized based on different metals and subsequent testing, highlighting its applications in the automotive industry. Electrochemical, wear, and microhardness tests are investigated to assess the potential applications of automotive metals.
]]>Metals doi: 10.3390/met14030338
Authors: Aljaž Blažič Igor Škrjanc Vito Logar
In steel recycling, the optimization of Electric Arc Furnaces (EAFs) is of central importance in order to increase efficiency and reduce costs. This study focuses on the optimization of electric arcs, which make a significant contribution to the energy consumption of EAFs. A three-phase equivalent circuit integrated with the Cassie–Mayr arc model is used to capture the nonlinear and dynamic characteristics of arcs, including arc breakage and ignition process. A particle swarm optimization technique is applied to real EAF data containing current and voltage measurements to estimate the parameters of the Cassie–Mayr model. Based on the Cassie–Mayr arc parameters, a novel Arc Quality Index (AQI) is introduced in the study, which can be used to evaluate arc quality based on deviations from optimal conditions. The AQI provides a qualitative assessment of arc quality, analogous to indices such as arc coverage and arc stability. The study concludes that the AQI serves as an effective operational tool for EAF operators to optimize production and increase the efficiency and sustainability of steel production. The results underline the importance of understanding electric arc dynamics for the development of EAF technology.
]]>Metals doi: 10.3390/met14030337
Authors: Yibo Liu Changzeng Fan Bin Wen Zhefeng Xu Ruidong Fu Lifeng Zhang
Although the Al2Fe phase has similar decagonal-like atomic arrangements as that of the orthorhombic Al5Fe2 phase, no evidence for intergrowth samples of Al2Fe and Al5Fe2 has been reported. In the present work, the co-existence of Al2Fe and Al5Fe2 phases has been discovered from the educts obtained with a nominal atomic ratio of Al:Fe of 2:1 by arc melting. First, single-crystal X-ray diffraction (SXRD) as well as scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscopy (EDX) measurements have been utilized to determine the exact crystal structures of both phases, which are refined to be Al12.48Fe6.52 and Al5.72Fe2, respectively. Second, the orientation relationship between Al2Fe and Al5Fe2 has been directly deduced from the SXRD data sets, and the co-existence structure model has been constructed. Finally, four pairs of parallel atomic planes and their unique orientation relations have been determined from the reconstructed reciprocal-space precession images of (0kl), (h0l), and (hk0) layers. In addition, one kind of interface atomic structure model is constructed by the orientation relations between two phases, correspondingly.
]]>Metals doi: 10.3390/met14030336
Authors: Ibrahim Alqahtani Andrew Starr Muhammad Khan
Aluminium alloys have been integral to numerous engineering applications due to their favourable strength, weight, and corrosion resistance combination. However, the performance of these alloys in coastal environments is a critical concern, as the interplay between fracture toughness and fatigue crack growth rate under such conditions remains relatively unexplored. This comprehensive review addresses this research gap by analysing the intricate relationship between fatigue crack propagation, fracture toughness, and challenging coastal environmental conditions. In view of the increasing utilisation of aluminium alloys in coastal infrastructure and maritime industries, understanding their behaviour under the joint influences of cyclic loading and corrosive coastal atmospheres is imperative. The primary objective of this review is to synthesise the existing knowledge on the subject, identify research gaps, and propose directions for future investigations. The methodology involves an in-depth examination of peer-reviewed literature and experimental studies. The mechanisms driving fatigue crack initiation and propagation in aluminium alloys exposed to saltwater, humidity, and temperature variations are elucidated. Additionally, this review critically evaluates the impact of coastal conditions on fracture toughness, shedding light on the vulnerability of aluminium alloys to sudden fractures in such environments. The variability of fatigue crack growth rates and fracture toughness values across different aluminium alloy compositions and environmental exposures was discussed. Corrosion–fatigue interactions emerge as a key contributor to accelerated crack propagation, underscoring the need for comprehensive mitigation strategies. This review paper highlights the pressing need to understand the behaviour of aluminium alloys under coastal conditions comprehensively. By revealing the existing research gaps and presenting an integrated overview of the intricate mechanisms at play, this study aims to guide further research and engineering efforts towards enhancing the durability and safety of aluminium alloy components in coastal environments.
]]>Metals doi: 10.3390/met14030335
Authors: Qian Feng Yanan Zeng Junguo Li Yajun Wang Guozhang Tang Yitong Wang
The bearing steel’s high-temperature brittle zone (1250 °C–1100 °C), second brittle zone (1100 °C–950 °C), and low-temperature brittle zone (800 °C–600 °C) were determined by the reduction in area and true fracture toughness. The crack sensitivity was strongest at temperatures of 1200 °C, 1000 °C, and 600 °C, respectively. Various experimental and computational methods were used to establish the phase type, microstructure, size, and mechanical properties of carbides in bearing steel. The critical conditions for crack initiation in the matrix (FCC-Fe, FCC-Fe, and BCC-Fe)/carbides (striped Fe0.875Cr0.125C, netted Fe2.36Cr0.64C, and spherical Fe5.25Cr1.75C3) were also investigated. The values for the high-temperature brittle zone, the second brittle zone, and the low-temperature brittle zone were 13.85 MPa and 8.21 × 10−3, 4.64 MPa and 6.52 × 10−3, and 17.86 MPa and 1.86 × 10−2, respectively. These were calculated using Eshelby’s theory and ABAQUS 2021 version software. The ability of the three carbides to cause crack propagation was measured quantitatively by energy diffusion: M3C > MC > M7C3. This study analyzed the mechanism of carbide precipitation on the formation of high-temperature cracks in bearing steel casting. It also provided the critical conditions for carbide/matrix interface cracks in bearing steel continuous casting, thus providing effective support for improving the quality of bearing steel casting.
]]>Metals doi: 10.3390/met14030334
Authors: Dirk Lehmhus
The present text is the second part of an editorial written for a Special Issue entitled Advances in Metal Casting Technology [...]
]]>Metals doi: 10.3390/met14030333
Authors: Chan-Byeol Han Dong-Geun Lee
Titanium alloys that are used in biomedical applications must possess biocompatibility and a low elastic modulus so that they protect host bone tissue without causing stress shielding. As the elastic modulus of beta Ti alloys is close to that of bone (10–30 GPa), these alloys are considered potential orthopedic implant materials. The elastic modulus of the single β-phase Ti-39Nb-6Zr (TNZ40) alloy is approximately 40 GPa, whereas the strength is lower than that of other types of Ti alloys. Interstitial oxygen in a Ti matrix is well known to improve the matrix strength by solid-solution hardening. The desired mechanical properties can be optimized using a thermo-mechanical procedure to maintain a low elastic modulus. In order to enhance the strength, TNZ40 alloys were fabricated with different amounts of oxygen. The TNZ-0.16O and TNZ-0.26O alloys were cold swaged into 11 mm diameter bars, subjected to solution treatment at 900 °C and 950 °C for 2 h, and furnace-cooled to room temperature. As a result, recrystallized grains were clearly observed in the β matrix. The TNZ-0.26O alloy that was cold-worked by swaging followed by solution treatment at 900 °C exhibited the best mechanical properties (Vickers hardness: 247 HV, ultimate tensile strength: 777 MPa, elongation at rupture: 18.6%, and compressive strength: 1187 MPa). This study reports the effects of oxygen content on the recrystallization behavior and mechanical properties of these alloys.
]]>Metals doi: 10.3390/met14030331
Authors: Md Hafijur Rahman Sarah Todaro Luke Warner Daudi Waryoba Aman Haque
Low-angle grain boundaries (LAGBs) accommodate residual stress through the rearrangement and accumulation of dislocations during cold rolling. This study presents an electron wind force-based annealing approach to recover cold-rolling induced residual stress in FeCrAl alloy below 100 °C in 1 min. This is significantly lower than conventional thermal annealing, which typically requires temperatures around 750 °C for about 1.5 h. A key feature of our approach is the athermal electron wind force effect, which promotes dislocation movement and stress relief at significantly lower temperatures. The electron backscattered diffraction (EBSD) analysis reveals that the concentration of low-angle grain boundaries (LAGBs) is reduced from 82.4% in the cold-rolled state to a mere 47.5% following electropulsing. This level of defect recovery even surpasses the pristine material’s initial state, which exhibited 54.8% LAGBs. This reduction in LAGB concentration was complemented by kernel average misorientation (KAM) maps and X-ray diffraction (XRD) Full Width at Half Maximum (FWHM) measurements, which further validated the microstructural enhancements. Nanoindentation tests revealed a slight increase in hardness despite the reduction in dislocation density, suggesting a balance between grain boundary refinement and dislocation dynamics. This proposed low-temperature technique, driven by athermal electron wind forces, presents a promising avenue for residual stress mitigation while minimizing undesirable thermal effects, paving the way for advancements in various material processing applications.
]]>Metals doi: 10.3390/met14030332
Authors: Zhuo Xu Guiquan Wang Yanxiang Li
The limited thermal conductivity of compacted graphite iron constrains its application in brake discs. The matrix plays a crucial role in balancing the thermal conductivity and mechanical performance of compacted graphite iron. Therefore, two kinds of compacted graphite brake discs with different ferrite proportions were utilized to investigate their thermal cracking and friction performance under intensive braking conditions based on inertia friction tests. The variations in peak temperature, pressure load and friction coefficient stability were also analyzed. The brake disc with a higher ferrite proportion exhibited a lower peak temperature, attributed to increased thermal conductivity. Moreover, the elevated content of soft ferrite resulted in a greater furrow height on the worn surface, contributing to an increase in friction force and stability. As a result, both the input pressure and mechanical stress decreased. It was observed that the compacted graphite iron brake disc with a higher ferrite proportion exhibited fewer thermal cracks without compromising wear resistance. Furthermore, the results suggest that lowering the disc temperature to 210 °C–250 °C can mitigate fatigue wear and matrix oxidation, hindering the propagation of thermal cracks.
]]>Metals doi: 10.3390/met14030330
Authors: Yajun Wu Zhanxin Li Yuzhong Wang Wenhua Guo Bingheng Lu
In recent years, there has been a heightened focus on multiplex porosity due to its significant adverse impact on the mechanical properties of aluminum alloy components produced through wire arc additive manufacturing (WAAM). This study investigates the impacts of the process parameters and dimension parameters on the relative densities of WAAM 2219 aluminum alloy components by conducting experiments and investigates the changes in high relative density process windows with different dimension parameters. The findings reveal a hierarchy in the influence of various parameters on the relative density of the 2219 aluminum alloy: travel speed (TS), wire feed speed (WFS), the number of printed layers (L), interlayer cooling time (ICT), and theoretical length of weld (TLW). A series of data for analysis was produced through a designed experiment procedure, and on the basis of this, by integrating the data augmentation method with the eXtreme Gradient Boosting (XGBoost) algorithm, the relationship among the process parameters, dimension parameters, and relative density was modeled. Furthermore, through leveraging the established model, we analyzed the changes in the optimized process window corresponding to a high relative density with the L. The optimal windows of WFS and TS change when the L reaches a certain value. In contrast, the optimal window of ICT remains consistent despite an increase in the L. Finally, the relative density and mechanical properties of the formed 20-layer specimens within the model-derived window were verified. The relative density of the specimens within the window reached 98.77%, the ultimate tensile strength (UTS) reached 279.96 MPa, and the yield strength (YS) reached 132.77 MPa. This work offers valuable insights for exploring the process window and selecting process parameters through a more economical and faster approach in WAAM aluminum components.
]]>Metals doi: 10.3390/met14030328
Authors: Lingqing Wu Joao Pedro Oliveira Jin Yang Ming Xiao Min Zheng Wenhu Xu Yixuan Zhao Feifan Wang Hua Zhang
This investigation employed different laser powers to conduct the laser welding–brazing process of 5052 aluminum alloy to both Al-Si coated and uncoated 22MnB5 steel. The flux-cored Zn-Al22 filler metal was employed during the procedure. The influence of Al-Si coatings on the microstructure and corrosion resistance of Al/Steel welded joints was investigated using microstructural characterization and electrochemical tests. It was noted that the interfacial microstructure of the laser Al/steel joints was significantly altered by the Al-Si coating. Moreover, the Al-Si coating suppressed the formation and growth of the interfacial reaction layer. Electrochemical corrosion tests showed that the impact of Al-Si coating on the corrosion resistance of laser joints depended on the laser powers and thickness of the interfacial intermetallic compound (IMC) layer. The research suggests that galvanic corrosion occurs due to the differences in corrosion potential between fusion zone (FZ), steel, and Fe-Al-Zn IMCs, which accelerate the corrosion of the joint. The IMC layer acts as a cathode to accelerate the corrosion of the FZ and as an anode to protect the steel from corrosion.
]]>Metals doi: 10.3390/met14030327
Authors: Diaoyu Zhou Jiasheng Yu Yiwei Dong Yalu Qin Xinwei Hao
In this work, the effects of plastic deformation on the indentation behaviors of commercial pure titanium alloy were investigated. Titanium experienced various kinds of deformation by cold rolling processes, and the indentation behaviors were measured using microindentation. The results showed the most deformed sample experienced the largest indentation resistance and had the highest dislocation density and the indentation size influenced the indentation behavior of the CP-Ti. The effect of strain on Vickers hardness demonstrated the dominant role of the dislocation motion in the indentation deformation of CP-Ti alloy. The dependence of the indentation hardness on both the maximum indentation load and the indentation residual depth suggested there exists size effect in the indentation. The effect of the plastic strain on the energy ratio suggested the energy ratio is related to the microstructure in materials. Additionally, the linear relationship between the energy ratio on the indentation depth ratio was obtained for hcp-structured Titanium alloys.
