Search Results (961)

TiAl alloy offers advantages including low density, high specific strength and stiffness, and excellent high-temperature creep resistance. It is widely used in the aerospace, automotive, and chemical sectors, as well as in other fields. However, at temperatures of 800 °C and above, it forms a porous oxide film predominantly composed of TiO₂, which fails to provide adequate protection. Applying high-temperature protective coatings is therefore essential. Oxides demonstrating protective efficacy at elevated temperatures include Al₂O₃, Cr₂O₃, and SiO₂. The Pilling–Bedworth Ratio (PBR)—defined as the ratio of the volume of the oxide formed to the volume of the metal consumed—serves as a critical criterion for assessing oxide film integrity. A PBR value greater than 1 but less than 2 indicates superior film integrity and enhanced oxidation resistance. Among common oxides, Al₂O₃ exhibits a PBR value within this optimal range (1−2), rendering aluminum-based compound coatings the most extensively utilized. Aluminum coatings can be applied via methods such as pack cementation, thermal spraying, and hot-dip aluminizing. Pack cementation, being the simplest to operate, is widely employed. In this study, a powder mixture with the composition Al:Al₂O₃:NH₄Cl:CeO₂ = 30:66:3:1 was used to aluminize γ-TiAl intermetallic compound specimens via pack cementation at 600 °C for 5 h. Subsequent isothermal oxidation at 900 °C for 20 h yielded an oxidation kinetic curve adhering to the parabolic rate law. This treatment significantly enhanced the high-temperature oxidation resistance of the γ-TiAl intermetallic compound, thereby broadening its potential application scenarios. 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

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. To optimize the process parameters, single-track depositions were analyzed for both laser-powder DED (feed rate of 2 m/min) and EHLA (feed rate 20 m/min) for AlSi10Mg and Al6061 powders. The cross-sections of single tracks revealed the bonding characteristics and provided laser-powder DED, a suitable parameter selection for the repair. Three damage types were identified on the Al component to define the specification of the repair process and to highlight the capabilities of laser-powder DED and EHLA in repairing intricate surface scratches and dents. Our research is based on variation of the powder mass flow and beam power, studying the influence of these parameters on the weld bead geometry and bonding quality. The evaluation criteria include bonding defects, crack formation, porosity, and dilution zone depth. The bidirectional path planning strategy was applied with a fly-in and fly-out path for the hatching adjustment and acceleration distance. Samples were etched for a qualitative microstructure analysis, and the HV hardness was tested. The novelty of the paper is the new process parameters for laser-powder DED and EHLA deposition strategies to repair large Al components (6061 T6), using AlSi10Mg and Al6061 powder. Our experimental research tested the defect-free deposition and the compatibility of AlSi10Mg on the Al6061 substrate. The readers could replicate the method presented in this article to repair by laser-powder DED/EHLA large Al parts and avoid the replacement of Al components with new ones. Full article

This study investigates the effectiveness of geopolymer-based binders for the stabilization of silty sand, aiming to improve its strength and durability under cyclic environmental conditions. A composite binder consisting of Ground Granulated Blast-furnace Slag (GGBS) and Recycled Glass Powder (RGP), modified with nano poly aluminum silicate (PAS), was used to treat the soil. The long-term performance of the stabilized soil was evaluated under cyclic wetting–drying (W–D) conditions. The influence of PAS content on the mechanical strength, environmental safety, and durability of the stabilized soil was assessed through a series of laboratory tests. Key parameters, including unconfined compressive strength (UCS), mass retention, pH variation, ion leaching, and microstructural development, were analyzed using field emission scanning electron microscopy (FE-SEM) and energy-dispersive X-ray spectroscopy (EDS). Results revealed that GGBS-stabilized specimens maintained over 90% of their original strength and mass after eight W–D cycles, indicating excellent durability. In contrast, RGP-stabilized samples exhibited early strength degradation, with up to an 80% reduction in UCS and 10% mass loss. Environmental evaluations confirmed that leachate concentrations remained within acceptable toxicity limits. Microstructural analysis further highlighted the critical role of PAS in enhancing the chemical stability and long-term performance of the stabilized soil matrix. Full article

