Search Results (215)

This study investigates the influence of laser spot size (Ø100 µm vs. Ø50 µm) on the microstructure, transformation behavior, and hardness of Ti-51.17 at.%Ni shape memory alloy samples fabricated by laser powder bed fusion. Samples were produced using identical processing parameters covering laser powers of 50–150 W, scanning speeds of 500–750 mm/s, and matched volumetric energy densities (28–83 J/mm³), with spot size as the only variable. Although both laser spot sizes produced comparable melt pool geometries and predominantly B2 austenite matrices with minor fractions of B19′ martensite, the Ø50 µm samples exhibited finer microstructures, higher residual stresses, and lower martensitic transformation temperatures in the as-built state. Heat treatment at 800 °C reduced residual stresses and partially homogenized the microstructure; however, differences in their transformation behavior remained. These differences were attributed to the spot-size-dependent Ni evaporation. Although transformation temperatures increased with increasing energy density for both conditions, the Ø50 µm samples consistently showed lower values. In the 55–83 J/mm³ volumetric energy density range, the estimated Ni content ranged from 51.15 to 50.42 at.%, and the Ø50 µm samples showed approximately 0.1–0.2 at.% greater Ni loss than their Ø100 µm counterparts. These findings demonstrate that Ni evaporation is a laser-spot-size-dependent phenomenon that must be considered when processing near-equiatomic Ti-Ni alloys. Full article

The impact of the oxide film in the remelted zone of a seed on the epitaxial solidification of single-crystal superalloys was investigated, with a specific focus on clarifying the hindrance mechanism of complex compositional oxide films during the epitaxial growth process. Experimental findings indicated that the oxide film was composed of multiple constituents, such as WO₃ and Al₂O₃, and displayed no remarkable texture in its crystal orientation. The formation mechanism of coherent oxides during the alloy oxidation process and their potential as nucleation sites for solidification were analyzed. Owing to disparities in symmetry along the growth direction, the γ phase formed through oxide nucleation that deviated from its original orientation. Moreover, the existence of polycrystalline oxide films impeded the effective transfer of single-crystal seed orientation information, leading the epitaxial growth to mainly rely on the mechanism where dendrites penetrate through the damaged areas of the oxide film to reach the upper region. Significantly, aluminum oxide within the oxide film could act as new nucleation sites, potentially triggering the formation of stray grains in the central region of the casting. Full article

For single-motor Formula Student Electric China (FSEC) race cars, current powertrain design methodologies commonly suffer from the disconnection among parameter matching, dynamic simulation, and structural optimization: gear ratio selection is mostly based on static theoretical calculations, lightweight design does not incorporate full-vehicle dynamic load spectra constraints, and the simulation toolchain (CarSim 2024, OptimumLap version 5, ANSYS 2022) lacks a standardized data closed-loop, leading to prolonged iteration cycles and unquantifiable reliability. To address these issues, this paper takes the Nanning University electric formula race car E66 as the research object and proposes a three-phase integrated design framework of “requirement-driven, multi-simulation co-validation, and lightweight iteration.” The study includes three core contributions: (1) establishing a powertrain parameter matching method based on power boundary calculations and multi-dimensional selection criteria, achieving the integrated selection of the Emrax 228 motor (power density 9.2 kW/kg, Emrax d.o.o., Kamnik, Slovenia) and the Unitek-D3 controller through comparative analysis with the JJE motor (5.7 kW/kg, Jing-Jin Electric Technologies Co., Ltd., Beijing, China); (2) constructing a co-simulation mechanism combining OptimumLap version 5 and CarSim 2024, completing the closed-loop optimization of the gear ratio from the range of 1.6–4.3 to the optimal value of 3.9 under the Hefei NIO track operating conditions, with a 75 m acceleration simulation result of 4.4 s and an endurance lap time of 86 s; (3) introducing ANSYS 2022 topology optimization technology to perform two-iteration lightweight design on the 7075 aluminum alloy main sprocket, achieving 35% mass reduction and 40% volume reduction while maintaining the maximum principal stress at 73.16 MPa (below yield strength). The expected outcome is a replicable development paradigm for single-motor powertrain systems, transforming drivetrain matching from experience-driven to simulation-driven, providing reliable data boundaries for physical vehicle commissioning, and effectively reducing trial-and-error costs. 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

