Search Results (898)

In contemporary engineering applications, deficiencies in dynamic mechanical properties, particularly impact toughness, are the leading cause of fracture incidents. Consequently, inadequate dynamic mechanical properties have emerged as the primary constraint limiting the further commercial application of precipitation-strengthened high-strength aluminum (Al) alloys, exemplified by the 2014 aluminum alloy. Since the dynamic mechanical properties of the 2014 wrought aluminum alloy are fundamentally governed by the decohesion and cracking of coarse second-phase constituent particles, it is necessary to quantify the correlation between microstructure and mechanical properties. Meanwhile, the size and volume fraction of constituent particles are largely dictated by the concentration of main and impurity alloying elements. Experimental results revealed that the volume fraction of coarse constituents increased with increasing Cu, Si, and Fe content, and that tensile ductility and impact toughness decreased following an inverse exponential relationship with the volume fraction of constituents. The aim of this study is to establish a quantitative relation to correlate the characteristics of coarse constituents with the tensile ductility and impact toughness of the 2014 aluminum alloy. A mathematical model was developed by regarding the coarse constituents as ellipsoidal inclusions. Their volume fraction and aspect ratio were considered in the model. Model predictions show broad agreement with experimental data. These properties are more sensitive to the volume fraction when it is low. Conversely, a larger aspect ratio leads to higher ductility and toughness. The sensitivity is also greater at a small aspect ratio. The model further indicates that reducing the volume fraction when it is high yields limited improvement, whereas further reduction at a low volume fraction leads to significant enhancement of ductility and toughness. This study correlates coarse constituent characteristics with tensile ductility and impact toughness quantitatively, and provides a theoretical framework for predicting and optimizing the mechanical properties of 2014 aluminum alloy. Full article

This study investigates the correlation between sintering temperature, microstructure, and mechanical properties in AlSi10Mg alloy produced by supersolidus liquid phase sintering and subsequent artificial aging. Sintering was performed at 571, 575, and 579 °C using different heating rates for a total duration of approximately 5 h, followed by a 2 h dwell at the sintering temperature. At low sintering temperature, the alloy exhibits relatively fine α-Al grains with uniformly distributed Si precipitates, whereas intermediate temperature promotes Si coarsening. At higher temperature, excessive liquid formation leads to coarse α-Al grains and the development of partially interconnected Si networks. β-Al₅FeSi progressively coarsen with increasing sintering temperature. In the as-sintered state, the modest mechanical properties result from coarse α-Al grain size and subgrain structure, as well as from the size, morphology, and distribution of the Si phase. After aging (at 160 °C for 6 h following solution treatment at 530 °C for 30 min), the hardness and UTS were almost double (going from 44 ± 1 to 103 ± 2 HV and from 121 ± 1 to 273 ± 40 MPa). Meanwhile, α-Al grain size and Si morphology remained unchanged and Fe-rich intermetallics partially transformed into the more stable γ-Al₃FeSi₂ phase. Full article

In this study, Fe₇₀Ni₃₀ metal was deposited onto continuous glass fiber composites via magnetron sputtering, followed by surface coating with SiO₂. The effects of key process parameters-including Fe₇₀Ni₃₀ sputtering duration (2, 5, 10, 20, and 30 min) and SiO₂ surface coating-on the electromagnetic properties and microwave absorption performance of the materials were systematically investigated. Scanning electron microscopy (SEM) characterization revealed that as sputtering time increased, the metal coating evolved from discrete small particles into a continuous film. Cross-sectional SEM analysis further demonstrated the formation of a bilayer structure after SiO₂ introduction. X-ray diffraction (XRD) patterns confirmed the presence of diffraction peaks corresponding to the Fe₇₀Ni₃₀ alloy solid solution. Electromagnetic parameter measurements indicated that the influence of sputtering time on electromagnetic properties was primarily pronounced during the metal layer growth stage; once a continuous film was formed, the variation in electromagnetic parameters diminished. Concurrently, the SiO₂ coating exhibited a significant regulatory effect on dielectric parameters. Reflection coefficient calculations showed that the optimal absorption thickness for the single-layer material ranged from 2.5 to 3.0 mm, with the absorption peak shifting toward lower frequencies as thickness increased. However, the effective absorption bandwidth (EAB) was only 3–5 GHz, failing to meet wideband requirements. In contrast, the three-layer composite structure (total thickness: 3.8 mm) optimized via genetic algorithm achieved impedance gradient and loss synergy, expanding the EBW (R < −10 dB) from 4.8 GHz (single layer) to 10 GHz (8–18.0 GHz)-a substantial improvement over the single-layer configuration. This work provides experimental evidence and technical support for the structural design and process optimization of lightweight, high-efficiency, wideband microwave-absorbing materials. Full article

