Search Results (3,557)

This study systematically investigates the tensile anisotropic mechanical behavior of ferritic steel under different orientations through an integrated experimental, theoretical modeling, and simulation approach employing advanced characterization techniques including electron backscatter diffraction (EBSD), digital image correlation (DIC), scanning electron microscopy (SEM), and finite element analysis. The results demonstrate pronounced orientation dependence in mechanical response, with initial yield strengths of 391, 391, and 405 MPa and fracture strains of 0.237, 0.220, and 0.212 observed for 0°, 45°, and 90° orientations, respectively, corresponding to orientation-induced variations of 3.6% in yield strength and 11.8% in fracture strain. These anisotropic characteristics are primarily attributed to the predominant α-fiber texture <110>||RD, which accounts for 59.8% of the texture components. Furthermore, crystallographic texture significantly influences fracture behavior, as evidenced by the distinct orientation-dependent macroscopic contraction characteristics and morphological features of fracture surfaces. Full article

Metal carbides (MCs) serve as essential strengthening phases in nickel-based superalloys, so the decomposition of MCs during high-temperature creep is regarded as detrimental to the mechanical properties and service life of these alloys. However, detailed investigations of the MC decomposition process at the microscale remain limited. In this study, the microstructure of MCs (where M is a mixture of Ti and Ta) in a nickel-based superalloy was characterized using aberration-corrected scanning transmission electron microscopy. The MCs exhibit a spherical core–shell structure, with Ta enrichment in the shell and Ti segregation in the core. Moreover, a high density of Cr-rich stacking faults, accompanied by Cr-rich M₂₃C₆ precipitates at their terminations, was identified in the Ti-rich cores, suggesting that these defects may be closely associated with the decomposition of MCs. This study may further expand the fundamental understanding of the interactions between defects and carbide properties. Full article

In this study, the effects of friction stir welding (FSW) parameters on the mechanical properties and formability of pre-hardened (PH) 2219 aluminum alloy welds were systematically investigated through tensile testing and Erichsen tests. Energy dispersive spectrometry (EDS), electron back scatter diffraction (EBSD), and a transmission electron microscope (TEM) were employed to characterize the microstructure of the PH alloy weld joints, revealing the strength–ductility synergy mechanism of the PH welded sheets. Experimental results indicated that with respect to mechanical properties, when the welding rotational speed was fixed at 1000 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the ultimate tensile strength (UTS) by 6.3% and decreased the EL by 21.4%. When the forward speed was fixed at 50 mm/min, increasing the rotational speed from 500 rpm to 1500 rpm resulted in only a 0.4% variation in UTS and maintained a stable EL, demonstrating that forward speed is the dominant parameter affecting mechanical properties. In terms of formability, at a lower forward speed (50 mm/min), the Erichsen value exhibited a single-peak trend with increasing rotational speeds. At higher forward speeds (100 or 150 mm/min), the Erichsen value was insensitive to changes in rotational speed. When the rotational speed was fixed at 1500 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the Erichsen value by 21.3%. Microstructural strengthening mechanism: In the weld zone, the cooperative precipitation of the θ″ and θ′ phases effectively hindered dislocation motion. Simultaneously, the high geometric compatibility factor promoted the activation of multiple slip systems, and dislocation rearrangement subsequently led to the formation of sub-grain boundaries, thereby achieving strength–ductility cooperation. These findings provide theoretical support for the performance-driven welding process design of high-strength aluminum alloy components in aerospace applications. Full article

The paper presents the results of investigations of the effect of current heating on the microstructure and properties of copper profile contact wires used in railway traction networks. The aim of the study was to determine the effect of the contact wire temperature rising as a result of current heating on the occurrence of permanent changes in material characteristics. The tests were conducted in laboratory conditions through controlled heating of samples with a current of approx. 1500–1600 A, reaching temperatures of up to approx. 280 °C. It was found that in the temperature range of 120–200 °C, changes in the mechanical properties of the material were insignificant, while above 200 °C, a marked decrease in microhardness and a reduction in the indentation modulus were observed. The results obtained indicate that long-term current load leading to an increase in the temperature of the contact wire may cause deterioration of the mechanical properties of the material, its increased susceptibility to permanent deformation and an increased risk of damage to the traction network, which has a direct impact on the durability of contact wires and the maintenance costs of the rail transport infrastructure. Full article

