Search Results (1,068)

Discarded NdFeB permanent magnets will become a significant source of rare earth elements (REEs) in the future. Electric vehicle (EV) motors utilize 2–5 kg of NdFeB magnets, and researchers are prioritizing the development of suitable extraction technologies. The objective of our research is to separate metal materials (Al, Cu, Fe and FEEs) from EV motors, based on their melting temperatures. REE magnets that pose the greatest challenge are melted together with the electrical steel of the motor, and the potential for extracting REEs in a selective manner from the molten steel was examined based on their significant oxidation potential using FeO–SiO₂ compounds, which act as an oxidizing slag-forming agent, to test the extraction method. Fayalite (2FeO·SiO₂) is the most easily created and ideal eutectic compound for carrying oxygen (FeO) and forming slag (${\mathrm{S}\mathrm{i}\mathrm{O}}_4^{4^{-}}$), typically generated during copper smelting. In this experiment, copper slag was used and the results were compared to a smelting test, which had previously used a synthesized fayalite flux as a model. The smelting test, utilizing synthesized fayalite flux, yielded a 91% Nd recovery rate. The Nd recovery rate in the smelting test with copper slag hit a high of 64.81%, influenced by the smelting’s holding time. The steel contained 0.08% Nd. Iron was recovered from the copper slag at a rate of 73%. During the smelting test, it was observed that the reaction between Nd₂O₃ and the Al₂O₃ crucible resulted in the formation of a layer on the surface of the crucible, diffusion into the crucible itself, and a subsequent reduction in the efficiency of Nd recovery. Full article

This article comprehensively reviews the tribological behavior of a Ti-6Al-4V alloy manufactured via electron beam powder bed fusion (EB-PBF), an additive manufacturing process for aerospace and biomedical applications. EB-PBF Ti-6Al-4V demonstrates wear resistance that is superior or comparable to conventional Ti-6Al-4V. The reported average friction coefficient ranges between ~0.22 and ~0.75 during sliding wear in dry and lubricated conditions against metallic and ceramic counterparts when loading 1–50 N under varied surface and heat treatment conditions, and between 1.29 and 2.2 during fretting wear against EB-PBF Ti-6Al-4V itself. The corresponding average specific wear rates show a broad range between ~8.20 × 10⁻⁵ mm³/Nm and ~1.30 × 10⁻³ mm³/Nm during sliding wear. Lubrication reduces the wear rates and/or the friction coefficient. Wear resistance can be improved via machining and heat treatment. Wear anisotropy is reported and primarily attributed to microhardness variations, which can be mitigated through lubrication and post-processing. The effects of applied load and frequency on EB-PBF Ti-6Al-4V are also discussed. The wear resistance at elevated temperatures shows a mixed trend that depends on the counterpart material and the testing methods. Wear mechanisms involve oxide tribo-layer formation, abrasive wear, and adhesive wear. Current limitations, future research directions, and a standardization framework are also discussed. Full article

The mixed metal oxides (MMOs) derived from layered double hydroxides (LDHs) are a typical class of porous materials and have attracted significant attention across various fields due to their high surface area, rich porous structures and various compositions. Regulating the pore structure of MMOs remains an urgent need because of the growing demand for numerous applications including adsorption, catalysis, and energy conversion. Controlling the lateral size of the lamellar crystals in the Co–Al LDH precursor allowed us to engineer the pore structure of Co–Al MMO, an architecture formed by the stacking of these lamellar flakes. The pore size distribution of the Co–Al MMO has been adjusted in the range from several nanometer to hundreds of nanometers. The sample with the optimized pore sizes exhibited a much higher catalytic reaction rate in the aerobic oxidation reaction of benzyl alcohol, about 4.2 times that of the control sample. Further research demonstrated that the high activity was favored by the improved mass transfer rate in the optimized pore architecture. Moreover, sodium silicate was employed as a cross-linking agent to enhance the cohesion within the secondary particles, which consist of stacked lamellar flakes. The resulting silicate-modified Co–Al MMO demonstrated significantly improved catalytic durability, maintaining stable performance over five consecutive reuse cycles—the performance that substantially exceeded that of its un-modified counterpart. Full article

