Search Results (200)

The quantification of solid debris in used lubricating oil is essential for assessing transmission system wear and optimizing maintenance strategies. This study introduces a low-cost capacitive proximity sensor for monitoring total solid particle contamination in lubricants, with a focus on ferrous (Fe), non-ferrous (Al), and non-metallic (SiO₂) debris. Controlled tests were performed using five mixing ratios of large-to-small particles (100:0, 75:25, 50:50, 25:75, and 0:100) at a fixed debris mass of 0.5 g per 25 mL of SAE 85W-140 automotive gear oil. Cubic regression analysis yielded high predictive accuracy, with average R² values of 0.994 for Fe, 0.943 for Al, and 0.992 for SiO₂. Further dimensionality reduction using Principal Component Analysis (PCA), along with Linear Discriminant Analysis (LDA) of multivariate statistical analysis, effectively classifies debris types and enhances interpretability. These results demonstrate the potential of capacitive sensing as an offline, non-invasive alternative to traditional techniques for wear debris monitoring in transmission systems. These results confirm the potential of capacitive sensing, supported by statistical modeling, as a non-invasive, cost-effective technique for offline classification and monitoring of wear debris in transmission systems. Full article

This study addresses the critical challenge of maintaining drilling fluid performance and wellbore stability in high-pressure, high-temperature (HPHT) environments, where conventional water-based drilling fluids often fail. This research investigates whether the integration of single- and dual-nanomaterial systems into base fluids can significantly enhance rheological behavior and shale inhibition potential. Using secondary experimental datasets and computational modeling, five nanomaterials—SiO₂, Al₂O₃, TiO₂, Fe₂O₃, and Fe₃O₄—were evaluated individually and in dual combinations with polymers. Key performance metrics, including plastic viscosity, fluid loss, and shale recovery, were analyzed and fitted to the Herschel–Bulkley rheological model. The results showed that single-nanomaterial systems modestly improved viscosity and fluid loss control, with SiO₂ and Fe₂O₃ offering the best standalone performance. Dual systems—particularly SiO₂–Al₂O₃ and Fe₃O₄–polymer combinations—demonstrated superior rheological performance with reduced viscosity (down to 19 cP), minimized fluid loss (<4 mL/30 min), and enhanced shale recovery (>90%). These improvements suggest synergistic effects between nanomaterials, supporting their use in designing advanced, thermally stable drilling fluids for extreme HPHT wells. Full article

This study investigates the influence of Si content (x = 0, 0.1, 0.3, 0.5) on the microstructure, mechanical properties, and wear behavior of FeNiCrAl_0.7Cu_0.3Si_x high-entropy alloys. With increasing silicon content, the microstructure evolves from a dendritic morphology in the silicon-free FeNiCrAl_0.7Cu_0.3 alloy to a transitional structure in the FeNiCrAl_0.7Cu_0.3Si_0.1 alloy that retains dendritic features; then to a chrysanthemum-like morphology in the FeNiCrAl_0.7Cu_0.3Si_0.3 alloy, and finally to island-like grains in the FeNiCrAl_0.7Cu_0.3Si_0.5 alloy. This evolution is accompanied by a phase transition from an Fe and Cr-rich body-centered cubic phase to an Al and Ni-rich body-centered cubic phase, with silicon showing a tendency to segregate alongside aluminum and nickel. The microhardness increases from 498.2 ± 15.0 HV for the FeNiCrAl_0.7Cu_0.3 alloy, to 502.7 ± 32.7 HV for FeNiCrAl_0.7Cu_0.3Si_0.1, 577.3 ± 24.5 HV for FeNiCrAl_0.7Cu_0.3Si_0.3, and 863.2 ± 23.5 HV for FeNiCrAl_0.7Cu_0.3Si_0.5. The average friction coefficients are 0.571, 0.551, 0.524, and 0.468, respectively. The wear mass decreases from 1.31 mg in the FeNiCrAl_0.7Cu_0.3 alloy to 1.28 mg, 1.11 mg, and 0.78 mg in the FeNiCrAl_0.7Cu_0.3Si_0.1, FeNiCrAl_0.7Cu_0.3Si_0.3, and FeNiCrAl_0.7Cu_0.3Si_0.5 samples, respectively. These trends are consistent with the increase in microhardness, supporting the inverse relationship between hardness and wear. As the silicon content increases, the dominant wear mechanism changes from abrasive wear to adhesive wear, with the high-silicon alloy exhibiting lamellar debris on the worn surface. These findings confirm that silicon addition enhances microstructural refinement, mechanical strength, and wear resistance of the alloy system. Full article

