Search Results (1,332)

The dispersion behavior of ceramic particles in aluminum alloys during rapid solidification critically affects the resulting microstructure and mechanical performance. In this study, we investigated the nucleation and growth of Al₃(Sc,Zr) on TiB₂ surfaces in a 2TiB₂/Al–8Ni–0.6Sc–0.1Zr alloy, fabricated via wedge-shaped copper mold casting and laser surface remelting. Thermodynamic calculations were employed to optimize alloy composition, ensuring sufficient nucleation driving force under rapid solidification conditions. The results show that the formation of Al₃(Sc,Zr)/TiB₂ composite interfaces is highly dependent on cooling rate and plays a pivotal role in promoting uniform TiB₂ dispersion. At an optimal cooling rate (~1200 °C/s), Al₃(Sc,Zr) nucleates heterogeneously on TiB₂, forming core–shell structures and enhancing particle engulfment into the α-Al matrix. Orientation relationship analysis reveals a preferred (111)α-Al//(0001)TiB₂ alignment in Sc/Zr-containing samples. A classical nucleation model quantitatively explains the observed trends and reveals the critical cooling-rate window for composite interface formation. This work provides a mechanistic foundation for designing high-performance aluminum-based composites with uniformly dispersed reinforcements for additive manufacturing applications. Full article

Asphalt plant reclaimed powder is a common solid waste in road engineering. Reusing reclaimed powder as filler holds significant importance for environmental protection and resource conservation. The key factors affecting the feasibility of reclaimed powder reuse are its acidity/alkalinity and cleanliness. Traditional evaluation methods, such as the methylene blue test and plasticity index, can assess reclaimed powder properties to guide its recycling. However, these methods suffer from inefficiency, strong empirical dependence, and high variability. To address these limitations, this study proposes a rapid and precise evaluation method for reclaimed powder properties based on Fourier transform infrared spectroscopy (FTIR). To do so, five field-collected reclaimed powder samples and four artificial samples were evaluated. Scanning electron microscopy (SEM), X-ray fluorescence spectroscopy (XRF), and X-ray diffraction (XRD) were employed to characterize their microphase morphology, chemical composition, and crystal structure, respectively. Subsequently, FTIR was used to establish correlations between key acidity/alkalinity, cleanliness, and multiple characteristic peak intensities. Representative infrared characteristic peaks were selected, and a quantitative functional group index (Is) was proposed to simultaneously evaluate acidity/alkalinity and cleanliness. The results indicate that reclaimed powder primarily consists of tiny, crushed stone particles and dust, with significant variations in crystal structure and chemical composition, including calcium carbonate, silicon oxide, iron oxide, and aluminum oxide. Some samples also contained clay, which critically influenced the reclaimed powder properties. Since both filler acidity/alkalinity and cleanliness are affected by clay (silicon/carbon ratio determining acidity/alkalinity and aluminosilicate content affecting cleanliness), this study calculated four functional group indices based on FTIR absorption peaks, namely the Si-O-Si stretching vibration (1000 cm⁻¹) and the CO₃²⁻ asymmetric stretching vibration (1400 cm⁻¹). These indices were correlated with conventional testing results (XRF for acidity/alkalinity, methylene blue value, and pull-off strength for cleanliness). The results show that the Is index exhibited strong correlations (R² = 0.89 with XRF, R² = 0.80 with methylene blue value, and R² = 0.96 with pull-off strength), demonstrating its effectiveness in predicting both acidity/alkalinity and cleanliness. The developed method enhances reclaimed powder detection efficiency and facilitates high-value recycling in road engineering applications. Full article

This study reports the synthesis and evaluation of iron molybdate (Fe₂(MoO₄)₃) and iron tungstate (FeWO₄) as photocatalysts for the degradation of a real industrial effluent from aluminum anodizing processes under visible light irradiation. The oxides were synthesized via a co-precipitation method in an aqueous medium, followed by microwave-assisted hydrothermal treatment. Structural and morphological characterizations were performed using X-ray diffraction, field-emission scanning electron microscopy, Raman spectroscopy, ultraviolet–visible (UV–vis), and photoluminescence (PL) spectroscopies. The effluent was characterized by means of ionic chromatography, total organic carbon (TOC) analysis, physicochemical parameters (pH and conductivity), and UV–vis spectroscopy. Both materials exhibited well-crystallized structures with distinct morphologies: Fe₂(MoO₄)₃ presented well-defined exposed (001) and (110) surfaces, while FeWO₄ showed a highly porous, fluffy texture with irregularly shaped particles. In addition to morphology, both materials exhibited narrow bandgaps—2.11 eV for Fe₂(MoO₄)₃ and 2.03 eV for FeWO₄. PL analysis revealed deep defects in Fe₂(MoO₄)₃ and shallow defects in FeWO₄, which can influence the generation and lifetime of reactive oxygen species. These combined structural, electronic, and morphological features significantly affected their photocatalytic performance. TOC measurements revealed degradation efficiencies of 32.2% for Fe₂(MoO₄)₃ and 45.3% for FeWO₄ after 120 min of irradiation. The results highlight the critical role of morphology, optical properties, and defect structures in governing photocatalytic activity and reinforce the potential of these simple iron-based oxides for real wastewater treatment applications. Full article