]]>Metals doi: 10.3390/met14030329
Authors: Luis Cáceres Alvaro Soliz Felipe M. Galleguillos-Madrid
In Northern Chile, large amounts of highly corrosive solutions are currently generated in the process of cathode washing after completing the electrowinning or electrorefining process of copper. This study investigates the electrochemical behavior of ASTM A36 carbon steel in pregnant-leach-solution (PLS) wash water. Measurements of electrochemical impedance spectroscopy and linear sweep voltammetry, complemented with weight loss measurements, were performed. Four ratios of PLS containing reverse osmosis (RO) water are evaluated, considering both quiescent and rotating conditions of the steel specimen. The results indicate that oxygen reduction, hydrogen evolution, and iron oxidation reactions are all involved during the corrosion of carbon steel in pure RO water, with the corrosion rate increasing up to 4 times under rotating conditions. In the case of corrosion in RO wash water containing PLS, a galvanic process occurs whereby copper is reduced at the expense of iron oxidation, superimposed on former partial reactions. The deposited copper induces notable corrosion inhibition of steel, observed as a significant drop in corrosion rate from high initial to constant residual values. Morphological and X-ray analyses support that corrosion is affected by oxide layer formation and galvanic copper deposition, confirming the results obtained from electrochemical analysis and weight loss measurements.
]]>Metals doi: 10.3390/met14030326
Authors: Wanjiao Duan Yunying Fan Baipo Shu Yichun Liu Yi Wan Rongguang Xiao Jianxin Xu Shan Qing Qingtai Xiao
In this work, phytic acid (PA) and 3-mercaptopropyltrimethoxysilane (MPTS) underwent a condensation process to produce a phytic acid–silane (abbreviated PAS) passivation solution. Additionally, it was applied to the surface of cold-rolled steel to create a composite phytic acid–silane film. The functional groups of the passivation solution were analyzed by Fourier transform infrared spectroscopy (FT-IR). The composite film was evaluated using an electrochemical workstation, scanning electron microscope (SEM), energy dispersive spectrometer (EDS), X-ray photoelectron spectroscopy (XPS) and pull-off test. These techniques allowed for the characterization of the film’s micromorphology, oxidation, chemical composition and adhesion strength. The results show that the PAS composite film provides higher protection efficiency compared to cold-rolled steel substrates, low phosphorus passivation films, single phytate passivation films and commercial phosphate films. This composite film also has a higher adhesion strength, which is beneficial for subsequent coating, and a possible corrosion resistance mechanism was proposed as well. The PAS layer successfully prevents the penetration of corrosive media into the cold-rolled steel surface utilizing P–O–Fe bonds, thus improving the corrosion barrier effect of the substrate.
]]>Metals doi: 10.3390/met14030325
Authors: Jian Zhang Zhiwei Peng Lingyun Yi Mingjun Rao
Cr-rich electroplating sludge (CRES) is a complicated solid waste with high contents of chromium and iron. It can be used as a main feed of the FINEX ironmaking process, which requires gas-based reduction before smelting reduction to produce molten iron with the proper addition of iron ore powder. In this study, the CO–H2 gas-based reduction behavior of CRES mixed with iron ore powder was evaluated between 700 °C and 850 °C, with a focus on the variations of key components containing Fe, Cr, and S with reduction temperature and time. It was found that the iron oxides in CRES had stepwise conversions to metallic iron as the reduction reaction proceeded. The iron metallization degree of the mixture of CRES and iron ore powder increased obviously below 750 °C and then grew minorly with the further increase of temperature. Moreover, this index varied similarly with an extension of reduction time up to 80 min. After reduction at 750 °C for 60 min with the volume concentration of H2 of 30% and flow rate of 160 mL/min, the iron metallization degree reached 79.08%. The rate in the process was limited by a chemical reaction with an activation energy of 41.32 kJ/mol. Along with the stepwise reduction of iron oxides to metallic iron, the chromium hydroxide and sulfates in CRES were reduced to Cr2O3 and sulfites and sulfides, respectively.
]]>Metals doi: 10.3390/met14030324
Authors: Torben Fiedler Eugen Seif Hans-Rainer Sinning Joachim Rösler
The knowledge of Young’s modulus is important for a quantitative assessment of strengthening contributions in CoRe alloys, such as strengthening by carbides. In this work, the temperature-dependent Young‘s modulus of monocarbide-strengthened CoRe-based alloys is measured using the vibrating reed technique. In this method, a reed-shaped sample is excited electrostatically, and the eigenfrequencies are determined. Using these frequencies, Young’s modulus can be derived analytically or, more reliably, assisted by finite element simulations. The resulting values for Young’s modulus are compared to theoretical estimations, and the influence of titanium- and tantalum-carbides on Young’s modulus is evaluated. It was found that low amounts of carbides increase Young’s modulus significantly. Analytical estimations are in good agreement with experimental results of TaC-containing alloys, whereas estimations for TiC-containing alloys are inaccurate.
]]>Metals doi: 10.3390/met14030323
Authors: Adelaide Nespoli Francesca Passaretti Davide Ninarello Marcella Pani Cristina Artini Francesca Ferro Carlo Fanciulli
In extreme temperature environments, a newly emerging engineering application involves both the active and passive control of structures using cryogenic shape memory alloys, which are smart materials able to recover high deformation below the freezing point. With the objective of carrying out new advances in this area, the present work aims to investigate the Cu-7.5Al-13.5Mn (wt.%) shape memory alloy. Thermal, microstructural, and thermomechanical analyses of as-cast and hot-rolled specimens were performed, taking into account the effects of annealing and solubilization. It was observed that the phase transition occurs at temperatures below 120 K and changes according to the thermo-mechanical path. Specifically, hot-rolling lowers the phase transition temperature range with respect to the as-cast condition–from 34 K to 23 K for Mf, and from 89 K to 80 K for Af. Additionally, when the annealing temperature rises, the phase transformation temperature increases as well, and the alloy loses its cryogenic features when heat treated above 473 K. Finally, loss factors of 0.06 and 0.088, which were respectively found in dynamic and static settings, validate the material’s good damping response.
]]>Metals doi: 10.3390/met14030322
Authors: Wei Jiang Dong Wu Qinyi Zhang Mingxuan Li Wei Liu
Martensitic stainless steels (MSSs) have been widely used in the manufacture of turbine blades, surgical instruments, and cutting tools because of their hardness and corrosion resistance. The MSSs are usually tempered at a temperature no higher than 250 °C after quenching to avoid the decline in the hardness, strength, and corrosion resistance of the steels. However, some short-time thermal shocks are inevitable in processes like welding, water grinding, laser marking, etc., in the manufacturing of kitchen knives, all of which may have negative effects on the mechanical properties and corrosion resistance. The effects of these short-time thermal shocks have rarely been studied. In this paper, the martensitic stainless steel 5Cr15MoV (X50CrMoV15 is European Standards) was selected to be tempered at the sensitization temperatures (480 to 600 °C) for a series of times (0.5 to 128 min) after quenching, and the microstructures, hardness, and corrosion resistance of the steel after tempering were investigated. It was shown that the variation in hardness and corrosion resistance of the 5Cr15MoV steel could be divided into four stages over time during tempering at the sensitization temperatures. The hardness of steel was found to increase at first and then decrease with time; accordingly, good corrosion resistance was retained in the initial few minutes of tempering, which then deteriorated fast. The variation in hardness and corrosion resistance of the 5Cr15MoV steel is related to the diffusion of C and Cr atoms at different tempering temperatures. The mechanism of the mechanical properties and corrosion resistance variation caused by the diffusion of C and Cr atoms during tempering at the sensitization temperatures was also discussed.
]]>Metals doi: 10.3390/met14030321
Authors: Saidov Rustam Mannapovich Kamel Touileb
This work aimed to compare the quality and properties of the welded joints of AMg6 aluminium alloy produced via conventional TIG welding with the properties of those produced with flux backing tape. This study focussed on the relative length of oxide inclusions (Δoi) and the amount of the excess root penetration (hroot) of the AMg6 alloy weld beads. The results show the influence of the thickness of the flux layer of the backing tape on the formation and quality on the AMg6 alloy welds, along with the effect of flux backing tape and edge preparation on the mechanical properties of the 6 and 8 mm thick welded plates. In accordance with the results obtained, the joints produced by means of TIG welding with flux back backing tape and without edge preparation have higher mechanical properties. Moreover, the TIG welding of AMg6 alloy using flux backing tape reduces the total welding time by 55%, reduces filler wire consumption by 35%, reduces shielding gas consumption by 43% and electricity consumption by 60% per 1 linear meter of the weld line.
]]>Metals doi: 10.3390/met14030320
Authors: Shuailong Gao Xuezheng Yue Hao Wang
Due to their outstanding mechanical properties and biocompatibility, additively manufactured titanium porous structures are extensively utilized in the domain of medical metal implants. Implants frequently undergo cyclic loading, underscoring the significance of predicting their fatigue performance. Nevertheless, a fatigue life model tailored to additively manufactured titanium porous structures is currently absent. This study employs multiple linear regression, artificial neural networks, support vector machines, and random forests machine learning models to assess the impact of structural and mechanical factors on fatigue life. Four standard maximum likelihood models were trained, and their predictions were compared with fatigue experiments to validate the efficacy of the machine learning models. The findings suggest that the fatigue life is governed by both the fatigue stress and the overall yield stress of the porous structures. Furthermore, it is recommended that the optimal combination of hyperparameters involves setting the first hidden layer of the artificial neural network model to three or four neurons, establishing the gamma value of the support vector machine model at 0.0001 with C set to 30, and configuring the n_estimators of the random forest model to three with max_depth set to seven.
]]>Metals doi: 10.3390/met14030319
Authors: Yunlong Pan Sheng Gao Haichao Li Wentao Zhang Yixuan Ma
The engine casing components operate in high-temperature and high-pressure environments. Process holes are drilled when defects occur. Welding is employed in the repair of process holes as a process for permanently joining materials. The traditional welding method relies on padding, which results in poor back formation of process holes. Additionally, the shape of the process holes imposes high requirements on the size of the droplet transition. The conventional approach of adjusting a welding current makes it difficult to achieve stable droplet transition and precise formation of small holes. It poses a challenge for the robotic welding process. To deal with this problem, the influence of the high-frequency vibration GTAW process on the directional transition of molten droplets is studied. The molten droplet directional transition process is developed. The impact of vibration energy on the molten pool is reduced. Welding repair experiments for process holes are successfully conducted. When the frequency is 3 Hz, the transition of droplets changes from a continuous one-droplet transition to a discontinuous liquid bridge transition. The residual height and mechanical properties of the repaired area are tested. The experimental results indicated that the residual height after dual-side repair is ≤0.7 mm. The X-ray and fluorescent penetration tests have a 100% first-pass qualification rate. The repaired area demonstrates a hardness of 480 HV and a room-temperature tensile strength of 1069 MPa. The repair process requirements for the casing are met.
]]>Metals doi: 10.3390/met14030318
Authors: Hongbo Wang Bowen Huang Wangyu Hu Jian Huang
Using molecular dynamics (MD) simulations, the transition of the plastic deformation mechanism of Ti-Nb alloys during the tensile process was studied, and the effects of temperature, Nb composition, and strain rate on the deformation mechanism were also investigated. The results show that the deformation process of Ti-Nb alloys involves defect formation, followed by twinning and ω-phase transition, and ultimately, dislocation slip occurs. The <111>{112} slip makes the ω-phase easily overcome the transition energy barrier, inducing the phase transition in the twinning process. Increasing temperature will enhance the plasticity and reduce the strength of the material, while increasing Nb composition will have the opposite effect on the deformation. The simulations show a competition between twinning and dislocation slip mechanisms. With the increase in Nb content, the plastic deformation mechanism of the alloy will change from twinning to dislocation slip. In addition, the plastic strain range increases with the increase in the deformation rate in Ti-Nb alloys. At a higher strain rate, the alloy’s plastic strain range is affected by various deformation mechanisms, which significantly influence the plasticity of the material. The findings of this study provide further insights into the design of Ti-Nb-based alloys.
]]>Metals doi: 10.3390/met14030317
Authors: Xiaolin Sun Shengyong Gao Wulin Shang Qingyuan Zhong Gaoyang Song Shuo Zhao
The evolution of MC-type primary carbonitrides (M=V, Ti, Mo; C=C, N) in terms of morphology, quantity, size and composition was systematically investigated in commercial H13 die steels with different Ti and N contents during thermal holding at 1250 °C for 5 h to 15 h. Results showed that the mean size and quantity of carbonitrides in the four samples had decreased during thermal holding. However, the mean size and quantity of MC carbonitrides had increased with increasing Ti contents when held at 1250 °C while the addition of N increased the quantity but decreased the sizes of the stable MC carbonitrides. It was concluded that the compact carbonitrides could be decomposed and changed into a fishnet structure when held at 1250 °C, especially in samples #1 and #2 containing lower Ti and N contents. The decomposition mechanism was illustrated considering the changes in Ti and Fe elements in carbonitrides. On the basis of the thermodynamic model, the thermal stability of (Tix,V1−x)(Cy,N1−y), with a larger x value, in samples #3 and #4 containing more Ti and N contents was generally higher than those in samples #1 and #2. To control the Ti-containing MC carbonitrides, the low Ti and N contents and high holding temperature should be taken into consideration.