This study presents a hybrid computational investigation into the radiation shielding behavior of Fe-enriched Al-based alloys (Al-Fe-Mo-Si-Zr) for potential use in nuclear applications. Four alloy compositions with varying Fe contents (7.21, 6.35, 5.47, and 4.58 wt%) were analyzed using a combination of Monte Carlo simulations, machine learning (ML) predictions based on multilayer perceptrons (MLPs), EpiXS, and SRIM-based charged particle transport modeling. Key photon interaction parameters—including mass attenuation coefficient (MAC), half-value layer (HVL), buildup factors, and effective atomic number (Z_eff)—were calculated across a wide energy range (0.015–15 MeV). Results showed that the 7.21Fe alloy exhibited a maximum MAC of 12 cm²/g at low energies and an HVL of 0.19 cm at 0.02 MeV, indicating improved gamma attenuation with increasing Fe content. The ML model accurately predicted MAC values in agreement with Monte Carlo and XCOM data, validating the applicability of AI-assisted modeling in material evaluation. SRIM calculations demonstrated enhanced charged particle shielding: the projected range of 10 MeV protons decreased from ~55 µm (low Fe) to ~50 µm (high Fe), while alpha particle penetration reduced accordingly. In terms of fast neutron attenuation, the 7.21Fe alloy reached a maximum removal cross-section (Σ_R) of 0.08164 cm⁻¹, showing performance comparable to conventional materials like concrete. Overall, the results confirm that Fe-rich Al-based alloys offer a desirable balance of lightweight design, structural stability, and dual-function radiation shielding, making them strong candidates for next-generation protective systems in high-radiation environments. Full article

This study examines the effect of silicon and manganese addition on the phase composition and electrical properties of Al-Fe alloys using both experimental methods and thermodynamic modeling with the ThermoCalc software package. This research focuses on the Al–Fe–Si–Mn system, which shows potential for developing conductive aluminum alloys with enhanced performance characteristics. It was found that when silicon and manganese are added in amounts up to 0.6%, the formation of intermetallic phases such as Al₈Fe₂Si and Al₁₅Mn₃Si₂ occurs. These phases significantly influence the electrical conductivity and mechanical stability of the alloy. Thermodynamic modeling proved effective in predicting phase formation, guiding the selection of alloy compositions, and optimizing heat treatment parameters. The optimal composition for a conductive aluminum alloy includes up to 0.8% Fe, 0.5% Si, and 0.6% Mn. Heat treatment in the range of 500–550 °C resulted in a favorable combination of strength, electrical conductivity, and thermal resistance. The findings support the use of Al–Fe–Si–Mn alloys in electrical and structural applications and demonstrate the value of combining computational and experimental approaches in alloy design. Full article

As an eco-efficient short-process manufacturing technique for aluminum alloys, twin-belt continuous casting and direct rolling (TBCCR) demonstrates significant production advantages. In this study, an Al-Fe-Si alloy system with different Fe-rich intermetallics (α-AlFe(Mn)Si and β-AlFe(Mn)Si) via TBCCR was developed for new energy vehicle batteries, utilizing the Computer Coupling of Phase Diagrams and Thermochemistry (CALPHAD) technique. Comprehensive microstructure and surface segregation analyses of continuous casted ingots and direct-rolled sheets revealed that the Al-Fe-Si alloy with a combined Fe + Si content of 0.7% and an optimal Fe/Si atomic ratio of 3:1 (FS31) presents optimized mechanical properties: ultimate tensile strength of 145.8 MPa, elongation to failure of 5.7%, accompanied by a cupping value of 6.64 mm. Notably, Mn addition further refined the grain structure of casting ingots and enhanced the strength of both ingots and rolled sheets. Among the experimental alloys, FS14 (optimal Fe/Si atomic ratio of 1:4) sheets displayed the least surface segregation upon Mn incorporation. Through systematic optimization, an Al-Fe-Si-Mn alloy composition (Fe + Si = 0.7%, Fe/Si = 1:4 atomic ratio, 0.8 wt.% Mn) was engineered for TBCCR processing, achieving enhanced comprehensive performance: ultimate tensile strength of 189.4 MPa, elongation to failure of 7.32%, and cupping value of 7.71 mm. This composition achieves an optimal balance between grain refinement, mechanical properties (strength–plasticity synergy), formability (cupping value), and corrosion resistance (corrosion current density). The performance optimization strategy integrates synergistic improvements in strength, ductility, and corrosion resistance, providing valuable guidance for developing high-performance aluminum alloys suitable for the TBCCR process. Full article

