Metals — Open Access Journal

Recent developments in artificial intelligence (AI) modeling tools allows for envisaging that AI will remove elements of human mechanical effort from welding operations. This paper contributes to this development by proposing an AI tungsten inert gas (TIG) welding algorithm that can assist human welders to select desirable end factors to achieve good weld quality in the welding process. To demonstrate its feasibility, the proposed model has been tested with data from 27 experiments using current, arc length and welding speed as control parameters to predict weld bead width. A fuzzy deep neural network, which is a combination of fuzzy logic and deep neural network approaches, is applied in the algorithm. Simulations were carried out on an experimental test dataset with the AI TIG welding algorithm. The results showed 92.59% predictive accuracy (25 out of 27 correct answers) as compared to the results from the experiment. The performance of the algorithm at this nascent stage demonstrates the feasibility of the proposed method. This performance shows that in future work, if its predictive accuracy is improved with human input and more data, it could achieve the level of accuracy that could support the human welder in the field to enhance efficiency in the welding process. The findings are useful for industries that are in the welding trade and serve as an educational tool. Full article

Degradation by the penetration of oxidation into the Cr12 roller steel is evaluated during thermal fatigue tests in the laboratory in the temperature range of 500–700 °C. A qualitative assessment is carried out with regard to the thermal load, the microstructure and the test temperature. The results show that the specific properties of the microstructure with respect to thermal stress and temperature have a significant influence on the oxidation behavior as well as on the crack propagation mode and crack growth. The conditions that lead to an increase in the oxidation rate and thus to premature and sudden local chipping of the roll surface layer are analyzed and explained. Full article

The aim of our study is to evaluate different implant surface treatments using TiIV and TiV in in vitro and in vivo studies. An in vitro study was established comprising four study groups with treated and untreated TiIV titanium discs (TiIVT and TiIVNT) and treated and untreated TiV titanium discs (TiVT and TiVNT). The surface treatment consisted in a grit blasting treatment with alumina and double acid passivation to modify surface roughness. The surface chemical composition and the surface microstructure of the samples were analyzed. The titanium discs were subjected to cell cultures to determine cell adhesion and proliferation of osteoblasts on them. The in vivo study was carried out on the tibia of three New Zealand rabbits in which 18 implants divided into three experimental groups were placed (TiIVT, TiIVNT, and TiVT). Micro-computed tomography (micro-CT) was performed to determine bone density around the implants. The results showed that cell culture had minor adhesion and cell proliferation in TiIVT and TiVT within the first 6 and 24 h. However, no differences were found after 48 h. No statistically significant differences were found in the in vivo micro-CT and histological study; however, there was a positive trend in bone formation in the groups with a treated surface. Conclusions: All groups showed a similar response to in vitro cell proliferation cultures after 48 h. No statistically significant differences were found in the in vivo micro-CT and histological study. Full article

This study investigates the morphology, composition and corrosion resistance of hot dip galvanized (HDG) steel bolts in fresh water, 1% NaCl saltwater in the presence of protective compounds L-Tryptophan and three conventional corrosion inhibitors: Inhibitor 1-VCI (amine-carboxylates-based), Inhibitor 2 (based on carboxylate acid), and Inhibitor 3 (water-based, carboxylate acid). Quantitative tests performed include gravimetric analysis and electrochemical techniques, such as linear polarization, Tafel extrapolation, and Electrochemical Impedance Spectroscopy (EIS). Electrochemical measurements determined the polarization resistance R_p, corrosion rate v_corr, and corrosion potential E_corr. Furthermore, Scanning Electron Microscopy (SEM) and ATR-FTIR spectrometry were used to evaluate and characterize the formed layers on the surface of hot-dip galvanized steel samples. The results reveal that upon corrosion new compounds are formed onto the exposed areas of the treated bolts such as zinc-carbonates, zinc-hydroxides, etc. The presence of these compounds on the surface of the HDG steel bolts hinders the corrosion process by reducing the rate of the anodic and cathodic reactions. The gravimetric test showed that L-tryptophan in distilled water has mass increase, resulting from the formation of white deposits on the sample surface. In fresh water and distilled water, the best corrosion resistance was achieved with Inhibitor 1-VCI, while L-tryptophan showed best results in 1% NaCl solution. Full article