The network architecture has demonstrated considerable potential for enhancing the strength–ductility synergy in metal matrix composites (MMCs). Intuitively, the intersections of network layers are expected to induce a stress concentration, leading to premature brittle fractures. Introducing chamfers to round the network cells may mitigate the local stress concentration and thereby improve elongation. Here, a numerical simulation framework was developed to investigate the effect of chamfering on the mechanical behavior of a three-dimensional (3D) continuous SiC_3D/Al composite with a network architecture. A Voronoi tessellation algorithm was employed to generate the continuous network structural SiC phase. By inducing ductile and brittle damage criterions in the matrix and reinforcement elements, respectively, the mechanical behavior can be predicted via the finite element method (FEM). The predicted mechanical properties reveal an unexpected trend: chamfering results in a simultaneous reduction in both strength (from 367 MPa to 312 MPa) and elongation (from 4.1% to 2.0%). With chamfering, the enlarged intersection of the network layer bears a lower load, whereas the narrower network plates exhibit higher stress concentrations. As a result, the overall load-bearing capacity of the SiC_3D reinforcement decreases monotonically with an increasing chamfer size f. Furthermore, the non-uniform stress distribution promotes the premature fracture of the SiC_3D, which reduces elongation. Additionally, the crack deflection behavior is suppressed in the chamfered models, leading to decreasing energy dissipation. This unanticipated outcome highlights an important architectural design principle: maintaining uniform geometric dimensions is critical for achieving optimal composite performance. Full article

Solidification cracking and liquation cracking have been reported frequently in additive manufacturing (AM) as well as welding. In the vast majority of weldability tests, a single-pass, single-layer weld is tested, though multiple-pass, multiple-layer welding is common in welding practice. In AM, evaluating the cracking susceptibility based on the total number or length of cracks per unit volume requires repeated cutting and polishing of a built object, and the cracks are often too small to open easily for fracture-surface examination. The present study identified an existing weldability test and modified it to serve as a cracking susceptibility test for AM. A single-pass, single-layer deposit of metal powder was made along a slender specimen that was pulled like in tensile testing but with acceleration. Cracks were visible on the deposit surface and opened easily for examination. The critical pulling speed, i.e., the minimum pulling speed required to cause cracking, was determined as an index for the cracking susceptibility. The lower the critical pulling speed is, the higher the cracking susceptibility. As a result, 6061 Al showed solidification cracking, and 7075 Al showed liquation cracking, consistent with their high susceptibility to such cracking. Full article

Friction stir additive manufacturing (FSAM) is a promising solid-state technique for fabricating high-strength aluminum alloys, such as Al-7075, which are difficult to process using conventional melting-based additive manufacturing (AM) methods. This study investigates the mechanical properties and tool wear behavior of seven-layered Al-7075 multi-layered composites reinforced with silicon carbide (SiC) and titanium carbide (TiC) fabricated via FSAM. Microstructural analysis confirmed defect-free multi-layered composites with a homogeneous distribution of SiC and TiC reinforcements in the nugget zone (NZ), although particle agglomeration was observed at the bottom of the pin-driven zone (PDZ). The TiC-reinforced composite exhibited finer grains than the SiC-reinforced composite in both as-welded and post-weld heat-treated (PWHT) conditions, achieving a minimum grain size of 1.25 µm, corresponding to a 95% reduction compared to the base metal. The TiC-reinforced multi-layered composite demonstrated superior mechanical properties, attaining a microhardness of 93.7 HV and a UTS of 263.02 MPa in the as-welded condition, compared to 88.6 HV and 236.34 MPa for the SiC-reinforced composite. After PWHT, the TiC-reinforced composite further improved to 159.12 HV and 313.46 MPa UTS, along with a higher elongation of 11.14% compared to 7.5% for the SiC-reinforced composite. Tool wear analysis revealed that SiC reinforcement led to greater tool degradation, resulting in a 1.17% weight loss. These findings highlight the advantages of TiC reinforcement in FSAM, offering enhanced mechanical performance with reduced tool wear in multi-layered Al-7075 composites. Full article

