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Metals, Volume 15, Issue 12

2025 December - 114 articles

Cover Story: This work demonstrates an effective Direct Energy Deposition strategy for fabricating crack-free Inconel 718–copper bimetallic structures, overcoming the large thermophysical mismatch between the two alloys. By depositing In718 directly onto a copper substrate with tailored process control, strong diffusion bonding and defect-free interfaces were achieved without post-processing. Microstructural analyses revealed uniform precipitate distribution and consistent penetration depth, while mechanical testing confirmed enhanced hardness, creep resistance, and interfacial integrity. Notably, precipitation strengthening occurred on the copper side already in the as-built condition. The proposed approach enables reliable, high-performance In718–Cu components for demanding aerospace and thermal-management applications. View this paper
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Articles (114)

  • Article
  • Open Access
1 Citations
965 Views
20 Pages

18 December 2025

The pitting corrosion resistance and the tribological behaviour of a ferritic stainless steel with high Mo content (AISI 436) and a commonly employed austenitic stainless steel (AISI 304) are compared. Special attention was paid to the role of Mo in...

(This article belongs to the Section Corrosion and Protection)
  • Article
  • Open Access
718 Views
13 Pages

18 December 2025

In the presented research, aluminum-doped zinc oxide (AZO) thin films were synthesized on high-power transmission lines using the RF magnetron sputtering process. The impact of deposition power (160 W to 280 W) and deposition pressure (2 Pa to 5 Pa),...

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
  • Article
  • Open Access
1 Citations
743 Views
15 Pages

18 December 2025

As research on new, lightweight energy vehicles continues to develop, the application of high-strength steel sheets with tensile strength greater than 1 GPa and their mechanical clinching technology, which is associated with aluminum alloys, has emer...

(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials (2nd Edition))
  • Article
  • Open Access
755 Views
16 Pages

18 December 2025

To reveal its influence on quasicrystal structure analysis, multiple diffraction effects in a basic Co-rich decagonal Al-Co-Ni quasicrystal have been investigated in-house and with synchrotron radiation. Two weak reflections were chosen as the main r...

(This article belongs to the Special Issue Research Progress of Crystal in Metallic Materials)
  • Article
  • Open Access
2 Citations
988 Views
17 Pages

Corrosion Behavior upon Laser Surface Texturing AISI 430 Stainless Steel

  • Edit Roxana Moldovan,
  • Liana Sanda Baltes,
  • Catalin Croitoru,
  • Alexandru Pascu and
  • Mircea Horia Tierean

18 December 2025

Laser surface texturing (LST) is an effective method for enhancing surface functionality, but its effect on corrosion resistance highly depends on texture design and processing parameters. This study investigates the influence of two LST patterns&mda...

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
  • Article
  • Open Access
873 Views
15 Pages

17 December 2025

This study investigates the influence of solidification conditions on the high-cycle fatigue (HCF) behavior of a second-generation DD6 single-crystal superalloy. Single-crystal bars with a [001] orientation were prepared using the high-rate solidific...

(This article belongs to the Section Metal Failure Analysis)
  • Review
  • Open Access
5 Citations
2,269 Views
26 Pages

Research Progress on Application of Machine Learning in Continuous Casting

  • Zhaofeng Wang,
  • Jinghao Shao,
  • Shuai Zhang,
  • Jiahui Zhang and
  • Yuqi Pang

17 December 2025

Continuous casting is a key core link in steel production with characteristics of strong nonlinearity, multi-parameter coupling and dynamic fluctuations under working conditions. Traditional experience-dependent or mechanism-driven models are no long...

  • Article
  • Open Access
1 Citations
1,042 Views
34 Pages

Data-Driven Method for Predicting S-N Curve Based on Structurally Sensitive Fatigue Parameters

  • Andrey Kurkin,
  • Alexander Khrobostov,
  • Vyacheslav Andreev and
  • Olga Andreeva

17 December 2025

Under cyclic loading, almost immediately after its onset, a surface layer forms where hardening and softening processes occur. The interaction of plastic deformation traces with each other, and with other structural elements, leads to the formation o...