Nanotextured thin film metallic glasses (TFMGs) have emerged as promising antimicrobial coatings for biomedical applications; however, systematic comparisons across compositionally distinct Ti- and Zr-based systems, as well as their early-stage bactericidal mechanisms, remain limited. Here, we show, for the first time, a comparative, compositionally resolved correlation linking alloy chemistry, nanotexture, and bactericidal mechanisms across polymorphic TFMGs. Three co-sputtered biocompatible coatings (Ti₄₇Fe₄₁Cu₁₂, Zr₇₁Fe₃Al₂₆, and Zr₅₈W₃₁Cu₁₁) were deposited on medical-grade titanium and stainless steel (SS316L) via magnetron co-sputtering, producing uniform amorphous films (190–298 nm) with nanoscale roughness of 1.6 ± 0.05 to 8.1 ± 0.05 nm. Surface wettability spanned hydrophilic (71.1 ± 5.6°) to hydrophobic (106.5 ± 3.5°), modulating bacterial interactions. Antimicrobial performance against Pseudomonas aeruginosa was evaluated using live/dead fluorescence imaging, quantitative image analysis, and electron microscopy after 2–4 h incubation. All coatings reduced bacterial adhesion and viability relative to bare substrates, with Zr₅₈W₃₁Cu₁₁ achieving >60% reduction in surface-associated bacterial coverage. Time-resolved analysis revealed a rapid transition to predominantly non-viable populations on coated surfaces, in contrast to sustained viability on controls. Mechanistically, bactericidal activity arises from the synergistic coupling of nanotopography-induced membrane stress, wettability-governed adhesion energetics, and in situ formation of CuO, Fe₂O₃, WO₃, and ZrO₂ oxides that promote electrostatic interactions and proposed reactive oxygen species generation, driving oxidative membrane damage. These results establish a scalable design framework for TFMGs, while highlighting the need for long-term biofilm and electrochemical validation. Full article

High-load sliding components, including gun barrels, are susceptible to accelerated wear and damage due to coupled thermal-mechanical stresses and reciprocating frictional conditions. Therefore, enhancing their operational lifespan requires the application of wear-resistant coatings with high melting points for effective surface protection. In this study, Ta-10W alloy coatings were deposited on CrNi3MoVA steel substrates through electricspark deposition, focusing on deposition voltage as a critical parameter. Experimental results indicate that the Ta-10W coatings are primarily composed of α-Fe, α-Ta₂O₅, δ-Ta₂O₅, α-Ta(W), and Fe-W intermetallic phases. An increase in deposition voltage facilitates enhanced melting and mass transfer, thereby promoting solid solution and oxidation strengthening, which results in improved hardness. However, higher voltages also induce defects such as porosity and microcracks. Hardness measurements and friction-wear tests demonstrate that coatings deposited at 80 V exhibit optimal performance, attaining the highest hardness (~753 HV) and a friction coefficient similar to that at 60 V. Conversely, the friction coefficient increases at 100 V due to defects and coating spalling. The wear mechanism transitions from adhesive wear at 60 V to adhesive wear with minor plastic deformation at 80 V and ultimately to spalling wear at 100 V. Finite element thermomechanical simulations reveal that increasing voltage significantly elevates the equivalent interfacial stress (600–1150 MPa), thus correlating with the propensity for microcracks to propagate into longitudinal semi-penetrating cracks at elevated voltages. This study establishes a theoretical foundation for optimizing electricspark deposition process parameters and contributes to the reliability design of Ta-W alloy coatings. Full article