Nowadays, nanosized mesoporous oxides are of increasing interest to scientists. They can be used as components of heterogeneous catalysts, for photo- and electrocatalysis, as gas sensors, etc. For instance, the desired properties in catalysts include a nano size and homogeneity of the particles that form the catalyst. The particle sizes of oxides are set at the initial stage of their formation, as precursors of precipitation in the context of wet chemistry. The creation of optimal conditions is possible through the use of homogeneous precipitation, where the precipitant is formed within the solution itself as a result of a hydrolysis reaction. The resolution of this issue involved the utilization of urea in our experimental setup, obtaining the hydrolysis products of ammonia and carbon dioxide. Consequently, precipitation reactions can be utilized to obtain hydroxides, carbonates, or hydroxy carbonates of metals. The precursors were calcined, obtaining nanosized mesoporous oxides, which can have a wide range of applications. Nanosized 0.1–50 nm metal oxides were obtained, including those aluminum, iron, indium, zinc, nickel, and cobalt. Full article

Understanding the limitations of cold-formed aluminum alloys in practice applications is essential, particularly due to the risk of substructural changes and a reduction in strength when exposed to elevated temperatures. In this study, the thermal stability of the ultra-fine-grained (UFG) structure formed by equal channel angular pressing (ECAP) at room temperature and the mechanical properties of the AlSi7MgCu0.5 alloy were investigated. Prior to ECAP, the plasticity of the as-cast alloy was enhanced by a heat treatment consisting of solution annealing, quenching, and artificial aging to achieve an overaged state. Four repetitive passes via ECAP route A resulted in the homogenization of eutectic Si particles within the α-solid solution, the formation of ultra-fine grains and/or subgrains with high dislocation density, and a significant improvement in alloy strength due to strain hardening. The main objective of this work was to assess the microstructural and mechanical stability of the alloy after post-ECAP annealing in the temperature range of 373–573 K. The UFG microstructure was found to be thermally stable up to 523 K, above which notable grain and/or subgrain coarsening occurred as a result of discontinuous recrystallization of the solid solution. Mechanical properties remained stable up to 423 K; above this temperature, a considerable decrease in strength and a simultaneous increase in ductility were observed. Synchrotron radiation X-ray diffraction (XRD) was employed to analyze the phase composition and crystallographic characteristics, while transmission electron microscopy (TEM) was used to investigate substructural evolution. Mechanical properties were evaluated through tensile testing, impact toughness testing, and hardness measurements. Full article

Aluminum matrix composites provide an ideal solution for lightweight brake disks, but conventional casting processes are prone to crack initiation due to inhomogeneous reinforcement dispersion, gas porosity, and inadequate toughness. To break the conventional trade-off between high wear resistance and low toughness of brake disks, this study fabricated a bimetallic structure of SiC_p/Al–Fe–V–Si aluminum matrix composite and cast ZL101 alloy using friction stir lap welding (FSLW). Then, the microstructural evolution, mechanical properties, and tribological behavior of the FSLW joints were studied by XRD, SEM, TEM, tensile testing, and tribological tests. The results showed that the FSLW process homogenized the distribution of SiC particle reinforcements in the SiC_p/Al–Fe–V–Si composites. The Al₁₂(Fe,V)₃Si heat-resistant phase was not decomposed or coarsened, and the mechanical properties were maintained. The FSLW process refined the grains of the ZL101 aluminum alloy through recrystallization and fragmented eutectic silicon, improving elongation to 22%. A metallurgical bond formed at the joint interface. Tensile fracture occurred within the ZL101 matrix, demonstrating that the interfacial bond strength exceeded the alloy’s load-bearing capacity. In addition, the composites exhibited significantly enhanced wear resistance after FSLW, with their wear rate reduced by approximately 40% compared to the as-received materials, which was attributed to the homogenized SiC particle distribution and the activation of an oxidative wear mechanism. Full article

