Search Results (1,848)

The interface between high-performance thermoelectric materials and electrodes critically governs the conversion efficiency and long-term reliability of thermoelectric generators under high-temperature operation. Here, we propose Al_xCoCrFeNi high-entropy alloys (HEA) as barrier layers to bond Cu-W electrodes with p-type skutterudite (p-SKD) thermoelectric materials. The HEA/p-SKD interface exhibited excellent chemical bonding with a stable and controllable reaction layer, forming a dense, defect-free (Fe,Ni,Co,Cr)Sb phase (thickness of ~2.5 μm) at the skutterudites side. The interfacial resistivity achieved a low value of 0.26 μΩ·cm² and remained at 7.15 μΩ·cm² after aging at 773 K for 16 days. Moreover, the interface demonstrated remarkable mechanical stability, with an initial shear strength of 88 MPa. After long-term aging for 16 days at 773 K, the shear strength retained 74 MPa (only 16% degradation), ranking among the highest reported for thermoelectric materials/metal joints. Remarkably, the joint maintained a shear strength of 29 MPa even after 100 continuous thermal cycles (623–773 K), highlighting its outstanding thermo-mechanical stability. These results validate the Al_xCoCrFeNi high-entropy alloys as an ideal interfacial material for thermoelectric generators, enabling simultaneous optimization of electrical and mechanical performance in harsh environments. Full article

Al-Mg-Si (6XXX) series aluminum alloys are widely applied in aerospace and transportation industries. However, exploring how varying compositions affect alloy properties and deformation mechanisms is often time-consuming and labor-intensive due to the complexity of the multicomponent composition space and the diversity of processing and heat treatments. This study, inspired by the Materials Genome Initiative, employs high-throughput experimentation—specifically the kinetic diffusion multiple (KDM) method—to systematically investigate how the pop-in effect, indentation size effect (ISE), and creep behavior vary with the composition of Al-Mg-Si alloys at room temperature. To this end, a 6016/Al-3Si/Al-1.2Mg/Al KDM material was designed and fabricated. After diffusion annealing at 530 °C for 72 h, two junction areas were formed with compositional and microstructural gradients extending over more than one thousand micrometers. Subsequent solution treatment (530 °C for 30 min) and artificial aging (185 °C for 20 min) were applied to simulate industrial processing conditions. Comprehensive characterization using electron probe microanalysis (EPMA), nanoindentation with continuous stiffness measurement (CSM), and nanoindentation creep tests across these gradient regions revealed key insights. The results show that increasing Mg and Si content progressively suppresses the pop-in effect. When the alloy composition exceeds 1.0 wt.%, the pop-in events are nearly eliminated due to strong interactions between solute atoms and mobile dislocations. In addition, adjustments in the ISE enabled rapid evaluation of the strengthening contributions from Mg and Si in the microscale compositional array, demonstrating that the optimum strengthening occurs when the Mg-to-Si atomic ratio is approximately 1 under a fixed total alloy content. Furthermore, analysis of the creep stress exponent and activation volume indicated that dislocation motion is the dominant creep mechanism. Overall, this enhanced KDM method proves to be an effective conceptual tool for accelerating the study of composition–deformation relationships in Al-Mg-Si alloys. Full article

This study investigates the mechanical, tribological, and electrochemical behaviour of a novel precipitation-hardenable martensitic alloy produced by selective laser melting (SLM). The alloy was specifically engineered with an optimised composition, free from cobalt and molybdenum, and featuring reduced nickel content (7 wt.%) and 8 wt.% chromium. It has been developed as a cost-effective and sustainable alternative to conventional maraging steels, while maintaining high mechanical strength and a refined microstructure tailored to the steep thermal gradients inherent to the SLM process. Several ageing heat treatments were assessed to evaluate their influence on microstructure, hardness, tensile strength, retained austenite content, dislocation density, as well as wear behaviour (pin-on-disc test) and corrosion resistance (polarisation curves in 3.5%NaCl). The results indicate that ageing at 540 °C for 2 h offers an optimal combination of hardness (550–560 HV), tensile strength (~1700 MPa), microstructural stability, and wear resistance, with a 90% improvement compared to the as-built condition. In contrast, ageing at 600 °C for 1 h enhances ductility and corrosion resistance (Rp = 462.2 kΩ; Ecorr = –111.8 mV), at the expense of a higher fraction of reverted austenite (~34%) and reduced hardness (450 HV). This study demonstrates that the mechanical, surface, and electrochemical performance of this novel SLM-produced alloy can be effectively tailored through controlled thermal treatments, offering promising opportunities for demanding applications requiring a customised balance of strength, durability, and corrosion behaviour. Full article