Using low-pressure cold spray technique, Fe-Al composite coatings with different Al contents were applied to the surface of 45 steel to improve its corrosion resistance in chloride-containing settings. The microstructure, mechanical characteristics, and electrochemical corrosion behavior of the coatings were thoroughly examined in relation to the Al content (2, 4, 6, and 8 wt.%). The findings show that the microhardness of the composite coating decreases monotonically (from 157.98 HV to 99.29 HV) as the Al content rises because of the increased proportion of the soft phase; in contrast, the porosity and corrosion current density show a pattern of first decreasing and then increasing. The coating porosity was reduced to a minimum (1.37%) when the Al concentration reached 6 wt.% because the soft Al particles experienced enough plastic flow to fill the holes in the hard Fe matrix. The 6Al composite coating demonstrated the best electrochemical protection performance in a 3.5 wt.% NaCl solution, with the lowest corrosion current density (2.237 × 10⁻⁴ A/cm²) and the strongest interfacial charge transfer resistance. The synergistic corrosion protection mechanism comprising significantly densified physical shielding and microgalvanic sacrificial anode protection by the active Al phase was clarified in this study. The ideal composition ratio for this system was determined to be 6 wt.% Al by carefully matching the coating’s mechanical load-bearing needs with long-term corrosion prevention goals. Full article

In this study, the carbothermic reduction of sodium antimonate in crucible smelting was investigated. The optimal process temperature was determined to be 900 °C, with 10% coke consumption (with an ash content up to 15.33%) and a feed particle size of minus 1 mm. The process does not involve the addition of slag-forming components. Sodium participates in the formation of the slag phase. According to the smelting results, the amount of antimony recovered as crude metal reached 71–72%, while the Sb content in the crude metal reached up to 94.5%. A significant portion of antimony (up to 27%) volatilizes with off-gases. A notable sodium content was detected in the crude antimony, reaching up to 8% in some samples, while more than 80% of sodium was transferred to the slag phase. Arsenic, present in the initial concentrate at a level of 0.6%, was distributed approximately equally among the metallic, slag, and gas phases. Lead was predominantly concentrated in the crude antimony. Iron preferentially dissolved in the crude antimony. Other impurities were distributed in comparable amounts between the metallic and slag phases. Tellurium, present in sodium antimonate at 0.79%, was detected in some samples within the slag phase. Full article

Producing high-conductivity aluminum conductors for power transmission involves 23 trace elements and multiple interconnected thermo-mechanical stages. The ultra-low alloying levels required to preserve high electrical conductivity create a narrow compositional window and highly imbalanced distributions, which hinder traditional data-driven learning. Here, we developed a physics-guided machine-learning framework based on 4458 valid industrial production records to predict tensile strength and electrical resistivity. In addition to raw composition and process parameters, we introduce ratio descriptors (e.g., Fe/Si and Al/Si) and propose a physics-informed metric termed the Equivalent Solute–Heat Index (ESHI) to couple key solute chemistry (Si, Fe, B) with normalized thermal-history intensity. Fe and Si primarily influence resistivity through impurity/solute scattering, while B mainly affects microstructural uniformity via grain refinement. Incorporating ESHI as an augmented signal into the best-performing XGB surrogate markedly improves generalizability, increasing the tensile strength R² from 0.75 to ~0.92. SHAP analysis reveals that ESHI dominates the decision logic by modulating both targets with metallurgically interpretable mechanisms: solute-controlled scattering and thermal history-traced second-phase evolution that stabilizes the microstructure. NSGA-III was further employed to map the Pareto front and identify composition–process combinations that optimize the strength–conductivity trade-off, enabling improved mechanical reliability while minimizing resistive losses in practical power-transmission applications. Experimental validation on industrial wires confirms this reliability. Full article

