Search Results (25,620)

This article comprehensively reviews the fatigue crack growth (FCG) models applied to Ti6Al4V alloy manufactured by electron beam melting (EBM) powder bed fusion (PBF). The current progress in FCG analytical and numerical models and their application to EBM Ti6Al4V are reviewed. Much experimental data for the creation of historical FCG models was based on conventionally manufactured (CM) aluminum alloys and various steels. With the growth of additive manufacturing (AM), recent studies have applied traditional models and modified new models to EBM Ti6Al4V and validated their use as accurate predictive models for the da/dN-ΔK curve and ΔK_th. Due to pores and surface roughness inherent in AM and the unique anisotropic microstructure developed from the EBM process, classical models may require modifications to accurately predict FCG of EBM Ti6Al4V. Full article

The microstructure, phase composition, and high-temperature oxidation behavior of Al_0.5CoCr_0.5NiPt_0.1 and AlCoCr_0.5NiPt_0.1 multi-principal element alloys (MPEAs) at 1100 °C in air were investigated. Depending on the content of aluminum, the microstructure of as-cast samples contains FCC and BCC solid solutions. Similarly, the ratio of two solid solutions varies depending on the aluminum content in the alloy. When the content of aluminum is x = 0.5, the microstructure is dominated by the FCC solid solution, while a BCC solid solution is dominated when the concentration of aluminum is increased to x = 1.0. Moreover, in both MPEAs, platinum exists as a part of solid solutions rather than a separate phase. High-temperature oxidation was carried out in a Plavka.Pro PM-1 SmartKiln muffle furnace under isothermal conditions at 1100 °C for 100 h exposure in air, and weighing was performed every 10 h. The maximum specific weight gain for the Al_0.5CoCr_0.5NiPt_0.1 alloy was 0.965 mg/cm², and 0.675 mg/cm² for the AlCoCr_0.5NiPt_0.1 alloy. Based on the high-temperature oxidation experiment results, it was established that AlCoCr_0.5NiPt_0.1 MPEA exhibits greater resistance towards high-temperature dry air corrosion with the formation of an exclusive Al₂O₃ scale on the surface with 3–5 μm thickness; the parabolic oxidation rate constant for this alloy is k_p = 20.2 × 10^–13 (g²/cm⁴s). Introduction of platinum into the composition of the Fe-free AlCoCr_0.5Ni alloy reduces the value of the parabolic oxidation rate constant by half. Full article

Atmospheric corrosion of carbon and low-alloy steels causes direct economic losses that are estimated at around 3.4% of the global GDP, and its accurate multi-year prediction is essential for protective coating selection, service-life estimation, and infrastructure maintenance scheduling. In this study, machine learning (ML) algorithms, including gradient boosting regressor (GBR), eXtreme gradient boosting (XGBoost), random forest (RF), support vector regression (SVR), and ridge regression, were trained on a 600-sample physics-grounded dataset to predict the cumulative atmospheric corrosion loss (µm) of low-alloy steels over 1–10 years of exposure. The dataset was constructed using the exact ISO 9223:2012 dose–response function (DRF) for a first-year corrosion rate and the ISO 9224:2012 power-law multi-year kinetic model (C(t) = C₁·t0.5), spanning ISO 9223 corrosivity categories C2–CX across 11 environmental and material input features. All models were evaluated on the original (untransformed) corrosion scale under an 80/20 train/test split and five-fold cross-validation. Gradient boosting achieved the best overall performance with test set R² = 0.968, CV-R² = 0.969, RMSE = 10.58 µm, MAE = 5.99 µm, and MAPE = 12.6%. XGBoost was a close second (R² = 0.958, CV-R² = 0.960). RF achieved an R² of 0.944. SHAP (SHapley Additive exPlanations) analysis identified SO₂ deposition rate, exposure time, relative humidity, Cl⁻ deposition rate, and temperature as the five most influential predictors. The dominance of the SO₂ deposition rate (mean |SHAP| = 26.37 µm) and the high second-place ranking of exposure time (13.67 µm) are fully consistent with the ISO 9223:2012 dose–response function and ISO 9224:2012 power-law kinetics, respectively, while among the material features, Cu and Cr contents showed the strongest negative SHAP contributions, confirming their corrosion-inhibiting roles in weathering steels. These results establish a physics-consistent, interpretable ML benchmark exceeding R² = 0.90 for multi-year cumulative corrosion loss prediction and provide a quantitative tool for alloy screening, coating selection in aggressive atmospheric environments, and service-life planning. Full article

