Search Results (365)

This study investigates the microstructural evolution, mechanical behavior, and electrochemical performance of CoCrFeNiNb and CoCrFeNiV HEAs fabricated via mechanical alloying and spark plasma sintering. Microstructural analyses reveal that the alloys have a face-centered cubic (FCC) matrix with Nb-enriched Laves and V-enriched σ phases. The CoCrFeNiNb HEA exhibits superior compressive strength and hardness than CoCrFeNiV due to uniform Laves phases distribution. Fracture surface analysis reveals that at lower sintering temperatures, the fracture is primarily caused by incomplete particle bonding, whereas at higher temperatures, brittle fracture modes dominated via transgranular cracking become predominant. The research results of potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) show that both alloys exhibited superior electrochemical stability in a 3.5 wt.% NaCl solution compared to the CoCrFeNi base alloy. X-ray photoelectron spectroscopy (XPS) analysis confirms the formation of stable oxide layers (Nb₂O₅ and V₂O₃) on the precipitated phases, acting as protective barriers against chloride ion penetration. The selective oxidation of Nb and V improves the integrity of the passive film, reducing the corrosion rates and enhancing the long-term durability. These findings highlight the critical role of precipitated phases in enhancing the corrosion resistance of HEAs, and emphasize their potential for use in extreme environments. Full article

The erosion resistance of materials against solid particles is a very important property, especially in the transportation of powders or in aeronautics (dust inside jet engines). There is a strong need to introduce new materials that have higher solid particle erosion resistance than state-of-the-art materials. Thus, in the present work, the solid erosion particles of high entropy alloys (HEAs) based on the Al0.7CoCrFeNi matrix were studied compared to the state-of-the-art stainless steel AISI 304. Furthermore, the effect of the addition of Ti to HEAs on hardness and erosion resistance was investigated. Current research included the development of the chemical composition of a new kind of HEA designed on the basis of thermodynamical calculations performed in CALPHAD, its manufacturing, full characterization involving microstructural and phase analyses, hardness measurements, solid particle erosion tests, and finally, the elucidation of erosion mechanisms. It was found that HEAs showed higher hardness as well as erosion resistance than AISI 304. Moreover, it was found that the increase in Ti content in an HEA resulted in an increase in the hardness and resistance to the erosion of the studied HEA. As the main reason for this phenomenon, the stabilization of the β-BCC phase, suppression of the α-FCC phase, and the appearance of the Ni₃Ti phase in the studied HEA were claimed. Full article

This article presents a review of the composition optimization progress of nickel-based single crystal (SC) superalloy design in recent years in order to obtain better high-temperature performance for the development of the aviation industry. The influence of alloying elements on the creep resistance, microstructure characteristics, oxidation resistance, castability, density, and cost of superalloys is analyzed and discussed. In order to obtain better high-temperature performance, the content of refractory elements (Ta + Re + W + Mo) and Co was increased gradually. The addition of Ru was added in the fourth-generation nickel-based SC superalloy to stabilize the microstructures and suppress the precipitation of the topologically close-packed (TCP) phase. However, the content of the antioxidant element Cr significantly decreased, while the synergistic effect of Al, Cr, and Ta received more attention. Therefore, synergistic effects should also receive more attention to meet the practical needs of reducing the content of refractory elements to reduce costs and density in future single crystal alloy designs without compromising critical performance. Full article

