Development and Research of New Hybrid Composites in Order to Increase Reliability and Durability of Structural Elements

Round 1

Reviewer 1 Report

This article presents a study on the structure and properties of hybrid composite materials, specifically focusing on Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - cBNCoMo and Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - B4CCoMo composites. The researchers employed the High-Velocity Oxygen Fuel (HVOF) method on mechanically activated powders in a protective environment, followed by high-temperature thermomechanical treatment. They found that this method resulted in a nanostructured state with improved mechanical and operational properties, and reduced porosity in the surface layers. The article delves into the formation mechanism of this nanostructural state under severe plastic deformation. Experimental tests were carried out for cyclic durability under conditions of high-cycle fatigue and friction-wear.

Reviewer's Comments and Suggestions:

1. The title needs to specify the type of hybrid composite materials investigated, reflecting the focus on Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - cBNCoMo and Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - B4CCoMo composites.
2. The abstract should be revised to clearly state the problem addressed (What), methodology used (How), the main results, and their implications/applications.
3. Expand the introduction by adding relevant background information, contextualizing the importance of the study. Statements in lines 46-52 need further details and supportive references.
4. Research objectives should be explicitly stated, described descriptively, and should indicate where in the article each objective is addressed.
5. Reconsider the use of all capital letters for section headings for better readability.
6. Pay attention to the organization of the 'Results and Discussion' sections. Ensure that the third level headings appropriately fit into the sections.
7. All figures should be improved for clarity, complete with informative captions and appropriate labeling.
8. Clarify how the process described in line 153 includes plastic deformation.
9. Please revise labels in Fig 2 (a and b) that are not in English.
10. Fig 2c needs to be better constructed for easier understanding. Revise to ensure it communicates the intended information clearly.
11. For Fig 3, clarify what part of the sample is being shown in the micrographs. Ensure consistency in the alignment of the images, and provide clear, appropriate labels.
12. Uniform formatting and styles should be used for all subplots in Fig 4.
13. Reconsider the placement of part 4.3. It seems more fitting in the results section rather than the discussion.
14. The conclusions need to be revised to fully reflect all the key findings of the study.
15. Include an author contribution statement. It is important to give credit to each author's contribution to the research.
16. See the annotated attached document for more details.

Comments for author File: Comments.pdf

1. Improve the language and writing style of the article to enhance readability and clarity. Consider getting a professional editing service if necessary.

Author Response

Dear Reviewer,

Thank you very much for taking the time to analyze the article and constructive criticism. The article has been corrected in accordance with the indicated comments. All changes in the text of the article are highlighted in green.

1. The title needs to specify the type of hybrid composite materials investigated, reflecting the focus on Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - cBNCoMo and Hastelloy X (NiCrFeMo) - AlCoCrCuFeNi - B4CCoMo composites.

The title of the article has been changed. A new version: Structure and properties of hybrid composite materials NiCrFeMo-AlCoCrCuFeNi-cBNCoMo(B4CCoMo).

2. The abstract should be revised to clearly state the problem addressed (What), methodology used (How), the main results, and their implications/applications.

The abstract of the article has been changed.

3. Expand the introduction by adding relevant background information, contextualizing the importance of the study. Statements in lines 46-52 need further details and supportive references.

Introduction expanded, added new links.

4. Research objectives should be explicitly stated, described descriptively, and should indicate where in the article each objective is addressed.

The objectives of the study have been adjusted in accordance with your comments.

5. Reconsider the use of all capital letters for section headings for better readability.

Section capital letters changed to lowercase letters.

6. Pay attention to the organization of the 'Results and Discussion' sections. Ensure that the third level headings appropriately fit into the sections.

In my opinion, the section headings fit right into it.

7. All figures should be improved for clarity, complete with informative captions and appropriate labeling.

Drawings aligned.