This paper examines the wettability and interactions between ceramic and composite materials soldered with Bi-based solder containing 11 wt.% of silver and 3 wt.% titanium using indirect electron beam soldering technology. The Bi11Ag3Ti solder, with a melting point of 402 °C, consisted of a bismuth matrix containing silver lamellae. Titanium, acting as an active element, positively influenced the interaction between the solder and the joined materials. SiC and Ni-SiC substrates were soldered at temperatures of 750 °C, 850 °C, and 950 °C. Measurements of wettability angles indicated that the lowest value (20°) was achieved with SiC substrates at 950 °C. A temperature of 750 °C appeared to be the least suitable for both substrates and was entirely unsuitable for Ni-SiC. It was also observed that the Bi11Ag3Ti solder wetted the SiC substrates more effectively than Ni-SiC substrates. The optimal working temperature for this solder was determined to be 950 °C. The shear strength of the joints soldered with the Bi11Ag3Ti alloy was 23.5 MPa for the Al₂O₃/Ni-SiC joint and 9 MPa for the SiC/Ni-SiC joint. Full article

Understanding the limitations of cold-formed aluminum alloys in practice applications is essential, particularly due to the risk of substructural changes and a reduction in strength when exposed to elevated temperatures. In this study, the thermal stability of the ultra-fine-grained (UFG) structure formed by equal channel angular pressing (ECAP) at room temperature and the mechanical properties of the AlSi7MgCu0.5 alloy were investigated. Prior to ECAP, the plasticity of the as-cast alloy was enhanced by a heat treatment consisting of solution annealing, quenching, and artificial aging to achieve an overaged state. Four repetitive passes via ECAP route A resulted in the homogenization of eutectic Si particles within the α-solid solution, the formation of ultra-fine grains and/or subgrains with high dislocation density, and a significant improvement in alloy strength due to strain hardening. The main objective of this work was to assess the microstructural and mechanical stability of the alloy after post-ECAP annealing in the temperature range of 373–573 K. The UFG microstructure was found to be thermally stable up to 523 K, above which notable grain and/or subgrain coarsening occurred as a result of discontinuous recrystallization of the solid solution. Mechanical properties remained stable up to 423 K; above this temperature, a considerable decrease in strength and a simultaneous increase in ductility were observed. Synchrotron radiation X-ray diffraction (XRD) was employed to analyze the phase composition and crystallographic characteristics, while transmission electron microscopy (TEM) was used to investigate substructural evolution. Mechanical properties were evaluated through tensile testing, impact toughness testing, and hardness measurements. Full article

Aluminium alloy foams have been widely used due to their excellent strength-to-weight ratio, low density, and outstanding properties such as high energy absorption and effective noise and heat insulation. In this study, aluminium machining chips have been used for foam production as a potential recycling method. The process has involved solution heat treatment followed by artificial ageing. Researchers have been analysing the microhardness of both the foam and the bulk material, as well as examining their microstructures. The maximum microhardness value of the bulk material has been found to be 158 ± 2 HV1 at an ageing temperature of 175 ± 1 °C for 2 ± 0.02 h. For the foams, the highest microhardness of 150 ± 2 HV1 has been achieved after ageing at 150 ± 1 °C for 9 ± 0.02 h. Experimental planning has been carried out using Design Expert software. The optimisation process has identified 150 ± 1 °C for 2 ± 0.02 h as the optimum condition for artificial ageing. Full article

The study investigates the influence of microstructures on fatigue behavior and failure mechanisms of the α-β titanium alloy Ti6246, fabricated via Powder Bed Fusion-Laser Beam (PBF-LB). In particular, the investigation assesses the effect of two post-processing heat treatments, namely α-β annealing at 875 °C (AN875) and solution treatment at 825 °C followed by aging at 500 °C (STA825), on the alloy’s rotating and bending fatigue behavior. The results indicate that the STA825 condition provides superior fatigue resistance (+25%) compared to AN875, due to the presence of a finer bilamellar microstructure, characterized by thinner primary α lamellae (α_p) and a more homogeneous distribution of secondary α lamellae (α_s) within the β matrix. Additionally, an investigation conducted using the Kitagawa–Takahashi (KT) approach and the El-Haddad model, based on the relationship between the fatigue limit and defect sensitivity, revealed improved crack propagation resistance from pre-existing defects (ΔK_th) for the STA825 condition compared to AN875. Notably, the presence of fine α_s after aging for STA825 is effective in delaying crack nucleation and propagation at early stages, while refined α_p contributes to hindering macrocrack growth. The fatigue behavior of the STA825-treated Ti6246 alloy was even superior to that of the PBF-LB-processed Ti64, representing a viable alternative for the production of high-performance components in the automotive and aerospace sectors. Full article