(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
  • Article
  • Open Access
3 Citations
685 Views
12 Pages

17 December 2025

The effect of Ni content on the improvement of low-temperature impact toughness and microstructure refinement in a simulated coarse-grained heat-affected zone (CGHAZ) of high-strength steel was studied. The impact toughness tests revealed that as the...

(This article belongs to the Special Issue Advances in Welding and Joining of Alloys and Steel)
  • Article
  • Open Access
949 Views
16 Pages

16 December 2025

FeCoNiCu(Cr, Mn, La, Ce)-Al high-entropy alloys (HEAs) were prepared via a combined centrifugal casting–self-propagating high-temperature synthesis process to serve as multifunctional catalyst precursors. The findings indicated that even with a...

  • Article
  • Open Access
4 Citations
1,043 Views
20 Pages

Deep Learning-Based Automatic Recognition of Segregation in Continuous Casting Slabs

  • Xiaojuan Wu,
  • Jiwu Zhang,
  • Fujian Guo,
  • R. Devesh Kumar Misra,
  • Xuemin Wang and
  • Xiucheng Li

16 December 2025

Central segregation, a typical internal defect in continuous casting slabs, significantly deteriorates the mechanical properties of steel products. However, traditional manual defect evaluation methods rely heavily on experience, are highly subjectiv...

  • Article
  • Open Access
956 Views
22 Pages

Computational Modeling of Multiple-Phase Transformations in API X70 and X80 Steels

  • Ry Karl,
  • Jonas Valloton,
  • Chad Cathcart,
  • Tihe Zhou,
  • Fateh Fazeli,
  • J. Barry Wiskel and
  • Hani Henein

16 December 2025

Continuous cooling transformation (CCT) diagrams for two thermo-mechanically controlled processed (TMCP) steels were produced using a modified Johnson–Mehl–Avrami–Kolmogorov (JMAK) model, which accounted for the simultaneous transfo...

(This article belongs to the Section Metal Casting, Forming and Heat Treatment)
  • Article
  • Open Access
1 Citations
754 Views
21 Pages

Interactions Effect Among the Electrolytes on Micro-Arc Oxidation Coatings of AZ91D Mg Alloy

  • Zhanying Wang,
  • Qinqin Zhao,
  • Ying Ma,
  • Leichao Meng and
  • Lingyun An

16 December 2025

Simplex-centroid mixture design (SCMD) is applied to change the combination of Na2SiO3, KF, NaOH and NaAlO2 to examine the influences of electrolyte components and their interactions on the thickness and corrosion resistance of micro-arc oxidation (M...

  • Article
  • Open Access
566 Views
30 Pages

A Novel Mathematical Model for Predicting Self-Excited Vibrations in Micromilling of Aluminium 7075

  • Cvijetin Mladjenovic,
  • Dejan Marinković,
  • Katarina Monkova,
  • Miloš Knežev and
  • Aleksandar Živković

15 December 2025

Micro milling of metallic materials presents unique dynamic challenges due to highly nonlinear cutting forces and the susceptibility to self-excited vibrations (chatter). This paper presents a novel mathematical model for chatter prediction in micro...

(This article belongs to the Special Issue Computational Methods in Metallic Materials Manufacturing Processes 2025)
  • Article
  • Open Access
697 Views
16 Pages

15 December 2025

The practical characterization algorithm is presented to find the optimized damage constants and critical damages of the traditional damage models formulated by some unknown damage constants. The flow characterization of the material SWCH45F is condu...

  • Article
  • Open Access
2 Citations
805 Views
13 Pages

Surface Integrity and Corrosion Resistance of Additively Manufactured AZ91 Mg Alloys Post-Processed by Laser Shock Peening

  • Shan Gao,
  • Wenquan Wang,
  • Xintian Zhao,
  • Wenhui Yu,
  • Hongyu Zheng,
  • Xingchen Yan,
  • Cheng Chang,
  • Harry M. Ngwangwa,
  • Xiaoli Cui and
  • Zongshen Wang

15 December 2025

Mg alloys show great potential in biomedical fields due to superior biocompatibility and biodegradability. Additive manufacturing (AM) provides opportunities in fabricating metallic implants with complex geometries while inherent defects during AM li...

