Search Results (63)

This study investigates the influence of detonation spraying parameters on the microstructure, mechanical properties and tribological performance of self-fluxing Ni–Cr–Fe–Si–B–C coatings deposited on AISI 321 stainless steel substrates. The effects of the barrel filling ratio (48–68%), the oxygen-to-fuel molar ratio (O/C = 1.026–1.856), and the delay time between detonation shots (0–1 s) were systematically evaluated. The coatings were characterized using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), microhardness measurements, instrumented indentation, and ball-on-disk tribological testing. Microstructural investigations revealed that the spraying parameters significantly influence coating thickness, porosity and defect formation. The lowest porosity (0.306 per cent) and the most homogeneous microstructure were obtained at a barrel filling ratio of 48 per cent, an O/C ratio of 1.026 and a shot delay of 1 s. XRD analysis identified a multiphase structure consisting of a Ni₃Fe matrix reinforced by Cr₇C₃ carbides, Ni₃B and CrB borides, and Ni₃₁Si₁₂ silicides. Tribological tests demonstrated that increasing the delay between shots significantly improved wear resistance, reducing the wear rate to 1.89 × 10⁻⁴ mm³/(N × m). The optimised coating exhibited an average coefficient of friction of 0.578 ± 0.093 and a wear rate of 1.03 × 10⁻⁴ mm³/(N × m). Instrumented indentation revealed a hardness of 1049.1 ± 43.4 HV and a Young’s modulus of 215.9 ± 8.5 GPa. The wear mechanism was predominantly abrasive–adhesive, whilst the wear rate of the 100Cr6 counter-body remained low at 1.20 × 10⁻⁵ mm³/(N × m). The results obtained demonstrate that appropriate optimisation of detonation spraying parameters enables the formation of dense Ni–Cr–Fe–B–Si–C coatings with superior mechanical and tribological properties, making them promising candidates for wear-resistant engineering applications. Full article

High-velocity oxy-fuel (HVOF)-sprayed NiCrBSi coatings containing 0, 10, 30, and 50 wt.% WC-Co were evaluated on AZ91D magnesium alloy to determine how the discrete reinforcement level affects surface topography, phase constitution, Vickers microhardness, dry-sliding friction, mass loss, and wear-track microchemistry. As-sprayed surfaces were characterized by three-dimensional profilometry; coating cross-sections and worn surfaces by optical microscopy and SEM/EDS; phase constitution by XRD; and mechanical response by HV_0.1 indentation. Dry-sliding tests were performed at 10, 30, and 50 N over 100–1000 m. Increasing WC-Co content raised Sa from 8.8 ± 0.3 to 13.0 ± 0.5 µm and Vickers microhardness from 776 ± 4 to 959 ± 5 HV_0.1. XRD indicated a γ-Ni-based matrix containing boride/carbide constituents, while WC, W₂C, and Co became increasingly prominent in the reinforced coatings. Boride assignments are based on diffraction evidence, whereas B and C EDS signals were treated semi-quantitatively. The 50 wt.% WC-Co coating exhibited the lowest mass loss and mean coefficient of friction at every load. Its mean friction coefficients were 0.31, 0.35, and 0.41 at 10, 30, and 50 N, corresponding to reductions of 40.1%, 38.9%, and 36.2% relative to AZ91D. At 1000 m, its mass-normalized wear rate indices were 9.0 × 10⁻⁴, 4.0 × 10⁻⁴, and 5.3 × 10⁻⁴ mg N⁻¹ m⁻¹, respectively. Post-wear mapping showed the largest field-scale W-Co-rich fraction in the 50 wt.% coating; however, isolated spectra containing more than 94 wt.% Mg are compatible with local coating penetration/substrate exposure and/or Mg-rich debris. The 50 wt.% composition therefore provided the best combined response among the four tested levels, while intermediate compositions are required to identify a continuous-composition optimum. Full article