In this study, scanning electron microscopy (SEM) analysis is used to reveal the real microstructure of C75S steel and to compare grain morphology and deformation features with numerical predictions. A micro-scale finite element model of C75S steel is developed to investigate its tensile response in order to understand how steel actually deforms and fails at the microstructure level. Subsequently, the validated microstructural model is employed to simulate the cutting process using the finite element method, focusing on stress concentration and damage initiation at the grain and interface zones. The results demonstrate that microstructural modelling provides improved insight into deformation and fracture mechanisms compared to homogenised approaches, highlighting the critical role of cementite distribution and interfacial behaviour during tensile loading and micro-scale cutting. The cementite particle sizes in C75S steel range from approximately 0.5 to 2.0 µm, with circularity values between 0.7 and 0.95 and a volume fraction of about 10–12%. The proposed framework offers a robust basis for predicting the cutting performance of high-carbon steels. Full article

Despite the crucial role of Young’s modulus in the structural performance of Al alloys, the effects of common strengthening approaches on its evolution, particularly at elevated temperatures, remain largely unexplored. In this study, an Al-7Si-4Cu alloy was modified by hot deformation, micro-alloying with 0.3 wt.% Sc, alloying with 4 wt.% Ni, and reinforcement with 0.8 vol.% Al₂O₃ nanoparticles. The effects of these strengthening approaches on the microstructure and the evolution of Young’s modulus from room temperature to 350 °C were examined. It was found that the Young’s modulus of the alloys decreased with the increase in temperature, while this tendency is much more obvious when the temperature exceeds 250 °C. The results showed that hot deformation markedly refines the α-Al grains while the Young’s modulus stays largely unchanged. The Sc addition leads to the formation of the W phase but has no significant effect on the Young’s modulus. In contrast, the addition of Ni substantially increases the Young’s modulus through the formation of Al₃CuNi intermetallic particles, with the Young’s modulus increasing from 72.15 to 76.47 GPa. With the addition of Al₂O₃ particles, the decreasing magnitude of Young’s modulus is optimized when the temperature is higher than 250 °C. This work may be referred to when designing high-modulus Al alloys by considering the utilization of various strengthening concepts. Full article

Since its introduction, focused ion beam (FIB) technology has expanded from micro/nanofabrication in the semiconductor industry to the field of multimodal characterization of metallic material microstructures. This article systematically reviews the latest research advances in FIB-SEM technology in the field of metallic materials science. The fundamental principles and system functions of FIB-SEM are introduced, with an emphasis on its key applications in two-dimensional and three-dimensional morphological characterization, as well as specimen preparation for transmission electron microscopy (TEM) and atom probe tomography (APT). The combined strategies of FIB-SEM with electron backscatter diffraction (EBSD), time-of-flight secondary ion mass spectrometry (TOF-SIMS), and other characterization techniques are also discussed. Current developments indicate that FIB-SEM technology is advancing toward multi-ion-source synergy and multimodal integration. In the future, combined with artificial intelligence and big data analysis, it is expected to enable high-throughput, correlative measurements of multidimensional properties at the micro scale, providing important technical support for “materials genome” research in metallic materials. Full article

The effects of different clay addition amounts and zircon powder contents on the properties of steel-pouring brick were studied using bauxite particles, sintered mullite powder, and other materials as the main raw materials. The results showed that with the decrease of clay content, the bulk density of the samples changed slightly, but the cold modulus of rupture, compressive strength, hot modulus of rupture, and high-temperature volume stability were improved; the addition of zircon powder did not significantly change the basic properties, such as the bulk density of the brick, but significantly increased the high-temperature flexural strength. Therefore, under the addition of 5 wt.% clay and 1.5 wt.% zircon powder were used for the application. The results show that samples with this formula have good performance, and the surface of the cast steel is smooth. Therefore, the optimization of the mullite steel-pouring brick formula can adopt the strategy of the synergy effect of clay and zircon to improve its comprehensive performance. Full article

Cost-effective β-titanium alloys were developed via the hydrogenation–dehydrogenation (HDH) process using low-cost β-stabilizers Mo and Fe. Ti-5Mo-xFe (x = 2, 4 wt%) alloys were fabricated by powder metallurgy and subjected to six post-heat treatment conditions to reduce porosity and improve properties. The as-sintered alloys exhibited high porosity (15–20%), which adversely affected mechanical and corrosion performance. Heat treatment above the β-transus significantly reduced porosity, with Ti-5Mo-4Fe treated at 900 °C for 2 h showing the greatest reduction. Microstructures evolved from α + β lamellar Widmanstätten to equiaxed β with TiFe precipitates. Increased Fe content and heat-treatment temperature enhanced strength, while TiFe precipitates degraded corrosion resistance. Thus, optimized post-heat treatment improves strength and corrosion performance, although Fe content must be controlled. Full article

