Search Results (3,192)

Recently, there has been growing interest in the synthesis of thin films made from metal diboride. Boron forms binary compounds with a wide variety of metals. These diborides are refractory, ultra-hard solids characterized by high melting points, exceptional thermal stability, and pronounced chemical inertness. This work describes the preparation of metal diboride coatings made of binary ZrHfB₂, HfTiB₂ and ZrTiB₂ as well as ternary HfZrTiB₂. In the low-pressure chemical vapor deposition (LPCVD) process used, MeCl₄ (Me = Zr, Hf, Ti), BCl₃, H₂, and Ar were employed at deposition temperatures of 850 °C. The coatings were characterized with respect to phase composition, crystal structure, hardness, residual stress and wear behavior. A hardness of 38 GPa was achieved with a modulus of elasticity of around 700 GPa and a moderate tensile residual stress of approx. 400 MPa was obtained for the ternary alloys as well as 44 to 633 MPa for the binary alloys, respectively. The phase composition and structure of the deposited layers were examined using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) analysis. The investigations revealed dense, crack-free, well defined crystalline single-phase diboride layers with grain sizes of 0.1–1.5 µm. A TiN interlayer applied prior to diboride deposition significantly enhanced adhesion between the diboride coating and hard-metal inserts. Scratch test measurements revealed critical loads of approximately 90 N. In the wear test milling against TiAl6V4, the HfZrTiB₂ coating (with ZrCl₄:HfCl₄:TiCl₄ = 1:2:1) demonstrated the best tool life with ~15% improvement over the state-of-the-art CVD TiB₂ reference coating using a single cutting condition. The tool life for the ZrTiB₂ coating was 20% below the tool life of the reference coating. Full article

This study investigates the hydrogen embrittlement susceptibility of laser melting deposition (LMD)-produced Ti-6Al-4V alloy with different build orientations (0°, 45°, 90°) through electrochemical hydrogen charging, slow strain rate testing, and microstructural characterization. Ti-6Al-4V alloys are widely used in marine and offshore engineering, where cathodic protection and corrosion reactions can generate hydrogen, leading to hydrogen ingress and potential embrittlement. Results show that prolonged hydrogen charging induces hydride formation, α-phase fragmentation, and β-phase dissolution, significantly degrading corrosion resistance and mechanical properties. Hydrogen embrittlement susceptibility exhibits notable anisotropy: elongation reductions for 0°, 45°, and 90° specimens are 40.1%, 40.8%, and 29.4%, respectively. The relatively superior resistance observed in the 90° orientation may be associated with its single-layer structure and more uniform dimple distribution. In contrast, the multilayer interfaces in other orientations are likely to serve as preferential sites for hydrogen accumulation, which may contribute to the increased embrittlement susceptibility. This research reveals the failure mechanism of LMD Ti-6Al-4V in hydrogen environments and supports its application in marine engineering. Full article

The instantaneous contact zone in robotic abrasive belt grinding involves highly coupled thermo-mechanical interactions between abrasive grains and the workpiece material. Acoustic Emission (AE) signals generated during this process are inherently nonlinear and nonstationary, posing challenges for accurate process monitoring and mechanistic understanding. To address this, this study introduces an innovative AE signal processing framework designed to elucidate the robotic grinding mechanism for Ti-6Al-4V (TC4) titanium alloy. An improved Completely Complementary Ensemble Empirical Mode Decomposition (CCEEMD) algorithm, building upon Empirical Mode Decomposition (EMD), is developed to precisely extract intrinsic mode functions (IMFs) from raw AE data. Subsequently, a novel denoising algorithm utilizing noise statistical characteristics effectively removes invalid noise from the robotic machining system. Validation through robotic grinding experiments on TC4 workpieces successfully established quantifiable relationships between extracted AE features and the underlying grinding mechanism. Significantly, implementing this methodology contributed to extending the effective service life of a structured abrasive belt by approximately 20% while increasing machining efficiency by approximately 12%. This work presents a novel methodology combining improved CCEEMD and statistical denoising for AE analysis in robotic grinding, providing a robust link between AE signatures and material removal mechanisms, ultimately enabling quantitative process optimization. Full article