8. Clarify how the process described in line 153 includes plastic deformation.

Thermomechanical processing includes plastic deformation of materials at high temperature and subsequent annealing. Annealing of materials was carried out in order to relax stresses arising after plastic deformation. Plastic deformation of the materials was carried out under the pressure of the rollers on the surface of the material at high temperature. Plastic deformation of materials was carried out on the device shown in Figure 1,b,c.

9. Please revise labels in Fig 2 (a and b) that are not in English.

Figure 2a,b corrected.

10. Fig 2c needs to be better constructed for easier understanding. Revise to ensure it communicates the intended information clearly.

Figure 2c, replaced with another figure, more readable.

11. For Fig 3, clarify what part of the sample is being shown in the micrographs. Ensure consistency in the alignment of the images, and provide clear, appropriate labels.

Figure 3 has been redone.

Figure 3a and Figure 3b show the structure of the Hastelloy X(NiCrFeMo) – AlCoCrCuFeNi – cBNCoMo composite. Figure 3a shows an enlarged part of the structure (the interface between the Hastelloy X(NiCrFeMo) and AlCoCrCuFeNi alloy layers) of the Hastelloy X(NiCrFeMo) – AlCoCrCuFeNi – cBNCoMo composite. Figure 3b shows an enlarged part of the structure (the interface between the AlCoCrCuFeNi and cBNCoMo alloy layers) of the Hastelloy X(NiCrFeMo) – AlCoCrCuFeNi – cBNCoMo composite. Figure 3c shows an enlarged part of the structure (the interface between the AlCoCrCuFeNi and B4CCoMo alloy layers) of the Hastelloy X(NiCrFeMo) – AlCoCrCuFeNi - B4CCoMo composite.

12. Uniform formatting and styles should be used for all subplots in Fig 4.

Figure 4 is also aligned.

13. Reconsider the placement of part 4.3. It seems more fitting in the results section rather than the discussion.

Part 4.3. moved to the Discussion section.

14. The conclusions need to be revised to fully reflect all the key findings of the study.

The findings have been revised.

15. Include an author contribution statement. It is important to give credit to each author's contribution to the research.

Authors' Contribution Statements are included at the end of the text of the article.

Author Response File: Author Response.pdf

Reviewer 2 Report

This manuscript is related to the complex formation method of hybrid materials. This paper is novel; however, some correction is needed before publication.

1.       The materials and methods section is very cluttered and should be classified in specific subcategories to make it easier for the reader to understand the content. E.g.1. Materials; 2. Milling; 3. Coating; 4. Mechanical test; 5. Characterization

2.       Milling time?

3.       Introduction section is weak and should completed with new studies. The author can refer to the new studies e.g. “High-temperature solid particle erosion characteristics and damage mechanism of AlxCoCrFeNiSi high-entropy alloy coatings prepared by laser cladding” and “Investigation on the mechanism of micro-milling CoCrFeNiAlX high entropy alloys with end milling cutters”.

4.       In the discussion section, the authors should use references for describe the mechanism and analysis.

5.       The results of the hardness measurement are given in the graph so that it is easier to compare the results. And add error bar for results.

6.       Line 78-81; rewrite the sentences.

This manuscript is related to the complex formation method of hybrid materials. This paper is novel; however, some correction is needed before publication.

1.       The materials and methods section is very cluttered and should be classified in specific subcategories to make it easier for the reader to understand the content. E.g.1. Materials; 2. Milling; 3. Coating; 4. Mechanical test; 5. Characterization

2.       Milling time?

3.       Introduction section is weak and should completed with new studies. The author can refer to the new studies e.g. “High-temperature solid particle erosion characteristics and damage mechanism of AlxCoCrFeNiSi high-entropy alloy coatings prepared by laser cladding” and “Investigation on the mechanism of micro-milling CoCrFeNiAlX high entropy alloys with end milling cutters”.

4.       In the discussion section, the authors should use references for describe the mechanism and analysis.

5.       The results of the hardness measurement are given in the graph so that it is easier to compare the results. And add error bar for results.