Background: Surface roughness in turning operations is still verified predominantly after machining, which limits the possibility of timely corrective intervention. Methods: This study examined whether normal-direction peak-to-peak vibration displacement can serve as a practical low-frequency indicator of surface roughness during finish turning of EN AW-2011 aluminum alloy. The analysis was based on 190 synchronized displacement-roughness observation pairs obtained in one controlled experimental campaign on a CQ6230 conventional precision lathe, using a VB-8206SD displacement logger mounted radially on the tool holder and contact profilometry measurements reported as Ra and Rz. The analytical workflow included explicit quality-control safeguards for malformed rows, missing values, and obvious artefacts; in the present dataset, these checks did not indicate a failure state that would invalidate the main calculations. The workflow combined descriptive statistics, moving-average trend inspection, low-frequency FFT and STFT descriptors, Pearson correlation analysis, and ordinary least squares regression. Results: The displacement signal exhibited a mean value of 0.0446 mm with a standard deviation of 0.0256 mm and showed strong within-dataset linear relations with roughness parameters: Ra = 14.204 + 24.191 V (R² = 0.9929, RMSE = 0.052 µm) and Rz = 63.207 + 105.253 V (R² = 0.9905, RMSE = 0.264 µm). Conclusions: The results support setup-specific roughness-related process-state assessment using low-rate normal-direction displacement measurements. However, because the 190 records represent a time-ordered synchronized sequence rather than 190 independent cutting trials, and because no separate validation set was available, the fitted equations should be interpreted as descriptive within-setup calibration rather than as universally validated predictive models. Full article

Ammonia is indispensable to the fertilizer and chemical industries, yet its manufacture still relies predominantly on the energy-intensive Haber–Bosch process operated at 400–500 °C and 150–250 bar, with a substantial carbon footprint. Single-atom catalysts (SACs) and sub-nanometric clusters have recently emerged as promising alternatives for thermocatalytic ammonia synthesis under milder conditions because they maximize metal utilization and enable precise control of the active site environment. This review first summarizes how the transition from conventional Fe and Ru nanoparticles to isolated or few-atom sites fundamentally alters the kinetic landscape, favoring associative N₂ activation pathways that lower apparent activation energies and alleviate H₂ poisoning. We then discuss Ru-based SACs and SAAs supported on zeolites, carbons, ceria, and MXenes, highlighting how strong metal–support and promoter interactions, tandem single-atom/nanoparticle motifs, and alloying strategies tune N₂ and H₂ binding to deliver high NH₃ productivities at 200–400 °C and ≤30 bar. In parallel, we review emerging non-noble systems based on Fe and Co, including high-loading Fe–N₄ sites prepared via MOF-derived post-metal-replacement routes and Co single atoms or Co₂ clusters on N-doped carbons, which already rival or surpass Ru benchmarks under similar conditions. Collectively, these studies show that tailoring the number of atom metal sites, coordination, and support polarity around isolated metal sites provides a useful tool to mitigate some aspects of volcano and scaling-relation limitations, indicating that SACs could contribute to low-temperature ammonia synthesis when combined with appropriate process design. Full article

