We have studied here the evolution of inclusions in ladle furnace (LF), Ruhrstahl & Heraeus furnace (RH), and simulated welded samples during Ti-Mg oxide metallurgy treatment and the mechanical properties of the heat-affected zone (HAZ) after high heat input welding. The study indicated that inclusions in an LF furnace station are silicomanganate and MnS of size range ~0.8–1.0 μm. After Mg addition, fine Ti-Ca-Mg-O-MnS complex oxides were obtained, which were conducive to the nucleation of acicular ferrite (AF). The corresponding microstructure changed from ferrite side plate (FSP) and polygonal ferrite (PF) to AF, PF, and grain boundary ferrite (GBF). After a simulated welding thermal cycle of 200 kJ/cm, disordered arrangements of acicular ferrite plates, fine size cleavage facets, small inclusions, and dimples all promoted high impact toughness. Full article

Iron contained in coal fly ash of the Ekibastuz power station is distributed between magnetite and hematite. XRD data showed that ~80 wt % of iron is contained in magnetite and ~20 wt % in hematite. The leaching of iron from CFA by HCl was studied. It was determined that leaching efficiency increased with the increase in hydrochloric acid concentration and temperature. The maximum iron extraction efficiency was 52%. Aluminum is contained in the mullite and was practically not leached. The maximum aluminum extraction efficiency was 3.7%. The kinetics investigation showed that the process of iron leaching was controlled by chemical reaction and diffusion process steps, with an activation energy of 33.25 kJ·mol⁻¹. The aluminum leaching process is controlled by a diffusion process step with an activation energy of 19.89 kJ·mol⁻¹. The reaction order of hydrochloric acid is determined to be 0.9 and 0.23 for iron and aluminum, respectively. Full article

Medical implants made of biodegradable materials could be advantageous for temporary applications, such as mechanical support during bone-healing or as vascular stents to keep blood vessels open. After completion of the healing process, the implant would disappear, avoiding long-term side effects or the need for surgical removal. Various corrodible metal alloys based on magnesium, iron or zinc have been proposed as sturdier and potentially less inflammatory alternatives to degradable organic polymers, in particular for load-bearing applications. Despite the recent introduction of magnesium-based screws, the remaining hurdles to routine clinical applications are still challenging. These include limitations such as mechanical material characteristics or unsuitable corrosion characteristics. In this article, the salient features and clinical prospects of currently-investigated biodegradable implant materials are summarized, with a main focus on magnesium alloys. A mechanism of action for the stimulation of bone growth due to the exertion of mechanical force by magnesium corrosion products is discussed. To explain divergent in vitro and in vivo effects of magnesium, a novel model for bacterial biofilm infections is proposed which predicts crucial consequences for antibacterial implant strategies. Full article

Due to their high strength, 7xxx aluminum sheets are increasingly used for structural automobile components. One of the major challenges is the formability of these alloys during the production process while retaining high strengths in service. One promising method is forming at elevated temperatures directly after solution annealing; this is known as hot forming. However, this thermomechanical process requires a detailed comprehension of the dissolution and precipitation behavior during heating, solution annealing, and subsequent combination of forming and cooling processes. Therefore, the kinetics of solid-solid phase transformations during continuous heating and continuous cooling of the aluminum alloys EN AW-7021 and EN AW-7075 were determined with differential scanning calorimetry and hardness testing. The suitable solution annealing conditions and the critical cooling rates were specified for both alloys and compared to the real hot forming processes. Full article

In this paper, a wear-resistant alloy with the chemical composition of 16 wt% Cr-3 wt% B-0.6 wt% C-1 wt% Mn-Fe, in which M₂B was the antifriction skeleton, was prepared in a medium-frequency induction furnace. The microstructure and mechanical properties were experimentally investigated. The results show that the microstructure of the Fe-Cr-B alloy was composed of lath martensite and clavate, reticular, and clustering borides (M₂B). After the thermal treatment, the morphology, chemical composition, and volume fraction of the M₂B did not change significantly. Because of the reduction in element saturation, secondary borides M₂₃(B,C)₆ precipitated from the matrix, which resulted in a decrease in matrix microhardness. As a result, the bulk hardness and abrasive resistance of the alloy accordingly decreased, and the impact toughness inversely increased. According to the results of XRD, electronic probe microanalyzer (EPMA), and TEM, the chemical formula of M₂B was FeCr_0.89Mn_0.14(B,C), which resulted in a body-centered tetragonal (BCT) structure. The chemical formula of the M₂₃(B,C)₆ was Fe_17.97Cr_4.13Mn_1.14 (B,C)₆, which resulted in a face-centered cubic (FCC) structure. Full article