We simulate the dispersoid distribution within the Al matrix grains of an aluminum 6082 alloy by combining finite difference cell modeling with mean-field precipitation simulations. The results demonstrate that the initial as-cast microstructure and the heating rate during the ramp-up to the isothermal homogenization temperature are the most important factors governing the dispersoid particle distribution. The simulation results are validated by Electron Probe Microanalysis (EPMA) and Optical Microscopy on experimental run products. The results indicate that dispersoids can only achieve uniform distribution throughout the grain when the heating rate to the homogenization temperature is sufficiently slow. Full article

Initially, the effects of sheet combinations for joining two sheets, including 780 MPa steel and A5052 aluminum alloy sheets, on the joined cross-sectional shapes of the sheets in a clinch-bonding process and the tension-shear load of joined sheets were investigated. The effect of an adhesive on the amounts of the interlock and the minimum thickness in the upper sheet was not large, whereas the effect of the sheet combination was observed. Subsequently, for joining the upper 980 MPa ultra-high-strength steel and lower aluminum alloy sheets in the clinch-bonding process, the effects of the die shape, punch velocity, and sheet holding force on the joinability were investigated. As a result, defect-free conditions were narrowly constrained. Finally, a method that involved controlling material flow using an adhesive with fine particles to increase friction between the sheets was introduced. The upper 980 MPa steel and lower aluminum alloy sheets were successfully joined using this approach. Full article

Silica/alumina composite particles were synthesized via the sol–gel method to promote fine dispersion and homogenous mixing. Aluminum chloride hydroxide served as the alumina precursor, while amorphous silica, obtained from rice husk, was directly incorporated into the alumina sol. Following synthesis, the material was calcined at 1000 °C, yielding an α-cristobalite form of silica and corundum-phase alumina. These hybrid particles were introduced into polymer composites at reinforcement levels of 1 wt.%, 3 wt.%, and 5 wt.%. Mechanical behavior was evaluated through three-point bending tests, Shore D hardness measurements, and controlled-energy impact testing. Among the formulations, the 3 wt.% composite exhibited optimal performance, displaying the highest flexural modulus and strength, along with enhanced impact resistance. Hardness increased with rising particle content. Fractographic analysis revealed that the 3 wt.% loading produced a notably rougher fracture surface, correlating with improved energy absorption. In contrast, the 5 wt.% composite, although harder than the matrix and other composites, exhibited diminished toughness due to particle agglomeration. Full article

A ceramic–metal composite was synthesized using sol–gel and electrospinning methods to serve as a SERS substrate. The precursors used were tetraethyl orthosilicate, aluminum nitrate, and zirconium, and polyvinylpyrrolidone was added to electrospun nonwoven fibrous membranes. The membranes were sintered, decorated with silver nanoparticles. The enhancement substrates were made of fibers of cylindric morphology with an average diameter of approximately 190 nm, a smooth surface, and 9 nm spherical particles decorating the surface of the fibers. The enhancement capacity of the substrates was tested using pyridine, methyl orange, methylene blue, crystal violet, and Eriochrome black T at different concentrations with Raman spectroscopy to determine whether the size and complexity of the analyte has an impact on the enhancement capacity. Enhancement factors of 2.53 × 10², 3.06 × 10¹, 2.97 × 10³, 4.66 × 10³, and 1.45 × 10³ times were obtained for the signal of pyridine, methyl orange, methylene blue, crystal violet, and Eriochrome black T at concentrations of 1 nM. Full article

This article presents the results of studies of the degradation of the structure and mechanical properties of the core materials BN-350 fast neutron and research WWR-K reactors required to justify the service life extension of early-generation power and research reactors. Extending the service life of nuclear reactors is a modern problem, since most operating reactors are early-generation reactors that have exhausted their design lifespan. The possibility of extending the service life is largely determined by the condition of the structural materials of the nuclear facility, i.e., their residual resources must ensure safe operation of the reactor. For the SAV-1 alloy, the structural material of the WWR-K reactor, studies were conducted on witness samples which were in the active zone during its operation for 56 years. It was found that yield strength and tensile strength of the irradiated SAV-1 alloy decreased by 24–48%, and relative elongation decreased by ~2% compared to the unirradiated alloy. Inside the grains and along their boundaries, there were particles of secondary phases enriched with silicon, which is typical for aged aluminum alloys. For irradiated structural steels of power reactors, studied at 350–450 C, hardening and a damping nature of creep were revealed, caused by dispersion hardening and the Hall–Petch effect. Full article