This study investigates the thermochemical reaction behaviour of scheelite–millscale aluminothermy for direct tungsten alloying in steel production. Experimental mixtures of aluminium, millscale, and scheelite concentrate were simulated using gas–slag–metal (g-s-m) equilibrium calculations in FactSage 8.3 at 2200 °C, and compared with previously reported experimental results. The simulations reproduced metal yields accurately with 0.901 to 0.940 correlation coefficients and predicted tungsten levels consistent with measured steel compositions. However, significant discrepancies were observed in predicted silicon levels, with simulations overestimating steel %Si by up to 3.5%, despite negligible gas-phase losses. Oxygen partial pressure calculations indicate that the Fe/FeO reaction equilibrium controls process reduction conditions. Backcalculation of activity coefficients revealed that FactSage minimisation routines understated silicon activity coefficient values. SiO₂ mass transfer may play a role in low %Si in steel, but this is not clear due to differences in expected mass transfer regimes in aluminothermy under ASR and SHS conditions. Overall, the simulations demonstrate adequate predictive capability for alloying trends and metal yields while highlighting limitations in predicting silicon partitioning. These findings confirm the utility of thermochemical simulation for designing aluminothermic feed mixtures, reducing the number of experiments needed to optimise the aluminothermic feed mixture ratios. Full article

In this work, to address the limitation of low strength and hardness of single-phase CoCrFeNi high-entropy alloy, SiC particles were introduced as a reinforcing phase to prepare CoCrFeNi matrix composites with SiC contents of 0 wt%, 1 wt%, 2.5 wt% and 5 wt% via spark plasma sintering (SPS). It was preliminarily predicted that SiC particles would be uniformly distributed along grain boundaries of the CoCrFeNi matrix. During sintering, partial SiC decomposes at high-temperature, high-activity interfaces, regulating carbide precipitation and phase structural evolution, while residual undecomposed SiC remains at grain boundaries to pin boundaries and refine grains, thereby synergistically enhancing mechanical properties and wear resistance. Microstructural characterization reveals that all samples maintain a face-centered cubic (FCC) solid-solution matrix, and samples with non-zero SiC addition contain Cr₇C₃ carbides, which are mostly distributed at grain boundaries. With the increase in SiC content, mechanical performance is remarkably improved compared with the unreinforced CoCrFeNi matrix: the hardness rises from 198.8 HV to 321.7 HV, the yield strength is greatly enhanced from 242.5 MPa to 673.4 MPa, and the tensile strength increases from 557.9 MPa to 755.7 MPa. The improved yield strength originates synergistically from grain refinement, solid-solution strengthening, grain-boundary strengthening and dislocation strengthening. By clarifying the influence of microstructural defects on critical shear stress (τ₀) and normal fracture stress (σ₀), the intrinsic mechanism governing tensile mechanical performance and ductile–brittle fracture transition was revealed. This optimized CoCrFeNi/SiC composite exhibits excellent strength–hardness comprehensive performance, showing promising application potential for high-load, wear-resistant and structural service components under severe tribological and pressure conditions. Full article