One of the advantages of numerical simulations over traditional experimental methodologies is that they can synchronize nucleation, growth and coarsening during solidification from the point of view of microstructural analysis. However, the computational cost and accuracy are bottlenecks restricting simulation approaches. Here, two cellular automaton (CA) modules with different grid dimensions are coupled to form a cross-scale model in order to simulate MnS precipitation, accompanied by the matrix growth of dendrites during the solidification of a Fe-C-Mn-S steel, where the matrix growth is computed through the CA module with large grids based on the solute conservation and the undercooling of thermal, constitutional, and curvature, and increments of solid fraction of MnS are solved in combination with the transient thermodynamic equilibrium on the locally re-meshed grids once the MnS precipitation is formed. We utilize the cross-scale mode to illustrate MnS evolution in a solidifying matrix and explain the reason why it coexists in three shapes. Further, we study the effects of the content of elements Mn and S on MnS precipitation based on two continuously cast steel objects, with the factor of concentration product fixed as a constant. A re-precipitation of MnS is observed during the solidification of a system with a high content of Mn and low content of S. Simultaneous computation using cross-scale modeling can effectively save on computational resources, and the simulation results agree well with the experimental cases, which confirm its reliable accuracy. Full article

The present work encompasses the effect of overaging on the strain-controlled low-cycle fatigue (LCF) behavior of an extruded AA6061 aluminum alloy at varying strain amplitudes. During the T7 aging treatment, the size of precipitates increased from 60 nm under T6 conditions to 220 nm after aging for 48 h at 200 °C, leading to a decrease in the monotonic tensile strength. During the LCF tests, nearly symmetrical hysteresis loops can be observed in the mid-life cycle under all test conditions, whereas the first-cycle hysteresis loops were moderately inflected under long-aging conditions. With increasing aging time, the cyclic peak stresses decreased and the plastic strain increased. Nearly ideal Masing behavior was exhibited under T6 conditions, while it was lost under T7 overaging conditions. The cyclic stress responses were similar under all tested conditions, involving stabilization at low strain amplitudes and softening at high strain amplitudes, with initial hardening for the first few cycles. Compared to the T6 condition, the fatigue life increased with increasing T7 aging time. Various LCF parameters were estimated based on the Coffin-Manson and Basquin relationships and on the LCF experimental results. The relationship between the fatigue life, strength, and microstructure of the investigated AA6061 aluminum alloy under various aging conditions was discussed. Full article

A high strength Al-Zn-Mg alloy 7A52 with T6 treatment was successfully friction stir welded. The grain structure, dislocations and precipitates in typical regions of the weld joint, including the weld nugget zone (WNZ), thermos-mechanically affected zones (TMAZ) and heat affected zones (HAZ) were investigated to understand the mechanical properties of each zone and the weld joint. In WNZ, a relatively higher density of dislocations is observed on the advancing side, caused by vacancy collapse induced by severe plastic deformation during stirring. However, in the center and on the retreating side, the dislocation density is very low. The strength of the WNZ is influenced by grain refinement, solution strengthening, or natural ageing hardening. In TMAZs, different mechanical properties on each side are due to different grain structures and precipitates introduced by the asymmetrical thermo-mechanical cycle. In HAZs, the mechanical properties are a strong function of the ratio of η′ to η phase. Compared to the micro-tensile results, premature failure of the weld joint occurs in HAZs on the advancing side, resulting from stress concentration near the area with the lowest hardness. Full article

In this study, dissimilar CuNiCrSi and CuCrZr butt joints were friction stir welded at a constant welding speed of 150 mm/min, but at different rotational speeds of 800, 1100, 1400, 1700, and 2100 rpm. Sound joints were achieved at the rotational speeds of 1400 and 1700 rpm. It was found that the area of retreating material and grain size in the nugget zone increased with the increase of tool rotational speeds. The base metal on the CuNiCrSi side (CuNiCrSi-BM) contains a large density of Cr and δ-Ni₂Si precipitates, and a great deal of Cr precipitates can be observed in the base metal on the CuCrZr side (CuCrZr-BM). All these precipitates are completely dissolved into the matrix in both the nugget zone on the CuCrZr side (CuCrZr-NZ) and the nugget zone on the CuNiCrSi side (CuNiCrSi-NZ). The precipitation strengthening plays a dominant role in the base metals, but the grain boundary strengthening is more effective in improving the mechanical properties in the nugget zone. Both the hardness and tensile strength decrease sharply from the base metal to the nugget zone due to the dissolution of precipitates. Mechanical properties such as microhardness and tensile strength in the nugget zone decrease with the increase of rotational speeds because the grain size is larger at a higher rotational speed. Full article

In this research, Australian fine iron ore is reduced by pressured carbon monoxide in a fluidized bed. This research aims to obtain the influence law of gas linear velocity, reduction pressure, reduction temperature, particle size, and reduction time on the reduction effect and the economic, convenient, and effective operating parameters, as well as clarify the effect of the pressurized decarbonization of CO, which inhibits the adhesion of fine iron ore particles during the reduction process. The experimental results show that the preferable operating parameters are a linear velocity of 0.8 m/s, reduction pressure of 0.2 MPa, reduction temperature of 1023 K, and particle size of 0.18 mm–0.66 mm. The graphite produced by the carbon precipitation reaction of carbon monoxide hinders the diffusion of iron atoms and avoids the direct contact between the iron atoms, thereby effectively controlling the sticking. Full article