In this work, a laboratory X-ray diffraction complex for in situ investigations of structural phase evolution of materials under gaseous atmosphere and elevated temperatures was developed. The approbation of the complex was carried out using a commercially pure titanium (CP-Ti) powder, zirconium (Zr-1Nb) alloy and electron beam melted Ti-6Al-4V alloy. It was established that hydrogenation of the CP-Ti powder occurred at a temperature of 500 °C and a hydrogen pressure of 0.5 atm, accompanied by the formation of metastable γ titanium hydride (γ-TiH) phase. The lifetime of the γ-TiH phase was 35–40 min. Decomposition of the γ-TiH occurred after reaching a temperature of 650 °C as a result of the thermally stimulated desorption of hydrogen. The α-Zr → δ-ZrH phase transformation was observed under hydrogenation of the zirconium Zr-1Nb alloy at a temperature of 350 °C and a hydrogen pressure of 0.5 atm. It was revealed that the increase in hydrogenation temperature to 450 °C accelerated this transformation by two times. Hydrogenation of the electron beam melted titanium Ti-6Al-4V alloy at a temperature of 650 °C and hydrogen pressure of 0.5 atm was accompanied by the α → α + β → β + α₂ phase transformations. Full article

Due to their advantageous properties, there is a growing interest in developing armor steels containing fully or partially bainitic microstructures. In this study, bainitic and martensitic microstructures were obtained in rolled homogeneous armor (RHA) steel samples and their ballistic protection performances were investigated. RHA (MIL-A-12560) steel samples were subjected to isothermal heat treatments at three different temperatures, where one temperature (360 °C) was above the martensite formation start (Ms) temperature of 336 °C while the other two (320 °C and 270 °C) were below. For the assessment of the ballistic protection performance, the kinetic energy losses of the 12.7 mm bullets fired at the test samples were determined. The promising nature of the bainite microstructure was confirmed as the sample isothermally treated at 360 °C provided approximately 10% higher ballistic protection as compared to the regular RHA sample of tempered martensite microstructure. However, the ballistic performances of the isothermally treated samples decreased as the treatment temperature went below the Ms temperature. Following the ballistic tests, hardness measurements, impact tests at −40 °C, and macro- and microstructural examinations of the samples were performed. No correlation was found between the hardness and impact energies of the samples and their ballistic performances. Full article

The aim of this study was to calibrate a material model with two fracture criteria that is available in the DEFORM software on DIN 34CrNiMo6. The purpose is to propose a type of simple test that will be sufficient for the determination of damage parameters. The influence of the quantity of mechanical tests on the accuracy of the fracture criterion was explored. This approach was validated using several tests and simulations of damage in a tube and a round bar. These tests are used in engineering applications for their ease of manufacturing and their strong ability to fracture. The prediction of the time and location of the failure was based on the parameters of the relevant damage model. Normalized Cockroft-Latham and Oyane criteria were explored. The validation involved comparing the results of numerical simulation against the test data. The accuracy of prediction of fracture for various stress states using the criteria was evaluated. Both fracture criteria showed good agreement in terms of the fracture locus, but the Oyane criterion proved more suitable for cases covering larger triaxiality ranges. Full article

In order to study the influence of MgO refractory on inclusions during the steelmaking process, laboratory quasi-equilibrium experiments were performed in MgO crucibles at 1873 K. It was found that there were no MgO-containing inclusions formed when ultra-low Al ultra-low C steel was used. When the contents of dissolved Al and C in steel changed, different composition ranges led to different types of inclusions. It was shown as well that for both low Al high C steel and high Al low C steel, the order of average MgO content in inclusions from large to small was: MgO-10% slag addition > MgO-free slag addition > no slag addition. Based on the results, a simple formation mechanism of MgO-containing inclusions in the steel with different compositions in MgO crucibles was proposed. The results could provide guidance for the reduction of MgO-containing inclusions in the industrial production of steels. Full article

The crystallization process, both at the initial and subsequent stages, of amorphous Al₈₈-RE₄-Ni₈ alloys (RE = Y, Sm and Ce) has been studied. Additionally, the consequences of adding 1 at.% Cu replacing Ni or Al were studied. The stability of the amorphous structure in melt spun ribbons was thermally studied by differential scanning calorimetry, with Ce alloys being the most stable. The effect of Cu to reduce the nanocrystal size during primary crystallization was analyzed by transmission electron microscopy. This latter technique and x-ray diffraction showed the formation of intermetallic phases at higher temperatures. A clear difference was observed for the Ce alloy, with a simpler sequence involving the presence of Al₃Ni and Al₁₁Ce₃. However, for the Y and Sm alloys, a more complex evolution involving metastable ternary phases before Al₁₉RE₅Ni₃ appears, takes place. The shape of the intermetallics changes from equiaxial in the Ce alloys to elongate for Y and Sm, with longer particles for Sm and, in general, when Cu is added to the alloy. Full article