In order to obtain the optimal heat treatment process of Er-containing 7075 aluminum alloy, the effects of pre-stretching and the interval time between pre-stretching and aging on the microstructure and mechanical properties of Er-containing 7075 aluminum alloy during solution treatment followed by pre-stretching and two-stage aging processes were investigated by mechanical property tests, metallographic tests, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The results show that the mechanical properties of Er-containing 7075 aluminum alloy can be significantly improved by increasing the extrusion ratio. Pre-stretching provides nucleation sites for the precipitation of reinforcing phases, accelerates the aging strengthening process, and shortens the peak aging time. The crack source of fracture in Er-containing 7075 aluminum alloy is attributed to the segregated second phases containing Cu and Er in the alloy. The research results have significant engineering significance for the optimization of the heat treatment process of Er-containing 7075 aluminum alloy. Full article

In this study, a Ag/ZrO₂ hybrid coating prepared by the sol–gel method on a β-type Ti45Nb alloy was applied by the spin coating technique, and the microstructural, mechanical, electrochemical, and tribological properties of the surface were evaluated in a multi-dimensional manner. The hybrid solution was prepared using zirconium propoxide and silver nitrate and stabilized through a low-temperature two-stage annealing protocol. The crystal structure of the coating was determined by XRD, and the presence of dense tetragonal ZrO₂ phase and crystalline Ag phases was confirmed. SEM-EDS analyses revealed a compact coating structure of approximately 1.8 µm thickness with homogeneously distributed Ag nanoparticles on the surface. As a result of the electrochemical corrosion tests, it was determined that the open circuit potential shifted to more noble values, the corrosion current density decreased, and the corrosion rate decreased by more than 70% on the surfaces where the Ag/ZrO₂ coating was applied. In the tribological tests, a decrease in the coefficient of friction, narrowing of wear marks, and significant reduction in surface damage were observed in dry and physiological (HBSS) environments. The findings revealed that the Ag/ZrO₂ hybrid coating significantly improved the surface performance of the Ti45Nb alloy both mechanically and electrochemically and offers high potential for biomedical implant applications. Full article

Au-Ag alloy nanoshells (ANSs) were synthesized via chemical reduction, exhibiting superior plasmonic photocatalytic performance. TEM revealed uniform hollow structures (~80 nm), while EDS mapping confirmed homogeneous Au-Ag distribution throughout the shell. According to EDX analysis, the alloy contained 71.40% Ag by weight. XRD verified the formation of a substitutional solid solution without phase separation. The photocatalytic activity was evaluated using p-nitrothiophenol (PNTP) to 4,4′-dimercapto-azobenzene (DMAB) conversion monitored by SERS. UV-Vis spectroscopy showed LSPR peaks of ANSs between Au and Ag NPs, confirming effective alloying. Kinetic studies revealed that ANSs exhibited reaction rates 250–351 times higher than those of Au NPs and 5–10 times higher than those of Ag NPs. This resulted from the synergistic catalysis of Au-Ag and enhanced electromagnetic fields. ANSs demonstrated dual functionality as SERS substrates and photocatalysts, providing a foundation for developing multifunctional nanocatalytic materials. Full article

This study presents the design and microstructural investigation of a single-crystal (SX) Re-bearing high-entropy superalloy (HESA-X1) featuring a thermally stable γ–γ′–γ hierarchical microstructure. The alloy exhibits FCC γ nanoparticles embedded within L1₂-ordered γ′ precipitates, themselves distributed in a γ matrix, with the suppression of detrimental topologically close-packed (TCP) phases. To elucidate solidification behavior and phase stability, Scheil–Gulliver and TC-PRISMA simulations were conducted alongside SEM and XRD analyses. Near-atomic scale analysis in 3D using Atom Probe Tomography (APT) revealed pronounced elemental partitioning, with Re strongly segregating to the γ matrix, while Al and Ti were preferentially enriched in the γ′ phase. Notably, Re demonstrated a unique partitioning behavior compared to conventional superalloys, facilitating the formation and stabilization of γ nanoparticles during two-step aging (Ag-2). These γ nanoparticles significantly contribute to improved mechanical properties. Long-term aging (up to 200 h) at 750–850 °C confirmed exceptional phase stability, with minimal coarsening of γ′ and retention of γ nanoparticles. The coarsening rate constant K of γ′ at 750 °C was significantly lower than that of Re-free HESA, confirming the diffusion-suppressing effect of Re. These findings highlight critical roles of Re in enhancing microstructural stability by reducing atomic mobility, enabling the development of next-generation HESAs with superior thermal and mechanical properties for high-temperature applications. Full article