(This article belongs to the Special Issue Laser Shock Peening: From Fundamentals to Applications)
  • Feature Paper
  • Review
  • Open Access
1 Citations
1,642 Views
29 Pages

15 December 2025

The promise of lithium–oxygen batteries lie not merely in their record-breaking theoretical energy density, but in the challenge of making such energy truly reversible. Rising as the key obstacle is the lithium metal anode, whose remarkable cap...

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
  • Article
  • Open Access
3 Citations
1,650 Views
24 Pages

Surrogate-Model Prediction of Mechanical Response in Architected Ti6Al4V Cylindrical TPMS Metamaterials

  • Mansoureh Rezapourian,
  • Ali Cheloee Darabi,
  • Mohammadreza Khoshbin,
  • Siegfried Schmauder and
  • Irina Hussainova

15 December 2025

A Machine Learning (ML)-based surrogate modeling framework is presented for mapping structure–property relationships in architected Ti6Al4V cylindrical TPMS metamaterials subjected to quasi-static compression. A Python–nTop pipeline autom...

(This article belongs to the Special Issue Application of Machine Learning in Metallic Materials)
  • Article
  • Open Access
1,188 Views
24 Pages

Computational Modeling of the Temperature Distribution in a Butt Weld of AISI 304L Stainless Steel Using a Volumetric Heat Source

  • Thiago da Silva Machado,
  • Thiago da Silveira,
  • Liércio André Isoldi and
  • Luiz Antônio Bragança da Cunda

14 December 2025

The Finite Element Method is an indispensable tool for analyzing the transient thermal phenomena in welding processes. This study aims to simulate the temperature field during Gas Metal Arc Welding of an AISI 304L V-groove butt joint, employing a vol...

  • Article
  • Open Access
1 Citations
1,267 Views
16 Pages

12 December 2025

Metallic interconnects are key components in planar solid oxide fuel cell (SOFC) stacks. In the present study, we evaluated four Fe-Cr powder metallurgy (PM) alloy specimens, obtained from a domestic manufacturer, at nominal compositions (in wt%) of...

(This article belongs to the Section Metallic Functional Materials)
  • Article
  • Open Access
1,157 Views
18 Pages

12 December 2025

The performance of ultra-high-purity copper sputtering targets is critical for nanoscale integrated circuit fabrication, yet challenges such as dynamic recovery and recrystallization hinder grain refinement and texture control. In the present work, c...

  • Article
  • Open Access
2 Citations
747 Views
11 Pages

Metastable Ferromagnetic B2 Phase in AlCr Alloy Through Co Addition

  • Esmat Dastanpour,
  • Haireguli Aihemaiti,
  • Valter Ström and
  • Levente Vitos

12 December 2025

Recently, we reported an antiferromagnetic ground state for equiatomic Al-Cr in the B2 structure. Here, by a joint theoretical–experimental study, we investigate the effect of Co additions to the Al-Cr alloy with the aim to synthesize a ferroma...

(This article belongs to the Special Issue Metallic Magnetic Materials: Manufacture, Properties and Applications)
  • Article
  • Open Access
1 Citations
1,090 Views
15 Pages

11 December 2025

The superconducting transition temperature, Tc, of the graphite intercalation compound, CaC6, was calculated using the Roeser–Huber (RH) formalism. This method was adapted to alloys with complex crystal structures by identifying symmetric paths...

(This article belongs to the Section Metallic Functional Materials)
  • Article
  • Open Access
5 Citations
959 Views
27 Pages

Micro and Macrostructural Assessment of Welded 6082 Aluminium Alloy T-Connections

  • Darko Landek,
  • Ivica Garašić,
  • Davor Skejić,
  • Anđelo Valčić,
  • Ivan Čudina and
  • Mislav Štefok

11 December 2025

One of the main challenges in welding aluminium concerns structural integrity and a significant reduction in mechanical properties in the region adjacent to the weld. Design provisions can result in a drastic reduction, which may exceed 50% of the ba...