]]>Metals doi: 10.3390/met14030316
Authors: Ming Zhang Hongping Xiang Lin Xu Aihan Feng Shoujiang Qu Daolun Chen
The adsorption and diffusion of oxygen at the B2(110)[1¯11]||O(001)[11¯0] interface in Ti2AlNb alloys were investigated via first-principles calculations. Only a 2.6% interfacial mismatch indicates that B2(110)–O(001) is basically a stable coherent interface. The calculated adsorption energies and diffusion energy barriers show that oxygen prefers to occupy the Ti-rich interstitial sites, and once trapped, it hardly diffuses to other interstitial sites, thus promoting the preferential formation of Ti oxides. Under the premise of a Ti-rich environment, a Nb-rich environment is more favorable for oxygen adsorption than an Al-rich environment. The electronic structures suggest that O 2p orbitals mainly occupy the energy region below −5 eV, bonding with its coordinated atoms of Ti, Al, and Nb. However, Al 3p and Nb 4d orbitals near the Fermi level couple with sparsely distributed O 2p orbitals, forming anti-bonding, which is not conducive to oxygen adsorption. Because Nb 4d electrons are more localized than Al 3p electrons are, Nb–O anti-bonding is weaker. O–Ti has almost no contribution to anti-bonding, suggesting good bonding between them. This is consistent with the experimental observations that TiO2 is the main oxidation product.
]]>Metals doi: 10.3390/met14030315
Authors: Zheng Zhao Yanling Zhang Kan Yu
The basic oxygen steelmaking process is based on the CaO-FeO-SiO2 ternary slag system, characterized by a high melting point and low lime dissolution rate, often becoming one of the key factors limiting the efficiency of the converter. The bulk solid waste red mud, produced by the Bayer alumina process and rich in Fe2O3/Al2O3/Na2O, significantly reduces the melting point of the steelmaking slag system and enhances the efficiency of lime dissolution. This study utilized red mud as the main raw material to prepare a fluoride-free flux. An in situ online observation system was used to measure the melting point of the flux and the dissolution rate of lime in the flux. The results indicate that the melting point of the red mud-based flux is below 1200 °C, and under the same conditions, the lime dissolution rate is 10 to 15 times higher than when this flux is not used. Experiments in a 10 kg induction furnace show that using this flux, the dephosphorization rate under conditions without oxygen blowing is close to 40%, far higher than the rate achieved using CaF2. Under oxygen-blowing conditions, the dephosphorization rate using the red mud-based flux is comparable to that of CaF2, and significantly higher than without any flux, especially under high [C] content conditions. The data show that the red mud-based flux has the potential to be widely used as a fluoride-free flux in the steelmaking process.
]]>Metals doi: 10.3390/met14030313
Authors: Xingwang Feng Yunxin Wang Jinxin Han Zhipeng Li Likun Jiang Bin Yang
Owing to the non-uniform distribution of chemical composition and temperature during the heat treatment process, the residual stress and deformation of the workpiece emerge as crucial factors requiring consideration in managing the service performance and lifespan of shield machine cutter rings crafted from H13 steel. Considering H13 steel with titanium microalloying as the research object for the shield machine cutter ring, we simulate the quenching process using Deform-3D. The temperature field, phase transformation, stress evolution, and deformation amount after quenching are analyzed. The results demonstrate a strong agreement between the simulation and experimental results, offering valuable insights for optimizing the heat treatment process and enhancing the overall performance of shield machine cutter rings.
]]>Metals doi: 10.3390/met14030314
Authors: Quan Zhou Jinfa Liao Chunfa Liao Baojun Zhao
The applications of rare earth metals and alloys are becoming increasingly widespread and there is a strong market demand. Currently, most of the production enterprises adopt the fluoride–oxide system for electrolytic preparation of rare earth metals and alloys. The solubility of rare earth oxides in molten salt directly affects the selection of operational parameters in the electrolysis process. When the added amount of RE2O3 is less than its solubility, it leads to a decreased electrolytic efficiency. Conversely, an excessive amount of oxide is prone to settle at the bottom of the electrolytic cell, impeding smooth production. The RE2O3 solubility in the fluoride salt can be represented by the phase equilibrium of the RE2O3-REF3-LiF system. The isothermal lines in the primary phase field of rare earth oxide represent the solubility of the oxide in the fluoride salt at the corresponding temperature. This paper outlines the research methods and experimental results on the phase equilibria of the RE2O3-REF3-LiF system. The characteristics and existing problems in the current phase equilibrium study are analyzed. The solubility data of RE2O3 are expressed in the forms of ternary and pseudo-binary phase diagrams of the RE2O3-REF3-LiF system, providing theoretical guidance for the establishment of an accurate and reliable rare earth electrolysis system database and the optimization of electrolytic processes.
]]>Metals doi: 10.3390/met14030312
Authors: Marek Brůna Marek Galcik Richard Pastircak Elena Kantorikova
In this paper, a naturally pressurized gating system has been designed to reduce the turbulence of the melt during casting. The influence of gate dimensions, foam filters, a trident gate and a vortex element were evaluated. Their effect on melt velocity, flow characteristics, number of oxides, casting properties and mechanical properties were observed. ProCAST Simulation software v.2023 and a water flow test were also evaluated to assist in the experimental evaluation of the castings. Melts showed a relationship between melt velocity and porosity of castings. Quantitative evaluation of the surface porosity showed a trend of decreasing porosity with decreasing melt velocity. The greatest reduction in the melt velocity was achieved by a M4 design, which was associated with the highest reduction in the oxides. The pores analyzed proved the presence of oxide layers on their inner surface and a possible theory of pore formation when the initiator of porosity is entrained double oxide layers. The best metal yield was achieved with M1, but the difference between M2 and M4 was negligible (2–5% yield difference), so it can be stated that the beneficial effect of the M4 design in providing the best quality castings is not negated by the increase in metal yield.
]]>Metals doi: 10.3390/met14030311
Authors: Gianluca Dall’Osto Davide Mombelli Carlo Mapelli
The consequences on the Italian steel sector following the conversion of the sole integrated steel plant and the establishment of a direct reduction/electric arc furnace (DR/EAF) grid in the period 2022–2050 were analyzed. Imported natural gas (pathway 0), green hydrogen (pathway 1) and biomethane (pathway 2) were studied as possible reducing gases to be exploited in the DR plant and to be introduced as a methane substitute in EAFs. The results showed that the environmental targets for the sustainable development scenario could be achieved in both 2030 and 2050. In particular, the main reduction would occur by 2030 as a result of the cease of the integrated plant itself, allowing for an overall reduction of 71% of the CO2 emitted in 2022. On the other hand, reaching the maximum production capacity of the DR plants by 2050 (6 Mton) would result in final emission reductions of 25%, 80% and 35% for pathways 0, 1 and 2, respectively. Finally, the creation of a DR/EAF grid would increase the energy demand burden, especially for pathway 1, which would require three times as much green energy as pathway 0 and/or 2 (36 TWh/y vs. ca. 12 TWh/y).
]]>Metals doi: 10.3390/met14030310
Authors: Olga A. Yakovtseva Andrey G. Mochugovskiy Alexey S. Prosviryakov Andrey I. Bazlov Nadezhda B. Emelina Anastasia V. Mikhaylovskaya
In the present research an Al–7.7%Mn–4.9%Zr–3.2%Cu (wt%) alloy was processed by mechanical alloying (MA) followed by hot press sintering. The microstructure, phase composition, and mechanical properties of the MA granules and sintered samples were investigated. The dissolution of Mn, Zr, and Cu with further precipitation of the Al6Mn phase were observed during high-energy ball milling. In the alloy processed without stearic acid after milling for ~10 h, an Al-based solid solution with ~4.9 wt%Zr, ~3.2 wt%Cu and a ~5 wt%Mn with a grain size of ~16 nm and a microhardness of ~530 HV were observed. The addition of stearic acid facilitated Mn dissolution and precipitation of the Al6Mn phase during milling but led to the formation of the ZrH2 phase that decreased the Zr solute and the microhardness. Precipitation of the Al6Mn, L12–Al3Zr, and Al2Cu phases during annealing and sintering of the MA granules in the temperate range of 350–375 °C was observed, and an additional Al20Cu2Mn3 phase was precipitated at 400–450 °C. Hot-press sintering at 450 °C provided a low fraction of cavities of ~1.5%, the yield strength of 1100 MPa, ultimate compressive strength of 1200 MPa, strain at fracture of 0.5% at room temperature, the yield strength of 380 MPa, ultimate compressive strength of 440 MPa, and strain at fracture of 3.5% at 350 °C. The microstructural evolution during high-temperature deformation on the sample surface was studied and the differences in deformation behavior for the alloys sintered at different temperatures were discussed.
]]>Metals doi: 10.3390/met14030309
Authors: Julio Cesar Garcia-Guerrero Francisco Fernando Curiel-López Víctor Hugo López-Morelos Jose Jaime Taha-Tijerina Teresita Jesus Sánchez-Cruz Maria del Carmen Ramirez-Lopez Eduardo Cortes-Carillo Miguel Angel Quinones-Salinas
The use of the orthogonal array L4 allows a determination of the effect between the welding parameters peak current (Ip), background current (Ib) and frequency (f) on the porosities in a dissimilar welded lap joint of CP800 and XPF1000 steel weldment by the gas metal arc welding process with the transfer pulsed mode. According to the results, modifications in the welding parameters affect the heat input during welding. A heat input higher than 0.30 KJ/mm generates up to 0.32% porosity in the weld metal, while a heat input lower than 0.25 KJ/mm generates up to 28% porosity in the weld metal. The variation in heat input generated by the process allowed the observation of the final microstructure of the welded joints and the effect of mechanical properties such as hardness because the results show values of hardness from 300 Hv to 400 Hv in the heat affected zone (HAZ).
]]>Metals doi: 10.3390/met14030308
Authors: Marwan T. Mezher Diego Carou Alejandro Pereira
The resistance spot welding (RSW) process is still widely used to weld panels and bodies, particularly in the automotive, railroad, and aerospace industries. The purpose of this research is to examine how RSW factors such as welding current, welding pressure, welding time, holding time, squeezing time, and pulse welding affect the shear force, micro-hardness, and failure mode of spot welded titanium sheets (grade 2). Resistance spot welded joints of titanium sheets with similar and dissimilar thicknesses of 1–1 mm, 0.5–0.5 mm, and 1–0.5 mm were evaluated. The experimental conditions were arranged using the design of experiments (DOE). Moreover, artificial neural network (ANN) models were used. Different training and transfer functions were tested using the feed-forward backpropagation approach to find the optimal ANN model. According to the experimental results, the maximum shear force was 5.106, 4.234, and 4.421 kN for the 1–1, 0.5–0.5, and 1–0.5 mm cases, respectively. The hardness measurements showed noticeable improvement for the welded joints compared to the base metal. The findings revealed that the 0.5–0.5 mm case gives the highest nugget and heat-affected zone (HAZ) hardness compared to other cases. Moreover, different failure modes like pull-out nugget, interfacial, and partial failure between the pull-out nugget and interfacial failure were noticed. The ANN outcomes based on the mean squared error (MSE) and coefficient of determination (R2) as validation metrics demonstrated that using the Levenberg–Marquardt (Trainlm) training function with the log sigmoid transfer function (Logsig) gives the best prediction, where R2 and MSE values were 0.98433 and 0.01821, respectively.
]]>Metals doi: 10.3390/met14030307
Authors: Byung-Hyun Shin Jinyong Park Seongjun Kim Jung-Woo Ok Doo-In Kim Jang-Hee Yoon
With increasing demand for Li-ion batteries, studies are focusing on enhancing battery performance and safety. However, studies on battery cases remain scarce. Herein, we propose the use of super duplex stainless steel SAF2507, which is a two-phase (austenite + ferrite) steel, for battery casings. Unlike conventional AISI304, SAF2507 maintains its corrosion resistance and strength at high temperatures and precipitates a secondary phase at approximately 975 °C. However, the effects of Ni plating on this secondary phase are not well documented. Therefore, the electroless Ni plating of SAF2507 after secondary-phase precipitation was studied. Briefly, heat treatment at 1000 °C was used to induce precipitation, and the electroless Ni plating behaviour over varying plating periods was analysed using open-circuit potential, potentiodynamic polarisation, and electrochemical impedance spectroscopy measurements. The plating state and corrosion behaviour were examined using scanning electron microscopy. Heat-treated SAF2507 steel with a secondary phase exhibited excellent electroless Ni plating behaviour, which enhances the safety and durability of Li-ion batteries. Furthermore, uniform plating and electrochemical behaviour were achieved after 180 s, suggesting that SAF2507 is superior to AISI304. These findings contribute to the development of safer and more efficient batteries and address the growing demand for Li-ion battery case materials.
]]>Metals doi: 10.3390/met14030306
Authors: Hai Qiu Rintaro Ueji Tadanobu Inoue
The Lüders phenomenon is one type of inhomogeneous plastic deformation occurring in the elastic-to-plastic transition region, and it is an undesirable plastic deformation behavior. Although conventional measures based on the chemical composition design, plasticity processing principle, or utilization of composited microstructures are used to suppress this phenomenon in engineering, demerits are present, such as high cost and low fracture behavior. The Lüders phenomenon begins with the formation of plastic bands (inhomogeneous yielding) at one or several local sites. If yielding simultaneously occurs everywhere rather than at several local sites, the formation of local plastic bands will be inhibited; as a result, the Lüders deformation will be suppressed. Based on this idea, a new approach was proposed in which the number of local yield sites was increased by heat treatments. A medium-carbon tempered martensite steel (Fe-0.3C-1.5Mn, in wt%) was used to verify the validity of the new approach, and the optimum heat-treatment conditions for the balance of mechanical property and deformation behavior were determined.
