Search Results (1,341)

This study focuses on realistic modeling of forming load and microstructural evolution during hot metal extrusion, emphasizing the effects of friction models and hydraulic press behavior. Rather than merely predicting load magnitudes, the objective is to replicate actual press operation by integrating a load limit response into finite element modeling (FEM). By applying Coulomb and shear friction models under both constant and hydraulically controlled press conditions, the resulting impact on grain size evolution during deformation is examined. The hydraulic press simulation features a maximum load threshold that dynamically reduces die velocity once the limit is reached, unlike constant presses that sustain velocity regardless of load. P91 steel is used as the material system, and the predicted grain size is validated against experimentally measured data. Incorporating hydraulic control into FEM improves the representativeness of simulation results for industrial-scale extrusion, enhancing microstructural prediction accuracy, and ensuring forming process reliability. Full article

UNS S41003 is a low-cost, low-carbon ferritic stainless steel that exhibits moderate corrosion resistance but limited mechanical performance. This study evaluates the electrochemical behavior of untreated and thermomechanically treated UNS S41003 samples. Corrosion tests were conducted in acidic electrolytes with varying pH to simulate aggressive environments relevant to industrial and structural applications where exposure to acidic media and corrosive pollutants occurs. Potentiodynamic polarization curves for all samples displayed passive regions typically associated with protective oxide film formation; however, localized pitting corrosion was detected post-test. Electrochemical impedance spectroscopy indicated a marked decrease in corrosion resistance as pH decreased. The corrosion resistance of the treated alloy remained comparable to that of the untreated condition, indicating that thermomechanical processing did not detrimentally affect passivity or corrosion performance under the tested conditions. The literature suggests that the applied treatment enhances mechanical properties, supporting the potential use of this alloy in structural components subjected to acidic environments requiring a balance of mechanical strength and corrosion resistance. Full article

This study systematically investigated the corrosion behavior of P110 pipeline steel in simulated carbonated concrete environments through a combination of electrochemical testing and multiphysics simulation, with particular focus on revealing the evolution mechanisms of corrosion product deposition and ion concentration distribution under half crevice structures, providing new insights into localized corrosion in concealed areas. Experimental results showed that no significant corrosion occurred on the P110 steel surface in uncarbonated simulated pore solution. Conversely, the half crevice structure significantly promoted the development of localized corrosion in carbonated simulated pore solution, with the most severe corrosion and substantial accumulation of corrosion products observed at the crevice mouth region. COMSOL Multiphysics simulations demonstrated that this phenomenon was primarily attributed to local enrichment of Cl⁻ and H⁺ ions, leading to peak corrosion current density, and directional migration of Fe²⁺ ions toward the crevice mouth, causing preferential deposition of corrosion products at this location. This “electrochemical acceleration-corrosion product deposition” multiphysics coupling analysis of corrosion product deposition patterns within crevices represents a new perspective not captured by traditional crevice corrosion models. The established ion migration-corrosion product deposition model provides new theoretical foundations for understanding crevice corrosion mechanisms and predicting the service life of buried concrete pipelines. Full article

Machining chromium–nickel alloy steel is challenging due to its material properties, such as high strength and toughness. These properties often lead to tool damage and degradation of tool life, which overall impacts the production time, cost, and quality of the product. Therefore, it is essential to investigate early signs of tool damage to determine the effective machining conditions for chromium–nickel alloy steel, thereby increasing tool life and improving product quality. In this study, the early signs of tool wear were observed in a physical vapor deposition (PVD) carbide-coated tool (Seco Tools, Björnbacksvägen, Sweden) during the machining of X5CrNi18-10 steel under both dry and wet conditions. A finish turning operation was performed on the outer diameter (OD) of the workpiece with a 0.4 mm nose radius tool. At the early stage, the tool was examined from the functional side (f–side) and the passive side (p–side). The results indicate that dry machining leads to increased coating removal, more heat generation, and visible damage, such as pits and surface scratches. By comparison, wet machining helps reduce heat and wear, thereby improving tool life and machining quality. These findings suggest that a coolant must be used when machining chromium–nickel alloy steel with a PVD carbide-coated tool. Full article