This study investigates the microstructural evolution, mechanical performance, and electrochemical corrosion behavior of nanocrystalline boride layers formed on an Fe-20Cr-5Al ferritic alloy by pack boriding at 950 °C for 4 h. X-ray diffraction (XRD) and scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDS) analyses confirmed the formation of a hierarchical boride layer approximately 80–85 μm in thickness, consisting of orthorhombic (Fe,Cr)B and tetragonal (Fe,Cr)₂B phases at the surface and (Fe,Cr)₂₃(C,B)₆ carboboride phases in the diffusion zone, the latter attributed to the carbon push-ahead mechanism. Rietveld refinement yielded a quantitative phase fraction of 51.9 wt.%. (Fe,Cr)B, 46.1 wt.% Fe₂B, and 2.0 wt.% (Fe,Cr)₂₃(C,B)₆, with a theoretical boride layer density of 7.40 g cm⁻³. Williamson–Hall analysis yielded an average crystallite size of 50.7 nm and a microstrain of 1.686 × 10⁻³, confirming the nanocrystalline character of the boride phases. Mechanical evaluation revealed a ~9-fold increase in surface hardness in Fe20Cr5Al-B relative to Fe20Cr5Al, reaching 1854 HV (18.18 GPa). Tribological testing demonstrated an ~18-fold reduction in wear rate (from 3.29 × 10⁻⁴ to 1.82 × 10⁻⁵ mm³/m) and a 14.5% reduction in the coefficient of friction (0.76→0.65), confirming the effectiveness of the boride layer as a tribological barrier. However, electrochemical analyses in 5 wt.% H₂SO₄ revealed a paradoxical deterioration in corrosion resistance: despite a noble shift in E_corr from −0.459 to −0.295 V, the corrosion rate increased ~4-fold (from 9.67 × 10⁻³ to 3.83 × 10⁻² mm/year), driven by Al-repulsion-induced passive film loss and micro-galvanic cell formation through micro-crack and porosity networks. These findings emphasize that while pack-boriding is highly effective for tribological enhancement of FeCrAl alloys, minimizing boride layer defects is essential to achieve concurrent corrosion protection in acidic environments. Full article

W₂CoB₂ is a ternary boride-based cermet. Featuring high hardness, high melting point, excellent wear resistance and corrosion resistance, it has been widely used in numerous industrial fields such as cutting processing, surface protection and mold manufacturing. Toughening is a major issue that needs to be addressed for ceramic materials. In this study, the toughness of cermets is improved by the combined addition of CNTs and La₂O₃. The W₂CoB₂ cermets were fabricated via vacuum sintering, and the effects of CNTs and La₂O₃ on the microstructure and properties of the cermets were systematically investigated. The microstructure and phase composition of the specimens were characterized using a SEM and X-ray diffractometry (XRD), respectively. The density of the specimens was measured by the Archimedes drainage method. A Vickers microhardness tester was employed to determine the microhardness and fracture toughness of the specimens. The transverse rupture strength was tested using an electronic universal testing machine, while the wear resistance was evaluated via a wear tester. The results indicate that the addition of either CNTs or La₂O₃ can refine the grain size and improve the toughness of the cermets. The simultaneous incorporation of CNTs and La₂O₃ further enhances grain refinement and mitigates the issue of uneven dispersion of CNTs in the specimens. When 0.5 wt.% CNTs and 0.3 wt.% La₂O₃ are added, the specimen exhibits the following optimal properties: a density of 9.33 g/cm³, a microhardness of 2046 HV_0.5, a fracture toughness of 12.36 MPa·m^1/2, a transverse rupture strength of 985 MPa, and a friction coefficient reduced to 0.36. Synergistic addition of CNTs and La₂O₃ achieves grain refinement and uniform microstructure, which significantly improves the friction and wear performance and service stability of the cermet. The material retains high hardness and wear resistance, accompanied by enhanced comprehensive mechanical and service properties. Further studies will aim to cut costs while preserving material performances, facilitating its industrial application. Full article

Nickel boride compounds have attracted considerable attention in the field of electrocatalysis due to their unique electronic structures and excellent chemical stability. However, the difficulty in obtaining single-phase products under traditional experimental conditions hinders the analysis of their intrinsic catalytic performance. Herein, we report the successful synthesis of three single-phase nickel boride compounds (Ni₂B, Ni₄B₃, and NiB) via a high pressure and high temperature (HPHT) method. The configurations of B in their respective structures are distinct. Their electrocatalytic hydrogen evolution reaction (HER) performance was systematically evaluated. The results demonstrate that NiB exhibits the lowest overpotentials of 182 mV (in acidic electrolyte) and 234 mV (in alkaline electrolyte) at a current density of 10 mA cm⁻², accompanied by the smallest Tafel slope, the lowest electron transfer resistance (R_ct), and the largest double-layer capacitance (C_dl). This superior HER activity is primarily attributed to the presence of strong B-B covalent bonds in NiB, which weaken the Ni-B interaction and reduce the orbital hybridization between Ni 3d and B 2p orbitals. Consequently, the hydrogen adsorption intermediate (H*) achieves the optimal adsorption strength on the NiB surface. This work provides a novel insight for the design of high-performance transition metal boride electrocatalysts. Full article