]]>Metals doi: 10.3390/met14030305
Authors: Mumin Yilmaz Imren Ozturk Yilmaz Onur Saray
This study investigates the impact of friction stir processing (FSP) on the deformation behavior of 1.1 mm-thick DP600 steel sheets under both static and dynamic loading scenarios, with a focus on the automotive applications of the material. During the process, the large plastic shear strains imposed by FSP resulted in a maximum temperature of 915 °C, leading to a morphological transformation of the martensite phase from well-dispersed fine particles into lath martensite and grain refinement of the ferrite phase. DP600 steel showed an almost two-fold increase in static strength parameters such as the hardness value, yield strength, and ultimate tensile strength. As-received and processed DP600 steel exhibited a plastic deformation behavior governed by strain hardening. However, uniform elongation and elongation to failure after FSP took lower values compared to those of the as-received counterpart. Following the improvement in the static strength of the steel, the fatigue strength of the steel increased from 360 MPa to 440 MPa after the FSP. The finite-life fatigue fracture surfaces of the as-received samples were characterized by the formation of fine bulges due to the variation in the crack propagation path in the vicinity of the martensite particles/clusters. After FSP, the transformation of the martensite particles into coarser lath martensite also transformed the fracture surface into a step-like morphology. The microstructural evolution after FSP caused a decrease in the absorbed impact energy and maximum striker reaction force from 239 J and 37.6 kN down to 183 J and 33.6 kN, respectively. However, the energy absorption capacity of the processed steel up to failure was higher than the absorbed energy value of the as-received steel at the same impact displacement. The simultaneous decrease in both impact energy and reaction force is attributed to the higher cracking tendency of the processed microstructure due to the lower volume fraction of the ferrite phase. The experimental results reported in this study mainly show that FSP is an easy-to-apply and functional solution to significantly improve the static and cyclic strength of DP600 steel. However, it is clear that the reduced total impact energy absorption capacity after FSP may be taken into account in design strategies.
]]>Metals doi: 10.3390/met14030304
Authors: Srecko Stopic Bernd Friedrich
Metallic materials play a vital role in the economic life of modern societies; hence, research contributions are sought on fresh developments that enhance our understanding of the fundamental aspects of the relationships between processing, properties, and microstructures. Disciplines in the metallurgical field ranging from processing, mechanical behavior, phase transitions, microstructural evolution, and nanostructures, as well as unique metallic properties, inspire general and scholarly interest among the scientific community. Three of the most important elements are included in unit operations in non-ferrous extractive metallurgy: (1) hydrometallurgy (leaching under atmospheric and high-pressure conditions, mixing of a solution with a gas and mechanical parts, neutralization of a solution, precipitation and cementation of metals from a solution aiming at purification, and compound productions during crystallization), (2) pyrometallurgy (roasting, smelting, and refining), and (3) electrometallurgy (aqueous electrolysis and molten salt electrolysis). Advances in our understanding of unit operations in non-ferrous extractive metallurgy are required to develop new research strategies for the treatment of primary and secondary materials and their application in industry.
]]>Metals doi: 10.3390/met14030303
Authors: Jordan Maximov Galya Duncheva Angel Anchev Vladimir Dunchev Petya Daskalova
Fastener holes are among the most common natural stress concentrators in metal structures. The life cycles of various structural elements, such as those in aircraft structures, automobiles, and rail-end bolt joints, are limited by fatigue damage around the holes. An effective approach to delay the formation and growth of fatigue macrocracks is to introduce residual hoop compressive stresses around the holes. Two methods have become established in the prestressing of fastener holes in aircraft components, split sleeve and split mandrel, which implement one-sided processes. The common disadvantage of both methods is the complex procedure due to the need for high accuracy of the initial holes. This article presents a new modified split mandrel method providing the same tightness (interference fit) with a wide tolerance of the pre-drilled hole diameters, reducing the number of technological cycle steps and production costs. To implement the new method, a functionally connected tool and a device with a hydraulic drive were developed. An extensive experimental study of 2024-T3 AA specimens was carried out to evaluate the effectiveness of the method under a high scattering of the pre-drilled holes. The new method provided a deep zone of residual hoop compressive stresses on both faces of the specimens after cold working and after hole final reaming. The removal of a plastically deformed layer around the hole of suitable thickness during the final reaming decreased the axial gradient of residual hoop stress distribution. Fatigue tests on a tensile pulsating cycle verified the effectiveness of the modified split mandrel method to significantly increase the fatigue life by 6.6 times based on 106 cycle fatigue strength compared to the conventional case of machining the holes. The obtained S-N curves for three groups of samples with initial hole diameters of 8.0, 8.1, and 8.2 mm, which were cold worked with the same tightness of 0.32 mm and final reamed, aligned well, indicating that the new method can provide constant fatigue strength for a given stress amplitude.
]]>Metals doi: 10.3390/met14030302
Authors: Tetiana Loskutova Michael Scheffler Vitalii Ivanov Inna Pohrebova Yaroslav Kononenko Maryna Bobina Nadiia Kharchenko Marian Bartoszuk Ivan Pavlenko
The physicochemical conditions of the siliconizing and boron–siliconizing processes of molybdenum-based alloys in a closed reaction space in an environment of chlorine and fluorine at reduced pressure were studied. Theoretical calculations of the equilibrium composition of systems with the participation of silicon, boron, molybdenum, nitrogen, oxygen, chlorine, and fluorine were carried out, which made it possible to determine the influence of process parameters (temperature, composition of the reaction medium) on the probable phase composition of the obtained coatings. Based on thermodynamic calculations, the composition and rational consumption of the initial powders and the temperature intervals of the chemical heat treatment (CHT) during the complex saturation of molybdenum-based alloys with silicon and boron were modeled. It was established that it is advisable to use chlorine as an activator, which leads to the formation of molybdenum chlorides MoCl4 and MoCl3 in the composition of the gas phase and can indicate the flow of exchange reactions between chlorides and the matrix of the processed material in the reaction space. The rational saturation temperature of alloys based on molybdenum with silicon and boron is determined—1100–1250 °C. The possibility of the existence of condensed phases MoSi2, MoB2.15, B6Si, MoB1.65, and MoB is shown.
]]>Metals doi: 10.3390/met14030301
Authors: Giulia Morettini Luca Landi Luca Burattini Giulia Stornelli Gianluca Foffi Andrea Di Schino Filippo Cianetti Claudio Braccesi
The study presented in this paper was undertaken in response to two instances of unexpected blade breakage in the cutting blade used in a Carton Wrap machine (CW). Failure of the Al7075 alloy blade occurred at an indentation during typical operational loading conditions. Subsequent metallographic examinations of the fractured samples confirmed that both cases were attributed to fatigue failure. The main objective of this study is to investigate potential causes of fatigue failure in the CW blade using simplified linear elastic static numerical simulations through Finite Element Analysis (FEA). In this research, we employed the well-established Theory of Critical Distance (TCD), and this case study provided a contextualization at an industrial level. Furthermore, the analysis focused on a second key aspect: proposing a new blade geometry aimed at mitigating the identified issues and eliminating possible causes of failure. In this context, the actual stress concentration at the indentation was determined using the TCD with Line Method (LM). The results from the numerical simulations indicated that the new blade geometry significantly reduced stress concentration, resulting in a risk factor reduction of approximately four compared to the original blade design, even under non-optimal operating conditions. Overall, in conjunction with simple linear static FEA, the proposed numerical approach provided substantial support for designers, especially in fault analysis and when comparing different industrial solutions.
]]>Metals doi: 10.3390/met14030300
Authors: Min-Kyu Song Eunsoo Choi Jong-Han Lee
Shape memory alloys (SMAs) demonstrate a shape memory effect and superelasticity that can provide recovery performance to structural members. In this study, a round SMA bar was designed to replace the conventional deformed steel bar, particularly within the plastic hinge section of structural members. To integrate the SMA bar and the existing steel bar, a mechanical coupler was proposed by utilizing the advantages of both one-touch and threaded couplers. Uniaxial tensile tests were conducted to analyze the performance of the proposed coupler and the mechanical properties of the SMA–steel connected bar. Stress and strain relationships were examined for steel bars mechanically connected with the SMA bar and for SMA bars before and after exhibiting the shape memory effect. To induce the shape memory effect, SMA should be heated above the finished austenite temperature. Due to the difficulty of accurately measuring strain on the heated bar using traditional contact methods, we employed digital image correlation technology for precise strain measurement of the heated SMA bar. The experimental results indicate the effective application of SMA bars within the plastic hinge region of structural members using the proposed mechanical coupler.
]]>Metals doi: 10.3390/met14030299
Authors: Liqiang Xu Baojun Zhao
Tungsten is a high-value resource with a wide range of applications. The tungsten metal is produced via ammonium paratungstate, which is a multi-stage process including leaching, conversion, precipitation, calcination, and reduction. A short process to produce tungsten metal from the electrolysis of molten sodium tungstate has been demonstrated. However, sodium tungstate cannot be directly produced from wolframite in the conventional hydrometallurgical process. There was no information reported in the literature on producing sodium tungstate directly from tungsten concentrates. The present study proposed a simple and low-cost process to produce sodium tungstate by high-temperature processing of wolframite. The mixtures of wolframite, sodium carbonate, and silica were melted in air between 1100 and 1300 °C. High-density sodium tungstate was easily separated from the immiscible slag, which contained all impurities from wolframite, flux, excess sodium oxide, and dissolved tungsten oxide. The slag was further water leached to recover sodium tungstate in the solution. Effects of Na2CO3/Ore and SiO2/Ore ratios, temperature, and reaction time on the recovery of tungstate and the purity of sodium tungstate were systematically studied. Sodium tungstate containing over 78% WO3 was produced in the smelting process, which is suitable for the electrolysis process. The experimental results will provide a theoretical basis for the direct production of sodium tungstate from wolframite. The compositions of the WO3-containing slags and sodium tungstate reported in the present study fill the knowledge gap of the tungsten-containing thermodynamic database. Further studies to use complex and low-grade tungsten concentrates to produce sodium tungstate are underway.
]]>Metals doi: 10.3390/met14030298
Authors: Victor Georgievich Shmorgun Oleg Victorovich Slautin Vitaliy Pavlovich Kulevich Artem Igorevich Bogdanov Leonid Moiseevich Gurevich Aleksey Gennadevich Serov
The diffusion processes during the contact melting at the boundary of explosively welded VT1-0 titanium with CuNi19 (melchior) and CuNi45 (constantan) alloy composites were studied. Heat treatment of composites led to the formation of the interaction zone at the joint boundary. The interaction zone in VT1-0 + CuNi19 consists of TiCuNi and αTi + Ti2Cu(Ni) continuous layers as well as a mixture of TiNi(Cu) + TiCu(Ni) + Ti2Cu(Ni) intermetallics. It has been shown that an increase in the nickel content in the case of VT1-0 + CuNi45 composite leads to a decrease in the temperature of contact melting, a change in its mechanism, an increase in the titanium content in the interaction zone, and the appearance of additional Ti2Ni(Cu) intermetallic in its composition.
]]>Metals doi: 10.3390/met14030297
Authors: Bo Zhang Shuiqing Yu Yudong Liang Maofa Jiang
The Bayan Obo ore deposit is a world-renowned polymetallic coexistence mine that integrates important elements, such as rare earths, iron, niobium, and titanium. The chemical properties of niobium and titanium are similar, and the two often coexist in the Bayan Obo deposit as isomorphs, making them difficult to separate. Therefore, the separation of niobium and titanium is crucial for the efficient utilization of niobium resources in the Bayan Obo ore deposit of China. To discuss the feasibility of separating niobium and titanium by selective electrolysis, cyclic voltammetry and square wave voltammetry were used to study the reduction mechanism of niobium oxide and titanium oxide in NaF–Na3AlF6 molten salt. The results revealed significant differences in the diffusion coefficients and reduction steps of Nb5+ and Ti4+ during reduction at a molybdenum cathode. At 950 °C, the diffusion coefficient of Nb5+ during reduction at a molybdenum cathode was 3.57 × 10–6 cm2/s. Also, in the NaF–Na3AlF6 system, Nb5+ underwent a three-step reduction as follows: Nb(V)→Nb(IV)→Nb(I)→Nb. The diffusion coefficient of Ti4+ during reduction at the molybdenum cathode was 9.92 × 10–7 cm2/s, and Ti4+ underwent a two-step reduction in the NaF–Na3AlF6 system: Ti(IV)→Ti(I)→Ti. When Nb2O5 and TiO2 were both present in the NaF–Na3AlF6 system, the deposition potential of niobium metal (−0.64 V) differed from that of titanium metal (−0.77 V). These differences in diffusion coefficient, reduction step, and deposition potential enabled selective electrolytic separation of niobium and titanium.
]]>Metals doi: 10.3390/met14030296
Authors: Francesco De Bona Francesco Mocera Jelena Srnec Novak
Virtual prototyping techniques, generally based on numerical methods, are widely used in the process of designing an industrial product [...]
]]>Metals doi: 10.3390/met14030295
Authors: Edyta Kobierska Megan J. Cordill Robert Franz Marisa Rebelo de Figueiredo
Thin film materials used in flexible electronics are deposited on polymer substrates and must withstand a variety of static and dynamic mechanical loading conditions to ensure adequate reliability of the device. Tribological loads are also among these loading conditions, and suitable characterization methods and strategies are required for analyzing friction and wear for a variety of tribological contact situations. In the present work, Mo films were deposited on polyimide substrates by high-power impulse magnetron sputtering and then pre-conditioned by straining to several strain levels, including crack onset strain and strains within the crack saturation regime. Subsequently, ball-on-disk tests against different counterpart materials, namely glass, steel, and polymer, were performed to evaluate different tribological contact situations. The comparison of the results of morphologies and characteristics of the films using surface images for strained and unstrained samples provide insight into how increasing straining of the films and crack formation affect the enhanced fracture of the deposited Mo films, which served as a model system in these investigations.
