Search Results (237)

This study investigated into how different current input levels during cold metal transfer (CMT) welding affected the characteristics of the weld bead. For the current variation, three input values were taken: 80 A, 90 A, and 100 A. Weld beads fabricated from all three current inputs were compared by analysing their microstructure, microhardness, tensile strength, and residual stress. The microhardness of the weld bead decreased when the current parameter was increased from 80 A to 100 A. The average tensile strength increased from 80 A to 90 A. The lowest residual stress calculated was −135 MPa with 100 A current. Full article

The anodic oxide layer’s porosity is considered a functional feature, acting as a reservoir of lubricants. This feature enables the design of self-lubricating systems that effectively reduce friction and wear. To improve the tribological performance of Al₂O₃ anodic coatings on EN AW 5251 aluminium alloys, this paper presents a modification of the coating with tungsten disulfide (IF-WS₂) nanopowder and its effect on coating resistance. The wear properties of Al₂O₃/IF-WS₂ coatings in contact with a cast iron pin were investigated. The results include the analysis of the friction coefficient in the reciprocating motion without oil lubrication at two loads, the analysis of the wear intensity of the cast iron pin, the characterisation of wear scars, and the analysis of SGP parameters. Two-level factorial analysis showed that load and nanomodification significantly affected the load-bearing parameter Rk. Incorporation of the modifier, especially under higher loads, reduced the Rk value, thus improving the tribological durability of the contact pair. Both load and nanomodification had a notable impact on the coefficient of friction. The use of IF-WS₂-modified coatings reduced the coefficient, and higher loads further enhanced this effect, by approximately 9% at a load of 0.3 MPa and 15% at a load of 0.6 MPa, indicating improved lubricating conditions under greater contact stress. Full article

Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a series of fatigue tests conducted at varying stress levels. The material showed significant variability under identical fatigue conditions, suggesting the presence of microstructural defects. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and scanning transmission electron microscopy (S/TEM) were used to identify the nature and location of the defects and evaluate the underlying mechanisms influencing the fatigue performance. Computer tomography (CT) also confirmed the presence of oxide inclusions on the fracture surface and near the edges of the samples. These oxide inclusions are distributed throughout the material heterogeneously and in the form of broken oxide films, suggesting that they might have originated during the material’s early processing stages. These oxides acted as stress concentrators, initiating microcracks that led to catastrophic and unpredictable early failure, ultimately reducing the fatigue life of micro-oxide-containing samples. These results highlight the need for better casting control and improved post-processing techniques to minimise the effect of oxide presence in the final components, thus enhancing their fatigue life. Full article

Approximately 20% of emissions from air travel are attributed to the auxiliary power units (APUs) carried in commercial aircraft. This paper proposes to reduce greenhouse gas emissions in international air transport by adopting proton-exchange membrane (PEM) fuel cells to replace APUs in commercial aircraft: we consider the design of three compressed hydrogen storage vessels made of 304 stainless steel, 6061-T6 aluminium, and Grade 5 (Ti-6Al-4V) titanium and capable of delivering 440 kW—enough for a PEM fuel cell for a Boeing 777. Complete structural analyses for pressures from 35 MPa to 70 MPa and wall thicknesses of 25, 50, 100, and 150 mm are used to determine the optimal material for aviation applications. Key factors such as deformation, safety factors, and Von Mises equivalent stress are evaluated to ensure structural integrity under a range of operating conditions. In addition, CO₂ emissions from a conventional 440 kW gas turbine APU and an equivalent PEM fuel cell are compared. This study provides insights into optimal material selection for compressed hydrogen storage vessels, emphasising safety, reliability, cost, and weight reduction. Ultimately, this research aims to facilitate the adoption of fuel cell technology in aviation, contributing to greenhouse emissions reduction and hence sustainable air transport. Full article

The forging industry has increasingly emphasised quality and reproducibility, making computer simulations essential for predicting and improving the process. A major challenge in cold upset forging is billet buckling, which leads to defective products. Existing numerical models, such as the Euler and Rankine-Gordon formulas, mainly focus on elastic buckling. This study aimed to develop a numerical model that defined inelastic buckling during forging, particularly in cold upset forging, which could be used to determine the buckled billets and their stresses, identify the deflection point for different billet geometries, and specify the optimum billet geometry for aluminium. A numerical approach was used to model the forging operation and obtain simulation data for stress variation against die strokes. Seven billet geometries (10–40 mm in diameter, each with a length of 120 mm) and three frictional conditions (µ = 0.12, 0.16, and 0.35) were applied. The simulation results showed that the billet geometry and the strain hardening exponent had a crucial impact on the buckling behaviour, while friction seemed to alter the overall billet stresses. Rigorous non-linear regression and iterations showed that the numerical model successfully estimated the buckling stresses but failed to identify the buckling points through stress differences. Full article