In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al₂₇Ca₃Cu₇ primary crystals and ultrafine eutectic particles of (Al,Cu)₄Ca and Al₂₇Ca₃Cu₇ phases in equilibrium with the aluminum solid solution. The solid solutions are additionally strengthened by alloying with Mn and micro additions of Zr, which contribute to the formation of coarsening-resistant phases without compromising the manufacturability of the alloys. Laser remelting, which simulates AM-typical solidification conditions, promotes the formation of a pseudoeutectic cellular structure without the occurrence of undesirable primary Al₂₇Ca₃Cu₇. The size of the dendritic cells and eutectic particles is 10 times smaller (for solidification rates of ~200 K/s) than that of the as-cast state. This structure provides for a higher hardness of the laser-remelted alloy (96 HV) as compared to the as-cast alloy (85 HV). Data for the alloy after 350–400 °C long-term annealing for up to 100 h show that the hardness of the Al–Ca–Cu–Mn–Zr alloys declines relatively slowly by ~7.5% as compared to the Zr-free alloy, whose hardness decreases by ~22%. Thus, one can consider these alloys as a promising candidate for AM processes that require high thermal stability. Full article

Ceramic dental prosthetics with internal metal structures are made from a cobalt–chromium alloy that is coated with ceramic. This study aims to validate surface treatments for the metal that enhance the adhesion of the ceramic coating under masticatory forces. Surface conditioning is performed using mechanical methods, like sandblasting (SB), and thermal methods, such as oxidation (O). The ceramic coating is applied to the metal component following the conditioning process, which can be conducted using either a single method or a combination of methods. Each conditioned sample undergoes characterization through various techniques, including drop shape analysis (DSA), scanning electron microscopy (SEM), X-ray diffraction (EDX), and atomic force microscopy (AFM). After the ceramic coating is applied and subjected to thermal sintering, the metal–ceramic samples are mechanically tested to assess the adhesion of the ceramic layer. The research findings, illustrated by scanning electron microscopy (SEM) images of the metal structures’ surfaces, indicate that alloy powder particles ranging from 10 to 50 µm were either adhered to the surfaces or present as discrete dots. Particles that exceed the initial design specifications of the structure can be smoothed out using sandblasting or mechanical finishing techniques. The energy-dispersive spectroscopy (EDS) results show that, after sandblasting, fragments of aluminum oxide remain trapped on the surface of the metal structures. These remnants are considered impurities, which can negatively impact the adhesion of the ceramic to the metal substrate. The analysis focuses on the exfoliation of the ceramic material from the deformed metal surfaces. The results emphasize the significant role of the sandblasting method and the micro-topography it creates, as well as the importance of the oxidation temperature in the treatment process. Drawing on 25 years of experience in dental prosthetics and the findings from this study, this publication aims to serve as a guide for applying the ceramic bonding layer to metal surfaces and for conditioning methods. These practices are essential for enhancing the adhesion of ceramic materials to metal substrates. Full article

With the gradual depletion of high-quality iron ore resources, global steel enterprises have shifted their focus to low-grade, high-impurity iron ores. Using low-grade iron ore to produce pellets for blast furnaces is crucial for companies to control production costs and diversify raw material sources. However, producing qualified pellets from limonite and other low-grade iron ores remains highly challenging. This study investigates the mechanism by which basicity affects the consolidation and reduction behavior of high-Al₂O₃ limonite pellets from a thermodynamic perspective. As the binary basicity of the pellets increased from 0.01 under natural conditions to 1.2, the compressive strength of the roasted pellets increased from 1100 N/P to 5200 N/P. The enhancement in basicity led to an increase in the amount of low-melting-point calcium ferrite in the binding phase, which increased the liquid phase in the pellets, thereby strengthening the consolidation. CaO infiltrated into large-sized iron particles and reacted with Al and Si elements, segregating the contiguous large-sized iron particles and encapsulating them with liquid-phase calcium ferrite. Calcium oxide reacts with the Al and Si elements in large hematite particles, segmenting them and forming liquid calcium ferrite that encapsulates the particles. Additionally, this study used thermodynamic analysis to characterize the influence of CaO on aluminum elements in high-aluminum iron ore pellets. Adding CaO boosted the liquid phase’s ability to incorporate aluminum, lessening the inhibition by high-melting-point aluminum elements of hematite recrystallization. During the reduction process, pellets with high basicity exhibited superior reduction performance. Full article

Oil condition monitoring can ensure the safe operation of mechanical equipment. Metal debris is full of friction information, and the identification of debris material helps to locate wear of parts. A method based on impedance analysis is proposed to identify debris material in this article. The differences in permeability and conductivity result in the nonlinear variation trend of inductance–resistance amplitude with debris volume. By establishing a database of amplitude–size curves, debris information (material and size) can be obtained through impedance analysis. Based on experimental and simulation results, iron, stainless steel, aluminum, copper, and brass particles are effectively distinguished. This method is not affected by oil’s light transmittance, other impurities, and debris surface dirt and can be used to distinguish metals with similar colors. This work provides a novel solution for debris material identification, which is expected to promote the development of fault diagnosis. Full article