]]>Metals doi: 10.3390/met14030294
Authors: Zachary P. Tener Xubo Liu Ikenna C. Nlebedim Matthew J. Kramer Michael A. McGuire Michael S. Kesler
We investigate the effect of an applied magnetic field on the entire HDDR process using a customized reactor vessel and a warm-bore superconducting magnet. We analyzed the resulting properties produced at both a 0 applied field and a 2 Tesla applied field. We show that the application of a magnetic field throughout the HDDR process results in powders that exhibit a greater level of anisotropy compared to their ambient field counterparts.
]]>Metals doi: 10.3390/met14030293
Authors: Yu Du Xiuhua Gao Xiaonan Wang Hongyan Wu Chao Sun Guosheng Sun Linxiu Du
Impact fracture behavior at low temperatures was investigated in medium manganese steel with bcc-fcc duplex microstructures. The impact energy was above 150 J (−80~20 °C) and the fractography showed dimples for inter-critical annealing at 630 °C (QHA) because of the high retained austenite stability and low martensite dislocation density. The impact energy was from 180 J (20 °C) to 60 J (−80 °C) and the fractography was intergranular for inter-critical annealing at 610 °C (QLA) because of the low stability of RA and carbides precipitated at the prior austenite grain boundaries. The impact energy was below 60 J (−80~20 °C) and the fractography showed cleavage for direct quenching (DQ) because of the high dislocation density of martensite.
]]>Metals doi: 10.3390/met14030292
Authors: Busisiwe J. Mfusi Patricia Abimbola Popoola Ntombizodwa R. Mathe
During powder-bed fusion (PBF), the irradiated material causes undesirable thermal stresses while experiencing large temperature oscillations over a rapid period. This requires the components produced by this technique to undergo thermal treatment. The characteristics of additively manufactured materials, which are rapid heating and cooling, do not accept conventional methods, such as thermal treatment, that alleviate stress for the removal of thermal stresses. In this research, the thermal treatment of age hardening is explored, in which AlSi10Mg is subjected to lower temperatures for longer periods of time. Other samples were thermally treated at 300 °C and 400 °C for various hours and quenched in ice water. This is conducted to identify the acceptable temperature and conditions that will improve the properties after thermal treatment without jeopardising other properties of the material and to investigate the effects of the thermal treatment profiles on the microstructural and mechanical characteristics of the AlSi10Mg samples.
]]>Metals doi: 10.3390/met14030291
Authors: Xinyue Li Kunyu Wang Yunlong Li Zhiqiang Wang Yang Zhao Jie Zhu
A porous Ni50Mn28Ga22 alloy was produced using powder metallurgy, with NaCl serving as the pore-forming agent. The phase structure, mechanical properties, and magnetic properties of annealed bulk alloys and porous alloys with different pore sizes were analyzed. Vacuum sintering for mixed green billets in a tube furnace was employed, which facilitated the direct evaporation of NaCl, resulting in the formation of porous alloys characterized by a complete sinter neck, uniform pore distribution, and consistent pore size. The study found that porous alloys within this size range exhibit a recoverable shape memory performance of 3.5%, as well as a notable decrease in the critical stress required for martensitic twin shear when compared to that of bulk alloys. Additionally, porous alloys demonstrated a 2% superelastic strain when exposed to 353 K. Notably, under a 1.5 T magnetic field, the porous Ni50Mn28Ga22 alloy with a pore size ranging from 20 to 30 μm exhibited a peak saturation magnetization of 62.60 emu/g and a maximum magnetic entropy of 1.93 J/kg·K.
]]>Metals doi: 10.3390/met14030290
Authors: Jiří Čapek Karel Trojan Jan Kec Nikolaj Ganev Ivo Černý Tomáš Mužík
Railway wheels are usually attached to axles by press-fitting; therefore, the mechanical processes taking place during operation can result in failure, with fatal consequences for the axle seats. This manuscript describes the effect of laser hardening on the residual stress state, microstructural parameters (lattice defects—dislocations, crystallites, microstrains, etc.), and mechanical properties of laser-hardened EA1N steel railway axles under fatigue life conditions. Differences were found between ground, single-track, and multi-track hardened surfaces. Tensile residual stresses, low dislocation densities and hardnesses, and different microstructures (tempered cubic martensite) were found at the overlapped tracks and at the boundary of the heat-affected zone and bulk surface compared with the hardened zone. As a result, the surface treatment of axle seats by laser hardening improved the fatigue failure resistance compared with untreated seats. Optimal properties of the integrity of the axle seat surface were achieved, including fatigue resistance, which seems to be positively influenced mainly by sufficient hardness and the appropriate microstructure. The influence of the other investigated parameters was not evident, and was reduced by the presence of fretting corrosion and press-fitting.
]]>Metals doi: 10.3390/met14030289
Authors: Tibra Das Gupta Thomas John Balk
Nanoporous structures with 3D interconnected networks are traditionally made by dealloying a binary precursor. Certain approaches for fabricating these materials have been applied to refractory multi-principal element alloys (RMPEAs), which can be suitable candidates for high-temperature applications. In this study, nanoporous refractory multi-principal element alloys (np-RMPEAs) were fabricated from magnesium-based thin films (VMoNbTaMg) that had been prepared by magnetron sputtering. Vacuum thermal dealloying (VTD), which involves sublimation of a higher vapor pressure element, is a novel technique for synthesizing nanoporous refractory elements that are prone to oxidation. When VMoNbTaMg was heated under vacuum, a nanoporous structure was created by the sublimation of the highest vapor pressure element (Mg). X-ray photoelectron spectroscopy depth profiling indicated significantly less ligament oxidation during VTD as compared to traditional dealloying methods. Furthermore, np-RMPEAs exhibited outstanding stability against coarsening, retaining smaller ligaments (~25 nm) at elevated temperature (700 °C) for a prolonged period (48 h).
]]>Metals doi: 10.3390/met14030288
Authors: Lin Mao Zhiwei Dai Xue Cai Zhongxin Hu Jian Zhang Chengli Song
Biodegradable suture anchors based on Mg-Nd-Zn-Zr alloy were developed for ligament-to-bone fixation in rotator cuff surgeries. The Mg alloy anchors were designed with structural features of narrow tooth and wide tooth, and simulated through finite element analysis (FEA). Meanwhile, the corrosion behaviors of the Mg alloy anchors were studied by immersion test and the mechanical properties were investigated by measuring the maximum torque and pull-out force. The simulation result showed that the wide-tooth anchor exhibited more a uniform stress distribution and lower shear stress in the torsion process, suggesting a satisfactory torsional resistance of this structure. Meanwhile, the wide-tooth anchor exhibited a lower Von-Mises stress after applying the same pull-out force in the simulation, indicating a higher resistance to pull-out failure of the anchor. The result of the immersion test indicated that the wide-tooth anchor exhibited a slightly slower corrosion rate in Hank’s solution after 14-day immersion, which was beneficial to enhance the structural and mechanical stability of the biodegradable suture anchor. Furthermore, the results of the mechanical properties test demonstrated that the wide-tooth anchor showed superior performance with higher maximum torques and axial pull-out forces before and after corrosion. More importantly, the axial pull-out force and maximum torque for the wide-tooth anchor decreased by 5.86% and 8.64% after corrosion, which were significantly less than those for the narrow-tooth anchor. Therefore, the wide-tooth suture anchor with lower corrosion rate, higher mechanical properties and structural stability is a promising candidate for ligament-bone fixation in the repair of rotator cuff injuries.
]]>Metals doi: 10.3390/met14030286
Authors: Joyce Ingrid Venceslau de Souto Jefferson Segundo de Lima Walman Benício de Castro Renato Alexandre Costa de Santana Antonio Almeida Silva Tiago Felipe de Abreu Santos João Manuel R. S. Tavares
Additive Manufacturing is a manufacturing process that consists of obtaining a three-dimensional object from the deposition of material layer by layer, unlike conventional subtractive manufacturing methods. Wire Arc Additive Manufacturing stands out for its high productivity among the Additive Manufacturing technologies for manufacturing metal parts. On the other hand, the excessive heat input promotes increased residual stress levels and the occurrence of defects, such as pores, voids, a lack of fusion, and delamination. These defects result in abnormalities during the process, such as disturbances in electrical responses. Therefore, process monitoring and the detection of defects and failures in manufactured items are of fundamental importance to ensure product quality and certify the high productivity characteristic of this process. Thus, this work aimed to characterize the effects of different contaminations on the electric arc behavior of the Wire Arc Additive Manufacturing process and the occurrence of microscopic defects in thin walls manufactured by this process. To investigate the presence of defects in the metal preforms, experimental conditions were used to promote the appearance of defects, such as the insertion of contaminants. To accomplish the electric arc behavior analysis, voltage and current temporal data were represented through histograms and cyclograms, and the arc stability was assessed based on the Vilarinho index for a short circuit. Effectively, the introduction of contaminants caused electric arc disturbances that led to the appearance of manufacturing defects, such as inclusions and porosities, observed through metallographic characterization. The results confirm that the introduction of contaminations could be identified early in the Wire Arc Additive Manufacturing process through electric arc data analysis.
]]>Metals doi: 10.3390/met14030287
Authors: Jiezhen Hu Guodong Lin Peichang Deng Ziyun Li Yuwan Tian
Marked changes in temperature, pH, dissolved oxygen (DO) content, and nutrient content typically occur in marine thermoclines, which are key factors that affect the corrosion of metals. Offshore platforms require marine metals to be exposed to deep-sea environments and thus increase their penetration into the marine thermocline. This study investigates the galvanic corrosion of E690 steel in a marine thermocline using a simulated marine thermocline (SMT). Specifically, the corrosion of E690 steel was analyzed using the wire beam electrode (WBE) technique, linear polarization (LP), corrosion morphology, and weight loss measurement. Results indicated that the SMT had a stable multilayer structure, and the variations in temperature, DO, pH, and nutrient concentration in the SMT were similar to those in the natural marine thermocline. There were two forms of E690 steel corrosion in the SMT: galvanic corrosion and seawater corrosion. The corrosion rate of seawater corrosion was influenced by the DO concentration. Galvanic corrosion occurred after the intrusion of E690 steel into the marine thermocline. The driver of galvanic corrosion was the difference values for Ecorrs of E690 steel at various depths of the marine thermocline. The Ecorr of E690 steel was influenced by the temperature, pH, and DO of the seawater, in the following order: DO >> T > pH. The continuous reduction in Ecorr with depth contributed to large-scale galvanic corrosion, and the oscillation variation in Ecorr with depth was the reason for small-scale galvanic corrosion. The primary anodic regions of galvanic corrosion were located in the area with the fastest temperature variation in the thermocline, and the position of the anodic regions rose with time. The anodic regions gradually expanded with time. The proportion of galvanic corrosion in the average corrosion rate could increase up to approximately 80% in the stable anodic region. There were many hemispherical corrosion pits on the surface of the single electrodes that were at the depths of 75 cm, 105 cm, and 135 cm. These single electrodes comprised a long-term, sustainable anodic region of galvanic corrosion.
]]>Metals doi: 10.3390/met14030285
Authors: Qingxin Chen Haichao Wang Zhanjiang Li Jun Tian Jianeng Huang Pinqiang Dai
Stainless steel (SS) exhibits excellent ductility; however, its low strength hinders its practical applications. To achieve good synergy between strength and ductility, a heterogeneous structure was introduced into a newly developed nitrogen-alloyed low-nickel austenitic steel, QN1803. The received QN1803 was cold-rolled and annealed at 993 K for different durations, and the microstructural evolution and tensile mechanical properties were investigated. The yield strength (1130 MPa) of the QN1803 annealed at a temperature of 993 K for 15 min was approximately three times higher than that of the as-received sample (314 MPa). The short annealing time of 15 min yielded a heterogeneous structure with grain size distributions ranging from nanoscale to micron-scale. The annealed QN1803 exhibited typical dislocation cells and dislocation walls caused by slipping after cold rolling. During annealing, a step-like lamellar structure is formed. The high yield strength was obtained from the large number of twins and hard ultrafine grains. The good ductility is due to the large number of dislocations generated in the soft grains and the GNDs around the heterogeneous interfaces. Additionally, the lamella structure of the material also contributes to improved ductility to a certain degree. The aim of this paper is to develop new materials with both high yield strength and excellent toughness based on more economical materials cost.
]]>Metals doi: 10.3390/met14030284
Authors: Dohyung Kim Seongjun Kim Jinyong Park Doo-In Kim Byung-Hyun Shin Jang-Hee Yoon
Carbon steel is subjected to several pretreatments to enable its use in highly corrosive environments, such as marine structures. However, its surface treatment is problematic owing to various processes, and these problems can be solved by replacing it with super duplex stainless steel (SDSS), which exhibits remarkable strength and corrosion resistance owing to its austenite and ferrite phases. EN 1.4410 and EN 1.4501 are the most extensively used SDSS grades in marine structures, as they exhibit exceptional strength and corrosion resistance in seawater. This study subjected EN 1.4410 and EN 1.4501 samples to specific heat treatment after casting and observed their structural alterations through field emission scanning electron microscopy. Their passivation states, with or without the Cu and W layers, were determined by examining their corrosion properties through open-circuit potential measurements, electrostatic polarisation tests, electrochemical impedance spectroscopy (EIS), and critical pitting temperature (CPT) analysis. The inclusion of Cu significantly improved the uniform corrosion resistance within the passivation layers, whereas the addition of W enhanced the pitting resistance (Epit, CPT). Additionally, the EIS analysis confirmed a double-layer structure in the passivation layer of EN 1.4501. Moreover, Cu did not act as a strengthening element of the passivation layer, whereas W significantly reinforced it.