This study investigates the fabrication of a Cu-Mn-Al alloy coating on 27SiMn steel using Cold Metal Transfer (CMT) technology with an innovative Ar-B(OCH₃)₃ mixed shielding gas, focusing on the effect of the gas flow rate (5–20 L/min). The addition of B(OCH₃)₃ was found to significantly enhance process stability by improving molten pool wettability, resulting in a wider cladding layer (6.565 mm) and smaller wetting angles compared to pure Ar. Macro-morphology analysis identified 10 L/min as the optimal flow rate for achieving a uniform and defect-free coating, while deviations led to oxidation (at low flow) or spatter and turbulence (at high flow). Microstructural characterization revealed that the flow rate critically governs phase evolution, with the primary κI phase transforming from dendritic/granular to petal-like/rod-like morphologies. At higher flow rates (≥15 L/min), increased stirring promoted Fe dilution from the substrate, leading to the formation of Fe-rich intermetallic compounds and distinct spherical Fe phases. Consequently, the cladding layer obtained at 10 L/min exhibited balanced and superior properties, achieving a maximum shear strength of 303.22 MPa and optimal corrosion resistance with a minimum corrosion rate of 0.02935 mm/y. All shear fractures occurred within the cladding layer, demonstrating superior interfacial bonding strength and ductile fracture characteristics. This work provides a systematic guideline for optimizing shielding gas parameters in the CMT cladding of high-performance Cu-Mn-Al alloy coatings. Full article

This study examines the influence of layer thickness (0.9, 1.6, 2.4, and 4 mm) on the distribution of residual stress, microstructural evolution, and tensile properties of Cu18150/Al1060/Cu18150 multilayered composites fabricated via a combined cast-rolling and hot-rolling technique. The grain refinement, dislocation density, and residual stress gradients across the interfaces were characterized and analyzed using integrated electron backscatter diffraction and kernel average misorientation mapping. The results demonstrated that specimens with a lower layer thickness (0.9–1.6 mm) possess a significantly improved tensile strength of 351 MPa, which is mainly due to the significant grain refinement and the presence of compressive residual stresses at the region of the Al/Cu interfaces. However, tensile strength decreased to 261 MPa in specimens with thicker layers (4 mm), accompanied by improved ductility, e.g., elongation of 30%. This is associated with a reduction in the degrees of interfacial constraint and the formation of more homogeneous deformation structures that accommodate a larger strain. The intermediate layer thickness of 2.4 mm offers an optimal compromise, achieving a tensile strength of 317 MPa while maintaining balanced mechanical performance. These results emphasize the importance of layer thickness in controlling such stress profiles and optimizing the mechanical behavior of hybrid metal composites, providing useful guidance on the design and fabrication of superior structural-form materials. Full article

The thickness of the LPCVD-Si₃N₄ gate dielectric layer significantly influences the electron transport properties of AlGaN/GaN metal–insulator–semiconductor high-electron-mobility transistors (MIS-HEMTs), but the mechanism by which it affects polarization Coulomb field (PCF) scattering remains largely unexplored. In this study, AlGaN/GaN MIS-HEMTs with LPCVD-Si₃N₄ gate dielectric thicknesses of 0 nm, 5 nm, and 20 nm were fabricated, and the influence of LPCVD-Si₃N₄ thickness on PCF scattering was systematically investigated. Through electrical measurements and theoretical calculations, the relationship between LPCVD-Si₃N₄ gate dielectric layer thickness, additional polarization charge (∆ρ), two-dimensional electron gas (2DEG) density, and 2DEG mobility was analyzed. The results show that increasing the LPCVD-Si₃N₄ thickness reduces the vertical electric field in the AlGaN barrier, weakening the inverse piezoelectric effect (IPE) and reducing ∆ρ. Further analysis reveals that the ∆ρ exhibits a non-monotonic dependence on negative gate voltage, initially increasing and subsequently decreasing, due to the competition between strain accumulation and stress relaxation. Meanwhile, the 2DEG mobility limited by PCF (μ_PCF) decreases monotonically with increasing negative gate voltage, mainly due to the progressive weakening of the 2DEG screening effect. The research results reveal the physical mechanism by which LPCVD-Si₃N₄ thickness regulates PCF scattering, providing theoretical guidance for optimizing gate dielectric parameters and enhancing the performance of AlGaN/GaN MIS-HEMTs. Full article