(This article belongs to the Special Issue Novel Insights into Welding and Joining Technologies of Metallic Materials)
  • Article
  • Open Access
1 Citations
1,303 Views
17 Pages

Laser Powder Bed-Fused Scalmalloy®: Effect of Long Thermal Aging on Hardness and Electrical Conductivity

  • Emanuele Ghio,
  • Lorenzo Curti,
  • Daniele Carosi,
  • Alessandro Morri and
  • Emanuela Cerri

11 December 2025

This study investigates the microstructural evolution, porosity characteristics, and mechanical behavior of LPBF-manufactured Scalmalloy®, which were investigated in the as-built conditions and after long-term exposure to direct aging of 275, 325...

(This article belongs to the Special Issue Recent Advances in Powder-Based Additive Manufacturing of Metals)
  • Article
  • Open Access
1 Citations
596 Views
15 Pages

Analysis of the Regulatory Effect of Semi-Solid Isothermal Treatment Time on Crystallization and Plasticity of Amorphous Composites

  • Xinhua Huang,
  • Guang Wang,
  • Bin Chen,
  • Chenghao Wei,
  • Jintao Zhao,
  • Longguang Wu,
  • Qi Li and
  • Yuejun Ouyang

11 December 2025

Ti48Zr27Cu6Nb5Be14 amorphous composites were prepared by copper mold suction casting to obtain as-cast specimens. Subsequently, the as-cast specimens were held at 900 °C for different durations (5, 10, 20, 30, and 40 min) and then water quenched...

(This article belongs to the Special Issue Research Progress of Crystal in Metallic Materials)
  • Article
  • Open Access
1,039 Views
15 Pages

11 December 2025

A leachate from alkaline leaching of copper shaft furnace (CSF) dust as a hazardous waste was used in this study for performing a chemical precipitation experiment of lead, zinc, and copper. The precipitation processes for lead, zinc, and copper were...

(This article belongs to the Special Issue Studies on Metal Leaching, Extraction and Recovery)
  • Article
  • Open Access
1 Citations
1,115 Views
25 Pages

Effect of Quenching and Partitioning on Microstructure, Impact Toughness and Wear Resistance of a Gray Cast Iron

  • Edson Luiz da Silva Junior,
  • Fábio Edson Mariani,
  • Selauco Vurobi Junior,
  • Camila Yuri Negrão Konno,
  • Adriano Corrêa Batista,
  • Tiago Manoel de Oliveira Santos,
  • Mariana Botelho Barbosa and
  • Kahl Dick Zilnyk

10 December 2025

This study investigates the influence of quenching and partitioning (Q&P) on the microstructure, hardness, wear resistance, and impact toughness of GG25 gray cast iron, in comparison with as-cast, quenched, quenched-and-tempered, and austempered...

(This article belongs to the Special Issue Mechanical and Structural Properties of Cast Irons)
  • Article
  • Open Access
3 Citations
834 Views
22 Pages

10 December 2025

In this study, simulations and analyses of arc characteristics in EP (positive polarity) and EN (negative polarity) stages (including the arc polarity transition stage) of variable polarity cold metal transition (VP-CMT) during arc additive manufactu...

(This article belongs to the Section Additive Manufacturing)
  • Article
  • Open Access
1 Citations
1,163 Views
29 Pages

Non-Ferrous Metal Bioleaching from Pyrometallurgical Copper Slag Using Spent Medium of Different Fungal Species

  • Plamen Georgiev,
  • Marina Nicolova,
  • Irena Spasova,
  • Mihail Iliev and
  • Ralitsa Ilieva

10 December 2025

Copper slag, a by-product of copper ore and concentrate smelting, is rich in non-ferrous metals; therefore, it has been considered a valuable raw material in recent years. This study aimed to compare the extraction of zinc, copper, and cobalt from tw...

(This article belongs to the Section Extractive Metallurgy)
  • Article
  • Open Access
753 Views
15 Pages

10 December 2025

Online roll profile measurement technology can measure in real time without changing the rolls, which has advantages that traditional roll profile measurement methods cannot compare with. To improve the accuracy of online roll profile measurement dur...