Brittle intermetallic phases are formed when steel and aluminum are joined. Therefore, it is difficult to use this combination of materials when applying the multimaterial design in the construction of load-adapted and weight-adapted structures. In order to largely avoid the formation of these brittle phases, joining processes based on diffusion processes, such as composite forging, depict a good solution approach. The materials are joined in a solid state. Furthermore, zinc additives are used to create the joint. Zinc forms a compound with both steel and aluminum without the formation of brittle phases. By combining the composite forging process with zinc additives, strength values of 26 N/mm² can be reached. This is higher, in comparison to former investigations of resistance spot welded and clinched joints. The joint properties depend on the composition of the zinc interlayer. Small amounts of magnesium in the zinc interlayer affected the strength and ductility values. While the strength decreased by about 30% in contrast to the zinc layer without magnesium, the ductility increased by 60%. This effect was probably due to the metallurgical impact of the alloying elements on phase formation, as could be shown by energy dispersive X-ray spectroscopy (EDX) analyses of the joint zones. Thereby, it was shown that the brittle intermetallic phases are located only in small areas. Full article

The present research investigates the effects of different welding techniques, namely traditional metal inert gas (MIG), cold metal transfer (CMT), and fiber laser-MIG hybrid, on the microstructural and mechanical properties of joints between extruded EN AW 6181/6082-T6 and cast EN AC 42100-T6 aluminum alloys. These types of weld are very interesting for junctions of Al-alloys parts in the transportation field to promote the lightweight of a large scale chassis. The weld joints were characterized through various metallurgical methods including optical microscopy and hardness measurements to assess their microstructure and to individuate the nature of the intermetallics, their morphology, and distribution. The results allowed for the evaluation of the discrepancies between the welding technologies (MIG, CMT, fiber laser) on different aluminum alloys that represent an exhaustive range of possible joints of a frame. For this reason, both simple bar samples and real junctions of a prototype frame of a sports car were studied and, compared where possible. The study demonstrated the higher quality of innovative CMT and fiber laser-MIG hybrid welding than traditional MIG and the comparison between casting and extrusion techniques provide some inputs for future developments in the automotive field. Full article

Residual stresses, existed in engineering structures, could significantly influence the mechanical properties of structures. Accurate and non-destructive evaluation of the non-equibiaxial residual stresses in these structures is of great value for predicting their mechanical performance. In this work, investigating the mechanical behaviors of instrumented spherical indentation on stressed samples revealed that non-equibiaxial residual stresses could shift the load-depth curve upwards or downwards and cause the residual indentation imprint to be an elliptical one. Through theoretical, experimental, and finite element (FE) analyses, two characteristic indentation parameters, i.e., the relative change in loading curvature and the asymmetry factor of the residual indentation imprint, were found to have optimal sensitivity to residual stresses at a depth of 0.01R (R is the radius of spherical indenter). With the aid of dimensional analysis and FE simulations, non-equibiaxial residual stresses were quantitatively correlated with these two characteristic indentation parameters. The spherical indentation method was then proposed to evaluate non-equibiaxial residual stress based on these two correlations. Applications were illustrated on metallic samples (AA 7075-T6 and AA 2014-T6) with various introduced stresses. Both the numerical and experimental verifications demonstrated that the proposed method could evaluate non-equibiaxial surface residual stresses with reasonable accuracy. Full article

The strain-aging of low alloyed, multiphase high-strength steels with strain-induced austenite to martensite transformation was studied. The influence of prestrain, aging time, and temperature dependence of the static strain aging was carried out. Ageing temperatures between 60 and 220 ${}^{\circ }$ C and aging times from 20 to 10,000 min were investigated. The choice of steel composition allowed studying the influence of alloying elements, such as Si and Al, on the static strain aging behavior. Samples after aging were studied using light-optical microscopy, X-ray diffraction, and in-depth transmission electron microscopy (TEM). The Harper model was used to describe the precipitation mechanisms occurring during aging. The study of thin foils after aging using TEM showed the precipitation of low temperature transition carbides in the microstructure, which was observed between 60 and 5000 min. By using X-ray diffraction, it was revealed that aging at 170 ${}^{\circ }$ C for a long time caused a slight decrease of the retained austenite volume fraction, but the C content remained constant. Full article

In this work, multi-pass compressions were performed at various strain rates (0.01 s⁻¹, 0.1 s⁻¹, 1 s⁻¹, 10 s⁻¹), temperatures (950 °C, 1050 °C, 1150 °C), inter-pass holding time (1 s, 10 s, 30 s, 120 s, 600 s), interrupt strains (0.3, 0.4, 0.5, 0.6), and total pass numbers (1, 2, 3, 4). The intriguing finding was that the recrystallized fraction, average dislocation density, and plastic cumulative strain were partly eliminated during inter-pass holding, resulting in the early occurrence of recrystallization in subsequent compression. Therefore, a parameter (Θ) to evaluate the overall softening fraction due to recrystallization was proposed, and it was then used to iteratively rectify the average dislocation density and plastic cumulative strain in flow-stress modeling. The flow-stress model parameters of 300M steel for multi-pass compression were identified using an optimization technique based on non-derivative method integrated in MATLAB software. The average deviation of calculated and experimental flow-stress was 0.88 MPa (1.35%), showing good accuracy of the flow-stress model. The microstructure evolution of 300M steel was analyzed by the change of softening fraction during multi-pass compression, which provided a useful reference for the research of stress–microstructure relationships of high-strength steels. Full article