This study systematically investigates the effects of welding current on the macro-morphology, microstructure, mechanical properties, and corrosion resistance of Cu-Mn-Al alloy coatings deposited on 27SiMn steel substrates using Cold Metal Transfer (CMT) technology. The 27SiMn steel is widely applied in coal mining, geology, and engineering equipment due to its high strength and toughness, but its poor corrosion and wear resistance significantly limits service life. To address this issue, a Cu-Mn-Al alloy (high-manganese aluminum bronze) was selected as a cladding material because of its superior combination of mechanical strength, toughness, and excellent corrosion resistance in saline and marine environments. Compared with conventional cladding processes, CMT technology enables low-heat-input deposition, reduces dilution from the substrate, and promotes defect-free coating formation. To the best of our knowledge, this is the first report on the fabrication of Cu-Mn-Al coatings on 27SiMn steel using CMT, aiming to optimize process parameters and establish the relationship between welding current, phase evolution, and coating performance. The experimental results demonstrate that the cladding layer width increases progressively with welding current, whereas the layer height remains relatively stable at approximately 3 mm. At welding currents of 120 A and 150 A, the cladding layer primarily consists of α-Cu, κII, β-Cu₃Al, and α-Cu + κIII phases. At higher welding currents (180 A and 210 A), the α-Cu + κIII phase disappears, accompanied by the formation of petal-shaped κI phase. The peak shear strength (509.49 MPa) is achieved at 120 A, while the maximum average hardness (253 HV) is obtained at 150 A. The 120 A cladding layer demonstrates optimal corrosion resistance. These findings provide new insights into the application of CMT in fabricating Cu-Mn-Al protective coatings on steel and offer theoretical guidance for extending the service life of 27SiMn steel components in aggressive environments. Full article

The 316L stainless steel, uncoated and coated with two types of EB-PVD thin-film deposits, was tested in liquid lead both under oxygen-saturated conditions (~10⁻³ wt.%) for exposure times of 1000 and 2000 h and under low-oxygen conditions (~10⁸ wt.%) for 1000 h. The first coating consisted of a ~1 µm NiCrAlY thin film. At the same time, the second was a NiCrAlY/Al₂O₃ multilayer with a total thickness of ~3 µm, on top of which an additional 100–200 nm metallic Cr layer was deposited. Uncoated specimens tested under oxygen-saturated conditions developed a duplex oxide layer on their surface. SEM-EDS analyses revealed that the inner layer was denser and contained Fe, Cr, and O, whereas the outer layer was more porous and composed mainly of Fe and O. Microscopic examinations indicated that the multilayer-coated specimens exposed to low-oxygen conditions exhibited no signs of material degradation. In contrast, both the uncoated samples and those coated only with a single NiCrAlY layer showed generalised corrosion over the entire surface after exposure to liquid lead at low oxygen concentrations. The austenitic microstructure was degraded to a depth of 100–200 µm. Vickers microhardness indentations performed on the structurally altered regions revealed two distinct corrosion zones with markedly different hardness values. Full article

This study investigates the influence of plasma electrolytic oxidation (PEO) on corrosion resistance of Ti6Al4V alloys produced by direct metal laser sintering (DMLS) for orthopedic implants. PEO (300 s) and flash-PEO (60 s) coatings containing Si, Ca, P, Mg and Zn were applied on both DMLS and wrought Ti6Al4V alloys. Samples, coated and uncoated, were characterized for microstructure, morphology and composition. Electrochemical behaviour was assessed by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) in simulated body fluid (SBF) at 37 °C. Ion release was quantified by inductively coupled plasma optical emission spectroscopy (ICP-OES). DMLS alloy was more passive than wrought Ti6Al4V, releasing ~60% less Ti and ~25% less Al, but ~900% more V. For both alloys, correlation of corrosion current and ion release indicated that 98–99% of oxidized Ti remained in the passive layer. Flash-PEO produced uniform porous coatings composed of anatase and rutile with ~50% amorphous phase, while PEO yielded heterogeneous layers due to soft sparking. In both cases, coatings were the main source of ions. For the DMLS alloy, the best protection was afforded by flash-PEO, releasing 0.01 μg cm⁻² d⁻¹ Ti, 26 μg cm⁻² d⁻¹ Al, and 0.25 μg cm⁻² d⁻¹ V over 30 days. Full article