Beneficial interactions between nitrogen-fixing soil bacteria and legumes offer a solution to increase crop yield on Earth and potentially in future Martian colonies. Paraburkholderia phymatum is a nitrogen-fixing beta-rhizobium, which enters symbiosis with more than 50 legumes and can survive in acidic or aluminium-rich soils. In a previous RNA-sequencing study, we showed that the beta-rhizobium P. phymatum grows well in simulated microgravity and identified phymabactin as the only siderophore produced by this strain. Here, the growth of the beta-rhizobium P. phymatum was assessed in Martian simulant soil using Enhanced Mojave Mars Simulant 2 (MMS-2), which contains a high amount of iron (18.4 percent by weight) and aluminium (13.1 percent by weight). While P. phymatum wild-type’s growth was not affected by exposure to MMS-2, a mutant strain impaired in siderophore biosynthesis (ΔphmJK) grew less than P. phymatum wild-type on gradient plates in the presence of a high concentration of MMS-2 or aluminium. This result suggests that the P. phymatum siderophore phymabactin alleviates aluminium-induced heavy metal stress. Ultra-high performance liquid chromatography–mass spectrometry (UHPLC-MS) showed that phymabactin can bind to aluminium more efficiently than iron. These results not only deepen our understanding of the behaviour of rhizobia in simulated extraterrestrial environments but also provide new insights into the potential use of P. phymatum for bioremediation of aluminium-rich soils and the multiple roles of the siderophore phymabactin. Full article

This work presents an exhaustive parametric study of the multi-scale residual stress analysis on arbitrary substrate geometry based on a one-way-coupled thermo-mechanical model in an Atmospheric Plasma Spray process. It was carried out by modifying key process parameters, such as substrate surface geometry, substrate pre-heating temperature, and coating thickness, in an Al₂O₃ coating process on an aluminium substrate. The relationship of these parameters to the generation of quenching stress, thermal stress and residual stress was analysed at three different sub-modelling scales, from the macroscopic dimension of the substrate to the microscopic dimension of the splats. The thermo-mechanical phenomena occurring during the deposition process at the microscopic level were discussed in the proposed cases. Understanding these phenomena helps to optimise the parameters of the coating process by identifying the underlying mechanisms responsible for the generation of residual stresses. The simulated residual stresses of the 200 μm Al₂O₃ outer coated aluminium cylinder were experimental validated using the incremental high-speed micro-hole drilling and milling method. Full article

The accuracy of numerical predictions in sheet metal processes involving multiaxial stress–strain states (e.g., blanking, riveting, and incremental forming) heavily depends on the characterisation of plastic anisotropy under multiaxial loading conditions. A fully calibrated 3D plastic anisotropy model is essential for this purpose. While in-plane material behaviour can be conventionally characterised through uniaxial and equi-biaxial tensile tests, calibrating out-of-plane material behaviour remains a significant challenge. This behaviour, governed by out-of-plane shear stress and associated material parameters, is typically described by out-of-plane shear yielding. These parameters are notoriously difficult to determine, leading researchers to frequently assume isotropic behaviour or identical shear parameters for in-plane and out-of-plane responses. Although advanced calibrations may utilise crystal plasticity modelling, there remains a critical need for macro-mechanical characterisation methods. This paper presents an out-of-plane shear testing and material characterisation procedure based on full-field strain measurements using digital image correlation (DIC). Strains within the shear zone are measured via DIC and employed in the Finite Element Model Updating (FEMU) to identify out-of-plane shear parameters of a 2.42 mm thick, cold-rolled AW5754-H22 aluminium alloy sheet, using the Yld2004-18p yield criterion. Given that the characteristic strain response at this scale may be influenced by local crystal structure behaviour on the surface, this paper evaluates the feasibility of such measurements. Finally, to test the validity of the full-field-based approach, the FEMU-identified parameters are compared against results obtained through a classical optimisation procedure based on force-elongation measurements from the shear zone. Full article