AlSi10Mg cubes were fabricated with the laser powder bed fusion (LPBF) process, using different exposure times and scan strategies to gain insight into the effect of energy density and part orientation on surface roughness. The results showed that, with increasing energy density, the five-face roughness first decreased and then increased, whereas the top roughness increased slightly. Moreover, considerable differences in roughness appeared for the different faces. A good surface quality was obtained at 175 J/mm³ and 200 J/mm³ when the rotation start angle and rotation increment angle were set as 0 in meander scan mode. The roughness variation was caused by the scan direction, gas flow direction, and wiper movement direction. The scan strategies with rotation increments of 90° effectively narrowed the variation. These results support direct part orientation and placement and can guide users to further reduce roughness through process optimisation or simplification of post-processing procedures. Full article

In this research, Australian fine iron ore was reduced by combining pressurized and energy-bearing waste plastics in a fluidized bed. This research aims to obtain preferable operating parameters by synthetically researching the effect of temperature, linear velocity, pressure, size, and mass content of energetic waste plastics, and to clarify the sticking mechanism and the inhibitory mechanism of fine iron ore during the reduction process. The experimental results show that the preferable operating parameters include a reduction temperature of 923–973 K, linear velocity of 0.8 m/s, reduction pressure of 0.15 MPa, particle size of energetic waste plastics of 0.18–0.66 mm, and mass content of energetic waste plastics of 8%. Under the conditions of theses preferable operating parameters, the sticking mechanism of fine iron ore is caused by the reunion of the metal iron atoms. The occurrence states of carbons deposited from waste plastics can be divided into two types: graphite and carbon from Fe₃C. Carbon from Fe₃C reduces the sticking of fine iron ore, while the graphite hinders the direct contact of iron atoms, thereby effectively controlling the sticking. Full article

In this paper, the effect of cold deformation on the microstructures and mechanical properties of 316LN austenitic stainless steel (ASS) was investigated. The results indicated that the content of martensite increased as the cold rolling reduction also increased. Meanwhile, the density of the grain boundary in the untransformed austenite structure of CR samples increased as the cold reduction increased from 10% to 40%, leading to a decreased size of the untransformed austenite structure. These two factors contribute to the improvement of strength and the decrease of ductility. High yield strengths (780–968 MPa) with reasonable elongations (30.8–27.4%) were achieved through 20–30% cold rolling. The 10–30% cold-rolled (CR) samples with good ductility had a good strain hardening ability, exhibiting a three-stage strain hardening behavior. Full article

Liquid layering, which is a general phenomenon adjacent to the solid substrates, is less understood for its role in heterogeneous nucleation. In this work, the structural features and dynamics of the liquid Al layers induced by the (0001) sapphire and the (0001) TiB₂ substrates, respectively, are quantitatively compared based on the ab initio molecular dynamics simulations. An almost fully ordered liquid Al layer is observed adjacent to the TiB₂ substrate above the Al melting point, while the liquid layers near the sapphire substrate are weakly ordered with virtually no in-plane translational symmetry. Further liquid layering is facilitated by the ordered liquid layer near the TiB₂ substrate, while impeded by the low in-plane ordering of the liquid layers near the sapphire substrate, resulting in different nucleation behaviors for the two systems. The difference in the liquid layering is caused, in part, by the lower adsorption strength at the sapphire–liquid Al interface than that at the TiB₂–liquid Al interface. Additionally, the compressive stress imposed on the liquid layers seriously hinders the sapphire-induced liquid layering. We conclude from this work that the interfacial adsorption strength and mismatch alter the heterogeneous nucleation by influencing the features of the substrate-induced liquid layering. Full article

Under impact loading conditions, the stress state derived from the contact between the projectile and the target, as well as from the subsequent mechanical waves, is a variable of great interest. The geometry of the projectile plays a dertermining role in the resulting stress state in the targeted structure. In this regard, different stress states lead to different failure modes. In this work, we analyze the influence of the stress state on the deformation and failure behaviors of three aluminum alloys that are commonly used in the aeronautical, naval, and automotive industries. To this purpose, tension-torsion tests are performed covering a wide range of stress triaxialities and Lode parameters. Secondly, the observations from these static tests are compared to failure mode of the same materials at high impact velocities tests with the aim of analysing the role of stress state and strain rate in the mechanical response of the aluminum plates. Experimental impacts are conducted with different projectile geometries to allow for the analysis of stress states influence. In addition, these experiments are simulated by using finite element models to evaluate the predictive capability of three failure criteria: critical plastic deformation, Johnson-Cook, and Bai-Wierzbicki. Full article