This study examines the corrosion characteristics of GRX-810, a NiCoCr-based high entropy alloy, in a simulated marine environment represented by 3.5 wt.% NaCl solution. The research employs electrochemical and surface analysis techniques to evaluate the corrosion performance and protective mechanisms of this alloy. Electrochemical characterization was performed using potentiodynamic polarization to determine critical corrosion parameters, including corrosion potential and current density, along with electrochemical impedance spectroscopy to assess the stability and protective qualities of the oxide film. Surface analytical techniques provided detailed microstructural and compositional insights, with scanning electron microscopy revealing the morphology of corrosion products, energy-dispersive X-ray spectroscopy identifying elemental distribution in the passive layer, and X-ray diffraction confirming the chemical composition and crystalline structure of surface oxide. The results demonstrated distinct corrosion resistance behavior between the different processing conditions of the alloy. The laser powder bed fused (LPBF) specimens in the as-built condition exhibited superior corrosion resistance compared to their hot isostatically pressed (HIPed) counterparts, as evidenced by higher corrosion potentials and lower current densities. Microscopic examination revealed the formation of a dense, continuous layer of corrosion products on the alloy surface, indicating effective barrier protection against chloride ion penetration. A compositional analysis of all samples identified oxide film enriched with chromium, nickel, cobalt, aluminum, titanium, and silicon. XRD characterization confirmed the presence of chromium oxide (Cr₂O₃) as the primary protective phase, with additional oxides contributing to the stability of the film. This oxide mixture demonstrated the alloy’s ability to maintain passivity and effective repassivation following film breakdown. Full article

The degradation of electrochemical materials during energy conversion and storage, in particular the electrocatalyst materials, is becoming increasingly important. The selection and design of sustainable materials is an important task. This work examines the synthesis, characterization, and application of an electrocatalyst (based on an amorphous alloy Co75Si15Fe5Cr4.5) having a structured surface in the form of nanocells for a “green” nitrate reduction reaction (NO₃RR), which can serve as an alternative to the well-known Haber-Bosch process for the synthesis of ammonia. The material for the electrocatalyst was obtained by anodizing the alloy in the ionic liquid BmimNTf₂ and characterized by using a combination of modern physicochemical and electrochemical methods. The Faradaic efficiency (FE) for the nanocell catalyst exceeds by more than three-fold and seven-fold catalyst with a polished surface and the initial catalyst having a natural oxide on the surface, respectively. A mechanism of this reaction on the studied electrocatalysts with structured and non-structured surfaces is proposed. It is mentioned that the nanocell electrocatalyst is an extremely stable material that passes all tests without visible changes. The authors consider their work as a starting point for the application of a nanostructured Co-electrocatalyst in NO₃RR. Full article

In this study, powders based on a high-entropy AlCoCrFeNi alloy obtained by mechanical alloying were successfully applied to a 316L stainless steel substrate by detonation spraying under various conditions. Their microstructural features, phase composition, hardness, and wear resistance were studied. A comparative analysis between the initial powder and the coatings was performed, including phase transformation modeling using Thermo-Calc under non-equilibrium conditions. The results showed that the phase composition of the powder and coatings includes body-centered cubic lattice (BCC), its ordered modification (B2), and face-centered cubic lattice FCC phases, which is consistent with the predictions of the Scheil solidification model, describing the process of non-equilibrium solidification, assuming no diffusion in the solid phase and complete mixing in the liquid phase. Rapid solidification and high-speed impact deformation of the powder led to significant grain refinement in the detonation spraying coating, which ultimately improved the mechanical properties at the micro level. The data obtained demonstrate the high efficiency of the AlCoCrFeNi coating applied by detonation spraying and confirm its potential for use in conditions of increased wear and mechanical stress. AlCoCrFeNi coatings may be promising for use as structural materials in the future. Full article

Based on the innovative mode driven by “data + artificial intelligence”, in this study, three methods, namely Gaussian noise (GAUSS Noise), the Generative Adversarial Network (GAN), and the optimized Generative Adversarial Network (GANPro), are adopted to expand and enhance the collected dataset of element contents and the hardness of the AlCoCrCuFeNi high-entropy alloy. Bayesian optimization with grid search is used to determine the optimal combination of hyperparameters, and two interpretability methods, SHAP and permutation importance, are employed to further explore the relationship between the element features of high-entropy alloys and hardness. The results show that the optimal data augmentation method is Gaussian noise enhancement; its accuracy reaches 97.4% under the addition of medium noise (σ = 0.003), and an optimal performance prediction model based on the existing dataset is finally constructed. Through the interpretability method, it is found that the contributions of Al and Ni are the most prominent. When the Al content exceeds 0.18 mol, it has a positive promoting effect on hardness, while Ni and Cu exhibit a critical effect of promotion–inhibition near 0.175 mol and 0.14 mol, respectively, revealing the nonlinear regulation law of element contents. This study solves the problem of revealing the mutual relationship between the element contents and hardness of high-entropy alloys in the case of a lack of alloy data and provides theoretical guidance for further improving the performance of high-entropy alloys. Full article