Al-Si alloys are essential in manufacturing automotive body structural components due to their superior casting properties, high specific strength, and excellent corrosion resistance. The microstructural evolution and mechanical properties of Al-Si alloy used in rear floors were systematically investigated based on a casting simulation. The results indicate that the alloy microstructure consists of α-Al, an Al-Si eutectic, and the Al₁₅(Mn,Fe)₃Si₂ intermetallic phases. The accumulation of Al₁₅(Mn, Fe)₃Si₂ intermetallic compounds increases toward the end of the filling process, leading to a reduction in mechanical properties. The optimal filling distance of the alloy ranges from 210 mm to 450 mm, while the optimal thickness ranges from 3.36 mm to 4.14 mm. With a filling distance and thickness increase, the yield strength, tensile strength, and elongation of the alloy initially increase and then decrease. The optimal properties are achieved when the filling distance is 210 mm and the thickness is 4.14 mm, with a yield strength of 122.35 MPa, a tensile strength of 258.43 MPa, and an elongation of 11.60%. At the same filling distance, near the gate position, when the thickness increases from 4.1 mm to 5.3 mm, the alloy’s tensile strength and elongation decrease. However, at positions farther from the gate, when the thickness increases from 2.94 mm to 4.93 mm, both the tensile strength and elongation of the alloy increase. This study provides a theoretical basis for the process design of large integrated die-casting components for new energy vehicles and supports the development of a high-strength ductile Al-Si alloy material system. Full article

This study utilizes the temperature–pressure reactor to simulate the real conditions of the reservoir to study rock dissolution and scale formation caused by strong and weak alkali during the ASP flooding in an oilfield in China. Mercury injection experiments showed that the porosity and permeability of rock increased by 10.3% and 15.3% under the action of strong alkali, while they increased by 7.2% and 10.1% under the action of weak alkali, indicating that both strong and weak alkali can cause rock dissolution. The structural morphology of the rock demonstrated that the clay content between the grains decreased significantly. The semi-quantitative analysis of XRD indicated that the content of kaolinite decreased from the initial 7% to 0%. The recrystallized carbonate was found, and the carbonate content increased from the initial 0% to 12%. According to the SEM, EDS, and Raman analyses of the scale, the scale formation was complex in the strong alkaline system, including silicate scale, carbonate scale, and hydroxide scale. In contrast, only carbonate scale was found in the weak alkaline system. The ICP-AES test for the liquid system revealed that the rock dissolution releases substantial Ca²⁺, Mg²⁺, Fe²⁺, SiO₃²⁻ and AlO₂⁻ ions, among which Si concentration can reach around 560 ppm. The chemical mechanism of rock dissolution and scale formation by strong and weak alkali includes the exchange of mineral cations by Na⁺ and the destruction of Si-O and Al-O bonds by OH⁻. These released ions migrate with the composite fluid, then recrystallize under the saturation state to form the scale. The dissolution of rock by strong alkali is more intense, while the dissolution of weak alkali is relatively mild. Moreover, the scale type in the weak alkaline system is simpler, which would be convenient to develop inhibitors. Full article

