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Additive manufacturing (AM) represents the present and the future of manufacturing production, thanks to a new design paradigm that allows the customization of components based on the needs of the final application, all framed in a perspective of sus...

Powder bed fusion (PBF) is recognized as one of the most common additive manufacturing technologies because of its attractive capability of fabricating complex geometries using many possible materials. However, the quality and reliability of parts pr...

This review offers a comprehensive analysis of thermal barrier coatings (TBCs) applied to metallic materials. By reviewing the recent literature, this paper reports on a collection of technical information, involving the structure and role of TBCs, v...

Bolted joints are widely used in the aerospace and automotive industries due to their ease of assembly, disassembly and design flexibility. Optimizing threaded fasteners is essential to achieve uniform load distribution and minimize the number of bol...

The exponential growth of electric and hybrid vehicles in the last five years forecasts a waste problem when their batteries achieve end-of-life. Li-ion batteries for vehicles have been assembled using materials from natural resources (as Li, Fe, Al,...

The objective of this study is to describe primary lithium production and to summarize the methods for combined mechanical and hydrometallurgical recycling of lithium-ion batteries (LIBs). This study also aims to draw attention to the problem of lith...

This paper presents a comprehensive review of recent advancements in surface engineering of metals, encompassing techniques, characterization methods and applications. The study emphasizes the significance of surface engineering in enhancing the perf...

While research on lightweight materials has been carried out for decades, it has become intensified with recent climate action initiatives leading pathways to net zero. Aluminum alloys are at the pinnacle of the light metal world, especially in the a...

The present text is the second part of an editorial written for a Special Issue entitled Advances in Metal Casting Technology [...]

Aluminum recycling is a promising solution to environmental and economic issues. Secondary aluminum production will rise in the near future; however, the process is not without challenges. Some of the major concerns during remelting of aluminum are t...

Lattice structures show advantages in mechanical properties and energy absorption efficiency owing to their lightweight, high strength and adjustable geometry. This article reviews lattice structure classification, design and applications, especially...

The excellent casting behavior and mechanical and corrosion properties of aluminum-silicon (Al-Si)-based alloys make them ideal for the manufacture of lightweight components with complex geometries. However, these properties depend directly on their...

Stainless steel is one of the most commonly used structural materials in industry for the transportation of liquids such as water, acids, and organic compounds. Corrosion is a major concern in industry due to the use of strong mineral acids, feedstoc...

Metallic materials are widely employed in engineering constructions, and one of the most common failure mechanisms in metals is fatigue failure. Even though metal fatigue has been studied for almost 160 years, many problems remain unsolved. Fatigue i...

Gallium alloys are ideal base carriers for temperature-sensitive ferrofluids, which can be used for energy convection, soft robotics, microchannels, magnetorheological devices, etc. In this study, gallium was mixed with different substances (In, Sn,...

Due to the time-consuming and costly nature of high-cycle fatigue experiments, correlations between fatigue strength and mechanical properties obtained through more simple and fast experiments can be interesting from an economic perspective. This rev...

In aeronautics, additive manufacturing (AM) leads to specific benefits, mainly connected to topological optimization for weight reduction, the decrease in “buy-to-fly” ratio, and the operations of maintenance, repair, and overhaul. Al all...

Surface modifications for titanium, a material of choice for dental implants, can greatly alter the surface micro/nanotopography and composition of implants, leading to notable enhancements in their hydrophilicity, mechanical properties, osseointegra...

Heavy metal(loid)s (HMs) play an important role in economic development since they are used in various branches of industry. However, all industrial activities emit HMs into the environment, where they are no longer useful but potentially toxic. It h...

Titanium has excellent all-round performance, but the high cost of its production limits its widespread use. Currently, the Kroll process used to commercially produce titanium sponge is inefficient, energy-intensive, and highly polluting to the envir...

Heusler alloys, which were unintentionally discovered at the start of the 20th century, have become intriguing materials for many extraordinary functional applications in the 21st century, including smart devices, spintronics, magnetic refrigeration...

This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting,...

The expected large growth in electric mobility presents challenges, such as requiring a very large amount of critical raw materials like nickel, cobalt, and lithium. Due to this expected growth significant amounts of production scrap from cell and ba...

Hardfacing is an efficient and economical surfacing technique widely used by heavy industries to remediate worn components in service or to enhance the component’s wear characteristics components prior to use. Efficient hardfacing for any targe...

The average lithium content in the Earth’s crust is estimated at about 0.007%. Despite this, lithium is considered abundant and widely distributed, with significant extraction from various sources. Notably, the brines in the Salar de Atacama ar...

Mine tailings deposits are often overlooked by the industry, posing significant environmental challenges due to chemical hazards and inadequate maintenance. Nevertheless, such mineral deposits hold considerable economic potential for processing, and...