]]>Metals doi: 10.3390/met14030283
Authors: E. Pineda Martínez E. J. Palmiere
A series of plane strain compression tests were carried out in order to simulate the thermomechanical controlled processing of a 0.09wt% Nb low carbon steel, in a scheme of multipass finish rolling at 950 °C with interpass times of 10 s. It was observed that after the first two finishing passes a remarkable grain refinement can be achieved, since the recrystallisation was fully suppressed and abundant ultrafine ferrite was transformed dynamically during the deformation. The addition of a third finishing pass however, led to partial recrystallisation. A deep characterisation of the dynamic ferrite was carried out by diverse methods conducting to relevant findings that contribute to a better elucidation of the dynamic transformation. The results obtained indicated that the dynamic formation of a colony of Widmanstätten ferrite plates during deformation, initiates with the formation of a pair of self-accommodating plates followed by face-to-face sympathetic nucleation of new plates at one of the faces of the pairs of plates already formed. Furthermore, the crystal orientation within the dynamic ferrite phase was analysed with EBSD, it was observed that during the coalescence of plates, prior to the full polygonisation of grains, the ferrite adopts a transitory morphology which possesses particular crystallographic characteristics.
]]>Metals doi: 10.3390/met14030281
Authors: Katarzyna Skibińska Safya Elsharkawy Karolina Kołczyk-Siedlecka Dawid Kutyła Piotr Żabiński
Ni–Cu alloys are suitable candidates as catalysts in hydrogen evolution reaction. Because of the different magnetic properties of Ni and Cu, the influence of an applied external magnetic field on the synthesis Ni–Cu alloys was studied. The coatings were prepared with visible changes in their appearance. The differences between the observed regions were studied in terms of morphology and chemical composition. In addition, the overall chemical and phase compositions were determined using X-ray fluorescence and X-ray diffraction methods, respectively. The catalytic activity was measured in 1 M NaOH using linear sweep voltammetry. The contact angle was determined using contour analysis. All samples were hydrophilic. Hydrogen evolution started at different times depending on the area on the surface. It started earliest on the coating obtained in parallel to the electrode magnetic field at 250 mT. We found that when the Lorenz force is maximal, Cu deposition is preferred because of the enhancement of mass transport.
]]>Metals doi: 10.3390/met14030282
Authors: Stephen Price Kiran Judd Matthew Gleason Kyle Tsaknopoulos Danielle L. Cote Rodica Neamtu
This study advances foundational knowledge regarding the impact of processing parameters and material selection on bead shape in Wire Arc directed energy deposition (Wire Arc DED) additive manufacturing. Through the collection and analysis of the largest Wire Arc DED bead shape dataset to date, this work confirms the dominant roles of the feed rate and travel speed on bead shape. Specifically, an increasing feed rate correlates with an increased bead size, while increasing the travel speed decreases the bead size. Furthermore, as the first dataset to directly compare bead shape across different wire–substrate combinations, this research identified that material selection has a smaller, but still relevant, impact on bead shape compared to the feed rate and travel speed. These insights into the roles of parameters and materials are critical for improving large-scale manufacturing efficiency and quality with Wire Arc DED. By generating a robust, multi-material dataset, this work enables applications of machine learning to optimize Wire Arc DED through quicker manufacturing, reduced material waste, and improved structural integrity.
]]>Metals doi: 10.3390/met14030280
Authors: Jidong Wang Hao Xue Yang Zhao Tao Zhang Fuhui Wang
The effects of surface roughness on the corrosion mechanism of HP-13Cr stainless steel in the dynamic aggressive oilfield environment were investigated through surface analysis, weight-loss measurements, and computational fluid dynamics simulations. The results showed that the surface roughness mainly changed the fluid state at the metal/solution interface. With the increase in the surface roughness, the vortex was more likely to form at the trough of the waves. The vortex could result in the deposition process and inhomogeneity in the thickness of the oxide film. The pitting corrosion occurred more easily. Furthermore, the temperature and CO2 pressure obviously facilitated the corrosion rate.
]]>Metals doi: 10.3390/met14030279
Authors: Lorena Freire Ignacio Ezpeleta Julio Sánchez Rubén Castro
Corrosion and scaling in metal pipelines are the major issues in the exploitation of geothermal sources. Geothermal fluids are complex mixtures consisting of dissolved gases and high-salinity solutions. This creates very aggressive environments primarily due to the high concentrations of carbon dioxide (CO2), hydrogen sulfide (H2S), chlorides, and other chemical species. Besides, the high temperature of the brines also increases corrosion rates, which can lead to failures related to stress and fatigue corrosion. On the other hand, reinjection of cooled brine exiting the heat exchanger favors the onset of scaling, since the chemicals dissolved in geothermal waters may tend to precipitate promoting inorganic depositions on the casing. Corrosion and scaling phenomena are difficult to detect visually or monitor continuously. Standard techniques based on pH, temperature pressure, electrical resistance measurements, chemistry composition, and physical properties are habitually applied as indirect methods for corrosion rate control. These methods, however, lack enough robustness for accurate and reliable measuring of the corrosion behavior of materials. To address this issue, a novel system has been proposed for the continuous monitoring of corrosion degradation caused by the effect of the geothermal brines. The present work aims to design, develop, and validate a dedicated electrochemical-based test system for online and onsite monitoring of the corrosion rate and scaling growth occurring on different materials exposed to real operating conditions. This system uses non-standard methods based on electrochemical impedance spectroscopy (EIS) to obtain quantitative data related to the material quality. It can be used to track the condition of the pipeline, reducing the operation and maintenance (O&M) costs and shutdown times. By providing early corrosion rate data, this system allows the prediction of failures in critical units of the plant.
]]>Metals doi: 10.3390/met14030278
Authors: Sui Xie Baojun Zhao
Pyrometallurgy is the primary technique for the production of many nonferrous metals such as copper, lead, and zinc. The phase equilibrium information of smelting slags plays an important role in the efficient extraction of metals and energy consumption. The experimental technologies used in phase equilibrium studies are compared. The presentation and applications of the pseudo-ternary and pseudo-binary phase diagrams are demonstrated in the Fe–Si–Ca–Zn–Mg–Al–Cu–S–O system. Experimental results are also compared with the predictions of FactSage to evaluate the accuracy of the current thermodynamic database. This review paper provides comprehensive information for the operation of nonferrous metals and optimization of the thermodynamic database.
]]>Metals doi: 10.3390/met14030277
Authors: Behrouz Abnar Mousa Javidani
In this study, friction stir welding (FSW) was employed to join AA3003-H18 sheets by incorporating in situ Al-Cu intermetallic compounds within the stir zone. The FSW process was carried out under three distinct conditions: (I) without applying powder, (II) by introducing Cu powder, and (III) by incorporating Cu-Al mixed powder (50 vol.% Cu, 50 vol.% Al). The powder was embedded into the gap between two sheets. Subsequently, two-pass FSW, involving both forward and backward movements, was conducted with a rotational speed of 1200 rpm and traverse speed of 100 mm/min across all three experimental conditions. In the second and third conditions, the formation of in situ intermetallic compounds occurred through a solid-state reaction between Cu particles and Al within the stir zone. Examination of the stir zone through optical and electron microscopic studies revealed that the utilization of Cu-Al mixed powder resulted in finer and more uniformly distributed Cu clusters and Al-Cu intermetallics than samples welded with Cu powder alone. Notably, the stir zone of samples incorporating Cu-Al mixed powder exhibited finely dispersed, completely gray Al-Cu intermetallic particles, whereas those with only Cu powder displayed predominantly coarse core-shell particles in the microstructure. The introduction of Cu-Al mixed powder during FSW resulted in a stir zone with an average hardness of 74 HB, showing a 14% increase compared to the cases where Cu powder alone was added (65 HB). Tensile tests, conducted in both transverse and longitudinal directions on the FSWed samples, did not exhibit a consistent trend across the three mentioned conditions. Transverse tensile strength consistently ranged between 107 and 110 MPa, with joint efficiency varying from 52% to 54%. However, the longitudinal tensile strength of the joint with added Cu-Al mixed powder (158 MPa) surpassed those welded with Cu powder alone (134 MPa).
]]>Metals doi: 10.3390/met14030276
Authors: Hee Young Son In Yong Jung Baig Gyu Choi Jong Ho Shin Chang Yong Jo Je Hyun Lee
The effects of chemical composition and solidification rate on the solidification behavior of high-Cr white irons were investigated through directional solidification. Increasing the solidification rate in hypoeutectic alloys caused finer dendrite-arm spacing, as expected. The eutectic structure, which formed in the interdendritic region, was comprised of M7C3 and austenite; however, secondary dendrite arms of hypoeutectic alloys contained a few M7C3 particles that solidified prior to the eutectic structure. The transition from cellular to dendritic solidification occurred at a solidification rate between 50 µm/s and 100 µm/s in a near-eutectic alloy. In the near-eutectic alloy with cellular solidification, a directionally arrayed in-situ composite of M7C3/austenite formed within the cell. Speckle-like features appeared in the intercellular region due to M23C6 carbide precipitation during subsequent cooling after freezing. Like dendrite-arm spacing in hypoeutectic alloys, the inter-speckle spacing and the inter-fiber spacing became finer with an increasing solidification rate in the cellular solidification range.
]]>Metals doi: 10.3390/met14030275
Authors: Yuxuan Yi Fei Yin Jiajun Zhai Yanxiong Liu
Ultrasonic shot peening (USP) is a surface treatment technology used in the mechanical properties strengthening of the engineering material and components during manufacturing. TC4 titanium alloy is a commonly used engineering material in the aerospace industry. In this study, a gradient nanostructured surface layer was successfully fabricated on the TC4 titanium alloy via USP technology at room temperature. The microstructure evolution of TC4 titanium alloy during USP was investigated. The surface microhardness was elevated from 330 HV to 438 HV with a penetrating depth of around 900 μm after USP with the duration of 8 min. EBSD characterization results confirmed the presence of high-density grain boundaries within the gradient structure in the region of 0–200 μm, accompanied by proliferation of dislocation density. TEM characterization indicated a substantial amount of nanograin with an average size of 74.58 nm. Furthermore, the USP process was also investigated by the finite element method to evaluate the surface-strengthening effect. The calculated maximum residual stress reached 973 MPa after multi-ball impact. The impact behavior of the shots during the USP process was studied. The effect of the parameters on the USP strengthening intensity was explored based on the validated model. This work provided a clearer understanding of the USP strengthening process of TC4 titanium alloy through an effective method of evaluating the process parameters.
]]>Metals doi: 10.3390/met14030274
Authors: Qian Zhao Shaoyuan Lyu Guopeng Zhang Minfang Chen
The effects of different MgO contents (0.3 wt.%, 0.5 wt.%, 0.7 wt.% and 1.0 wt.%) on the microstructure and properties of Mg-1Zn-0.5Ca alloy (ZX) were systematically investigated to promote the clinical application of Mg alloys. The results showed that a MgO addition promoted the precipitates of Ca2Mg6Zn3 and Mg2Ca after hot extrusion. Meanwhile, the average grain size of the ZX alloy decreased abruptly from 17.73 μm to 5.54 μm after the addition of 0.3 wt.% MgO and then reduced slowly as further increasing the MgO contents to 1.0 wt.%. The microhardness and yield strength (YS) increased gradually from 59.43 HV and 102.0 MPa in ZX to 69.81 HV and 209.5 MPa in ZX1.0, respectively. However, the elongation to failure (EL) decreased from 26.7% in ZX to 21.2% in ZX1.0 due to the increase of volume fraction of the second phase and decrease of grain size as increasing the MgO. The corrosion result showed that ZX alloy exhibited local corrosion while ZX composites (ZX0.3, ZX0.5 and ZX0.7) displayed relatively uniform corrosion owing to the fine grain size, dispersed fine second and the protective effect of corrosion product after MgO hydrolyzation. However, excessive MgO (ZX1.0) easily caused the aggregation of itself and the precipitates and deteriorated the corrosion resistance of the material.
]]>Metals doi: 10.3390/met14030273
Authors: Xiaoke Li Wenbo Xing Qianlong Jiang Zhenzhong Chen Wenbo Zhao Yapeng Xu Yang Cao Wuyi Ming Jun Ma
The axle bridge plays a crucial role in the bogie of low-floor light rail vehicles, impacting operational efficiency and fuel economy. To minimize the total cost of the structure and turning of axle bridges, an optimization model of structural and turning parameters was built, with the fatigue life, maximum stress, maximum deformation, and maximum main cutting force as constraints. Through orthogonal experiments and multivariate variance analysis, the key design variables which have a significant impact on optimization objectives and constraints (performance responses) were identified. Then the optimal Latin hypercube design and finite element simulation was used to build a Radial Basis Function (RBF) model to approximate the implicit relationship between design variables and performance responses. Finally, a multi-island genetic algorithm was applied to solve the integrated optimization model, resulting in an 8.457% and 1.1% reduction in total cost compared with the original parameters and parameters of sequential optimization, proving the effectiveness of the proposed method.