Semi-solid processes of aluminium alloys, characterised by the coexistence of solid and liquid phases, offer advantages in terms of mechanical properties and fatigue resistance, thanks to the more globular microstructure. Thermodynamic models can be used to analyse the solidification behaviour and to predict the solidification window, ΔT. The CALPHAD method enables the calculation of the phases formed during solidification and the optimisation of alloy composition to meet specific industrial requirements. This study aims to assess how thermodynamic properties in both liquid and solid phases affect the ΔT. Initially, the influence of thermodynamic properties of pure components and interaction parameters was analysed in simplified regular binary systems. To compare these findings with real industrial systems, Al-based alloys were examined. Using available databases, the ΔT was estimated via the CALPHAD method adding alloying elements commonly found in secondary Al-alloys. Finally, the same minority alloying elements were added to Al-Si 8 and 11 wt.% alloys, and the corresponding ΔT were calculated. Cr, Fe, Mg, Mn, and Ti increase the ΔT, while Cu, Ni, and Zn decrease it. The obtained results may serve as a valuable tool for interpreting phenomenological observations and understanding the role of minority elements in the semi-solid processing of secondary Al-Si casting alloys. Full article

This research focuses on the structural and bonding characteristics of the Al(111)/CrB2(0001) interface, aiming to clarify the adhesion mechanisms of CrB₂ coatings on aluminum composites. Utilizing first-principles calculations grounded in density functional theory (DFT), we systematically examined the interfacial properties of both clean and doped Al(111)/CrB₂(0001) systems. And key aspects such as binding energy, electron density distribution, and chemical bonding types were thoroughly evaluated. The results demonstrate that the Cr-terminated HCP stacking arrangement at the Al(111)/CrB₂(0001) interface achieves the maximum adhesion work and minimal interfacial energy. This is primarily due to the strong covalent interactions between Al-p and Cr-p orbitals, which contribute to exceptional interfacial strength and stability. Furthermore, the incorporation of Fe, Mg, and Mn at the interface not only markedly improves working adhesion but also effectively lowers the interfacial energy for the Cr-terminated HCP stacking configuration. This phenomenon significantly enhances the overall bonding performance of the Al/CrB₂ system. Conversely, the addition of Cu, Zn, and Si leads to an increase in interfacial energy, negatively impacting the bonding quality. Analysis of binding energies at the doped interface revealed a consistent trend among the elements: Fe > Mn > Mg > Si > Zn > Cu. These findings offer valuable guidance for the design and optimization of Al-based surface coatings with improved performance. Full article

The development of new materials with low weight for the transport industry is required for the saving of natural resources and protection of the environment from carbon dioxide pollution. The microstructure and mechanical properties of the Fe-30Mn-10Al-3.3Si-1C steel in as-cast, quenched, aged, and hot-deformed states were investigated. Austenite, ferrite, and κ-carbides are present in the steel in an as-cast state. Hot deformation of steels was made using the thermal and mechanical simulation system Gleeble-3800 at temperatures of 900–1050 °C and strain rates of 0.1–10 s⁻¹. Mechanical properties in as-cast, annealed, aged, and hot-deformed states were determined by Vickers hardness and compression tests. A constitutive model of the hot deformation behavior of Fe-30Mn-10Al-3.3Si-1C steel with high accuracy (R² = 0.995) was constructed. The finite element analysis of the deformation behavior of the steel under the plane-strain scheme was performed. Compression tests at room temperature have shown an increase in strength and ductility after hot deformation. The strain hardening of ferrite and austenite grain refinement during dynamic recrystallization are the main reasons for the growth of steel’s plasticity and strength. A specific strength of the investigated material is in the range from 202,000 to 233,000 m²/s² which is higher than high-strength steels previously developed and used in the automotive industry. Full article

A new molecular theory of slag suggests that complex oxides in the phase diagram are also present in liquid slag. In contrast to the ion‒molecule coexistence theory, basic oxides (CaO, MgO, MnO, FeO, etc.) in slag are considered to agglomerate in the liquid state due to their strong mutual attraction, although they are ionized (M²⁺ and O²⁻). The predicted slag structure agrees with the experimental results, and when the model is applied to the CaO-SiO₂, CaO-Al₂O₃, and CaO-SiO₂-Al₂O₃ slag systems, the calculated molar fractions of CaO, SiO₂, and Al₂O₃ ($N_{\mathrm{CaO}},N_{{\mathrm{SiO}}_2},N_{{\mathrm{Al}}_2{\mathrm{O}}_3}$) are close to the measured activities (${\alpha }_{\mathrm{CaO}},a_{{\mathrm{SiO}}_2} \mathrm{and} a_{{\mathrm{Al}}_2{\mathrm{O}}_3}$) reported by different researchers. In the CaO-Al₂O₃ slag system, the results based on the new molecular theory are closer to the experimental values than the results of other theoretical calculations. In the practical application of the new molecular theory, the maximum concentration of each complex molecule is consistent with the position of the melting point of the same solid‒liquid components in the phase diagram, indicating that complex molecules have a strong influence on the melting point of slag. In addition, it is believed that the formation and decomposition of different complex molecules are responsible for changes in component activity in the CaO-SiO₂ and CaO-Al₂O₃ slag systems, and it is further deduced that 3CaO-SiO₂ is formed in two steps. Full article