Although cemented carbides have been manufactured by the powder metallurgy (P/M) technology for over a century now, systematic developmental efforts are still underway. In the present study, tool life improvements in metal grooving applications are the key objective. Four PVD-coated cemented carbides compositions, dedicated to groove steel, stainless steel, cast iron, and aluminium alloys, have been newly designed, along with their manufacturing conditions. Physical, mechanical and chemical characteristics—such as sintered density, modulus of elasticity, hardness, fracture toughness, WC grain size, and the chemical composition of the substrate material, as well as the chemical composition, microhardness, structure, and thickness of the coatings—have been studied. A series of grooving tests have also been conducted to assess whether modifications to the thus far marketed tool materials, tool geometries, and coatings can improve cutting performance. In order to compare the laboratory and application properties of the investigated materials with currently produced by reputable companies, commercial inserts have also been tested. The experimental results obtained indicate that the newly developed grooving inserts exhibit excellent microstructural characteristics, high hardness, fracture toughness, and wear resistance and that they show slightly longer tool life compared to the commercial ones. Full article

Background/Objectives: Maxillofacial silicone prostheses’ long-term color stability remains a challenge. This study aimed to evaluate and compare the color stability of conventional and digital maxillofacial silicone elastomers mixed with nano-sized antimicrobial additives (ZnO nanoparticles and chlorhexidine salt-CHX) at various concentrations over a 10-week period. Methods: A total of nine groups (n = 10) of maxillofacial silicone elastomers were prepared. These included a control group (no additives), conventionally pigmented silicone, digitally pigmented silicone (Spectromatch system), and silicone mixed with ZnO or CHX at 1%, 3%, and 5% by weight. Specimens were fabricated in steel molds and cured at 100 °C for 1 h. Color measurements were performed at baseline and after 1, 4, 6, and 10 weeks using a Minolta Chroma Meter (CIELAB system, ΔE₀₀ formula). Data were analyzed using two-way ANOVA and Tukey HSD post hoc tests (α = 0.05). Results: Color changes (ΔE₀₀) ranged from 0.74 to 2.83 across all groups. The conventional pigmented silicone group showed the highest color difference (ΔE₀₀ = 2.83), while the lowest was observed in the ZnO 1% group (ΔE₀₀ = 0.74). Digital silicone and all antimicrobial-modified groups exhibited acceptable color stability (ΔE₀₀ < 3.1). Time significantly affected color difference, with the largest change occurring during the first four weeks (p < 0.05), followed by stabilization. Regression analysis confirmed high color stability over time for all groups except the conventional pigmented group. Conclusions: This is one of the first studies to directly compare digital and conventional pigmentation methods combined with nano-antimicrobials in maxillofacial silicones. Maxillofacial silicone elastomers mixed with up to 5% ZnO or CHX maintained acceptable color stability over 10 weeks. Digital pigmentation is similar to conventional methods. The incorporation of nano-antimicrobials offers significant microbial resistance and improved color retention. Full article

Steel pickling sludge serves as a valuable iron source for synthesizing Fe-based catalysts in heterogeneous advanced oxidation processes (AOPs). Here, MoS₂@CoFe₂O₄ catalyst derived from steel pickling sludge was prepared via a facile solvothermal approach and utilized to activate peroxymonosulfate (PMS) for tetracycline hydrochloride (TCH) degradation. Comprehensive characterization using scanning electron microscopy (SEM)-energy dispersive spectrometer (EDS), X-ray photoelectron spectroscopy (XPS), and X-ray diffraction (XRD) confirmed the supported microstructure, composition, and crystalline structure of the catalyst. Key operational parameters—including catalyst dosage, PMS concentration, and initial solution pH—were systematically optimized, achieving 81% degradation efficiency within 30 min. Quenching experiments and electron paramagnetic resonance (EPR) analysis revealed SO₄^∙− as the primary oxidative species, while the catalyst maintained high stability and reusability across cycles. TCH degradation primarily occurs through hydroxylation, decarbonylation, ring-opening, and oxidation reactions. This study presents a cost-effective strategy for transforming steel pickling sludge into a high-performance Fe-based catalyst, demonstrating its potential for practical AOP applications. Full article

Spot-welding joints are widely used in modern industries, and their fatigue life is crucial for the safety and reliability of structures. This paper proposes a method for predicting the fatigue life of spot-welding joints by integrating traditional structural stress methods and machine learning algorithms. Systematic fatigue tests were conducted on Q&P980 steel spot-welding joints to investigate the influence of the galvanized layer on fatigue life. It was found that the galvanized layer significantly reduces the fatigue life of spot-welding joints. Further predictions of fatigue life using machine learning algorithms, including Random Forest, Artificial Neural Networks, and Gaussian Process Regression, demonstrated superior prediction accuracy and generalization ability compared to traditional structural stress methods. The Random Forest algorithm achieved an R² value of 0.93, with lower error than traditional methods. This study provides an effective tool for the fatigue life assessment of spot-welding joints and highlights the potential application of machine learning in this field. Full article