A three-factor, four-level orthogonal design was employed to optimize the overall forming quality of powder bed fusion with a laser beam (PBF-LB)-fabricated TC4 alloy containing 0.3 wt.% YH₂. Sixteen process-parameter combinations were established, and two specimens were fabricated for each combination. Laser power, scanning speed, and hatch spacing were selected as the investigated variables. Relative density, surface roughness, and Vickers hardness were evaluated using the entropy weight method combined with the weighted-sum method. On this basis, the microstructure of the specimens produced under the optimal process parameters was systematically characterized. The results showed that the influence of the investigated factors on overall forming quality followed the order: hatch spacing > laser power > scanning speed. The optimal process parameters were a laser power of 200 W, a scanning speed of 1100 mm/s, and a hatch spacing of 0.10 mm, under which the specimens exhibited superior overall forming quality. The addition of 0.3 wt.% YH₂ did not significantly alter the dominant phase constitution of the alloy, but promoted α′ martensite refinement and weakened the texture through the in situ formation of Y₂O₃ nano-oxide particles. Full article

Concentrated Solar Power (CSP) tower systems require receiver materials capable of operating above 1000 °C to meet the efficiency targets of third-generation technologies (25–30%). Hybrid solutions, combining ceramic coatings with metallic substrates, offer promising thermomechanical stability under severe thermal cycling. This study investigates the high-temperature behavior of silicon carbide (SiC) coatings deposited on Fe-C-Al-Mo alloys under concentrated solar flux. Substrates were pre-oxidized to form a continuous 1–2 µm α-Al₂O₃ interlayer, serving as a chemical and mechanical buffer. SiC coatings (10–24 µm thick) were deposited via High-Temperature Chemical Vapor Deposition (HT-CVD). Characterization using XRD, SEM, EDS, and optical spectrophotometry identified cubic 3C-SiC with a globular microstructure and high compressive residual stresses (−2000 to −2400 MPa), inducing microcracking. Stress relaxation was achieved by increasing coating thickness or post-deposition annealing. Controlled oxidation formed a thin silica layer, enhancing solar absorptivity to over 90%. Accelerated thermal cycling (up to ~900 kW/m², 1050–1200 °C) revealed that coating stability depends on SiC thickness, residual stress evolution, α-Al₂O₃ interlayer thickness, and cycling severity. Optimizing these parameters is essential for ensuring the long-term durability of hybrid CSP receivers. Full article

Despite the crucial role of Young’s modulus in the structural performance of Al alloys, the effects of common strengthening approaches on its evolution, particularly at elevated temperatures, remain largely unexplored. In this study, an Al-7Si-4Cu alloy was modified by hot deformation, micro-alloying with 0.3 wt.% Sc, alloying with 4 wt.% Ni, and reinforcement with 0.8 vol.% Al₂O₃ nanoparticles. The effects of these strengthening approaches on the microstructure and the evolution of Young’s modulus from room temperature to 350 °C were examined. It was found that the Young’s modulus of the alloys decreased with the increase in temperature, while this tendency is much more obvious when the temperature exceeds 250 °C. The results showed that hot deformation markedly refines the α-Al grains while the Young’s modulus stays largely unchanged. The Sc addition leads to the formation of the W phase but has no significant effect on the Young’s modulus. In contrast, the addition of Ni substantially increases the Young’s modulus through the formation of Al₃CuNi intermetallic particles, with the Young’s modulus increasing from 72.15 to 76.47 GPa. With the addition of Al₂O₃ particles, the decreasing magnitude of Young’s modulus is optimized when the temperature is higher than 250 °C. This work may be referred to when designing high-modulus Al alloys by considering the utilization of various strengthening concepts. Full article