Platinum group metals (PGMs: Pt, Pd, Rh, Ru, Os, Ir) are critical strategic metals. Spent automotive catalysts (SACs) represent one of the most significant secondary sources of PGMs, and their recovery is essential for alleviating the supply–demand imbalance. In the recycling chain, pyrometallurgical processing of SACs generates Fe-Si-based alloy concentrates (termed Fe−Si−PGMs), serving as an important yet challenging intermediate resource for PGM recovery. This review first summarizes the pyrometallurgical and hydrometallurgical processes used for recovering PGMs from SACs, before shifting its focus to the treatment technologies for PGMs in Fe–Si–PGMs alloy. These techniques, including direct extraction, extraction following desilication (via alkaline roasting, slagging, or hydrometallurgical routes), and in situ mechanochemical extraction, are critically evaluated in terms of their advantages and limitations. Furthermore, given that the accurate quantification of trace-level yet high-value PGMs represents another key challenge in the recovery chain due to complex sample matrices, this work systematically outlines and compares the analytical methods commonly employed, such as fire assay, spectroscopic and mass spectrometric techniques, electrochemical methods, and alkali fusion. Finally, several recommendations are provided regarding PGM recovery from SACs, with emphasis on Fe−Si−PGMs alloy processing and analytical methods for PGMs. Full article

This study evaluated the production of aluminosilicochrome alloy (ASC) from technogenic wastes generated by ferroalloy and coal production. Chromite spinel dust from high-carbon ferrochrome gas cleaning, microsilica from ferrosilicon gas cleaning, and coal sludge as a reductant were used as raw materials. Thermodynamic modeling of the Fe–Cr–Si–Al–C–O system in HSC Chemistry 10 predicted that ASC formation is most favorable at 2000–2200 °C, where the metallic phase should contain (wt. %) 28.27–29.46 Cr, 35.21–36.06 Si, 10.14–11.89 Al, and 10.21–10.45 Fe. These predictions were tested by smelting a pre-agglomerated monocharge in a 100 kVA single-electrode electric arc furnace. The resulting alloy contained (wt. %) 24.23 Fe, 32.03 Si, 22.32 Cr, 18.70 Al, 0.36 C, 0.028 P, and 0.015 S. The experiments confirmed the formation of Si-, Cr-, and Al-rich ASC and demonstrated the feasibility of carbothermic production from these wastes. SEM-EDS revealed a multicomponent metallic matrix with pronounced microstructural heterogeneity and local redistribution of Fe, Si, Cr, and Al. Overall, the results support the use of fine technogenic wastes for producing a complex Fe–Cr–Si–Al alloy. Full article

This study investigates the possibility of producing a complex W–Mo–Cr-containing alloy via metallothermic reduction of oxide concentrates in the presence of direct reduced iron (DRI) in an induction furnace under atmospheric conditions. A complex FeAlSiCa alloy was used as a reductant due to its high exothermicity and combined reducing potential. Thermodynamic analysis showed that the reduction of WO₃ and MoO₃ is more favorable compared to Cr₂O₃, which is reflected in the temperature profiles of the process. Experimental results confirmed that the addition of FeAlSiCa leads to intensive exothermic reactions and promotes melt formation. The estimated apparent recovery of W and Mo reached up to ~99%, while Cr estimated apparent recovery remained lower (up to ~70%) due to its higher thermodynamic stability and kinetic limitations. Microstructural analysis revealed a heterogeneous structure consisting of an Fe-based matrix and W–Mo-rich phases, including characteristic “fishbone” morphologies. An increase in reductant amount led to higher Si content in the alloy, indicating the need for composition optimization. The results demonstrate the feasibility of direct complex alloying as an alternative to conventional ferroalloy-based methods and highlight the potential for developing resource-efficient and low-carbon metallurgical technologies. Full article