Thermal spray deposition techniques have been well-established, owing to their flexibility in addressing degradation due to wear and corrosion issues faced due to extreme environmental conditions. With the adoption of these techniques, a broad spectr...

Since gas turbines are used in airplanes, ship engines and power plants, they play a significant role in providing sustainable energy. Turbines are designed for a certain lifetime according to their operating conditions and the failure mechanisms the...

Nowadays, the use of metal processing additive technologies is a rapidly growing field in the manufacturing industry. These technologies, such as metal 3D printing (also known as additive manufacturing) and laser cladding, allow for the production of...

Due to their exceptional electrical and thermal conductivity properties, high-purity copper (Cu-DHP) and copper alloys of similar composition, such as electrolytic tough-pitch (ETP), oxygen-free electronic (OFE) and oxygen-free (OF), have often been...

Silicon stands out as an exceptionally viable anode material, distinguished by its substantial capacity, plentiful natural reserves, eco-friendliness, and favorable low working potential. Nonetheless, the material’s pronounced volume fluctuatio...

This paper focuses on the study of current knowledge regarding the use of hydrogen as a reducing agent in the metallurgical processes of iron and steel production. This focus is driven by the need to introduce environmentally suitable energy sources...

In recent years, under the background of global low-carbon development, the production of NdFeB magnets has increased dramatically. With the end of magnet life, a large number of discarded products will be produced in the future. At the same time, 6&...

This paper presents a review on the formability evaluation of AHSS, enhancing necking-based failure criteria limitations. Complementary fracture/damage constitutive modeling approaches specifically tailored to formability evaluation, validated throug...

The orthodontic supply market is a prosperous billion-dollar industry, driven by an increasing demand for orthodontic appliances. The supremacy of metallic first-generation biomaterials is evident for manufacturing brackets, archwires, bands, and oth...

Twinning is a major mechanism of plastic deformation in hexagonal close-packed (hcp) structures. However, a mechanistic understanding of twin nucleation and growth has yet to be established. This paper reviews the recent progress in the understanding...

More and larger blast furnaces have been constructed for ironmaking across the world in recent years due to the advantages of high productivity, high energy efficiency and low cost. Slag plays important role in a blast furnace to produce high-quality...

Hydrogen-based direct reduction is a promising technology for CO₂ lean steelmaking. The electric arc furnace is the most relevant aggregate for processing direct reduced iron (DRI). As DRI is usually added into the arc, the behavior in this area is o...

Advanced manufacturing techniques such as Additive Manufacturing (AM) have grown rapidly in major industries such as aerospace, automotive, and biomedical device manufacturing. Biomedical industry has benefitted immensely from AM because of its flexi...

Owing to excellent high-temperature mechanical properties, i.e., high heat resistance, high strength, and high corrosion resistance, Ti alloys can be widely used as structural components, such as blades and wafers, in aero-engines. Due to the complex...

Friction Stir Welding is a suitable solid-state joining technology to connect dissimilar materials. To produce an effective joint, a phase of optimization is required which leads to the definition of process parameters such as pin geometry, tool rota...

The concept of repair and restoration using additive manufacturing (AM) is to build new metal layers on a broken part. It is beneficial for complex parts that are no longer available in the market. Optimization methods are used to solve product desig...

Part I of this series of papers focuses on plant and reactor engineering aspects of the TSL reactor technology. A general flowsheet is presented, while emphasis is given to the definition of different reactor zones in terms of fluid dynamics and occu...

With multiple principal components, high entropy alloys (HEAs) have aroused great interest due to their unique microstructures and outstanding properties. Recently, the corrosion behavior of HEAs has become a scientific hotspot in the area of materia...

To realize rare-earth-free magnets, we studied iron nitride (α″-Fe₁₆N₂) magnets, which contain no rare-earth elements. Fe-N powder with the α″-Fe₁₆N₂ phase has a high saturation magnetization comparable to high-performance rar...

Microwave irradiation is widely used to intensify various chemical processes, including in the synthesis of nanomaterials. The purpose of this review is to present recent trends in the application of microwave heating for the preparation of monometal...

Corrosion is recognized as an unavoidable phenomenon and steel, particularly carbon steel, is strongly susceptible to corrosion. Corrosion damages cause serious material, energy, and economic losses as well as negative impacts on the environment. As...

Rare earth elements (REEs) are key materials for the development of renewable energy devices such as high-power magnets for wind turbines, electric vehicles, or fuel cells for hydrogen generation, aiming to fulfill the objectives of the European Gree...

High-entropy alloys (HEAs) have attracted worldwide interest due to their excellent properties and vast compositional space for design. However, obtaining HEAs with low density and high properties through experimental trial-and-error methods results...

Exploring theoretical energy consumption introduces a fresh perspective for energy-saving research within the iron and steel industry, with a primary focus on the energy expended during material transformation. Building upon the theory of theoretical...