Heat-assisted metal spinning comprises incremental forming routes, conventional spinning, shear spinning and flow forming, performed at elevated temperature to increase formability. This review consolidates the main advances of the last fifteen years. It outlines spinning mechanics and the rationale for heating (higher ductility, lower forming forces and microstructure control), then compares global and local heating strategies (furnace, flame, induction, laser and hot-gas convection) in terms of temperature uniformity, industrial practicality, energy efficiency and cost. Key process parameters (spindle speed, feed rate and thickness reduction) are discussed with respect to defect formation, and representative windows for defect mitigation are reported. Progress in modeling is reviewed, including coupled thermo-mechanical finite element simulations, damage/formability prediction and emerging data-driven optimization. The review also summarizes microstructural evolution under heat-assisted conditions, phase transformation, dynamic recrystallisation and grain growth, and its impact on final properties. Across more than 100 studies, evidence shows that robust thermal management can roughly double achievable deformation before failure and enables property tailoring in difficult-to-form alloys (Ni-based alloys, high-strength steels, Al, Mg and Ti). Remaining challenges include reliable in situ temperature measurement/control and improved predictive fidelity of simulations. Future opportunities include digital twins, real-time sensing and adaptive, machine-learning-assisted control. Full article

Hydralloy^® C5, an intermetallic TiMn₂-based alloy, has been manufactured industrially (GfE, Nuremberg) for decades and is used on a large scale for hydrogen storage. During use, the alloy is stored in gas-tight and pressure-resistant storage containers. At the end of service, the alloy is a fine powder with pyrophoric character (Ti- and Zr- content). This significantly hinders the safe extraction from the containers and subsequent recycling of the alloy due to unavoidable reactions with ambient air. The major concern on passivation and maximum permissible content with O/N must be clarified for safe handling in ambient air as well as regarding the pyrometallurgical recycling. Considering this, and in preparation for the opening of real large-scale storage containers, end-of-life Hydralloy C5 was synthesized with two different levels of O (~0.15 and ~1 wt.%) and N (~0.04 and ~8 wt.%) contamination. Vacuum induction melting (VIM) and cold crucible arc melting (CCAM) were chosen as potentially suitable for recycling. The preliminary remelting trials from both aggregates ascertained that the recovery of metal content is not feasible with heavily O/N-contaminated alloys. It is concluded that extreme caution should be taken to minimize contamination when extracting the powdered alloy from the storage containers. Hydralloy C5 with moderate gas impurities (~0.15 wt.% O and ~0.04 wt.% N) can be remelted, on the other hand, in both VIM and CCAM. Contact between molten Hydralloy C5 with selected refractories (Al₂O₃-TiO₂ and CaO-stabilized ZrO₂) in the VIM leads to the formation of a multi-layered transition zone dominated by Ti and Zr. While the Al₂O₃ in the titanium aluminate is infiltrated and reduced by Ti and Zr, the crucible wall made of CaO-stabilized ZrO₂ remains intact. Despite low gas contents, significant losses in melt yield are recognized due to crucible wall deposits from the formation of non-metallic inclusions during VIM. Against this background, the use of fluxes is being considered for future melts in addition to the use of deoxidants. Full article

The article presents the results of modeling and experimental studies of the ingotless rolling-extrusion (IRE) process of Al-5Ti-1B alloy rods. The objective of this research is to develop a set of technical and technological solutions for the creation of a technology for producing ligature rods from Al-Ti-B alloys with an effective modifying effect. Using the QForm software package, the temperature and energy-force characteristics of the IRE process for producing 9 mm diameter rods from the investigated alloy were determined at the specified deformation and speed parameters. The optimal process parameters were obtained. The melt temperature was 720 ± 10 °C; the temperature of the billet crystallized in the rolls was 520 °C; the roll rotation frequency was 4 rpm; the strain during rolling was 50%; and the drawing ratio during extrusion should be in the range of 4.7–12.9. It was found that rods of Al-5Ti-1B alloy obtained from the melt by the IRE method have an effective modifying capacity comparable to industrial ligatures made from Al-Ti-B alloys. Full article