We engineered a compact methanol steam reforming (MSR) system tailored to power a 1 kW High-Temperature Proton Exchange Membrane (HT-PEM) fuel cell. The unit integrates an evaporator, reformer, and burner within a cylindrical titanium-alloy vacuum flask to minimize parasitic heat loss. Guided by an Artificial Intelligence Complex System Response (AICSR) framework, we developed a segmented catalyst architecture that positions an optimized Pd/ZnO/Al₂O₃ catalyst downstream of a commercial Cu–Zn catalyst bed. This spatial configuration reduces palladium consumption by >50% while maintaining a hydrogen generation rate of 8000 sccm at 250 °C. During a 40 h stability test, the system exhibited a low deactivation rate of 0.235% h⁻¹, with methanol conversion decaying gradually from 98.1% to 88.7%. The downstream PdZn intermetallic phase actively promoted the water–gas shift (WGS) reaction, restricting CO concentration to an average of 3.9% (minimum 2.5%). Achieving a system thermal efficiency of 88.589% and a 20 min startup time, this design validates AI-assisted spatial catalyst distribution as a highly viable strategy for compact hydrogen generation. Full article

The present study demonstrates that the corrosion behavior of dental cobalt–chromium (Co–Cr) alloys is strongly influenced by the interaction between microstructure, manufacturing technique, and oral chemical environment. A comparative investigation was conducted on Co–Cr specimens fabricated using four technological routes: conventional casting, CAD/CAM machining, Selective Laser Melting (SLM), and Direct Metal Laser Sintering (DMLS). The study included microstructural characterization, evaluation of generalized corrosion behavior using the rotating electrode technique, assessment of localized crevice corrosion, and quantitative analysis of the release of twenty metallic cations. Extraction tests were performed for 168 h in two media simulating aggressive oral environments: 0.07 N HCl (acidic medium) and a fluoride-containing electrolyte (0.1% NaF + 0.1% KF). Electrochemical measurements were recorded in the current density range of 10⁻¹⁰ to 10⁻⁷ A/cm², while released cation concentrations were quantified at the µg/L level. All alloys exhibited very low corrosion current densities (icorr in the 10⁻⁸ to 10⁻⁹ A·cm⁻² range), confirming overall good corrosion resistance. Among all manufacturing routes, CAD/CAM specimens demonstrated the highest electrochemical performance, with a wide passivity domain extending up to approximately 740 mV/SCE. A statistical interaction analysis between extraction media and manufacturing techniques was performed using the non-parametric Mann–Whitney (MW) U test. Among the analyzed elements, only chromium showed a statistically significant difference between media (p < 0.05), with an approximately 25-fold-higher release in acidic conditions compared with the fluoride medium, confirming the predominant role of proton-induced destabilization of the protective Cr₂O₃ passive film. In contrast, fluoride-containing media induced selective release of elements such as Cu (3× higher), W (2.5× higher), and Mo (1.4× higher), associated with complexation phenomena. The manufacturing route significantly influences corrosion behavior. Although additive manufacturing technologies (SLM/DMLS) enable highly accurate and customized prosthetic designs, rapid solidification and microstructural heterogeneities may increase susceptibility to localized corrosion compared with more homogeneous CAD/CAM materials. Clinically, these findings suggest that future restorative strategies should incorporate corrosion-aware material selection within digital workflows. As digital dentistry evolves, predictive models integrating patient-specific oral conditions may assist clinicians in selecting the most appropriate material system for long-term performance. In conclusion, the long-term success of dental Co–Cr prosthetic devices depends not only on mechanical strength and precision of fit, but also on sustained electrochemical stability in the complex oral environment. Full article

There has been no experimental work on CuCrO₂-ZnSnN₂ heterojunctions (HJs), though theoretical work shows that their photoelectric conversion efficiency is around 20%. Here, CuCrO₂ thin films and p CuCrO₂-n ZnSnN₂ HJs are prepared by varying the sputtering power of the Cu-Cr alloy target while the other parameters are held constant. The as-deposited Cu_xCr_yO_z thin films are amorphous, with CuCrO₂ as the major phase. The CuCrO₂ thin films are p-type conductive, with an optical band gap of about 3.64–3.84 eV. The ZnSnN₂ thin films are wurtzite and n-type conductive. The dark current density J versus voltage V curve measurements show that all the HJs showed rectification, while only the samples deposited at 40 and 50 W had a photo-induced current. Further analysis shows the HJs deposited at 40 W have the lowest shunt conductance, saturation current density, and trap density, implying an effect of fabrication conditions on the properties of HJs. Full article