(This article belongs to the Special Issue Advanced Rolling Technologies of Steels and Alloys)
  • Editorial
  • Open Access
1 Citations
1,308 Views
6 Pages

10 December 2025

After the success of the two prior editions, a third edition of a Special Issue of Metals has been commissioned, specifically devoted to aspects of mineral processing and hydrometallurgy [...]

(This article belongs to the Special Issue Advances in Mineral Processing and Hydrometallurgy—3rd Edition)
  • Editorial
  • Open Access
763 Views
4 Pages

10 December 2025

Engineering reliable metallic components across transportation, energy, manufacturing, and cryogenic technologies hinges on controlling how processing routes determine microstructure and how microstructure governs strength, toughness, and durability...

(This article belongs to the Special Issue Recent Insights into Mechanical Properties of Metallic Alloys)
  • Article
  • Open Access
853 Views
20 Pages

9 December 2025

Porous Ti-6Al-4V foams are excellent materials due to their low density, high specific strength, and excellent biocompatibility. This study investigates the fabrication of open-cell Ti-6Al-4V foams using the replica impregnation method with polyureth...

  • Article
  • Open Access
3 Citations
1,124 Views
22 Pages

Selection of Processing Parameters in Laser Powder Bed Fusion for the Production of Iron Cellular Structures

  • Pedro Nogueira,
  • João P. G. Magrinho,
  • Rodolfo L. Batalha,
  • Maria J. Rosa,
  • Ana Cabral,
  • Paulo J. Morais,
  • Luis Reis,
  • Catarina Santos,
  • Maria J. Carmezim and
  • Maria Fátima Vaz
  • + 3 authors

9 December 2025

Metal additive manufacturing (AM) offers promising advancements in producing implants with complex geometry for biomedical applications, where accuracy and near-net-shape production are essential. Metal AM by laser powder bed fusion (PBF-LB) is a pro...

(This article belongs to the Special Issue Application-Driven Development of Metal Additive Manufacturing: From Laboratory Research Towards Industrial Adoption)
  • Article
  • Open Access
3 Citations
1,133 Views
27 Pages

Reducing Maximum Punching Force in Sheet Cold Forming: A Numerical Study of a New Punch Design (Part II)

  • Abdelwaheb Zeidi,
  • Mabrouka Akrout,
  • Khaled Elleuch and
  • António Pereira

9 December 2025

Punching is a widely adopted cold sheet metal forming process, prized for its cost-effectiveness and high production efficiency. However, premature tool failure remains a persistent challenge, leading to increased downtime and maintenance costs. This...

(This article belongs to the Special Issue Editorial Board Members’ Collection Series: “Laser Welding and Additive Manufacturing”)
  • Article
  • Open Access
1 Citations
816 Views
11 Pages

9 December 2025

CoCrNi medium-entropy alloys (MEAs) have emerged as a promising class of structural materials due to their exceptional strength–ductility synergy. However, the lack of composition-dependent predictive models severely hinders rational alloy desi...

(This article belongs to the Special Issue Advanced Theoretical Technology for Understanding Microstructures and Mechanical Properties of Alloys)
  • Article
  • Open Access
929 Views
11 Pages

Study on the Kinetics of Zinc Leaching Residue Smelting Reduction

  • Zihao Wang,
  • Mei Zhou,
  • Yingjiang Wang,
  • Xinwei Du and
  • Qiuyue Zhao

9 December 2025

This study investigates the desulfurization and smelting reduction processes of zinc leaching residue and analyzes the kinetics of the desulfurization and smelting reduction processes of zinc leaching residue. The results showed that, when the desulf...

(This article belongs to the Special Issue Metal Extraction and Recovery from Slag: Separation and Reduction Processes)
  • Article
  • Open Access
867 Views
12 Pages

9 December 2025

This study aimed to investigate the growth behavior of key precipitates in 9–12 wt.% Cr ferritic/martensitic heat-resistant steel as a function of tempering duration. Tempering was carried out at 670 °C for durations between 1 h and 300 h....

  • Review
  • Open Access
6 Citations
3,570 Views
55 Pages

8 December 2025

The rapid advancement of machine learning (ML) has ushered in a new era for materials science, particularly in the design and understanding of high-entropy alloys (HEAs). As a class of compositionally complex materials, HEAs have greatly benefited fr...