The degradation process of HVOF-MCrAlY + APS-nanostructured YSZ (APS-nYSZ) thermal barrier coatings, produced using gas turbine OEM-approved MCrAlY powders, is investigated by studying the TGO growth and crack propagation behaviors in a thermal cycling environment. The TGO growth yields a parabolic mechanism on the surfaces of all HVOF-MCrAlYs, and the growth rate increases with the aluminum content in the “classical” MCrAlYs. The APS-nYSZ layer comprises micro-structured YSZ (mYSZ) and nanostructured YSZ (nYSZ) zones. Both mYSZ/mYSZ and mYSZ/nYSZ interfaces appear to be crack nucleation sites, resulting in crack propagation and consequent crack coalescence within the APS-nYSZ layer in the APS-nYSZ/HVOF-MCrAlY vicinity. Crack propagation in the TBCs can be characterized as a steady-state crack propagation stage, where crack length has a nearly linear relationship with TGO thickness, and an accelerating crack propagation stage, which is apparently a result of the coalescence of neighboring cracks. All TBCs fail in the same way as APS-/HVOF-MCrAlY + APS-conventional YSZ analogs, but the difference in thermal cycling lives is not substantial, although the HVOF-low Al-NiCrAlY encounters chemical failure in the early stage of thermal cycling. Full article

Al-based nanocomposite energetic materials have broad application prospects in explosives and propellants, owing to their excellent energy release efficiency. However, their insufficient reliability, poor stability, and difficulty of formation limit their practical application. This study employed self-assembly using a hydrophilic polymer polyvinylpyrrolidone (PVP) together with nano-aluminum powder (Al), copper oxide (CuO), and ammonium perchlorate (AP) to obtain high-strength and high-activity composite micrometer-sized microspheres. The influence of PVP concentration on the mechanical behavior of Al/AP composite microspheres was systematically investigated, and Al was replaced with ultrasonically dispersed Al/CuO to explore the mechanism of action of PVP in the system and the catalytic behavior of CuO. PVP significantly enhanced the interfacial bonding strength. The Al/AP/5%PVP microspheres achieved a strength of 8.4 MPa under 40% compressive strain, representing a 365% increase relative to Al/AP. The Al/CuO/AP/5%PVP microspheres achieved a strength of 10.2 MPa, representing a 309% increase relative to Al/CuO. The mechanical properties of the composite microspheres were improved by more than threefold, and their thermal reactivities were also higher. This study provides a new method for the controlled preparation of high-strength, high-activity, micrometer-sized energetic microspheres. These materials are expected to be applied in composite solid propellants to enhance their combustion efficiency. Full article

In this work, the development of Al-based metal matrix composites (MMCs) is achieved using hybrid SiC and ZrO₂ reinforcement particles for automotive applications. Powder metallurgy (PM) is employed with various combinations of important process parameters for the fabrication of MMCs. MMCs were characterized using scanning electron microscopy (SEM), X-ray diffractometry (XRD), and a microhardness study. All XRD graphs adequately exhibit Al, SiC, and ZrO₂ peaks, indicating that the hybrid MMC products were satisfactorily fabricated with appropriate mixing and sintering at all the considered fabrication conditions. Also, no impurity peaks were observed, confirming high composite purity. MMC products in all the XRD patterns, suitable for the desired applications. According to the SEM investigation, SiC and ZrO₂ reinforcement components are uniformly scattered throughout Al matrix in all produced MMC products. The occurrence of Al, Si, C, Zr, and O in EDS spectra demonstrates the effectiveness of composite ball milling and sintering under all manufacturing conditions. Moreover, an increase in interfacial bonding of fabricated composites at a higher sintering temperature indicated improved physical properties of the developed MMCs. The highest microhardness value is 86.6 HVN amid all the fabricated composites at 7% silica, 14% zirconium dioxide, 500° sintering temperature, 90 min sintering time, and 60 min milling time. An integrated Particle Swarm Optimization–Support Vector Machine (PSO-SVM) model was developed to predict microhardness based on the input parameters. The model demonstrated strong predictive performance, as evidenced by low values of various statistical metrics for both training and testing datasets, highlighting the PSO-SVM model’s robustness and generalization capability. Specifically, the model achieved a coefficient of determination of 0.995 and a root mean square error of 0.920 on the training set, while on the testing set, it attained a coefficient of determination of 0.982 and a root mean square error of 1.557. These results underscore the potential of the PSO-SVM framework, which can be effectively leveraged to optimize process parameters for achieving targeted microhardness levels for the developed Al-SiC-ZrO₂ Composites. 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