Zinc oxide (ZnO) is a wide-band-gap semiconductor that is promising for use as a transparent conductive oxide film. To date, to improve their optoelectrical properties, pristine ZnO films have been doped with metals using various techniques. In this study, nanostructured Cu-ZnO thin films were synthesized using a modified two-step radio frequency magnetron sputtering technique with separate ZnO and metallic Cu targets. Controlling the timing of the Cu/ZnO co-sputtering and ZnO-only sputtering steps afforded a significant change in the resulting nanostructures, such as uniform Cu-ZnO and broccoli-structured Cu-ZnO thin films. Using various measurement techniques, the influence of Cu doping was analyzed in detail. Furthermore, a crystal growth model for the formation of the broccoli-like clusters was suggested. The Cu-ZnO thin films synthesized using this technique demonstrate a highly improved conductivity with some loss in optical transmittance. Full article

The thermal regime and microstructural phenomenon are studied by using finite-element (FE) modelling and the analytical Rosenthal equation during laser welding of aluminum alloy 5456 (AA5456) components. A major goal is to determine the merits and demerits of this analytical equation which can be an alternative to FE analysis, and to evaluate the effect of imperative assumptions on predicted consequences. Using results from the analytical and numerical approaches in conjunction with experiments, different physical features are compared. In this study, the results obtained from experiments in terms of melt pool shapes are compared with the predicted ones achieved from the numerical and analytical approaches in which the FE model is more accurate than the Rosenthal equation in the estimation of the melt pool dimensions. Furthermore, as to the partially melted zones, the estimations achieved from the numerical modeling are more genuine than ones from the analytical equation with regards to the experimental results. At high energy density, near keyhole welding mode, the reported results show that experimental melt widths are supposed to be narrower than the fusion widths estimated by the analytical solution. The primary explanation could be the influence of thermal losses that occurred during convection and radiation, which are neglected in the Rosenthal equation. Additionally, the primary dendrite arm spacing (PDAS) estimated with the numerical modeling and the analytical Rosenthal solution is comparable with the experimental results obtained. Full article

The present study aims to reveal the mechanism of element vaporization of Ti-6Al-4V alloy during selective laser melting (SLM). The equations of Redlich–Kister and the thermodynamics principles were employed to calculate the vaporization thermodynamics, which contributes to the obtaining the vaporization kinetic based on the Chapman-Enskog theory and the diffusion model. According to the achieved vaporization model, the elements with the most prominent tendency and flux to vaporize were distinguished. Moreover, the effect of the process parameters on the vaporization of Al and Ti is experimentally investigated using inductively coupled plasma optical emission spectrometer (ICP) technology. The analyzed results of the chemical composition of the powders and builds show a great agreement with the kinetic results calculated by the vaporization model. Notably, the element vaporization can be curbed by regulating the laser energy input. Full article

With the development of society, every year there are increasing demands in the automotive industry on cost savings, environmental safety, reduction of raw material consumption, performance improvement, material life cycle and recycling of components. In this review, emphasis is given on ferrous and non-ferrous alloys, which are used as components, where both groups can be treated by deep cryogenic treatment (DCT). DCT has shown to increase hardness, tensile strength and wear resistance, reduce density of defects in crystal structure, improve toughness and corrosion resistance. Though, some researchers also reported results that showed no change in material properties, or even deterioration of material properties, when subjected to DCT. This additionally points out to lack of consistency and reliability of the DCT process, which is needed for its successful incorporation in automotive applications. However, to prove with certainty the resulting outcome on the material properties and knowledge about the reasons for the variation of this effect on metallic materials, further approach and testing with different variables should be conducted in the future. This review provides a synopsis of different approaches of DCT on different materials for automotive applications in order to indicate effects on the material performance during DCT. Full article

In this study, calcination tests were performed on a mixed sample of lithium cobalt oxide and activated carbon at 300–1000 C under an argon atmosphere. The tests were conducted to discover an effective method for recovering lithium and cobalt from the cathode active material used in lithium-ion batteries. Additionally, the effect of soluble fluorine on the purification of lithium carbonate was investigated by the addition of lithium fluoride to an aqueous lithium hydroxide solution and a CO₂ flow test was performed. The lithium recovery was ≥90% when the calcination occurred at temperatures of 500–600 C. However, the percent recovery decreased at temperatures ≥700 C. It was demonstrated that in order to increase the recovery while maintaining 99% purity of lithium carbonate in the recovered material, it was imperative to increase the temperature of the solution and to limit the F/Li ratio (mass%/mass%) in the solution to a value that did not exceed 0.05. Full article