Nickel is used in aerospace, military, energy, and chemical sectors. Commercially pure (CP) Ni, and its alloys, including solid-solution strengthened (SSS), precipitation strengthened (PS), and specialty alloys (SA), are widely utilized, typically at elevated temperatures, in corrosive settings and in cryogenic milieu. Ni or Ni-based alloys frequently require welding realized, inter alia, via methods using electric arc and beam power. Tungsten inert gas (TIG) and Electron-beam welding (EBW) have been utilized most often. Friction stir welding (FSW) is the most promising solid-state welding technique for connecting Ni and its alloys. The primary weldability issues related to Ni and its alloys are porosity, as well as hot and warm cracking. CP Ni exhibits superior weldability. It is vulnerable to porosity and cracking during the solidification of the weld metal. Typically, SSS alloys demonstrate superior weldability when compared to PS Ni alloys; however, both types may experience weld metal solidification cracking, liquation cracking in the partially melted and heat-affected zones, as well as ductility-dip cracking (DDC). Furthermore, PS alloys are prone to strain-age cracking (SAC). The weldability of specialty Ni alloys is limited, and brazing might provide a solution. Employing appropriate filler metal, welding settings, and minimal restraint can reduce or avert cracking. Full article

This article presents the results of studies of the degradation of the structure and mechanical properties of the core materials BN-350 fast neutron and research WWR-K reactors required to justify the service life extension of early-generation power and research reactors. Extending the service life of nuclear reactors is a modern problem, since most operating reactors are early-generation reactors that have exhausted their design lifespan. The possibility of extending the service life is largely determined by the condition of the structural materials of the nuclear facility, i.e., their residual resources must ensure safe operation of the reactor. For the SAV-1 alloy, the structural material of the WWR-K reactor, studies were conducted on witness samples which were in the active zone during its operation for 56 years. It was found that yield strength and tensile strength of the irradiated SAV-1 alloy decreased by 24–48%, and relative elongation decreased by ~2% compared to the unirradiated alloy. Inside the grains and along their boundaries, there were particles of secondary phases enriched with silicon, which is typical for aged aluminum alloys. For irradiated structural steels of power reactors, studied at 350–450 C, hardening and a damping nature of creep were revealed, caused by dispersion hardening and the Hall–Petch effect. Full article

In a previous article, an estimation procedure for calculating the liquidus and solidus lines of binary equilibrium phase diagrams was presented. In this article, keeping the thermodynamic basics, the estimation method for the approximate calculation of the liquidus and solidus surfaces of ternary phase diagrams was further developed. It is shown that the procedure has a hierarchical structure, and the ternary functions contain the binary functions. The applicability of the method is checked by calculating the liquidus and solidus surfaces of the Ag-Au-Pd isomorphous ternary equilibrium phase diagram. The application of each level of the developed four-level procedure depends on the data available and the aim. It is shown that in the case of a concentration range close to the base alloy pure element, the liquidus and solidus surfaces of the ternary equilibrium phase diagram can be calculated from the liquidus and solidus functions of the binary equilibrium phase diagrams with a few K errors, which is 0.2 at% at 10 K/at% slope. The equilibrium phase diagrams were available in graphical form, so the data obtained via digitalisation of the diagrams for the calculations was used. The functions describe the slope of the surfaces, and the approximate method developed for the calculation of the partition ratios is also shown. Full article

This study investigates the fabrication and residual stress behavior of a 0.5 wt.% graphene-reinforced AA2195 aluminum matrix composite, developed for advanced aerospace structural applications. The composite was synthesized via squeeze casting, followed by a multi-pass hot rolling process and subsequent T8 heat treatment. The evolution of residual stress was systematically examined after each rolling pass and during thermal treatments. The successful incorporation of graphene into the matrix was confirmed through Energy-Dispersive Spectroscopy (EDS) analysis. Residual stress measurements after each pass revealed a progressive increase in compressive stress, reaching a maximum of −68 MPa after the fourth hot rolling pass. Prior to the fifth pass, a solution treatment at 530 °C was performed to dissolve coarse precipitates and relieve internal stresses. Cold rolling during the fifth pass reduced the compressive residual stress to −40 MPa, and subsequent artificial aging at 180 °C for 48 h further decreased it to −23 MPa due to recovery and stress relaxation mechanisms. Compared to the unreinforced AA2195 alloy in the T8 condition, which exhibited a tensile residual stress of +29 MPa, the graphene-reinforced composite in the same condition retained a compressive residual stress of −23 MPa. This represents a net improvement of 52 MPa, highlighting the composite’s superior capability to retain compressive residual stress. The presence of graphene significantly influenced the stress distribution by introducing thermal expansion mismatch and acting as a barrier to dislocation motion. Overall, the composite demonstrated enhanced residual stress characteristics, making it a promising candidate for lightweight, fatigue-resistant aerospace components. Full article