This study investigates the effect of boron carbide (B₄C) ceramic reinforcement on the microstructural, mechanical, electrical, and electrochemical properties of CoCrMo, Ti, and 17-4 PH alloys produced via powder metallurgy for potential biomedical applications. A systematic experimental design was employed, incorporating varying B₄C contents into each matrix through mechanical alloying, cold pressing, and vacuum sintering. The microstructural integrity and dispersion of B₄C were examined using scanning electron microscopy. The performance of the materials was evaluated using several methods, including Vickers hardness, pin-on-disk wear testing, ultrasonic elastic modulus measurements, electrical conductivity, and electrochemical assessments (potentiodynamic polarization and EIS). This study’s findings demonstrated that B₄C significantly enhanced the hardness and wear resistance of all alloys, especially Ti- and CoCrMo-based systems. However, an inverse correlation was observed between B₄C content and corrosion resistance, especially in 17-4 PH matrices. Ti-5B₄C was identified as the most balanced composition, exhibiting high wear resistance, low corrosion rate and elastic modulus values approaching those of human bone. Weibull analysis validated the consistency and reliability of key performance metrics. The results show that adding B₄C can change the properties of biomedical alloys, offering engineering advantages for B₄C-reinforced biomedical implants. Ti-B₄C composites exhibit considerable potential for application in advanced implant technologies. Full article

High-entropy alloys are known for their promising mechanical properties, wear and corrosion resistance, which are maintained across a wide range of temperatures. In this study, a CoCrFeNiCu-based high-entropy alloy, distinguished from conventional CoCrFeNi systems by the addition of Cu, which is known to enhance toughness and wear resistance, was investigated to better understand the effects of compositional modification on processability and performance. The influence of key process parameters, specifically laser power and scan speed, on the processability of CoCrFeNiCu-based high-entropy alloys produced by laser powder bed fusion additive manufacturing was investigated, with a focus of low laser power, which is critical for minimizing defects and improving the resulting microstructure and mechanical performance. The printed sample density gradually increases with higher volumetric energy density, achieving densities exceeding 99.0%. However, at higher energy densities, the samples exhibit susceptibility to hot cracking, an issue that cannot be mitigated by adjusting the process parameters. Mechanical properties under optimized parameters were further evaluated using Charpy impact and (in situ) tensile tests. These evaluations were supplemented by in situ tensile experiments conducted within a scanning electron microscope to gain insights into the behavior of defects, such as hot cracks, during tensile testing. Despite the sensitivity to hot cracking, the samples exhibited a respectable ultimate tensile strength of 662 MPa, comparable to fine-grained steels like S500MC (070XLK). These findings underscore the potential of CoCrFeNiCu-based high-entropy alloys for advanced applications. However, they also highlight the necessity for developing strategies to ensure stable and reliable processing methods that can mitigate the susceptibility to hot cracking. Full article