Phosphonate-based antiscalants such as 1-hydroxyethane-1,1-diphosphonic acid (HEDP) are extensively employed in industrial water treatment but pose significant environmental challenges due to their persistence and phosphorus content. In this study, Mg-Al layered double hydroxide (Mg-Al LDH) was synthesized and evaluated for its capacity to adsorb and remove HEDP. Mg-Al LDH showed a pronounced adsorption affinity and an exceptionally high capacity of 276.0 mg g⁻¹ at pH 7.0. The adsorption process was remarkably fast, attaining 97% of equilibrium uptake within 45 min at 298 K. The adsorption data fit well to the Elovich kinetic model and the Langmuir isotherm, indicating that the adsorption process is dominated by chemisorption. Thermodynamic analysis further confirmed its spontaneous nature. Additionally, Mg-Al LDH demonstrated strong tolerance to environmental fluctuations. Characterization techniques, including XRD, FTIR, and zeta potential measurements, confirmed that HEDP adsorption onto Mg-Al LDH primarily occurs via surface complexation with metal sites and electrostatic attraction. These findings demonstrate that Mg-Al LDH is a highly effective adsorbent for removing persistent phosphonate pollutants from wastewater streams. Full article

The photoelectrochemical oxidation method was utilized to directly grow a gate oxide layer and simultaneously create gate-recessed regions for fabricating GaN-based depletion-mode metal-oxide-semiconductor high-electron mobility transistors (D-mode MOSHEMTs). The LiNbO₃ gate ferroelectric layer and stacked gate oxide layers of LiNbO₃/HfO₂/Al₂O₃ were respectively deposited on the created gate-recessed regions using the photoelectrochemical etching method to fabricate the GaN-based enhancement mode MOSHEMTs (E-mode MOSHEMTs). GaN-based complementary integrated circuits were realized by monolithically integrating the D-mode MOSHEMTs and the E-mode MOSHEMTs. The performances of the inverter circuit manufactured using the integrated GaN-based complementary MOSHEMTs were measured and analyzed. Full article

Rechargeable aqueous Zn-MnO₂ batteries are positioned as a highly promising candidate for next-generation energy storage, owing to their compelling combination of economic viability, inherent safety, exceptional capacity (with a theoretical value of ≈308 mAh·g⁻¹), and eco-sustainability. However, this system still faces multiple critical challenges that hinder its practical application, primarily including the ambiguous energy storage reaction mechanism (e.g., unresolved debates on core issues such as ion transport pathways and phase transition kinetics), dendrite growth and side reactions (e.g., the hydrogen evolution reaction and corrosion reaction) on the metallic Zn anode, inadequate intrinsic electrical conductivity of MnO₂ cathodes (≈10⁻⁵ S·cm⁻¹), active material dissolution, and structural collapse. This review begins by systematically summarizing the prevailing theoretical models that describe the energy storage reactions in Zn-Mn batteries, categorizing them into the Zn²⁺ insertion/extraction model, the conversion reaction involving MnO_x dissolution–deposition, and the hybrid mechanism of H⁺/Zn²⁺ co-intercalation. Subsequently, we present a comprehensive discussion on Zn anode protection strategies, such as surface protective layer construction, 3D structure design, and electrolyte additive regulation. Furthermore, we focus on analyzing the performance optimization strategies for MnO₂ cathodes, covering key pathways including metal ion doping (e.g., introduction of heteroions such as Al³⁺ and Ni²⁺), defect engineering (oxygen vacancy/cation vacancy regulation), structural topology optimization (layered/tunnel-type structure design), and composite modification with high-conductivity substrates (e.g., carbon nanotubes and graphene). Therefore, this review aims to establish a theoretical foundation and offer practical guidance for advancing both fundamental research and practical engineering of Zn-manganese oxide secondary batteries. Full article