In this study, a Ti–48 at.% Al–2 at.% Nb–2 at.% Cr alloy was cast by bottom-pouring cold crucible induction melting (CCIM), and the shrinkage depressions formed in ingots during solidification were investigated. Ingots with different heights were produced, and shrinkage depression height and yield were evaluated based on longitudinal cross-sectional observations. The normalized ingot height ranged from 4 to 25, and the shrinkage depression height increased from 20 mm to 105 mm with increasing ingot height. The yield ranged from 77% to 97% and did not increase monotonically, exhibiting noticeable scatter even among ingots with similar heights. The casting rate ranged from 0.025 kg/s to 0.18 kg/s, and the shrinkage depression height increased with increasing casting rate, whereas no clear correlation was observed between the yield and the casting rate. When the nozzle inner diameter ranged from 2 mm to 5 mm, both the shrinkage depression height and the yield increased, accompanied by scatter. The Reynolds number was evaluated as a parameter representing the average flow condition of the pouring stream; however, shrinkage depression formation could not be uniquely explained by the Reynolds number alone, indicating that melt feeding behavior and heat extraction conditions must also be considered. Full article

6063 aluminum alloy has broad application prospects in aerospace and microelectronic thermal management systems due to its good thermal conductivity and moderate strength. However, its extremely high hot cracking susceptibility during the laser powder bed fusion (LPBF) process limits the direct manufacturing of complex components. This study proposes a strategy combining material composition modification with advanced structural design. By introducing TiH₂ nanoparticles (1.0~4.5 wt.%) to modify the 6063 aluminum alloy powder, Diamond-type porous structures based on triply periodic minimal surfaces (TPMS) were successfully fabricated using LPBF technology. The results show that the introduction of TiH₂ significantly suppresses the solidification cracking of the aluminum alloy. The underlying mechanism is that the L1₂-structured Al₃Ti particles, generated by the in situ decomposition of TiH₂ in the melt pool, provide high-density heterogeneous nucleation sites. This leads to a drastic decrease in the average grain size from 30.46 μm to 0.75 μm (a reduction of 97.5%), achieving a remarkable columnar-to-equiaxed transition (CET). In terms of mechanical properties, the 3.0 wt.% TiH₂ addition group exhibits excellent plateau stress (28.5 MPa) and energy absorption capacity, which is mainly attributed to the synergistic effect of fine-grain strengthening and Orowan dispersion strengthening. Thermal tests reveal that the thermal conductivity of the 3.0 wt.% group reaches 123 W/(m·K) at 100 °C. The healing of cracks reconstructs the macroscopic heat conduction paths, resulting in a significant improvement in thermal conductivity compared with the unmodified group. This work provides a theoretical reference for the development of high-performance, crack-free, and multi-functional integrated aluminum alloy components via additive manufacturing. Full article

Machine learning interatomic potentials (MLIPs) are typically developed for globally ordered homogeneous systems (GOHomS), which exhibit only minor local deviations from equilibrium configurations. Consequently, most existing MLIPs trained on GOHomS often perform inadequately when applied to locally ordered heterogeneous systems (LOHetS), e.g., substitutional alloying elements in multicomponent alloys. To describe doping alloy systems, we develop a fine-tuned MLIP based on the MACE foundation model, specifically tailored for Mo-based dilute alloys containing one or two out of 20 substitutional elements: Cr, Fe, Mn, Nb, Re, Ta, Ti, V, W, Y, Zr, Al, Zn, Cu, Ag, Au, Hg, Co, Ni, and Hf. The model is built on more than 7000 equilibrium and non-equilibrium structures derived from first-principles density functional theory (DFT) calculations. The optimized large-scale fine-tuned model attains state-of-the-art accuracy, with a mean absolute error (MAE) and root-mean-square error (RMSE) of 2.27 meV/atom and 3.79 meV/atom for energy predictions, and 13.83 meV/Å and 24.26 meV/Å for force predictions, respectively. Systematic evaluation under different data-splitting protocols shows that unknown element extrapolation remains challenging under strict dopant hold-out, whereas substantially improved accuracy can be achieved in partial-exposure transfer settings. The fine-tuned models reduce the MAE by approximately 7–10 times compared to models trained from scratch, and by 10–20 times relative to zero-shot foundation models. This performance gain remains consistent across varying dataset sizes (equilibrium vs. non-equilibrium structures) and model scales. Our work illustrates the efficacy of transfer learning from globally ordered homogeneous systems to locally ordered heterogeneous multicomponent alloy environments. However, direct transfer to entirely unknown elements remains challenging, especially when proxy embeddings are employed without fine-tuning. Thus, to achieve high accuracy without incurring additional cost, it is essential to include unknown elements in the training dataset while minimizing the number of configurations containing known elements. Moreover, the current findings are primarily validated for dilute Mo-based alloy systems. Extending this approach to more compositionally complex alloy spaces may necessitate additional data and further fine-tuning. Full article