Determining the concentration of light elements in the Earth’s outer core is crucial for understanding the generation of the geomagnetic field, as well as the Earth’s internal dynamics and thermal evolution. However, as a potential dominant light element in the outer core, the precise composition of silicon (Si) is still a topic of intense debate. Due to the limited experimental data, significant controversies exist between theoretical models and experimental predictions regarding the Si content in the outer core. In this work, we have calculated pressure (P)–volume (V)–temperature (T) data of Fe-X wt.% Si, where X = 0, 2.4, 4.9, 7.5, and 10.3 at ~136–330 GPa and 4000–7000 K by first-principles molecular dynamics (FP-MD) simulations. We employed pressure correction to address the discrepancy between theoretical and experimental measurements. Based on the corrected data, we established an equation of state (EoS) for Fe-Si alloys. We calculated thermodynamic properties, including density (ρ), thermal expansivity, Grüneisen parameter, isothermal and adiabatic bulk moduli, and sound velocity (V_P). To constrain the silicon content in the outer core, the ρ and V_P of Fe-X wt.% Si computed along the outer core geotherm were compared with the Preliminary Reference Earth Model (PREM). Assuming Si is the only light element in the outer core and is constrained by PREM data, the maximum Si content at T_ICB = 5400 K is 2.4 ± 1.7 wt.%. Considering the uncertainty in T_ICB, the maximum Si content in the outer core ranges from 1.8 to 3.0 ± 1.7 wt.%. The fact that a homogeneous binary alloy cannot match all seismic observations provides evidence that the content of Si in the outer core may vary with depth. Besides, the work states that pressure correction helps bridge the gap between theoretical and experimental estimates of Si concentration. The pressure-corrected equation of state provides a robust benchmark for constraining multi-component core models. Full article

Intragranular orientation gradients play a critical role in deformation and recrystallization texture evolution of silicon steel. In this study, the dependence of intragranular orientation gradients on grain orientation in a cold-rolled Fe-3%Si alloy was systematically investigated through electron backscatter diffraction (EBSD), complemented by a rate-dependent crystal plasticity model, incorporating grain boundary resistance. A comparative assessment of intragranular orientation gradients in the grain core and grain boundary regions revealed that they are markedly sensitive to grain orientation, with the grain boundary region exhibiting a higher orientation gradient than the grain core. The formation of intragranular orientation gradients is governed by the orientation stability during plastic deformation: stable convergent α (<110>//RD, rolling direction) and γ (<111>//ND, normal direction) orientations develop lower orientation gradients, whereas grains with unstable divergent λ (<001>//ND) orientations exhibit higher orientation gradients. Furthermore, intergranular interactions during rolling reduce orientation stability near grain boundaries, thereby promoting higher orientation gradients in the grain boundary region compared to the grain core. Full article

AlCrFeNi-based high-entropy alloys (HEAs) have attracted considerable interest owing to their adjustable phase constitution and attractive mechanical performance. In this study, AlCr_1.6Fe_xNi_(3.2−x)Si_0.2 HEAs (x = 1.0–2.0) were fabricated by vacuum arc melting to systematically evaluate the influence of the Fe/Ni ratio on phase evolution, microstructural characteristics, and mechanical behavior. The results indicate that, with increasing Fe content, the phase constitution gradually changes from BCC + B2 + σ to BCC + B2. Correspondingly, the microstructure evolves from floral and cellular eutectic morphologies to branch-like BCC-rich regions with inter-branch/intercellular eutectic constituents. At the same time, the Vickers hardness decreases from 584.1 HV to 365.7 HV as the Fe content increases. Compression results show a gradual reduction in alloy strength, whereas the deformation ability is noticeably improved. Fracture surface analysis further reveals that the alloys with x ≤ 1.4 exhibit typical brittle fracture features, while those with x ≥ 1.6 display incomplete fracture and enhanced plastic deformation. These results clarify the relationship among Fe/Ni ratio, phase constitution, microstructural evolution, and mechanical properties in AlCrFeNiSi-based HEAs. Full article

Hot-press forming (HPF) steel is a promising lightweight material for automotive applications but suffers from oxidation and reduced corrosion due to high-temperature processing. Aluminized coatings, particularly Al-10Si, are widely used to mitigate this issue. However, HPF heat treatment can create brittle alloy layers with cracks, compromising retention and increasing corrosion risk. This study investigated the effects of Sr addition on the microstructure and corrosion resistance of Al-Si-coated HPF steel. Al-Si and Al-Si-Sr coatings were applied to steel substrates and subjected to heat treatment to produce heat-treated (HT) Al-Si and HT Al-Si-Sr samples. Sr addition refined and spheroidized eutectic Si particles, improved coating homogeneity, and mitigated vertical crack formation in the Al-Fe-Si intermetallic layer. The resulting dense, crack-free alloy layer effectively shielded the Fe substrate from corrosion. After heat treatment, Sr facilitated the formation of a fine lamellar microstructure and a dense, continuous oxide film, enhancing coating retention and sustaining barrier protection. These improvements significantly delayed corrosion propagation into the Fe substrate. Corrosion resistance was evaluated using salt-spray tests (ASTM B117), potentiodynamic polarization, and electrochemical impedance spectroscopy in 3.5 wt.% NaCl solutions. Microstructural analyses revealed that even minimal Sr content (0.05%) considerably enhanced the performance of Al-Si coatings, demonstrating industrial applicability. This study highlights the potential of Sr-added Al-Si coatings in addressing the demand for lightweight and corrosion-resistant materials in the automotive industry, offering a viable solution for high-performance and environmentally sustainable applications. Full article