The slurry aluminizing process is widely employed to enhance the oxidation and corrosion resistance of nickel-based superalloys used in high-temperature environments such as gas turbines and aerospace engines. This study investigates the effects of the concentration of Al vapors in the reactor chamber and the initial slurry layer thickness on the microstructure, chemical composition, and phase composition of aluminide coatings. Coatings were manufactured on Ni-based superalloy substrates using CrAl powders as an aluminum source and chloride- and fluoride-based activator salts. The effect of the initial thickness of the slurry layer was studied by varying the amount of deposited slurry in terms of mg_slurry/cm²_sample (with constant mg_slurry/cm³_chamber). The microstructure and phase composition of the produced aluminide coatings were evaluated by SEM, EDS, and XRD analysis. Slurry thickness can affect concentration gradients during diffusion, and the best results were obtained with an initial slurry amount of 100 mg_slurry/cm²_sample. The effect of the Al vapor phase in the reaction chamber was then investigated by varying the mg_slurry/cm³_chamber ratio while keeping the slurry layer thickness constant at 100 mg_slurry/cm²_sample. This parameter influences the amount of Al at the substrate surface before the onset of solid-state diffusion, and the best results were obtained for a 6.50 mg_slurry/cm³_chamber ratio with the formation of 80 µm coatings (excluding the interdiffusion zone) with a β-NiAl phase throughout the thickness. To validate process flexibility, the same parameters were successfully applied to produce platinum-modified aluminides with a bi-phasic ζ-PtAl2 and β-(Ni,Pt)Al microstructure. Full article

Thermally conductive polymer composites are essential for effective heat dissipation in electronic packaging, where both thermal management and mechanical reliability are critical. Although diglycidyl ether of bisphenol-A (DGEBA)-based epoxies exhibit favorable properties, their intrinsically low thermal conductivity limits broader applications. Incorporating conductive fillers, such as expanded graphite (EG) and metal powders, enhances heat transport but often compromises mechanical strength due to poor filler–matrix compatibility. In this study, we address this trade-off by employing a titanate coupling agent to surface-modify aluminum (Al) fillers, thereby improving interfacial adhesion and dispersion within the DGEBA matrix. Our results show that incorporating 10 wt% untreated Al increases thermal conductivity from 7.35 to 9.60 W/m·K; however, this gain comes at the cost of flexural strength, which drops to 18.29 MPa. In contrast, titanate-modified Al (Ti@Al) not only preserves high thermal conductivity but also restores mechanical performance, achieving a flexural strength of 35.31 MPa (at 5 wt% Ti@Al) and increasing impact strength from 0.60 to 1.01 kJ/m². These findings demonstrate that interfacial engineering via titanate coupling offers a compelling strategy to overcome the thermal–mechanical trade-off in hybrid composites, enabling the development of high-performance materials for advanced thermal interface and structural applications. Full article

This study examines the corrosion characteristics of GRX-810, a NiCoCr-based high entropy alloy, in a simulated marine environment represented by 3.5 wt.% NaCl solution. The research employs electrochemical and surface analysis techniques to evaluate the corrosion performance and protective mechanisms of this alloy. Electrochemical characterization was performed using potentiodynamic polarization to determine critical corrosion parameters, including corrosion potential and current density, along with electrochemical impedance spectroscopy to assess the stability and protective qualities of the oxide film. Surface analytical techniques provided detailed microstructural and compositional insights, with scanning electron microscopy revealing the morphology of corrosion products, energy-dispersive X-ray spectroscopy identifying elemental distribution in the passive layer, and X-ray diffraction confirming the chemical composition and crystalline structure of surface oxide. The results demonstrated distinct corrosion resistance behavior between the different processing conditions of the alloy. The laser powder bed fused (LPBF) specimens in the as-built condition exhibited superior corrosion resistance compared to their hot isostatically pressed (HIPed) counterparts, as evidenced by higher corrosion potentials and lower current densities. Microscopic examination revealed the formation of a dense, continuous layer of corrosion products on the alloy surface, indicating effective barrier protection against chloride ion penetration. A compositional analysis of all samples identified oxide film enriched with chromium, nickel, cobalt, aluminum, titanium, and silicon. XRD characterization confirmed the presence of chromium oxide (Cr₂O₃) as the primary protective phase, with additional oxides contributing to the stability of the film. This oxide mixture demonstrated the alloy’s ability to maintain passivity and effective repassivation following film breakdown. Full article