The pull-back method for determining dynamic tensile strength assumes one-dimensional stress wave propagation and material homogeneity. This study validates these assumptions for unidirectional reinforced concrete (UDRC) through experiments and numerical simulations. Split Hopkinson pressure bar tests were conducted on plain concrete, plain UDRC, and deformed UDRC specimens containing a central 6 mm steel bar. Ultra-high-speed digital image correlation at 500,000 fps enabled precise local strain rate measurements (3 s⁻¹ to 55 s⁻¹) at fracture locations. Finite element simulations revealed that while reinforcement induces localized multi-axial stresses near the steel–concrete interface, the bulk concrete maintains predominantly uniaxial stress conditions. Experimental results showed less than 1% variation in pull-back velocity between specimen types. Statistical analysis confirmed a unified strain rate-strength relationship: ${\sigma }_{\mathrm{spall}}=4.1+4.7{log}_{10}\left(\dot{\epsilon }\right)$$\mathrm{M}\mathrm{Pa}$, independent of reinforcement configuration (ANCOVA: $p=0.2182$ for interaction term). The dynamic tensile strength is governed by concrete matrix properties rather than reinforcement type. These findings are the first to experimentally and numerically validate the pull-back method’s applicability to UDRC systems, establishing that dynamic tensile failure is matrix-dominated and enabling simplified one-dimensional analysis for reinforced concrete under impact. Full article

This paper, based on the Johnson–Cook damage model, investigates the damage mechanism of high-strength steel tailor welded blanks (TWBs) (Usibor1500P and Ductibor500) during the forming process. Initially, specimens with varying notch sizes were designed and fabricated to perform uniaxial tensile tests to determine their mechanical properties. Then, the deformation process of the notched specimens was simulated using finite element software, revealing the distribution and variation of stress triaxiality at the fracture surface. By combining both experimental and simulation data, the parameters of the Johnson–Cook (J–C) damage model were calibrated, and the effects of temperature, strain rate, and stress triaxiality on material fracture behavior were further analyzed. Based on finite element analysis, the relevant coefficients for stress triaxiality, strain rate, and temperature were systematically calibrated, successfully establishing a J–C fracture criterion for TWB welds, Usibor1500P, and Ductibor500 high-strength steels. Finally, the calibrated damage model was further validated through the Nakajima-type bulge test, and the simulated Forming Limit Diagram (FLD) closely matched the experimental data. The results show that the analysis based on the J–C damage model can effectively predict the fracture behavior of tailor welded blanks (TWB) during the forming process. This study provides reliable numerical predictions for the damage behavior of high-strength steel laser-customized welded sheets and offers a theoretical basis for engineering design and material performance optimization. Full article

Diverging from conventional dephosphorization approaches, this study employs a novel pre-reduction and smelting separation (PR-SS) to efficiently co-recover iron and phosphorus from high-phosphorus oolitic iron ore, directly yielding Fe–P alloy, and the Fe–P alloy shows potential as feedstock for high-phosphorus weathering steel or wear-resistant cast iron, indicating promising application prospects. Using oolitic magnetite concentrate (52.06% Fe, 0.37% P) as feedstock, optimized conditions including pre-reduction at 1050 °C for 2 h with C/Fe mass ratio of 2, followed by smelting separation at 1550 °C for 20 min with 5% coke, produced a metallic phase containing 99.24% Fe and 0.73% P. Iron and phosphorus recoveries reached 99.73% and 99.15%, respectively. EPMA microanalysis confirmed spatial correlation between iron and phosphorus in the metallic phase, with undetectable phosphorus signals in vitreous slag. This evidence suggests preferential phosphorus enrichment through interfacial mass transfer along the pathway of the slag phase to the metal interface and finally the iron matrix, forming homogeneous Fe–P solid solutions. The phosphorus migration mechanism involves sequential stages: apatite lattice decomposition liberates reactive P₂O₅ under SiO₂/Al₂O₃ influence; slag–iron interfacial co-reduction generates Fe₃P intermediates; Fe₃P incorporation into the iron matrix establishes stable solid solutions. Full article

Alkali-activated building materials have attracted the interest of many researchers due to their low cost and eco-efficiency. Different binders with different chemical compositions can be used for their production, so the reaction mechanism can become complex and the results of studies can vary widely. In this work, several alkali-activated mortars based on marginal by-products as binders, such as high calcium fly ash and ladle furnace slag, are investigated. Their mechanical (flexural and compressive strength, ultrasonic pulse velocity, and modulus of elasticity) and physical (porosity, absorption, specific gravity, and pH) properties were determined. After evaluating the mechanical performance of the mortars, the optimum mixture containing fly ash, which reached 15 MPa under compression at 90 days, was selected for the production of precast compressed slabs. Steel or glass fibers were also incorporated to improve their ductility. To reduce the density of the slabs, 60% of the siliceous sand aggregate was also replaced with recycled polyethylene terephthalate (PET) plastic aggregate. The homogeneity, density, porosity, and capillary absorption of the slabs were measured, as well as their flexural strength and fracture energy. The results showed that alkali activation can be used to improve the mechanical properties of weak secondary binders such as ladle furnace slag and hydrated fly ash. The incorporation of recycled PET aggregates produced slabs that could be classified as lightweight, with similar porosity and capillary absorption values, and over 65% achieved strength compared to the normal weight slabs. Full article