]]>Metals doi: 10.3390/met14030272
Authors: Jing Liu Yang Liu Guodong Wang Naiwei Lu Jian Cui Honghao Wang
Multiple fatigue cracks are generally present in practical engineering due to the existence of welding; the size and number of cracks of orthotropic steel bridge decks are greatly uncertain. The component failure conditions caused by these cracks may have correlations. Currently, it is still a challenging issue to develop a physical model of multiple fatigue crack propagation in bridge decks and perform a fatigue reliability assessment, which is also the motivation that drives the innovation of this study. A fatigue reliability evaluation method is presented for orthotropic steel bridge decks, considering the coupling effect of multiple cracks and the randomness of vehicle loading. A numerical simulation method for multifatigue crack growth is developed by combining the ABAQUS and FRANC3D programs. The equivalent crack depth under different spacing and depths of collinear cracks is calculated by using numerical simulation and the multicrack equivalent characterization method. The critical damage accumulation function of multiple fatigue cracks is established using linear elastic fracture mechanics. Subsequently, the critical damage accumulation function of multiple fatigue cracks is established based on linear elastic fracture mechanics. In order to solve the time-consuming problem of traditional Monte Carlo method, the iHL-RF method and AK-MCS method are developed for fatigue reliability analysis. The results show that compared with the single-crack model, the fatigue reliability of orthotropic steel deck will be crucially reduced considering the coupling effect of double cracks. The MCS, iHL-RF and AK-MCS methods can effectively solve the fatigue reliability analysis problem. Compared with the MCS method, the reliability calculation time based on AK-MCS method is significantly reduced. The AK-MCS method-based method reduces the time for calculating the reliability of orthotropic steel decks by 50% compared with the iHL-RF method. The reliability analysis of orthotropic steel deck bridge based on AK-MCS method is proved to be efficient and accurate.
]]>Metals doi: 10.3390/met14030271
Authors: Ehab Samuel Hicham Tahiri Agnes M. Samuel Fawzy H. Samuel
The objective of the current work is to establish, on the one hand, the conventional mechanisms of grain refining and, on the other hand, the effect of the refining-modification interaction in Sr-modified Al-Si alloys on the achieved grain refining and the modification of eutectic silicon. For this purpose, the hypereutectic alloy A390.1 (~17%Si) was used. Various grain refiners were used, namely, Al-10%Ti, Al-5%Ti-1%B, and Al-4%B. After the preparation of the liquid metal, several concentrations of these master alloys were added to the liquid bath according to the desired objective. The different melts prepared were heated at 750 °C and cast in a preheated graphite mold with a solidification rate of around 0.8 °C/s. The liquid metal was. The presence of strontium (added in the form of Al-10%Sr master alloy) and boron completely affects the microstructure of the alloy. An atom of Sr unites with 6 atoms of B to form a compound whose stoichiometric formula is of the SrB6 type, leading to a significant reduction in the modification. A strong relationship exists between the addition of B and the recovery level of Sr. The affinity between titanium and boron is stronger than the affinity between boron and strontium. Both B and TiB2 phase particles do not react with Si; it is only the Ti part of the Al-Ti-B master that forms (Al, Si)3Ti. Regardless of the amount of Si content in the alloy, the Al-4%B master alloy achieves the best grain refining compared to Ti-containing master alloys.
]]>Metals doi: 10.3390/met14030270
Authors: Antonio Enrique Salas-Reyes Abdullah Qaban Barrie Mintz
The intermediate-temperature embrittlement range was examined for Fe, Al, Cu, and Ni alloys. It was found that this embrittlement occurs in many alloys, although the causes are very diverse. Embrittlement can be due to fine matrix precipitation, precipitate free zones, melting of compounds at the grain boundaries, segregation of elements to the boundaries, and, additionally for steel, the presence of the soft ferrite film surrounding the harder austenite matrix. Grain boundary sliding and segregation to the boundaries seem to dominate the failure mode at the base of the trough when intergranular failure takes place. When cracking is due to the presence of hydrogen or liquid films at the boundary, then the dissociation along the boundaries is so easy, it is often independent of the strain rate and is always intergranular. In the other cases when failure occurs, if the deformation is carried out at a high strain rate, it is normally transgranular (e.g., hot rolling giving rise to edge cracking). However, when the strain rate is reduced to that of creep (e.g., bending during continuous casting of steel), failure can also take place by grain boundary sliding, and intergranular failure then becomes the favoured mode.
]]>Metals doi: 10.3390/met14030269
Authors: Alexandra Kaas Christian Wilke Johannes-Samuel Rabaschus Thomas Mütze Urs A. Peuker
The recycling of lithium-ion batteries, in particular, has become increasingly important in recent years. Due to the materials contained, such as copper or nickel, the return to the economic cycle is important. To ensure this, binding measures have been introduced by the European Commission. As part of the mechanical recycling of lithium-ion batteries, the zig-zag air classifier is used to separate battery components. One application is the separation of the current conductor foils from each other, which is investigated and modelled here. Existing models deriving from the literature are evaluated for material fractions coming from the recycling of different automotive lithium-ion batteries. Since the separation depends on the geometry of the foil particles, similarities for separation depending on the geometric characteristics of the electrodes are derived. It turns out that the material is too complex for the empirical model. However, the model can be used to evaluate the suitability of the apparatus and the quality of the separation.
]]>Metals doi: 10.3390/met14030268
Authors: Andrea Corrado Raffaele De Biasi Daniele Rigotti Fabrizio Stecca Alessandro Pegoretti Matteo Benedetti
In the contemporary emphasis on weight reduction, the utilization of advanced materials like Carbon Fiber Reinforced Polymers (CFRPs) and cutting-edge technologies such as 3D printing of metal is increasingly crucial. This study delves into the junction of CFRP and titanium, aiming to conduct Single Lap shear tests on specimens featuring a co-lamination of long fiber composite onto a metal lattice structure. Different specimens with different dimensions of the Simple Cubic (SC) unit cell were subjected to testing. A microscope investigation facilitated an exploration of junction failure and epoxy resin infiltration into the lattice substrate. Employing an efficient 2D Finite Element Model, the homogenization process yielded theoretical models underestimating the Young Modulus by approximately 10% compared to real specimens. Despite the challenges in bonding titanium and CFRP, the novel junction exhibited a shear stress of 17.25 MPa, which is nearly equivalent to those of a co-lamination between sandblasted steel and CFRP, that is 17.15 MPa.
]]>Metals doi: 10.3390/met14030267
Authors: Lei Han Zhanxing Yu Dejun Yan Yuzhong Rao Lin Ma
Achieving high-strength welding joint of aluminum to steel is a highly pressing and challenging task in the manufacturing industries, and friction stir lap welding (FSLW) has advantages for joining these two metals. To further heighten the strength of dissimilar aluminum and steel metals (Al/steel) FSLW joint, the ultrasonic-assisted FSLW (UAFSLW) process was used, and the upper 2024-T4 aluminum alloy and the lower 304 stainless steel were chosen as research object. The results show that the addition of ultrasound eliminates the micro pores, changes the aluminum-rich intermetallic compounds (IMCs) into the iron-rich IMCs and enhances the micro and macro mechanical interlocking structures along the Al/steel lap interface. Under the rational IMCs layer thickness lower than 1.5 μm, the UAFSLW joint has the failure load higher than the traditional FSLW joint. The maximum failure load of UAFSLW joint reaches 7.06 kN, and the loading capacity of this joint is higher than that of reported Al/steel traditional FSLW joint. The UAFSLW process is an effective way to fabricate the high-strength Al/steel lap joint.
]]>Metals doi: 10.3390/met14030266
Authors: Vítor M. G. Gomes Carlos D. S. Souto José A. F. O. Correia Abílio M. P. de Jesus
Leaf springs are components of railway rolling stock made of high-strength alloyed steel to resist loading and environmental conditions. Combining the geometric notches with the high surface roughness of its leaves, fatigue models based on local approaches might be more accurate than global ones. In this investigation, the monotonic and fatigue behaviour of 51CrV4 steel for application in leaf springs of railway rolling stock is analysed. Fatigue models based on strain-life and energy-life approaches are considered. Additionally, the transient and stabilised behaviours are analysed to evaluate the cyclic behaviour. Both cyclic elastoplastic and cyclic master curves are considered. Lastly, different fatigue fracture surfaces are analysed using SEM. As a result, the material properties and fatigue models can be applied further in either the design of leaf springs or in the mechanical designs of other components made of 51CrV4 steel.
]]>Metals doi: 10.3390/met14030265
Authors: Xiaojian Dong Min Zeng Hong Yan
Carbon nanotubes (CNTs) are considered ideal nanoscale reinforcement for the development of high-performance metal matrix composites due to their unique structure and excellent mechanical properties. However, CNTs are easy to agglomerate and have poor wettability with the aluminum matrix, resulting in unsatisfactory effects when added to the aluminum melt. In this study, Cu-coated carbon nanotubes (Cu@CNTs)-reinforced aluminum matrix composites were fabricated by high-energy ultrasonic-assisted casting. Moreover, the effects of different Cu@CNTs content on the microstructure and mechanical properties of aluminum matrix composites were explored. Meanwhile, Fluent 19.0 software was used to further explore the function of ultrasonic vibration in the melt. The results demonstrated that the mechanical properties of composite with 1.2 wt% Cu@CNTs are optimal. Compared with the matrix, the composite with 1.2 wt% Cu@CNTs displayed a 39.3% increase in yield strength, 53.5% increase in ultimate tensile strength, and 5.7% increase in elongation. The simulation results showed that the uniform dispersion of Cu@CNTs and grain refinement can be attributed to the acoustic streaming effect and cavitation effect of high-energy ultrasound. The improvement of the properties of the composites can be attributed to the grain refinement and the load-bearing effect of CNTs.
]]>Metals doi: 10.3390/met14030264
Authors: Weiwei Zhang Dongxiao Kan Jing Liang Yanchao Li Wei Bai Benqi Jiao Jianfeng Li Wen Zhang
High-entropy alloys (HEAs) attract much attention as possible radiation-resistant materials due to their several unique properties. In this work, the generation and evolution of the radiation damage response of an FeNiCrCoCu HEA and bulk Ni in the early stages were explored using molecular dynamics (MD). The design, concerned with investigating the irradiation tolerance of the FeNiCrCoCu HEA, encompassed the following: (1) The FeNiCrCoCu HEA structure was obtained through a hybrid method that combined Monte Carlo (MC) and MD vs. the random distribution of atoms. (2) Displacement cascades caused by different primary knock-on atom (PKA) energy levels (500 to 5000 eV) of the FeNiCrCoCu HEA vs. bulk Ni were simulated. There was almost no element segregation in bulk FeNiCrCoCu obtained with the MD/MC method by analyzing the Warren–Cowley short-range order (SRO) parameters. In this case, the atom distribution was similar to the random structure that was selected as a substrate to conduct the damage cascade process. A mass of defects (interstitials and vacancies) was generated primarily by PKA departure. The number of adatoms grew, which slightly roughened the surface, and the defects were distributed deeper as the PKA energy increased for both pure Ni and the FeNiCrCoCu HEA. At the time of thermal spike, one fascinating phenomenon occurred where the number of Frenkel pairs for HEA was more than that for pure Ni. However, we obtained the opposite result, that fewer Frenkel pairs survived in the HEA than in pure Ni in the final state of the damage cascade. The number and size of defect clusters grew with increasing PKA energy levels for both materials. Defects were suppressed in the HEA; that is to say, defects were “cowards”, behaving in an introverted manner according to the anthropomorphic rhetorical method.
]]>Metals doi: 10.3390/met14030261
Authors: Donghwan Eom Sangbong Yi Dietmar Letzig No-Jin Park
In this work, the microstructure and texture of Mg-1.0Al-xZn-0.2Mn-0.5Ca (wt.%, x = 0, 1) alloys, which were produced via conventional casting or twin roll casting (TRC), were investigated, and their relation to the mechanical properties of the sheets at the final gage was analyzed. In the Zn-containing AZMX1100 alloy sheets, the amount and size of the secondary phases were significantly reduced, in comparison to the Zn-free AMX100 alloy sheet. The TRC sheet shows a smaller grain structure and fine secondary phases in comparison to the sheets produced via the conventional casting process. The texture of the AMX100 sheet is characterized by the basal poles tilted in the sheet rolling direction (RD). In the AZMX1100 sheets, the texture with the tilted basal poles towards the RD and transverse direction (TD) was developed after recrystallization annealing, while the tilting angle of the basal pole in the TD is larger than in the RD. There is no significant difference in the texture between the sheets produced by the casting and TRC process. The highest yield strength was obtained in the AZMX1100 sheet produced by the TRC process, and all examined sheets showed the mechanical anisotropy in accordance with their textures.
]]>Metals doi: 10.3390/met14030260
Authors: Daniel Shtuckmeyster Nitzan Maman Moshe Vaknin Gabriel Zamir Victor Y. Zenou Ulrich Kentsch Itzchak Dahan Roni Z. Shneck
The factors that influence the formation of helium blisters in copper were studied, including crystallographic grain orientation and thermomechanical conditions. Helium implantation experiments were conducted at 40 KeV with a dose of 5 × 1017 ions/cm2, and the samples were then subjected to post-implantation heat treatments at 450 °C for different holding times. A scanning electron microscope (SEM) equipped with an electron backscatter diffraction (EBSD) detector was used to analyze the samples, revealing that the degree of blistering erosion and its evolution with time varied with the crystallographic plane of the free surface in different ways in annealed and cold rolled copper. Out of the investigated states, rolled copper with a (111) free surface had superior helium blistering durability. This is explained by the consideration of the multivariable situation, including the role of dislocations and vacancies. For future plasma-facing component (PFC) candidate material, similar research should be conducted in order to find the optimal combination of material properties for helium blistering durability. In the case of Cu selection as a PFC, the two practical approaches to obtain the preferred (111) orientation are cold rolling and thin layer technologies.