CoCrMo alloys are interesting materials for implantable devices due to their favorable mechanical properties, high wear resistance, and good biocompatibility with the human body. Recent studies have demonstrated the possibility to further increase their wear resistance with an innovative approach consisting of nitriding treatments by the High-Power Impulse Magnetron Sputtering (HiPIMS) technique. Given the novelty of this treatment, it is relevant to develop a preliminary sustainability analysis of the processes to highlight the total environmental impact and to evaluate possible strategies to decrease it. Here, a Life Cycle Assessment (LCA) of HiPIMS nitriding treatments of CoCrMo alloys using a tantalum or molybdenum target is presented. The main impact driver in all impact categories was the electrical consumption of the vacuum apparatus and cooling system of HiPIMS instrumentation with a 45–47% and 37–39% contribution for Ta-based, and 39–40% and 41–42% for Mo-based treatments, respectively. Climate Change was found to be the most impacted category, followed by Resource Use both for Mo and Ta nitriding targets. Therefore, some perspectives to enhance the environmental sustainability of the synthesis process have been considered by means of a sensitivity analysis. Moreover, a Critical Raw Material (CRM) assessment is discussed, providing a complete sustainability evaluation of the proposed HiPIMS treatments. Full article

This study aimed to comparatively evaluate the effects of various surface treatment protocols on the shear bond strength (SBS) between heat-polymerized polymethyl methacrylate (PMMA) and different CAD/CAM framework materials, including cobalt–chromium (Co–Cr) alloys, ceramic particle-reinforced polyetheretherketone (PEEK), and glass fiber-reinforced composite resin (FRC). A total of 135 disc-shaped specimens were prepared from Co–Cr, PEEK, and FRC materials. Surface treatments specific to each material, including airborne-particle abrasion, sulfuric acid etching, laser irradiation, plasma activation, and primer application, were applied. PMMA cylinders were polymerized onto the treated surfaces, and all specimens were subjected to 30,000 thermal cycles. SBS values were measured using a universal testing machine, and the failure modes were classified. The normality of data distribution was assessed using the Kolmogorov–Smirnov test, and the homogeneity of variances was evaluated using Levene’s test. Group comparisons were performed using the Kruskal–Wallis test, and Dunn’s post hoc test with Bonferroni correction was applied in cases where significant differences were detected (α = 0.05). The highest SBS values (~27–28 MPa) were obtained in the Co–Cr group and in the PEEK groups treated with sulfuric acid and primer. In contrast, the PEEK group with additional laser treatment exhibited a lower SBS value. The untreated PEEK group showed significantly lower SBS (~3.9 MPa) compared to all other groups. The Trinia groups demonstrated intermediate SBS values (16.5–17.4 MPa), which exceeded the clinically acceptable threshold of 10 MPa. SEM observations revealed material- and protocol-specific surface responses; plasma-treated specimens maintained topographic integrity, whereas laser-induced surfaces showed localized degradation, particularly following dual-step protocols. Fracture mode analysis indicated that higher SBS values were associated with cohesive or mixed failures. SEM observations suggested that plasma treatment preserved surface morphology more effectively than laser treatment. This study highlights the importance of selecting material-specific surface treatments to optimize bonding between CAD/CAM frameworks and PMMA. Sulfuric acid and primer provided strong adhesion for PEEK, while the addition of laser or plasma offered no further benefit, making such steps potentially unnecessary. Trinia frameworks also showed acceptable performance with conventional treatments. These findings reinforce that simplified conditioning protocols may be clinically sufficient, and indicate that FRC materials like Trinia should be more fully considered for their broader clinical potential in modern CAD/CAM-based prosthetic planning. Full article

Co-Cr-based alloys are outstanding materials widely used in applications ranging from engineering to biomedical devices due to their excellent physico-mechanical properties, chemical stability, and biocompatibility. The demand for these alloys is steadily increasing, prompting a shift from conventional fabrication methods, such as casting and subtractive manufacturing, to advanced additive manufacturing (AM) techniques. These modern methods enable the production of complex geometrical shapes with enhanced properties. However, comprehensive information on current trends in 3D printing of Co-Cr-based alloys and their performance in specific applications remains limited. Therefore, the present article addresses this gap by reviewing recent advancements in the AM of Co-Cr-based alloys, offering insights for manufacturers, engineers, and researchers looking to develop optimized products. Key characteristics, including physical, mechanical, tribological, chemical, and biocompatibility properties, are thoroughly discussed, along with their applications, with a focus on potential future developments in this field. The exhaustive outlook of this paper provides a strong basis for future research endeavors in the domain of Co-Cr-alloy part production using AM. Full article