We herein present a comprehensive investigation of the eudialyte group minerals from the nepheline syenites of Rouma Island in the Los Archipelago, Conakry region, Guinea. Two distinct mineral phases were identified: an oneillite-like phase, associated with the agpaitic rock suite, and, for the first time in this locality, kentbrooksite, occurring in pegmatites. The oneillite-like phase crystallizes in the trigonal system (space group R3), with unit cell parameters a = 14.1489(2) Å, c = 30.1283(5) Å and an idealized crystal chemical formula of Na₁₅(Mn,REE)₃(Ca,Mn)₃(Fe,Mn)₃Zr₃(Zr,Si,Al,Nb,Ti)₁ (Si₂₅O₇₃)(O,OH,H₂O)₃(OH,Cl,F)₂. Kentbrooksite also exhibits trigonal symmetry (space group R3m), with unit cell parameters a = 14.2037(3) Å c = 30.1507(9) Å and an idealized formula of (Na,REE)₁₅(Ca,Mn)₆(Mn,Fe)₃Zr₃(Nb,Si)₁(Si₂₅O₇₃)(O,OH,H₂O)₃(F,Cl,OH)₂. Compared to the oneillite-like phase, kentbrooksite is markedly enriched in Mn and rare earth elements (REE). This geochemical distinction aligns with the progressive mineralogical evolution of the system, transitioning from the miaskitic to agpaitic suite (oneillite-like phase) and subsequently to pegmatites (kentbrooksite). These findings are consistent with the broader-scale observations regarding the syenite ring structure of the Los Archipelago. Full article

AlCrFeNi-based high-entropy alloys (HEAs) have emerged as a prominent research system, attracting significant interest due to their compositional diversity and the tunability of their phase structures. However, in practical applications, single-phase AlCrFeNi-based HEAs often face a trade-off between toughness and strength. Therefore, designing multi-phase composite eutectic high-entropy alloys (EHEAs) to optimize their mechanical properties and microstructure has become a key research focus. Si, a common non-metallic element, plays a significant role in strengthening metal materials. In this paper, AlCrFeNi with Si doping strengthening (AlCrFeNi)100-xSix composite EHEAs were successfully fabricated. A systematic analysis was conducted to investigate the impacts of Si doping on the microstructure and mechanical properties of AlCrFeNi-based composite EHEAs. This study shows that with increasing Si content, the biphasic lamellar composite structure at the grain boundaries gradually expands, forming flower petals. The precipitate structure within the grains evolves into flower disks, which form a sunflower-like composite structure in the alloy. The volume fraction of lamellar structures increases in the petals, accompanied by grain refinement. Furthermore, the yield strength of the alloy increases from 1131 MPa to 1360 MPa with increasing Si content. This provides guidance for the design of high-performance composite EHEAs. Full article

This study investigates the eutectic equilibrium phases in a multicomponent system through 3-D multi-phase-field simulations. Emphasizing the directional solidification process, the work examines the growth dynamics of intermetallic phase ${\mathrm{Al}}_{13}{\mathrm{Fe}}_4$, a lamellar structure ($\mathrm{FCC}$-A1), and a quaternary phase beta-AlMnSi from the liquid that is solidified at a specific temperature. The eutectic transformation, described by the four phase reaction $\mathrm{L}\to {\mathrm{Al}}_{13}{\mathrm{Fe}}_4+\mathrm{FCC}$-A$1+\mathrm{beta}$-AlMnSi, is analyzed to develop a microstructure selection map. This map correlates stable growth modes with initial system composition and lamellar spacing. The results provide detailed insights into the segregation behaviour of alloying elements and their influence on transformation kinetics, enhancing the understanding of eutectic microstructure evolution in complex alloy systems. Full article