This study investigates the phase formation and smelting process of a complex Al-Si-Mn alloy based on thermodynamic diagram analysis (TDA). The Fe-Si-Mn-Al system was analyzed considering binary and ternary subsystems, and the standard Gibbs free energy of formation of selected ternary compounds was calculated using the additive method. Based on these results, phase equilibrium diagrams were constructed, and the system was tetrahedralized, leading to the identification of 15 thermodynamically stable tetrahedra. It was established that compositions of industrial interest are predominantly localized within tetrahedra enriched in silicide and aluminosilicide phases, particularly FeSi-Fe₂Al₂Si-Fe₃Al₁₁Si₆-Mn₅Si₃. Experimental verification was carried out in a 250 kVA ore-thermal furnace using manganese ore, high-ash coal, and quartzite. The smelting process was conducted under slag-free conditions with stable electrical operation. The obtained alloy had the following composition (wt.%): Fe ~ 12.1, Si ~ 44.7, Mn ~ 34.5, and Al ~ 5.1, with low impurity levels (C < 0.5%, S < 0.02%, p < 0.09%). Microstructural analysis using SEM-EDS confirmed the formation of silicide (FeSi, Mn₅Si₃) and aluminosilicide phases, which ensure the structural stability of the alloy. It is shown that the localization of alloy compositions within specific tetrahedra of the Fe-Si-Mn-Al system prevents self-disintegration. The results demonstrate that TDA is an effective tool for predicting phase composition and optimizing the production technology of complex ferroalloys. Full article

Phase formation characteristics during the thermochemical reduction of metals from natural coltan using aluminum and calcium–aluminum alloy at 1400–1450 °C were investigated to develop methods for extracting niobium and tantalum from rare metal raw materials. The studied coltan sample consists of a columbite–tantalite solid solution with the composition (Mn,Fe)(Nb,Ta)₂O₆, cassiterite Sn_0.9O₂, tapiolite (Ta,Nb)₂(Mn,Fe)O₆, and calcioolivine Ca₂SiO₄. This study established that the choice of reducing agent determines the sequence of oxide phase transformations. During the aluminothermic process, orthorhombic columbite–tantalite is completely reduced, while tetragonal tapiolite persists even at 1400 °C. The use of a calcium–aluminum alloy containing 69.4 wt.% Ca results in a reversal of this trend: tapiolite is reduced at the early stages (800–1250 °C) through an intermediate (Ta,Nb)O₂ phase, whereas the columbite–tantalite solid solution remains up to 1250 °C. Calcium, having a high affinity for oxygen, forms intermediate perovskite-type oxide phases that act as diffusion barriers, limiting the access of the reducing agent to residual mineral inclusions (mainly Nb-Ta minerals of the orthorhombic crystal system). A temperature rise to 1450 °C initiates the redistribution of oxide components: the content of CaNbO₃ decreases, the Ca₂(Nb,Ta)AlO₆ phase disappears, and its components are involved in the formation of Ca(Nb,Ta)_0.25MnO_2.74 and Ca₄Nb₂O₉. Diffusion constraints are reduced, and the residual columbite–tantalite solid solution is reduced, as confirmed by its complete absence in the products at 1450 °C. In the metallic phase, solid solutions of tantalum and niobium, Ta-Nb-Sn intermetallic compounds (Ta,Nb)₃Sn, titanium aluminide, and ferroalloys with an increased (Ta,Nb)/(Fe,Mn) ratio are formed. The phase transformations elucidated during metallothermic reduction of coltan using different reducing agents, together with the formation of metallic and intermetallic phases, establish a scientific foundation for the development of advanced rare metal extraction processes. Full article