Boriding is a widely used thermochemical treatment to improve surface hardness and wear resistance in steels used in demanding mechanical applications. However, boronizing processes using new boron paste increase costs and generate waste, creating a need for more sustainable alternatives. In this context, the reuse of dehydrated boron paste has proven effective in the formation of Fe₂B layers on AISI 9254 steel. In this study, AISI 9254 steel was boronized using reused dehydrated boron paste at 1173 K, 1223 K, and 1273 K for 3600, 7200, 10,800, and 14,400 s. Optical microscopy revealed layer thicknesses ranging from 16.07 $\mathsf{\mu }\mathrm{m}$ to 69.35 $\mathsf{\mu }\mathrm{m}$ X-ray diffraction confirmed the formation of single-phase Fe₂B, while EDS indicated elemental redistribution within the layer. The Vickers microhardness profile characterized the mechanical behavior, and the adhesion force showed HF1-HF2 ratings. The activation energy for boron diffusion in Fe₂B was calculated at 106.567 kJ ${\mathrm{mol}}^{-1}$. Auto-affine analysis verified the fractal nature of interface growth, with a scale $\omega \left(d\right)$ according to $\omega \left(\delta \right)\sim {\delta }^H$. These results confirm that reused paste allows the formation of Fe₂B layers, supporting sustainable boronization strategies with controlled interfacial evolution. Full article

Boriding is widely used in various industries due to the unique combination of high mechanical, corrosion, and tribological properties of boride layers formed on the surface of steel components. In this work, the powder boriding of 40 Kh steel was investigated in a closed capsule using a specially prepared powder mixture containing boric acid as the boron source. Boriding was carried out in a furnace at 850, 900, and 950 °C for 10 h. The resulting boride layers were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD), which confirmed that all three coatings consist exclusively of the Fe₂B phase. It was found that with increasing temperature, the thickness of the boride layer increased from 68 μm to 160 μm. The tribological properties were evaluated using the pin-on-disk method, followed by analysis of the wear surfaces using optical profilometry and SEM. The most significant reduction in wear rate was observed at 850 °C, where the wear decreased by a factor of 4.2—from 8.471 × 10⁻⁵ to 1.999 × 10⁻⁵ mm³·N⁻¹·m⁻¹. In addition, the hardness increased fivefold compared to the untreated material. These results demonstrate the high potential of diffusion boriding for enhancing the operational performance of parts subjected to severe wear conditions. Full article

ZrB₂-HfB₂ composites allow us to obtain materials characterized by the high chemical resistance characteristic of HfB₂ while reducing density and improving sinterability due to the presence of ZrB₂. Since boride composites are difficult-to-sinter materials. One way to achieve high density during sintering is to add phases that activate mass transport processes and, after sintering, remain as composite components that do not degrade and even improve some properties of the borides. The following paper is a comprehensive review of the effects of various and the most commonly used sintering aids, i.e., SiC, B₄C, WC, MoSi₂, and CrSi₂, on the thermo-chemical properties of the ZrB₂-HfB₂ composites. High-density composites with a complex phase composition dominated by (Zr,Hf)B₂ solid solutions were obtained using a hot pressing method. The tests showed differences in the properties of the composites due to the type of sintering additives used. From the point of view of the thermo-chemical properties, the best additive was silicon carbide. The composites containing SiC, when compared to the initial, pure borides, were characterized by high thermal conductivity λ (80–150 W/m·K at 20–1000 °C), a significantly reduced thermal expansion coefficient (CTE ~6.20 × 10⁻⁶ 1/K at 20–1000 °C), and considerably improved oxidation resistance (up to 1400 °C). Full article