CoCrFeNiMn high-entropy alloy (HEA) composite coatings with 0, 10, and 20 wt% TiC are synthesized through laser cladding technology, and their corrosion and wear resistance are systematically investigated. The X-ray diffraction (XRD) results show that with the addition of TiC, the phases of TiC and M₂₃C₆ are introduced, and lattice distortion occurs simultaneously (accompanied by the broadening and leftward shift of the main Face-Centered Cubic (FCC) peak). Scanning electron microscopy (SEM) reveals that the incompletely melted TiC particles in the coating (S2) are uniformly distributed in the matrix with 20 wt% TiC, while in the coating (S1) with 10 wt% TiC, due to gravitational sedimentation and decomposition during laser processing, the distribution of the reinforcing phase is insufficient. When rubbed against Si₃N₄, with the addition of TiC, S2 exhibits the lowest friction coefficient of 0.699 and wear volume of 0.0398 mm³. The corrosion resistance of S2 is more prominent in the simulated seawater (3.5 wt% NaCl). S2 shows the best corrosion resistance: it has the largest self-corrosion voltage (−0.425 V vs. SCE), the lowest self-corrosion current density (1.119 × 10⁻⁷ A/cm²), and exhibits stable passivation behavior with a wide passivation region. Electrochemical impedance spectroscopy (EIS) confirms that its passivation film is denser. This study shows that the addition of 20 wt% TiC optimizes the microstructural homogeneity and synergistically enhances the mechanical strengthening and electrochemical stability of the coating, providing a new strategy for the making of HEA-based layers in harsh wear-corrosion coupling environments. Full article

In order to obtain high-performance 3D printed parts, this study focuses on the key performance indicator of impact toughness. The parametric modeling software Rhino 6 is used to design impact specimens, and the laser selective melting equipment DiMetal-100, independently developed by the South China University of Technology, is used to manufacture impact specimens. Subsequently, the CoCrMo alloy parts were annealed using an MXQ1600-40 box-type atmosphere furnace and subjected to impact testing using a cantilever beam impact testing machine XJV-22. Fractal theory was applied to analyze the fractal behavior of the resulting impact fracture surfaces. The research results indicate that the 3D-printed impact specimens exhibited excellent surface quality, characterized by brightness, low roughness, and the absence of significant defects such as warping or deformation. In terms of annealing treatment, lower annealing temperatures did not improve the impact performance of SLM-formed CoCrMo alloy parts but instead led to a decrease in toughness. While increasing the annealing temperature can improve toughness to some extent, the effect is limited. Furthermore, the relationship between impact energy and heat treatment temperature exhibits a U-shaped trend. The fractal dimension analysis shows that the parts annealed in a 1200 °C furnace have the highest fractal dimension and better toughness performance. This study introduces a novel approach by comprehensively integrating advanced 3D printing technology, annealing processes, and fractal theory analysis to systematically investigate the influence of annealing temperature on the impact properties of 3D-printed CoCrMo alloy parts, thereby establishing a solid foundation for the application of high-performance 3D printed parts. Full article

This study evaluates the predictive capabilities of various machine learning (ML) algorithms for estimating the hardness of AlCoCrCuFeNi high-entropy alloys (HEAs) based on their compositional variables. Among the ML methods explored, a backpropagation neural network (BPNN) model with a sigmoid activation function exhibited superior predictive accuracy compared to other algorithms. The BPNN model achieved excellent correlation coefficients (R²) of 99.54% and 96.39% for training (116 datasets) and cross-validation (39 datasets), respectively. Testing of the BPNN model on an independent dataset (14 alloys) further confirmed its high predictive reliability. Additionally, the developed BPNN model facilitated a comprehensive analysis of the individual effects of alloying elements on hardness, providing valuable metallurgical insights. This comparative evaluation highlights the potential of BPNN as an effective predictive tool for material scientists aiming to understand composition–property relationships in HEAs. Full article