6.       Line 78-81; rewrite the sentences.

Author Response

Dear reviewer, thank you very much for your interest and your time. The article has been corrected according to your comments. All changes in the text of the article are highlighted in green.

1. The materials and methods section is very cluttered and should be classified in specific subcategories to make it easier for the reader to understand the content. E.g.1. Materials; 2. Milling; 3. Coating; 4. Mechanical test; 5. Characterization

       Section 2 has been corrected in accordance with the indicated comments.

2. Milling time?

In the course of work, we studied the effect of high-energy machining time on: morphology, changes in the chemical and phase composition of a mixture of powders. The analysis performed shows that during the processing of the investigated multicomponent powder materials at the initial moment (3-6 minutes) the destruction of surface films and a slight increase in the specific surface occurs. The work done to destroy the surface layers of the particles ensures the activation of the reacting components of the powder mixture, and, in addition to the work of plastic deformation of the particles, leads to an increase in temperature at the point of contact with the grinding media. A significant increase in temperature leads to the welding of particles into conglomerates. With an increase in the machining time for more than 7 minutes, the formation of conglomerates consisting of powder particles begins, the contact area of which increases many times over. The formation of conglomerates is influenced by the number of grinding media involved in the process. The number of grinding media determines the flow of energy supplied to the powder particles. With an increase in the number of balls (in relation to the mass of the powder), the flow of generated energy increases, with an increase in the frequency of collisions, the temperature increases, which also leads to welding of the particles. At the same time, the concentration of nonequilibrium defects on the newly formed surface increases. With an increase in the time of machining up to 15-20 minutes, the newly formed conglomerates are destroyed and again participate in multiple mechanical fusion. This leads to an increase in the defectiveness of the powder, which undoubtedly leads to an increase in reactive activity. In the process of mechanical processing for 20-40 minutes, the chemical composition of mechanically activated powder particles is leveled and stabilized.

The time of high-energy mechanical processing of powder materials is: AlCoCrCuFeNi - 20 min; B4CCoMo - 30 min; cBNCoMo - 40 min.

3. Introduction section is weak and should completed with new studies. The author can refer to the new studies e.g. “High-temperature solid particle erosion characteristics and damage mechanism of AlxCoCrFeNiSi high-entropy alloy coatings prepared by laser cladding” and “Investigation on the mechanism of micro-milling CoCrFeNiAlX high entropy alloys with end milling cutters”.

     The introduction section was supplemented with new works.

4. 4.       In the discussion section, the authors should use references for describe the mechanism and analysis.

      Links in the "Discussion" section put down.

5. The results of the hardness measurement are given in the graph so that it is easier to compare the results. And add error bar for results.

A graph of the distribution of microhardness and a photo of the measurement of hardness were added to the text of the article.

      

                                              (a)                                                                            (b)

Figure. (a) Microhardness of composite materials: Hastelloy X(NiCrFeMo) - AlCoCrCuFeNi – cBNCoMo (1); Hastelloy X(NiCrFeMo) - AlCoCrCuFeNi - B4CCoMo (2); (b) Photo of measuring the microhardness of a composite material AlCoCrCuFeNi – cBNCoMo

6. 6.       Line 78-81; rewrite the sentences.

Reworked text: At first we implemented high energy machining of the powder compositions. Then we carried out high velocity oxygen fuel spraying in a protective environment. In order to improve functional and mechanical properties of composites AlCoCrCuFeNi-cBNCoMo, AlCoCrCuFeNi-B4CCoMo, we implemented high energy machining of powder mixtures in a water-cooled centrifugal ball mill GEFEST-2 (AGO-2U).