The improvement of densification and fracture toughness in high-entropy ceramics is important to realizing their practical applications. In this study, SiC whiskers and metal Ni additions were incorporated to solve these problems of high-entropy boride ceramics. The influence of sintering temperatures (1450–1650 °C) on the densification, microstructure, hardness, fracture toughness, and bending strength of (M_0.2Ti_0.2Ta_0.2V_0.2Nb_0.2)B₂-SiC_w-Ni (M=Hf, Zr, or Cr) composites prepared by hot-pressing technology were studied. Results showed that when SiC whiskers and metal Ni additions were used as additives, increasing sintering temperatures from 1450 to 1600 °C promoted the densification of high-entropy boride ceramics. This was mainly attributed to the high sintering driving force. However, when the temperature further increased to 1650 °C, their densification behavior decreased. At a sintering temperature of 1600 °C, these high-entropy borides ceramics all had the highest densification behavior, leading to their high hardness and fracture toughness. The highest relative density was 96.3%, the highest hardness was 22.02 GPa, and the highest fracture toughness was 13.25 MPa·m^1/2, which was improved by the co-function of SiC whiskers and plastic metal Ni. Meanwhile, in the adopted sintering temperature range of 1450 to 1650 °C, the highest bending strength at room temperature of these high-entropy boride ceramics could reach 320.8 MPa. Therefore, this research offers an effective densification, strengthening, and toughening method for high-entropy boride composites at a low sintering temperature. Full article

Transition metal borides have garnered significant research interest due to their versatile properties, including superconductivity and exceptional hardness. This study examines the stable crystal structures of Rhodium-Boron (Rh-B) compounds under high pressure using first-principles structural searching. Beyond the previously known Rh₂B, RhB₂, and RhB₄ phases, three new boron-rich phases—C2/m-RhB₆, Amm2-RhB₆, and Cmca-RhB₈—are identified, each characterized by three-dimensional covalent bonding networks. Their mechanical and thermodynamic stability is validated through elastic property assessments and phonon dispersion calculations. Surprisingly, these phases exhibit low bulk and shear moduli, ruling them out as candidates for hard materials. The metallic character of these borides is evident from their electronic density of states, which exhibits a sharp peak at the E_F-a signature often associated with superconducting systems. Indeed, our calculations predict T_c values of 8.93 K and 9.36 K for Amm2-RhB₆ and Cmca-RhB₈, respectively, at 100 GPa. Full article

Transition metal-based catalysts designed for efficient urea oxidation reactions (UOR) are essential for hydrogen production via urea-assisted water electrolysis. A series of amorphous nickel–cobalt boride catalysts supported on nickel foam were in situ synthesized via a stepwise chemical deposition method (SCDM). The systematic investigation focused on the relationships between synthesis parameters (deposition cycles, reactant feed ratio), morphological characteristics, and UOR performance. Notably, the optimized Co-NiB@NF catalyst exhibits a porous hierarchical architecture composed of metallic nanoparticles encapsulated by surface-wrinkled nanosheets, forming abundant exposed active sites. Electrochemical measurements demonstrate that this catalyst requires a low cell potential of 1.29 V to achieve a current density of 10 mA cm⁻². Moreover, it maintains 83% of the initial current density after 10 h of continuous electrolysis, highlighting its superior durability. The structural-property relationship revealed here provides valuable insights into the rational design of efficient amorphous boride catalysts for urea-assisted hydrogen production. Full article

The global energy shortage and the gradual depletion of lithium resources have become increasingly prominent. Improving the energy density of lithium-based secondary batteries and developing other high-performance alkali-metal secondary batteries have become the research focus. In this study, two-dimensional (2D) hexagonal metal borides (h-MBenes) are investigated as ordered alkali metal adsorption substrates for alkali-metal-based battery anode materials using density functional theory (DFT). Twelve thermodynamically stable h-MBenes are screened out from thirty-three structures, and their excellent stability and metallic electronic characteristics are confirmed. The ordered multilayered growth in alkali metal adsorption is found to depend on two factors: low lattice mismatching and dynamic matching of the work function. In particular, Mg/Al/V-based h-MBenes exhibit excellent lithium lattice matching (<3.35% mismatch), enabling layer-by-layer hexagonal (001) Li growth for ≥5 layers. They have ultrahigh lithium capacities (2170–3818 mAh·g⁻¹), low migration barriers (0.01–0.05 eV), and low voltages (0.003–0.714 V). Mg/Y-based h-MBenes enable three Na layers’ adsorption with a capacity of 1717/605 mAh·g⁻¹, and Al₂B₂ achieves a 472 mAh·g⁻¹ potassium storage capacity, respectively. Due to the orderly multilayered growth mechanism, Mg/Al/V-based h-MBenes show great potential as high-safety and ultrahigh-capacity alkali-metal battery anode materials. Full article