Aluminium is an attractive material for proton-exchange-membrane fuel cell bipolar plates as it has a much lower density than steel and is easier to form than both steel and graphite. This work focused on the development of amorphous carbon films deposited using closed-field unbalanced magnetron sputtering (CFUBMS) in order to improve the corrosion resistance of aluminium bipolar plates and to enhance fuel cell performance and durability. Chromium and tungsten adhesion layers were used for the coatings. It was possible to achieve good electrical conductivity and high electrochemical corrosion resistance up to 70 °C on polished Aluminium alloy 6082 by tuning the deposition parameters. Coatings with a tungsten adhesion layer showed better corrosion resistance than those with a chromium adhesion layer. In situ, accelerated stress testing of single cells was performed using uncoated and coated Al6082 bipolar plates. Both coatings resulted in improved fuel cell performance compared to uncoated aluminium when used on the cathode side of the fuel cell. Full article

In the present article, the effect of artificial ageing on tensile mechanical properties and resistance to corrosion of aluminium alloy 2198-T3 was investigated. The results were obtained under the framework of the Greek National project “CorLi”, which was targeted to document the mechanical behaviour of the alloy under different artificial ageing conditions, simulating the natural ageing of aircraft structures during their operation lifespan. Four (4) different ageing conditions corresponding to under-aged (UA), peak-aged (PA), and over-aged (OA) tempers based on the initial, T3 temper, were considered. In the PA condition, the conventional yield stress R_p0.2% increased by more than 50% with a simultaneous 46% decrease in tensile elongation at fracture A_f. Additionally, the effect of corrosion was found to be different for the different artificial ageing tempers of AA2198, with lower charge transfer resistance (R_CT) observed for artificially aged specimens. Nevertheless, the corrosion-induced degradation rate of R_CT was found to decrease with increasing ageing time. Full article

The widespread adoption of metal implants in orthopaedics and dentistry has revolutionized medical treatments, but concerns remain regarding their biocompatibility, toxicity, and immunogenicity. This study conducts a comprehensive literature review of traditional biomaterials used in orthopaedic surgery and traumatology, with a particular focus on their historical development and biological interactions. Research articles were gathered from PubMed and Web of Science databases using keyword combinations such as “toxicity, irritation, allergy, biomaterials, corrosion, implants, orthopaedic surgery, biocompatible materials, steel, alloys, material properties, applications, implantology, and surface modification”. An initial pool of 400 articles was screened by independent reviewers based on predefined inclusion and exclusion criteria, resulting in 160 relevant articles covering research from 1950 to 2025. This paper explores the electrochemical processes of metals like iron, titanium, aluminium, cobalt, molybdenum, nickel, and chromium post-implantation, which cause ion release and wear debris formation. These metal ions interact with biological molecules, triggering localized irritation, inflammatory responses, and immune-mediated hypersensitivity. Unlike existing reviews, this paper highlights how metal–protein interactions can form antigenic complexes, contributing to delayed hypersensitivity and complications such as peri-implant osteolysis and implant failure. While titanium is traditionally considered bioinert, emerging evidence suggests that under certain conditions, even inert metals can induce adverse biological effects. Furthermore, this review emphasizes the role of oxidative stress, illustrating how metal ion release and systemic toxicity contribute to long-term health risks. It also uncovers the underappreciated genotoxic and cytotoxic effects of metal ions on cellular metabolism, shedding light on potential long-term repercussions. By integrating a rigorous methodological approach with an in-depth exploration of metal-induced biological responses, this paper offers a more nuanced perspective on the complex interplay between metal implants and human biology, advancing the discourse on implant safety and material innovation. Full article

This study addressed the challenges of excessive eddy current losses and elevated thermal risks to permanent magnets in titanium alloy rotor sleeves for high-speed permanent magnet synchronous motors (HSPMSMs). Focusing on a 10 kW, 30,000 rpm high-speed motor, we innovatively propose incorporating insulating layers between axially laminated sleeve structures. Current research primarily mitigates eddy currents through the limited axial segmentation of sleeves/permanent magnets or radial shielding layers, while the technical approach of applying insulating coatings between laminated sleeves remains unexplored. This investigation demonstrated that compared with conventional solid sleeves, segmented sleeves, and carbon fibre sleeves, the laminated structure with a coordinated design of aluminium oxide and epoxy resin insulating layers effectively blocked the eddy current paths to achieve a substantial reduction in the sleeve eddy current density. This research concurrently highlights that the dynamic stress response and long-term operational reliability require further experimental validation. Subsequent investigations could explore optimised lamination patterns, parameter matching of insulating layers, and integration with emerging cooling technologies, thereby advancing synergistic breakthroughs in lightweight design and thermal management for high-speed motor rotors. Full article