The study addresses a selected issue in industrial cooling, that is, how to transport heat more efficiently when the process involves fiber spinning and extrusion, in which conventional fluids usually cannot work. We considered a ternary nanofluid that passed around a porous stretching cylinder and particularly considered the synergistic effect of quadratic thermal buoyancy, and the thermally generated double-diffusive heat and solute (TGDHS) effect. Through the Casson fluid model and considering the magnetic fields, radiations, and nonlinear chemical reactions, we reduced complex PDEs to simple ODEs. The results were evident using the BVP4C numerical method. Although in reality, magnetic fields and thermal radiation become a retarding force, the quadratic thermal buoyancy is the driving force behind accelerating the flow. An important trade-off that we discovered is that a heavier Casson fluid reduces heat and mass transfer. The addition of Nimonic 80A, AA7072, and AA7075 nanoparticles to ethylene glycol consistently enhances heat transfer, outperforming the base fluid by 7.8% even at low concentrations. While AA7072 and AA7075 drive significant increases of over 16%, Nimonic 80A offers a much more marginal contribution of 1.23%. Consequently, the Nusselt number is far more sensitive to the concentration of the aluminum alloys than to the Nimonic 80A. Finally, this work demonstrates that the most significant parameter in intensifying convective heat and mass transfer in such industrial systems is the strong forces of buoyancy. Full article

Research on hydrogen production by chemical methods has focused on combining metals to carry out the hydrolysis reaction under ambient conditions. In particular, aluminum and lithium metals were considered, with lithium used at low concentrations in order to activate aluminum. Under these conditions, the metals can react with water to obtain the maximum hydrogen yield. The main objective of this work was to prepare the lithium−aluminum alloy by mechanical milling and its chemical reaction with water to produce hydrogen under laboratory conditions. A high–energy Spex mill was used for material preparation and the time scheduled for alloys preparation was relatively short. Several techniques were used for its characterization, such as X–ray diffraction, scanning electron microscopy, gas chromatography, and low-temperature physical adsorption. According to the results, two phases were produced during the milling process when using 5% lithium. The volume of hydrogen generated was measured using a graduated burette. Depending on the volume obtained, the aluminum reacted to generate hydrogen with an efficiency of 95.24%. No additives or catalysts were used in material synthesis or hydrogen production. According to these results, the hydrogen does not require any purification because it is clean hydrogen and can therefore be used directly in fuel cells. Full article

Mn₅₄Al₄₆ alloys with τ-phase as their main component were successfully obtained in a reproducible processing window combining melt-spinning, annealing at intermediate temperatures (450 °C) and low-energy milling. The complete ε → τ phase transformation was driven by thermal decomposition of ε-phase and favored by high grain boundary density inherent to the melt-spun microstructure. An improved magnetic response of the melt-spun Mn₅₄Al₄₆ alloys was observed, as they exhibited saturation magnetization values between 80 and 90 emu/g, together with intrinsic coercivities around 2000 Oe and Curie temperatures between 640 and 648 K. Significant coercivity enhancement over 6000 Oe was predicted, by means of micromagnetic calculations, for alloys with grain size refinement below 100 nm. The efficient, single-step experimental phase transformation with no additional stabilizers for the τ-phase was explained in terms of microstructural features, whereas magnetic enhancement was attributed to lattice distortions promoted by the milling process. This integrated approach introduces a pathway to achieve τ-phase Mn-Al with tunable magnetic performance useful for applications. Full article

In this research, the effects of density and porosity on the mechanical properties of a stir-cast hybrid magnesium ZE41 alloy strengthened with 2% weight of silicon carbide (SiC) and boron carbide (B₄C) are assimilated. The experimental and theoretical densities of the ZE41 hybrid matrix were found and compared. From the results of density analysis, it can be inferred that the experimental density of hybrid matrix is smaller when compared to the pure ZE41 matrix. The percentage porosity of hybrid matrix was also analyzed, and it was observed that the hybrid matrix has a slight increase in porosity when compared to the pure ZE41 matrix. The ultimate strength and hardness of the ZE41 hybrid matrix have increased significantly due to its moderate density and acceptable porosity values. Full article