This study investigates the influence of highly thermally conductive coatings on the combustion thresholds of a TC4 titanium alloy, aiming to address the flame-retardant protection requirements for titanium alloys. The findings reveal that, in terms of combustion thermodynamics, as the thickness of the copper coating increases from 100 μm to 300 μm, the critical ignition power rises by 125–170 W compared to the substrate (235 W). Additionally, the critical oxygen pressure increases by 0.21–0.51 MPa relative to the substrate (0.03 MPa), and the ignition temperature is elevated by 119–184 K above that of the substrate (848.80 K). This phenomenon is primarily due to the high thermal diffusivity of copper. Increased coating thickness further enhances heat dissipation, significantly suppressing the local heat accumulation rate and thereby improving the coating’s combustion resistance. In terms of combustion kinetics, under fixed experimental conditions, the copper coating extends the ignition delay time by 0.670 s and reduces the combustion propagation rate by approximately 21% compared to the substrate (26.772 mm/s). The post-combustion microstructural analysis indicates that during the reaction process, the copper coating forms a TiCu₂Al-type intermetallic compound (Ti_0.5Al_0.5)Cu. This structure exerts an “anchoring” effect on the substrate material, decreases the Ti/O reaction efficiency, and consequently achieves effective flame retardancy. These findings inform the subsequent design and optimization of copper-based abradable coatings with enhanced combustion resistance. Full article

The design of ladle furnace (LF) refining pathways for weathering steels requires precise control of multi-component steel/slag reactions governed simultaneously by thermodynamics and interfacial mass transfer kinetics. An EERZ-based kinetic modeling strategy was employed using the Thermo-Calc^® (version 2022a) Process Metallurgy Module and the CALPHAD TCOX11 database to develop LF refining schedules capable of upgrading conventional S355J2R steel to weathering steel grades: S355J2W and S355J2WP. First, the sensitivity of predicted compositions to key kinetic inputs was quantified. The validated model was then used to simulate deoxidation and desulfurization sequences, predicting the evolution of liquid–steel and slag compositions, slag basicity, and FeO activity throughout the LF cycle. Subsequently, Cr- and P-ferroalloys were introduced to design tap-to-tap schedules that meet the EN 10025-5 chemical specifications for S355J2W and S355J2WP. To correlate simulation outcomes with material performance, plates produced following the modeled schedules were evaluated through a 1000 h accelerated salt spray test. Steel density and steel phase mass transfer coefficients were found to produce the highest prediction sensitivity (up to 7.5 wt.% variation in C and S), whereas slag phase parameters exhibited a lower impact. The predicted steel compositions showed strong agreement with industrial values obtained during plant trials. SEM-EDS analyses confirmed the development of a Cr-enriched protective patina and validated model-based alloying strategies. Full article

Welding repair of cracks in FSX-414 cobalt-based alloy, used in high-temperature components, poses significant challenges due to the presence of surface oxide films within the cracks. By comparing the formation of oxide films on the external surface and inside the narrow crevice of FSX-414 alloys preserved at 900 °C for up to 1000 h, we found that the oxide film growth rate on the external surface was slightly larger than that inside the narrow crevice, and the latter slowed down after 672 h. Additionally, the oxide films on both surfaces were mainly composed of O and Cr elements, providing excellent protection to the underlying metal and resulting in minimal internal oxidation. A compositional transition region formed between the oxide film and the base metal. The width of the transition region decreased with heating duration and was narrower in the external surface sample, leading to a steeper composition gradient between the oxide film and the inner metal. With prolonged exposure, increasing numbers of “pores” rich in W and O appeared near the oxide films, creating channels that connect the oxide layer with the internal metal and accelerate material degradation. “Pores” extended deeper into the metal within the narrow crevice compared to those on the surface. Prior to welding repair, channels composed of W and O near the oxide films must be cleaned along with the oxide layer itself, and the removal of oxide from narrow cracks poses greater difficulty. Full article