The microstructure and mechanical properties of welded joints of API 5L X-52 steel plates cladded with AISI 316L-Si austenitic stainless steel were evaluated. The gas metal arc welding process with pulsed arc (GMAW-P) and controlled arc oscillation were used to join the bimetallic plates. After the root welding pass, buttering with an ERNiCrMo-3 filler wire was performed and multi-pass welding followed using an ER70S-6 electrode. The results obtained by optical and scanning electron microscopy indicated that the shielding atmosphere, welding parameters, and electric arc oscillation enabled good arc stability and proper molten metal transfer from the filler wire to the sidewalls of the joint during welding. Vickers microhardness (HV) and tensile tests were performed for correlating microstructural and mechanical properties. The mixture of ERNiCrMo-3 and ER70S-6 filler materials presented fine interlocked grains with a honeycomb network shape of the Ni–Fe mixture with Ni-rich grain boundaries and a cellular-dendritic and equiaxed solidification. Variation of microhardness at the weld metal (WM) in the middle zone of the bimetallic welded joints (BWJ) is associated with the manipulation of the welding parameters, promoting precipitation of carbides in the austenitic matrix and formation of martensite during solidification of the weld pool and cooling of the WM. The BWJ exhibited a mechanical strength of 380 and 520 MPa for the yield stress and ultimate tensile strength, respectively. These values are close to those of the as-received API 5L X-52 steel. Full article

Soil acidification, salinization, and heavy metal pollution pose serious threats to global food security and sustainable agricultural development. Biochar, with its high porosity, large surface area, and abundant functional groups, can effectively improve soil properties. However, due to variations in feedstocks and pyrolysis conditions, it may contain potentially harmful substances. Industrial wastes such as fly ash, steel slag, red mud, and phosphogypsum are rich in minerals and show potential for soil improvement, but direct application may pose environmental risks. The co-application of biochar with these wastes can produce composite amendments that enhance pH buffering capacity, nutrient availability, and pollutant immobilization. Therefore, a review of biochar-industrial waste composites as soil amendments is crucial for addressing soil degradation and promoting resource utilization of wastes. In this study, the literature was retrieved from Web of Science, Scopus, and Google Scholar using keywords including biochar, fly ash, steel slag, red mud, phosphogypsum, combined application, and soil amendment. A total of 144 articles from 2000 to 2025 were analyzed. This review summarizes the physicochemical properties of biochar and representative industrial wastes, including pH, electrical conductivity, surface area, and elemental composition. It examines their synergistic mechanisms in reducing heavy metal release through adsorption, complexation, and ion exchange. Furthermore, it evaluates the effects of these composites on soil health and crop productivity, showing improvements in soil structure, nutrient balance, enzyme activity, and metal immobilization. Finally, it identifies knowledge gaps as well as future prospects and recommends long-term field trials and digital agriculture technologies to support the sustainable application of these composites in soil management. Full article

Researchers conduct experiments to discover factors influencing the experimental subjects, so the experimental design is essential. The response surface methodology (RSM) is a special experimental design used to evaluate factors significantly affecting a process and determine the optimal conditions for different factors. The relationship between response values and influencing factors is mainly established using regression analysis techniques. These equations are then used to generate contour and surface response plots to provide researchers with further insights. The impact of regression techniques on response surface methodology (RSM) model building has not been studied in detail. This study uses complete regression techniques to analyze sixteen datasets from the literature on semiconductor manufacturing, steel materials, and nanomaterials. Whether each variable significantly affected the response value was assessed using backward elimination and a t-test. The complete regression techniques used in this study included considering the significant influencing variables of the model, testing for normality and constant variance, using predictive performance criteria, and examining influential data points. The results of this study revealed some problems with model building in RSM studies in the literature from three engineering fields, including the direct use of complete equations without statistical testing, deletion of variables with p-values above a preset value without further examination, existence of non-normality and non-constant variance conditions of the dataset without testing, and presence of some influential data points without examination. Researchers should strengthen training in regression techniques to enhance the RSM model-building process. Full article