  • Article
  • Open Access
4 Citations
907 Views
18 Pages

8 December 2025

To address the technical challenge of balancing formability and strength in automotive aluminum alloys, this study examined an Al-4.35Mg-3.6Zn-0.2Cu alloy subjected to a combined heat-treatment schedule consisting of a two-step solution treatment (47...

  • Article
  • Open Access
1 Citations
1,602 Views
27 Pages

Modeling and Experimental Analysis of the Dislocation Structure Evolution During Deformation of High-Purity Aluminum

  • Abbas Sadeghi,
  • Robert Kahlenberg,
  • Tomasz Wojcik,
  • Roman Schuster,
  • Philipp Retzl,
  • Yao V. Shan and
  • Ernst Kozeschnik

8 December 2025

In this study, the three internal variables model (3IVM) for dislocation density evolution is further developed into the advanced ABC (advABC) model to simulate the thermo-mechanical behavior of high-purity aluminum (5N). In contrast to conventional...

(This article belongs to the Section Metal Casting, Forming and Heat Treatment)
  • Review
  • Open Access
10 Citations
2,231 Views
40 Pages

Research Progress on the Corrosion Behavior of Metallic Glass and Its Composites

  • Liyuan Li,
  • Yi Qian,
  • Zihao Wang,
  • Qing Tong,
  • Miqi Wang,
  • Qiuyi Pan and
  • Yuan Yu

8 December 2025

In the context of growing demands for durable, high-performance materials capable of operating in increasingly harsh environments, metallic glasses and their composites have attracted extensive research interest. Metallic glasses and their composites...

  • Article
  • Open Access
3 Citations
1,672 Views
30 Pages

A Statistical-Based Model of Roll Force During Commercial Hot Rolling of Steel

  • Edikan Udofia,
  • Luke Messer,
  • Gus Greivel,
  • Alexandra Newman and
  • Brian G. Thomas

8 December 2025

This research introduces a new model to predict the roll force during hot rolling of steel, based on a statistical analysis of approximately 38,980 sets of measurements in a commercial mill with five finishing stands. The study includes ten different...

(This article belongs to the Special Issue Advanced Rolling Technologies of Steels and Alloys)
  • Article
  • Open Access
722 Views
11 Pages

Static Magnetic Field Impact on Laser Weld Bead Morphology of Sn-10%wt.Pb Alloy

  • Imants Kaldre,
  • Aleksandrs Kleinhofs,
  • Valdemars Felcis and
  • Valters Dzelme

8 December 2025

Additive manufacturing (AM) offers significant potential but faces challenges in controlling rapid solidification processes due to thermal conditions. The application of magnetic fields provides a promising path to influence liquid metal behavior dur...

(This article belongs to the Section Additive Manufacturing)
  • Article
  • Open Access
1 Citations
1,133 Views
19 Pages

Research into the Properties of Wear-Resistant Coatings Produced Using HVOF Technology on the Functional Surfaces of Injection Molds

  • Janette Brezinová,
  • Milan Fiľo,
  • Viktor Puchý,
  • Ján Viňáš,
  • Jakub Brezina and
  • Ema Nováková-Marcinčínová

7 December 2025

The paper presents the results of research aimed at verifying the possibility of creating renovation layers using HVOF (High Velocity Oxygen Fuel) technology. HVOF ceramic coatings represent a promising way to increase the efficiency, reliability, an...

  • Article
  • Open Access
1 Citations
1,040 Views
16 Pages

The Effect of NbC Precipitates on Hydrogen Embrittlement of Dual-Phase Steels

  • Wei Li,
  • Kejia Qiang,
  • Boyu Cao,
  • Yu Tang,
  • Fengcang Ma,
  • Wei Li and
  • Ke Zhang

7 December 2025

New grades of dual-phase (DP) steels with ultimate tensile strength (UTS) up to 1500 MPa have been developed using a continuous annealing process. This study investigates the effects of over-aging temperature and NbC precipitates on the microstructur...

(This article belongs to the Special Issue Advances in Corrosion and Failure Analysis of Metallic Materials)

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Metals - ISSN 2075-4701