]]>Metals doi: 10.3390/met14030263
Authors: Sicheng Song Yanhui Sun Chao Chen
This paper presents a numerical simulation of the steel grade transition from the ladle nozzle to the solidification end of the bloom. The simulation is based on models encompassing fluid flow, solidification, heat transfer, an electromagnetic field, and solute transport. To validate the accuracy of the steel grade transition model, transition blooms of high-carbon steel are sampled. Subsequently, the model is applied to investigating the steel grade transition between medium-carbon steel and low-carbon steel. The findings indicate that the regions exhibiting significant differences between their molten steel flow velocity and bloom casting speed in the strand model are primarily concentrated within 1 m below the meniscus. Additionally, the mushy zone in the strand model possesses a substantial volume. Solute elements continuously permeate the liquid phase from the solid phase through the mushy zone. Consequently, the distribution of solute elements in the transition bloom is primarily influenced by the molten steel flow in the tundish and macro-segregation in the casting process. The segregation degree of each solute element varies among grades with different carbon contents. In the austenite phase, the segregation degree of each element follows the order C > Si > Mo > Mn > Cr > Ni, while in the ferrite phase, the segregation degree is ordered as C > Si = Mn. Considering macro-segregation, the transition bloom partition model proves to be more stringent than the original partition method. This results in longer transition blooms when a significant difference exists between the new and old grades. For example, in Scheme 1, the original plan transition bloom length is 8.88 m, whereas the new plan transition bloom length is 10.88 m. Similarly, in Scheme 2, the original plan transition bloom length is 34.64 m, and the new plan transition bloom length is 35.16 m. Conversely, shorter partition intervals occur when there is an overlap in the composition of the new and old grades. In Scheme 3, the original plan partition interval for the new and old grades is 4.08 m, while the new plan partition interval is reduced to 0.94 m.
]]>Metals doi: 10.3390/met14030262
Authors: Wei Tang Stylianos Chatzidakis Caleb Matthew Schrad Roger G. Miller Robert Howard
The confinement boundaries of spent nuclear fuel (SNF) canisters are typically fusion welded. Welded microstructures, strain hardening, and residual stresses combined with a chemically aggressive, chloride-rich environment led to concerns that the welded canister may be susceptible to chloride-induced stress corrosion cracking (CISCC). A comprehensive understanding of the modification of stainless steel (SS) metallurgical and mechanical properties by fusion welding could accelerate the predictive analysis of CISCC susceptibility. This paper describes a submerged arc welding (SAW) procedure that was developed and qualified on 12.7 mm (0.5 in.) thick AISI 304/304L SS to produce joints in a way similar to actual SNF canister manufacturing. This procedure has the potential to reduce the production cost and weld CISCC susceptibility by using fewer welding passes and lower heat input than current industrial applications. Global and local mechanical behaviors and properties, as well as residual stress distributions on the welded joint, were studied. The results indicate that hardness values in the fusion zone (FZ) and heat-affected zone (HAZ) are slightly higher than that of the base metal. Strain localization was presented in the HAZ before the tensile stress reached its maximum value, and then it shifted to the FZ. The specimen finally broke in the FZ. High tensile residual stresses exhibited in the FZ and the nearby HAZ suggest the highest CISCC-susceptible spots. The maximum tensile residual stresses were along the welding direction, indicating that if cracks occur, they would be perpendicular to the welding direction. This study involved developing and qualifying a SAW procedure for SNF canister production. The new procedure yielded cost savings (SAW working efficiency increased by about 80%), improved mechanical properties, and presented moderate residual stresses. Analysis revealed that the welded joint’s low-stress and high-stress damage assessments may be affected by shifts in the strain localization spot under loading.
]]>Metals doi: 10.3390/met14030259
Authors: Wenjie Liu Changjiang Zhang Qun Shi Fuyin Han Peng Cao
In this paper, the electron backscatter diffraction (EBSD) technique was used to analyze the dynamic recrystallization (DRX), twinning, slip behavior, and texture evolution during forging and subsequent extruding deformation. The results show that, as the degree of strain increased (forging to extruding), the degree of DRX increased, and the DRX mechanism changed from discontinuous DRX (DDRX) during forging to DDRX and continuous DRX (CDRX) during extruding. Particle stimulation nucleation (PSN) promoting DRX occurred during deformation. The deformation process mainly produced {10–12} twins (TTW) and played a role in coordinating the deformation. The slip behavior also changed according to an analysis of in-grain misorientation axes (IGMA) results, changing from slip-dominated with a basal <a> slip to co-dominated with multiple slip modes, with the activation of mainly prismatic <a> and pyramidal <c+a> slip. Meanwhile, the strong basal texture at the beginning of the deformation also changed, and the texture strength decreased from 24.81 to 15.56. The weakening of the texture was mainly due to the formation of DRX grains and twins, as the newly formed DRX and twins reoriented. In the later stages of deformation, the activation of prismatic <a> slip and pyramidal <c+a> slip changed the basal texture component. Based on microstructural analysis, the improvement in mechanical properties was due to fine-grain strengthening and load-transfer strengthening. The ultimate tensile strength (UTS) was 370.5 MPa, the yield strength (YS) was 340.1 MPa, and the elongation (EL) was 15.6%.
]]>Metals doi: 10.3390/met14030258
Authors: Julia Dölling Moritz Kuglstatter Ulrich Prahl Heinz Werner Höppel Patrick Ortner Benedict Ott Stefanie Felicia Kracun Martin Fehlbier Andreas Zilly
Copper alloys containing chromium and hafnium combine elevated mechanical strength and high electrical and thermal conductivity. For the simultaneous enhancement of both material properties, precipitation hardening is the utilized mechanism. Therefore, the aim is to analyze the influence of chromium and hafnium in binary and ternary low-alloyed copper alloys and to compare the precipitation processes during temperature exposure. Atom probe tomography (APT) and differential scanning calorimetry (DSC) measurements enable to understand the precipitation sequence in detail. CuCr0.7 starts to precipitate directly, whereas CuHf0.7 is highly influenced by prior diffusion facilitating cold rolling. Within the ternary alloy, hafnium atoms accumulate at the shell of mainly Cr-containing precipitates. Increasing the local hafnium concentration results in the formation of intermetallic CuHf precipitates at the sites of mainly Cr-containing precipitates. Indirect methods are utilized to investigate the materials’ properties and show the impact of cold rolling prior to an aging treatment on binary alloys CuCr and CuHf. Finally, ternary alloys combine the benefits of facilitated precipitation processes and decelerated growing and coarsening, which classifies the alloys to be applicable for usage at elevated temperatures.
]]>Metals doi: 10.3390/met14030257
Authors: Libang Lai Jann-Erik Brandenburg Paul Chekhonin Arnaud Duplessi Fabien Cuvilly Auriane Etienne Bertrand Radiguet David Rafaja Frank Bergner
Ion irradiation combined with nanoindentation is a promising tool for studying irradiation-induced hardening of nuclear materials, including reactor pressure vessel (RPV) steels. For RPV steels, the major sources of hardening are nm-sized irradiation-induced dislocation loops and solute atom clusters, both representing barriers for dislocation glide. The dispersed barrier hardening (DBH) model provides a link between the irradiation-induced nanofeatures and hardening. However, a number of details of the DBH model still require consideration. These include the role of the unirradiated microstructure, the proper treatment of the indentation size effect (ISE), and the appropriate superposition rule of individual hardening contributions. In the present study, two well-characterized RPV steels, each ion-irradiated up to two different levels of displacement damage, were investigated. Dislocation loops and solute atom clusters were characterized by transmission electron microscopy and atom probe tomography, respectively. Nanoindentation with a Berkovich indenter was used to measure indentation hardness as a function of the contact depth. In the present paper, the measured hardening profiles are compared with predictions based on different DBH models. Conclusions about the appropriate superposition rule and the consideration of the ISE (in terms of geometrically necessary dislocations) are drawn.
]]>Metals doi: 10.3390/met14030256
Authors: Yang Zhou Junlan Wang
In this study, Cu/Ni and Cu/Al multilayers, with individual layer thickness varying from 25 nm to 200 nm, and co-sputtered Cu-Ni and Cu-Al single layer films were deposited at room temperature via magnetron sputtering and further annealed from 100 °C to 300 °C. The mechanical and microstructural properties of the as-deposited and annealed samples were characterized by nanoindentation, x-ray diffraction, and scanning electron microscopy. Both multilayer systems exhibit an increase in hardness with increasing annealing temperature. However, the Cu/Ni system shows a gradual and moderate hardness increase (up to 30%) from room temperature to 300 °C, while the Cu/Al system displays a sharp hardness surge (~150%) between 125 °C and 200 °C. The co-sputtered Cu-Ni and Cu-Al samples consistently demonstrate higher hardness than their multilayered counterparts, albeit with distinctly different temperature dependence—the hardness of Cu-Ni increases with annealing temperature while Cu-Al maintains a constant high hardness throughout the entire temperature range. The distinct thermal strengthening mechanisms observed in the two metallic multilayer systems can be ascribed to the formation of solid solutions in Cu/Ni and the precipitation of intermetallic phases in Cu/Al. This study highlights the unique advantage of intermetallic strengthening in metallic multilayer systems.
]]>Metals doi: 10.3390/met14030255
Authors: Abbas Tamadon Dirk J. Pons Don Clucas Kamil Sued
In the original publication [...]
]]>Metals doi: 10.3390/met14030254
Authors: Mingyang Yuan Xinbao Zhao Quanzhao Yue Yuefeng Gu Ze Zhang
Crack initiation plays a major role in very high cycle fatigue (VHCF) life, and the initiation of cracks is related to slip behavior. There is a need for improvement in the understanding of the influence of Ti-6Al-4V microstructures on VHCF performance and crack initiation modes. In this study, through an investigation of Ti-6Al-4V VHCF in equiaxed and bimodal microstructures, two different crack initiation modes were identified. The change in crack initiation mode is related to the variation in microtexture, for which a corresponding model is proposed. The VHCF performance of the bimodal microstructure is significantly improved compared to that of the equiaxed microstructure.
]]>Metals doi: 10.3390/met14030253
Authors: Jana Pirošková Jakub Klimko Silvia Ružičková Martina Laubertová Vladimír Marcinov Erika Múdra Marek Vojtko Dušan Oráč
During hot-dip galvanization, wastes such as bottom dross, zinc ash, spent pre-treatment solutions, and galvanizing flue dust (GFD) are generated. In scientific publications, research devoted to GFD waste recycling is absent, and companies generating this waste require a solution to this complex problem. GFD is often landfilled in hazardous waste landfills. However, it is possible to process this waste hydrometallurgically, where GFD is first leached, the solution is refined, and finally, zinc metal is obtained by electrowinning. During specific environmentally friendly leaching, not all solid GFD is dissolved, and the aim of this study is to process the remaining solid GFD residue. The analysis shows that the GFD residue material mainly contains zinc (42.46%) in the form of oxides, but there is also a small amount of polluting elements such as Al, Fe, and Pb. This study examines the leaching of the samples in HCl and H2SO4 under different conditions with the aim of obtaining a solution with a high concentration and high leaching efficiency of zinc. The L/S ratio of 3, 4 M H2SO4, and ambient temperature proved to be optimal for the leaching of the GFD residue, where 96.24% of zinc was leached out, which represents a zinc concentration of 136.532 g/L.
]]>Metals doi: 10.3390/met14020252
Authors: Jian Yin Huaiyu Hou Jing-Tao Wang Xiangbing Liu Chaoliang Xu Yuanfei Li Wangjie Qian Xiao Jin Huanchun Wu Wenqing Jia Qiwei Quan
Shear-coupled grain boundary motion (SCGBM) is an important and efficacious plasticity mechanism in the deformation of metals. In this work, a molecular dynamic (MD) simulation of the interaction between the SCGBM of Σ9[110](221) GB and Cu-rich precipitates in α-iron was carried out. The effects of the size, the temperature, and the composition of the Cu precipitates were also studied. It was found that the precipitates inhibited the GB motion significantly, and the configuration transformation from spheroid to ellipsoid was also investigated in the simulation results. The critical stress of the interaction increased with the size of the precipitates. At higher temperatures, the GB sliding event increased the critical stress of the GB motion, which was higher than that of the interaction, inducing no stress-rise stage in the stress–time curve. The critical stress of the CuNi precipitates on the SCGBM was higher than that of the pure Cu precipitates with the same size, which was one of the reasons for the outstanding strength of the high-strength low-alloy (HSLA) steels compared with the traditional Cu-containing steels.
]]>Metals doi: 10.3390/met14020251
Authors: Michaela Roudnicka Zdenek Kacenka Drahomir Dvorsky Jan Drahokoupil Dalibor Vojtech
The 3D printing of Ti-Al6-V4 alloy is subject to much current investigation, with Laser Beam Powder Bed Fusion (PBF-LB/M) being one of the most applied technologies. Ti-Al6-V4 alloy, despite its great material properties, is susceptible to hydrogen penetration and consequent embrittlement. The level of susceptibility to hydrogen penetration depends on the microstructural state of the alloy. In this work, we compare the effect of electrochemical charging by hydrogen on Ti-Al6-V4 alloy prepared by PBF-LB/M, either in the as-built state or annealed, and conventionally prepared alloy. At the same charging conditions, considerably different hydrogen concentrations were achieved, with the as-built 3D-printed material being the most susceptible. The changes in mechanical properties are discussed in relation to changes in microstructure, studied using microscopy, X-ray, and electron diffraction techniques.
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