This work investigated the effect of yttrium addition on the pre-oxidation behavior of Fe–25Ni–20Cr–4Al–1Nb–1Mn–1.5Si-based alloys at 1000 °C in a 4% H₂ + 0.2% CH₄ + Ar + 0.25% H₂O atmosphere. The oxidation resistance and oxide scale adhesion were evaluated through cyclic oxidation tests and micro-scratch measurements. Results show that the Y-free alloy formed a discontinuous oxide layer, whereas all Y-containing alloys formed a continuous and dense Al₂O₃ scale. Incorporating 0.2 wt.% Y increased the work of adhesion by approximately 7 to 9 times relative to the Y-free sample, indicating a pronounced interfacial strengthening effect. The role of yttrium content and oxygen partial pressure in promoting alumina-scale formation was discussed based on thermodynamic considerations and microstructural evidence. Full article

The massive discharge of methylene blue causes severe water pollution, and the development of efficient and stable heterogeneous Fenton catalysts is crucial for wastewater treatment. To address the shortcomings of traditional iron-based amorphous catalysts, such as low activity and poor stability, this study employed Fe₈₀Si₆B₁₀Cu₁Nb₃ five-component amorphous alloy as the catalyst to investigate its catalytic degradation performance, cyclic stability, and catalytic mechanism for MB. Batch experiments, SEM, XRD characterization, and kinetic fitting were combined to carry out the research. The results showed that under the optimal conditions (25 °C, pH = 3, H₂O₂ concentration of 5 mM, catalyst dosage of 0.5 g/L), the catalyst could completely degrade methylene blue within 9 min with a reaction rate constant k_obs of 0.44 min⁻¹, and the degradation efficiency showed no obvious attenuation after 20 consecutive cyclic degradation runs. After degradation, slight selective corrosion occurred on the catalyst surface, while the amorphous structure of the matrix remained stable. This study confirms that the Cu/Nb dual synergy improves the catalytic performance and stability, clarifies the relevant catalytic mechanism, and provides theoretical and technical support for the design of high-performance iron-based amorphous catalysts and the treatment of dye-containing wastewater. Full article

Dissimilar 7075-T6 and 6061-T6 aluminum alloy joints were fabricated using pulsed metal inert gas (P-MIG) welding with ER5356 filler wire. The effects of welding current (224 A, 234 A, and 244 A) on macro-morphology, microstructure, mechanical properties, and corrosion behavior were systematically investigated. As welding current increased, the top and bottom reinforcements first increased and then decreased, reaching maximum values at 234 A, while the front weld width exhibited the opposite trend. The weld zone consisted of equiaxed and dendritic grains, with partial remelting of AlFeMnSi intermetallic compounds observed in the heat-affected zones. The microhardness and tensile strength of the joints followed a similar trend of first decreasing and then increasing with welding current, achieving a maximum tensile strength of 203.9 MPa at 244 A, corresponding to 89.5% of the 6061-T6 base metal strength. Corrosion resistance varied across regions depending on the evaluation method. In intergranular corrosion tests, the 7075-HAZ showed the highest susceptibility due to grain boundary segregation of Mg and Zn. In electrochemical tests, the WZ exhibited the poorest corrosion resistance. For the 7075-HAZ, optimal corrosion resistance was achieved at 234 A, attributed to a stable passive film and uniform precipitate distribution. These findings provide valuable guidance for optimizing P-MIG welding parameters for dissimilar 7075/6061 aluminum alloy joints. Full article