There is currently no research examining the rheological properties of cementitious paste backfill (CPB) materials containing aluminium oxide nanoparticles (nAlO). Knowing the yield stress and viscosity of CPB containing nAlO is crucial, especially when applying nano-CPB technology in underground mines. The purpose of this work is to thoroughly examine how nAlO affects the rheological characteristics of CPB and how those characteristics change over time. Yield stress and viscosity measurements are performed on CPB samples with different compositions (e.g., nAlO content, binder type, and superplasticizer content) at intervals of 0 min, 20 min, 1 h, 2 h, and 4 h. The study also includes measurements of the pH and zeta potential of the materials, microstructural studies (TG/DTG and XRD), and electrical conductivity (EC). The findings show that adding nAlO to CPB significantly changes its rheological properties, which in turn affects flowability. The yield stress and viscosity of CPB samples are greatly increased by the incorporation of nAlO, with the degree of influence varying based on variables including water content, curing duration, and type of binder. Because of the nAlO-induced microstructural changes in the CPB material, the interaction of nAlO and a larger fraction of nAlO, along with an increase in curing time, raises rheological characteristics and decreases paste flowability. The results of EC, DTG, and XRD, which show that binder hydration improves with nAlO dosage, corroborate this. Moreover, as nAlO content increases, the zeta potential decreases in magnitude, resulting in stronger repulsion forces and reduced flowability. However, EC, XRD, and DTG analyses suggest that the addition of 0.125% superplasticizer counteracts the flowability reduction caused by nAlO, as the superplasticizer slows down the cement hydration rate at very early curing stages. Moreover, the increase in the slag percentage from 0% to 50% and 75% of the binder content slightly decreases viscosity but greatly increases yield stress. The study’s fresh perspectives contribute to the advancement of nano-CPB technology and have important ramifications for the practical use of this technology in underground mine backfill operations. Full article

Aluminum (Al) toxicity is a major constraint to crop productivity in acidic soils, frequently encountered in banana-growing regions. This study investigates physiological and biochemical responses to Al stress in two Cavendish banana genotypes, Baodao and Baxi (Musa acuminata L.), which exhibit contrasting levels of Al tolerance. Banana plantlets were grown hydroponically under three AlCl₃ concentrations (0, 100, and 500 μM) for 24, 48, and 72 h. Root elongation was progressively inhibited with increasing Al concentrations, with Baodao showing greater inhibition than Baxi. Al primarily accumulated in roots and displayed genotype-specific distribution patterns: Baodao concentrated more Al in root tips, suggesting lower exclusion efficiency. In contrast, Baxi, the Al-tolerant genotype, translocated Al from roots to shoots more effectively, indicating potential sequestration mechanisms in less sensitive tissues. Al stress influenced enzyme activities, with Baxi exhibiting higher phosphoenolpyruvate carboxylase and citrate synthase activities at 100 µM Al, while both genotypes showed similar reductions at 500 µM. Baodao experienced more pronounced reductions in H⁺-ATPase activity. At 100 µM Al, Baxi retained higher levels of key nutrients (P, Zn, Mg, Mn, Fe, K, and B) in essential tissues than Baodao. However, nutrient levels were reduced in both genotypes at 500 µM Al. These findings highlight Baxi’s superior resilience under Al stress, making it a suitable genotype for cultivation and breeding in acidic soils. Full article

An EN AW-6082 aluminium alloy is one of the 6000 series aluminium alloys with the highest strength properties. Due to its favourable strength-to-density ratio, it is used, among others, in the automotive and aviation applications. It is also characterised by good formability, especially in the annealed condition. This article presents the results of investigations on the possibility of forming a 2 mm thick EN AW-6082 alloy sheet using the incremental sheet-forming process depending on the material condition (O, W, T4, T6). The microstructure of the material after heat treatment and the mechanical properties of the workpiece material in as-received state, as well as after forming, were examined. Additionally, for selected cases, additional heat treatment of the drawpieces was performed to improve their mechanical strength. The values of the limit-forming angle were determined for the materials tested. The values of this angle varied from 69° for the annealed sheet to 61° for the material in the T6 condition. The highest yield stress (YS) and ultimate tensile strength (UTS) were found for sheets (YS = 305 MPs and UTS = 324 MPa) and the artificially aged drawpieces (YS = 333 MPa and UTS = 390 MPa). Additional ageing after incremental sheet forming resulted in an increase in strength properties compared to drawpieces without additional heat treatment only in the case of drawpieces made of sheet metal after the solutionising and in T4 condition. Full article