The poor tribological and mechanical performance of Al alloys hinders their use in practical applications where low COF and high durability are required. This study examined and evaluated a novel laser-sintered Ni-Cr coating to improve the load-carrying capacity and tribological performance of an Al alloy (Al 6061) substrate. The authors demonstrate that laser sintering cycle count is a decisive process variable governing coating dispersion, microstructural consolidation, and tribological performance in Ni-Cr coatings fabricated via Selective Laser Sintering (SLS). Increasing the laser cycle count progressively refined the surface morphology, improved coating dispersion, and strengthened interparticle bonding. As a result, the average durability after three cycles was seven times that after one laser cycle, accompanied by markedly improved COF. To further improve durability and load-carrying capacity, Ti₃SiC₂ was introduced into the Ni-Cr coating. The coating containing 10 wt% Ti₃SiC₂ exhibited a 20-fold increase in durability, extending the time to failure to approximately 70,000 s (700 m) while maintaining a low coefficient of friction (~0.48) compared with the coating containing no Ti₃SiC₂. The greater durability of the Ni-Cr-10wt%Ti₃SiC₂ coating in this novel study was attributed to improved adhesion to the substrate, better particle distribution during sintering, and greater load-carrying capacity. While further process changes do not yield feasible samples, this study showed that surface properties can be improved within the available small-process regime. Overall, laser sintering of a Ni-Cr-10wt%Ti₃SiC₂ coating shows promise as a means to improve the tribological and mechanical performance of Al 6061. This study should aid researchers and other stakeholders in fabricating well-adhering, durable, and tribotactic composite coatings on Al6061 and similar material systems. Full article

High-grade non-oriented silicon steel is a critical material for new energy vehicles and energy-efficient appliances due to its superior magnetic properties. However, these properties are significantly degraded by non-metallic inclusions, particularly Ti(C,N). This study employs integrated thermodynamic and kinetic calculations to systematically analyze the formation and growth mechanisms of Ti(C,N) inclusions in high-grade non-oriented silicon steel, trace the sources of [Ti], and propose targeted theoretical control strategies. Results indicate that Ti(C,N) inclusions do not precipitate above the liquidus temperature (1779 K). During solidification, microsegregation enriches Ti, C, and N; however, only TiN precipitates in the final stage as its ion product exceeds the solubility limit, whereas TiC remains undersaturated—findings valid within the present composition window and modeling framework. Inclusion size is governed by cooling rate and initial Ti/N content, where higher cooling rates yield finer inclusions and lower Ti/N content suppresses precipitation. Titanium originates from primary sources (raw materials and alloys) and secondary sources (decomposition or reduction of TiO₂ in slag/refractories). Therefore, mitigating [Ti] requires strictly limiting primary input and suppressing secondary formation through optimized process control, such as reducing BOF slag carryover, lowering refining temperature, and controlling [Al] content. Full article