Author Response File: Author Response.pdf

Reviewer 3 Report

This manuscript mainly shows that a complex formation method of hybrid materials can form nanostructured state with an increased level of mechanical and operational properties. However, the manuscript can be further improved if the following comments and suggestions can be addressed in the next revision:

1.      Lines 38-43, Page 1: The Introduction can be improved, since some advanced studies on the ceramic materials used as surface layers for corrosion resistance can be also supplemented. For example, “Microstructure and corrosion behavior of ZrO₂ coated carbon fiber reinforced magnesium matrix composites sprayed with different powder characteristics” and “The influence of different preparation methods on the erosion behavior of NiP-ZrO₂ nanocomposite coating”.

2.      Fig. 3: Please supplement TEM images of the interface between layers to further characterize the phase composition of the composites.

3.      Fig. 5: Please add the ruler of the image of Layer of high-entropy material AlCoCrCuFeNi.

4.      Fig. 5: Please provide the data of hardness and corrosion resistance of Layer of high-energy wear-resistance materials cBNCoMo to further explain the efficiency of it.

Minor editing of English language required.

Author Response

Dear reviewer,

Thank you very much for your constructive criticism and help in improving the article. The article has been corrected according to your comments. All changes in the text of the article are highlighted in green.

1. Lines 38-43, Page 1: The Introduction can be improved, since some advanced studies on the ceramic materials used as surface layers for corrosion resistance can be also supplemented. For example, “Microstructure and corrosion behavior of ZrO₂coated carbon fiber reinforced magnesium matrix composites sprayed with different powder characteristics” and “The influence of different preparation methods on the erosion behavior of NiP-ZrO₂ nanocomposite coating”.

       The introduction section has been supplemented with additional links.

2. Fig. 3: Please supplement TEM images of the interface between layers to further characterize the phase composition of the composites.

       I redid and enlarged Figure 3. We have no way to do phase analysis at the interface between the layers. The phase analysis of composite layers is shown in Figure 4.

3. Fig. 5: Please add the ruler of the image of Layer of high-entropy material AlCoCrCuFeNi.

        Added.

4. Fig. 5: Please provide the data of hardness and corrosion resistance of Layer of high-energy wear-resistance materials cBNCoMo to further explain the efficiency of it.

       Data on the hardness of layers of composite materials are presented in Figure 5. We have not yet performed tests of materials for corrosion resistance. We plan to perform corrosion resistance tests in the future.

Author Response File: Author Response.pdf

Round 2

Reviewer 1 Report

Thank you for revising the article based on the comments, it seems much better now. I agree with all the changes that you have made. 

The research objectives are usually written in a Paragraph and not in bullets, the figures can still be further constructed and improved. The title is now more complicates, choose a simpler and more relatable version of that.

none

Author Response

Dear reviewer,

I am sincerely grateful to you for your time spent on reviewing the work and comments.

1.Added paragraph: 1.1. Research objectives.

2.Corrected the figures.

3. Title changed, new version: Development and research of new hybrid composites in order to increase reliability and durability of structural elements

Reviewer 2 Report

 Accept in present form

Author Response

Dear reviewer,

I am sincerely grateful to you for your time spent on reviewing the work and comments. 

Reviewer 3 Report

Authors have made modifications as required. However, some issues could be further dealt with in order to enhance the quality of the article, which are listed below:

1.      Fig. 5: Fig. 5b is lack of ruler including “10 mm” and corresponding length of horizontal line. Moreover, why have the images of functional layers and their corresponding requirements and efficiency been removed in the revised manuscript?

Authors have made modifications as required. However, some issues could be further dealt with in order to enhance the quality of the article, which are listed below:

1.      Fig. 5: Fig. 5b is lack of ruler including “10 mm” and corresponding length of horizontal line. Moreover, why have the images of functional layers and their corresponding requirements and efficiency been removed in the revised manuscript?

Author Response

Dear reviewer,

I am sincerely grateful to you for your time spent on reviewing the work and comments. I put a ruler on Figure 5b. Images of functional layers and their respective requirements and performance have been moved to section 4.2, Figure 8.