High-entropy intermetallic (HEI) nanomaterials have recently been established as a representative class of high-performance nanocatalysts. However, the synthesis of HEI nanomaterials remains a significant challenge, with only a limited number of types being reported to date. This review aims to provide a systematical overview of the current state of research on HEI nanomaterials. The synthesis strategies are first discussed, with a special emphasis on the pivotal role that supports play in the formation of HEI nanomaterials. Following this, we provide a summary of key catalytic applications and focus on the structure–performance relationships. Finally, the review concludes by discussing the challenges faced in this area and suggesting potential research directions for the future. Full article

Hydrogen is a promising CO₂-free energy carrier, but conventional production from fossil fuels generates CO₂. This study explores an alternative—reacting waste-derived aluminum alloy powder with water under stirring to generate hydrogen, combining recycling with carbon-neutral hydrogen production. In a 500 mL stirred reactor, the hydrogen yield using alloy powders was six times greater than in a 100 mL reactor, exceeding simple volume-based scaling. Excess hydrogen production is attributed to impeller-driven particle fragmentation. To quantify this, correlations between alloy mass–power input and hydrogen yield were examined, but no clear relationship was found. Future work will systematically analyze the effects of the reactor scale, stirring speed, and alloy mass on hydrogen generation. Full article

Efficient joining of hard metals to steels is crucial for supporting sustainable manufacturing under emissions strategies to minimize CO₂. CoNiCrFeCu high-entropy alloy containing scandium (Sc) was designed as a filler for laser braze-welding of WC-Co and steel. The designed compositions with different Sc levels were melted and cast in a high-vacuum non-consumable arc furnace. The results showed that the as-cast microstructure was a complex mixture of a networked Ni₂Si, elongated Cr-Fe-Co solid-solution phase, and Fe-Ni-Co-Cu solid-solution phase. Scandium was shown to have formed compounds with nickel/cobalt and copper. The TG-DSC analysis confirmed that the melting points of the designed compositions were between 973.7 °C and 981.5 °C. The maximum spreading area of the CoNiCrFeCu-0.9Sc composition on AISI 1045 steel was 64.83 mm², and on the WC-Co cermet it was 78.63 mm². The interface between the fusion zone and AISI 1045 steel exhibited an epitaxial growth of dendrites from the steel base metal. The interface between WC-Co and the fusion zone exhibited a partial penetration of brazing filler into the Co matrix, forming a metallurgical bonding between the dissimilar materials. Sc, as an alloying element in the filler metal, enhanced the bond formation because it decreased the solidus temperature and increased wetting. Full article

To address the surface wear issues of tungsten alloys in die-casting mold applications—where low hardness coupled with severe service conditions involving high-pressure impact from molten metal, thermal cycling, and component counter-friction—this study employed three techniques: laser cladding, plasma spraying, and vacuum surface carburization. Three distinct strengthening coatings were prepared on a tungsten heavy alloy (WHA) substrate. X-ray diffraction (XRD), scanning electron microscopy (SEM), a Vickers hardness tester, and block-on-ring friction and wear tests were employed to characterize the phase composition, microstructure, hardness, and wear resistance of the coatings. The results indicate that all three coatings significantly enhanced the hardness of the substrate, albeit through different strengthening mechanisms. The hardness increase in the laser-clad coating is attributed to the combined strengthening effect of rapid solidification-induced fine grains and dispersed WC particles. The enhanced hardness of the plasma-sprayed coating is due to the intrinsic hardness of WC and its dense layered structure. The carburized layer exhibits the highest hardness, resulting from the continuous WC phase formed via in situ reaction and an interface-free gradient transition with the substrate, which eliminates interfacial weak zones. Under loads of 50 N and 100 N, the plasma-sprayed coating demonstrated the best wear resistance, with wear volumes of 0.16% and 0.18% of that of the substrate, and wear depths of 4.57% and 3.50% of that of the substrate, respectively. It also exhibited the optimal load adaptability, making it a preferred solution for surface strengthening of tungsten alloy die-casting molds. Full article