The increasing demand for lightweight aerospace structures has driven the continuous development of ultra-high-strength aluminum alloys (UHSAAs). Owing to their low density and high specific strength, UHSAAs remain the primary materials for next-generation aerospace structural components. Over the past decades, their tensile strength has increased from the 500 MPa level to beyond 700 MPa, accompanied by a shift in research focus from strength maximization to the synergistic optimization of strength, ductility, and damage tolerance. This work concentrates on 7xxx series and Al–Li alloys, systematically reviewing recent research advances and key challenges in alloy design and forming. Particular emphasis is placed on new strategies for strength–ductility synergy and the associated microstructural strengthening and toughening mechanisms. Finally, future development directions are discussed to provide guidance for the design and engineering application of high-performance aerospace aluminum alloys. Full article

This study systematically investigates the effects of solution temperature ranging from 1060 to 1150 °C on grain growth kinetics, microstructural evolution, and tensile properties of GH4698 superalloys. The results indicate that grain size coarsens parabolically with increasing solution temperature. Based on the Sellars model, the grain growth time exponent n is determined to be 3.4 and the activation energy Q is 478.7 kJ·mol⁻¹. This confirms that the grain growth process is significantly influenced by both MC carbide pinning and alloying element drag effects. Additionally, due to the coarsening of grains, the precipitation density of M₂₃C₆ carbides per unit grain boundary length increased from 0.26 μm⁻¹ to 0.39 μm⁻¹. The ultimate tensile strength at room temperature decreased from 1268 MPa to 1226 MPa, and the yield strength decreased from 840 MPa to 807 MPa, while the elongation remained at 28–32%. At 700 °C, the ultimate tensile strength decreases from 974 MPa to 904 MPa, and the yield strength decreases from 755 MPa to 696 MPa, with the elongation remaining at ~6%. Quantitative analysis reveals that the decrease in strength is primarily due to the weakening of grain boundary strengthening caused by grain coarsening. At 700 °C, the deformation mechanism transitions from dislocation shearing at room temperature to stacking fault shearing. This not only leads to a reduction in strength but also, accompanied by grain boundary weakening, results in a decrease in elongation. Full article

Hydralloy^® C5, an intermetallic TiMn₂-based alloy, has been manufactured industrially (GfE, Nuremberg) for decades and is used on a large scale for hydrogen storage. During use, the alloy is stored in gas-tight and pressure-resistant storage containers. At the end of service, the alloy is a fine powder with pyrophoric character (Ti- and Zr- content). This significantly hinders the safe extraction from the containers and subsequent recycling of the alloy due to unavoidable reactions with ambient air. The major concern on passivation and maximum permissible content with O/N must be clarified for safe handling in ambient air as well as regarding the pyrometallurgical recycling. Considering this, and in preparation for the opening of real large-scale storage containers, end-of-life Hydralloy C5 was synthesized with two different levels of O (~0.15 and ~1 wt.%) and N (~0.04 and ~8 wt.%) contamination. Vacuum induction melting (VIM) and cold crucible arc melting (CCAM) were chosen as potentially suitable for recycling. The preliminary remelting trials from both aggregates ascertained that the recovery of metal content is not feasible with heavily O/N-contaminated alloys. It is concluded that extreme caution should be taken to minimize contamination when extracting the powdered alloy from the storage containers. Hydralloy C5 with moderate gas impurities (~0.15 wt.% O and ~0.04 wt.% N) can be remelted, on the other hand, in both VIM and CCAM. Contact between molten Hydralloy C5 with selected refractories (Al₂O₃-TiO₂ and CaO-stabilized ZrO₂) in the VIM leads to the formation of a multi-layered transition zone dominated by Ti and Zr. While the Al₂O₃ in the titanium aluminate is infiltrated and reduced by Ti and Zr, the crucible wall made of CaO-stabilized ZrO₂ remains intact. Despite low gas contents, significant losses in melt yield are recognized due to crucible wall deposits from the formation of non-metallic inclusions during VIM. Against this background, the use of fluxes is being considered for future melts in addition to the use of deoxidants. Full article