Laser cladding technology is an effective method for producing wear-resistant coatings on damaged substrates, improving both wear and corrosion resistance, which extends the service life of components. However, the fabrication of hard and brittle materials is highly susceptible to the problem of cracking. Using gradient transition layers is an effective strategy to mitigate the challenge of achieving crack-free laser-melted wear-resistant coatings. This study presents the cracking issue of laser cladding Ni60B (NiCrBSi) coatings on 38CrMoAl (18CrNiMo7-6) steel by designing a gradient transition layer infused with varying amounts of Ni powder. We examine how different levels of Ni doping in the transition layer influence the fabrication of the Ni60B coating. The results indicate that the cracking mechanism of Ni60B is primarily due to the brittleness and hardness of the fusion cladding layer, which can result in cold cracks under residual tensile stress. Increasing the nickel content in the transition layer reduces the difference in thermal expansion coefficients between the cladding layer and the substrate. Additionally, the nickel in the transition layer permeates the cladding layer due to the laser remelting effect. The physical phase within the cladding layer transitions from the initial CrB, M₇C₃, and γ-Ni solid solution to γ-Ni solid solution and Ni-B-Si eutectic, with a small amount of boride and carbide hard phases. As the nickel doping in the transition layer increases, the proportion of the toughness phase dominated by Ni elements significantly rises, leading to a decrease in the hardness of the fused cladding layer. However, the average hardness of the fusion cladding layer in crack-free samples was measured at 397.5 ± 5.7 HV_0.2, which is 91% higher than that of the substrate. Full article

In this paper, quantitative two-dimensional (2-D) phase-field simulations were performed to gain insight into the effects of B and Nb for Al-Ti-Nb balanced-ratio GH4742 alloys. The microstructure evolution during the precipitation process was simulated using the MICRESS (MICRostructure Evolution Simulation Software) package developed in the formalism of the multi-phase field model. The coupling to CALPHAD (CALculation of PHAse Diagram) thermodynamic databases was realized via the TQ interface. The morphological evolution, concentration distribution, and thermodynamic properties were extensively analyzed. It is indicated that a higher Nb content contributes to a faster precipitation rate and higher amounts and the smaller precipitate size of the γ′ phase, contributing to better mechanical properties. The segregation of the W element in γ′ precipitate due to its sluggish diffusion effect has also been observed. Higher temperatures and lower B contents accelerate the dissolution of boride and reduce the precipitation of borides. With the increased addition of B, the formation of borides may have a pinning effect on the grain boundary to hinder the kinetic process. In addition, borides are prone to precipitate around the interface rather than in the bulk phase. Once the M₃B₂ borides nucleate, they grow in the consumption of γ′ phases. Full article

The surface of 17-4PH martensitic stainless steel was laser-cladded with Ni60 and Ni60+nano-WC composites and a comprehensive investigation was conducted of the microstructure and wear mechanism. The findings demonstrate that despite the added nano-WC particles being fused and dissolved during laser cladding, they still lead to a reduction in grain size and a decrease in crystallographic orientation strength. Furthermore, the dissolution of nano-WC makes the lamellar M₂₃C₆ carbides transform into a rod or block morphology, and leads to the CrB borides becoming finer and more evenly dispersed. This microstructural evolution resulted in a uniform increase in hardness and wear resistance, effectively preventing crack formation. When the nano-WC addition increased to 20 wt.%, there was a 27.12% increase in microhardness and an 85.19% decrease in volume wear rate compared to that of the pure Ni60 coating. Through analysis of the microstructure and topography of wear traces, it can be inferred that as the nano-WC addition increased from 0 wt.% up to 20 wt.%, there was a gradual transition from two-body abrasive wear to three-body abrasive wear, ultimately resulting in adherent wear. Full article