Ti alloys are widely used in aerospace and biomedical fields due to their high mechanical properties under severe loading. Interest in additively manufactured Ti6Al4V has increased, but further research is needed to fully characterize their properties. This work compares the effects of surface properties, internal defects, microstructure, hardness, and Hot Isostatic Pressing (HIP) or Vacuum Heat Treatment (VHT) on the fatigue behavior of Ti6Al4V produced by Selective Laser Melting (SLM) and Electron Beam Melting (EBM). Printing parameters and post-processing were optimized to achieve high density and minimal porosity, providing a solid basis for realistic fatigue comparisons. Samples were characterized in terms of microstructure (optical microscopy and SEM), mechanical properties (hardness mapping), surface texture (confocal microscopy), and internal defects (image-based analysis). Uniaxial fatigue limits were determined by a Dixon-Mood staircase method, and failed specimens were analyzed for fracture surfaces and defect areas. Applied load on flaws was evaluated to identify root causes of fatigue failure. Results showed that fatigue of as-printed samples is governed by surface roughness, while machined specimens are controlled by internal defect size. Machining increased the fatigue limit roughly threefold, and HIP further improved it by 10–20% by reducing internal porosity. In conclusion, with properly optimized melting parameters, both EBM and SLM produce similar mechanical performance at comparable roughness, supporting their use for structural components. Full article

Based on the thermodynamic design of metallurgical reduction, this paper investigates the thermodynamic principles and reaction regulation mechanism of aluminothermic self-propagating reduction for the in situ synthesis of a Ti₄₅Al₈Nb (at%) titanium–aluminum–niobium alloy. The influence of the aluminum distribution coefficient (ADC) on the self-propagating reaction process was verified via high-temperature thermal state experiments. The results show that the thermodynamically predicted trends of phase composition and alloy composition are consistent with the experimental results, with only a ~20% lateral offset in the ADC. When the ADC is set to 0.8, the mass fractions of Ti, Al, Nb, O, and N in the alloy are 51.8%, 29.5%, 17.4%, 1.2%, and 0.0016%, respectively, with a homogeneous microstructure and inclusion size no larger than 8 µm. The alloy presents a typical coarse-grained structure, where 83.1% of the total grain boundary length is low-angle grain boundaries, and the <111> orientation is dominant. A low-energy coherent interface is formed between the Ti-enriched and Nb-enriched regions by TiAl, TiAl₃ and Al₃Nb phases, which enhances the structural stability of the alloy. Full article

Conventional titanium alloy production based on the Kroll process features high energy consumption and long procedures, making low-cost, short-process fabrication a research focus in titanium metallurgy. In this work, low-interstitial γ-TiAl alloys were prepared via a coupled self-propagating high-temperature synthesis (SHS)–slag washing refining–vacuum arc remelting (VAR) process using TiO₂ as the raw material. Slag washing refining was performed at 1750 °C with 150 g of CaO-Al₂O₃-SiO₂-CaF₂ mold flux and 1.5 wt.% Ca, followed by VAR under a vacuum of 10⁻²–10⁻³ Pa. γ-TiAl alloy with a composition of Ti 66.01 ± 0.5 wt.%, Al 33.8 ± 0.5 wt.%, O 0.054 ± 0.002 wt.%, N 0.046 ± 0.005 wt.%, and C 0.085 ± 0.008 wt.% was obtained, and the inclusion size was refined to 0–3 μm. This coupled approach provides a scalable, low-cost route for the industrial preparation of low-interstitial γ-TiAl alloys. Full article

Titanium and its alloys are widely used for orthopedic implants, but their intrinsic bioinertness may hinder osseointegration. In this study, titanium dioxide nanotube (TNT) arrays were fabricated on Ti-6Al-4V scaffolds via anodization, and their effects on the adhesion behavior of human bone marrow mesenchymal stem cells (hBMSCs) were investigated. Surface characterization showed that anodization successfully generated ordered TNT layers, increased surface roughness, enhanced protein adsorption, and induced an apparent superhydrophilic wetting response. Compared to the untreated scaffold and TNT50, the small-diameter TNT10 surface significantly promoted hBMSC adhesion and proliferation. Microscope imaging further revealed enhanced cell spreading, F-actin organization, and vinculin expression on TNT surfaces, with the most prominent focal adhesion-related staining observed in TNT10. Quantitative proteomic analysis showed that TNT10 was associated with coordinated remodeling of adhesion- and cytoskeleton-related molecular programs, including focal adhesion, cell–substrate junction, and regulation of the actin cytoskeleton. In contrast, TNT50, despite supporting obvious cytoskeletal remodeling, was more compatible with a dynamic, higher-turnover adhesion state. Overall, these findings suggest that small-diameter TNTs provide a more favorable interfacial microenvironment for stable early hBMSC adhesion on porous titanium scaffolds. Full article