Aluminum and its alloy magnetron sputtering targets, owing to their superior electrical/thermal conductivity and robust substrate adhesion, serve as critical materials in advanced electronics and information technologies. It is known that the microstructure of the target, including grain uniformity and crystallographic texture, directly affects the sputtering performance and the quality of the deposited thin film. Despite extensive research efforts, the review paper focused on the microstructure of aluminum target materials is still absent. In that context, the recent progress on the Al alloy target is reviewed, focusing on grain refinement and texture control strategies. The roles of alloying elements, such as Si, Cu, and rare-earth Sc and Nd, are described first. The two conventional manufacturing techniques of fabricating Al targets, including melting and powder metallurgy, are introduced. Then, studies on grain refinement by thermomechanical processing routes (hot/cold rolling, annealing and forging) are summarized. Lastly, texture engineering through deformation and heat treatment protocols (unidirectional/multidirectional rolling, deformation thickness, and composite deformation modes) is reviewed. By establishing the relationship between thermomechanical processing and microstructure, this review provides insights for designing high-performance aluminum targets tailored to next-generation advanced thin-film applications. Full article

This study presents a novel flake powder metallurgy approach for fabricating Al/CNT composites, combining the dual-matrix (DM) method with shift-speed ball milling (SSBM) to optimize mechanical performance. Samples prepared via DM-SSBM were systematically compared to those produced by conventional high-speed ball milling (HSBM), single-stage SSBM, and dual-matrix (DM) routes. Tensile testing revealed that the DM₁MR₅₀-SSBM composite achieved a superior balance of strength and ductility, with an ultimate tensile strength of ~267 MPa, elongation of ~9.9%, and the highest energy absorption capacity (~23.4 MJ/m³) among all tested samples. In contrast, the HSBM sample, while achieving the highest tensile strength (~328 MPa), exhibited limited elongation (~4.7%), resulting in lower overall toughness. The enhanced mechanical response of the DM-SSBM composites is attributed to improved CNT dispersion, refined cold-welding interfaces, and pure Al matrix softness, which together facilitate superior load transfer and hinder crack propagation under tensile stress. In the final consolidated state, aluminum forms a continuous matrix embedding the CNTs, justifying the use of the term “aluminum matrix” to describe the composite structure. These findings highlight the DM-SSBM approach as a promising method for developing lightweight, high-toughness aluminum composites suitable for energy-absorbing structural applications. Full article

Pyrometallurgical recycling of lithium-ion batteries presents distinct advantages including streamlined processing, simplified pretreatment requirements, and high throughput capacity. However, its industrial implementation faces challenges associated with high energy demands and lithium loss into slag phases. This investigation develops an integrated reduction smelting–chloridizing volatilization process for the comprehensive recovery of strategic metals (Li, Mn, Cu, Co, Ni) from spent ternary lithium-ion batteries; calcium chloride was selected as the chlorinating agent for this purpose. Thermodynamic analysis was performed to understand the phase evolution during reduction smelting and to design an appropriate slag composition. Preliminary experiments compared carbon and aluminum powder as reducing agents to identify optimal operational parameters: a smelting temperature of 1450 °C, 2.5 times theoretical CaCl₂ dosage, and duration of 120 min. The process achieved effective element partitioning with lithium and manganese volatilizing as chloride species, while transition metals (Cu, Ni, Co) were concentrated into an alloy phase. Process validation in an induction furnace with N₂-O₂ top blowing demonstrated enhanced recovery efficiency through optimized oxygen supplementation (four times the theoretical oxygen requirement). The recovery rates of Li, Mn, Cu, Co, and Ni reached 94.1%, 93.5%, 97.6%, 94.4%, and 96.4%, respectively. This synergistic approach establishes an energy-efficient pathway for simultaneous multi-metal recovery, demonstrating industrial viability for large-scale lithium-ion battery recycling through minimized processing steps and maximized resource utilization. Full article

The synthesis of oxide nanopowders through ultrasonic spray pyrolysis (USP) represents a sustainable method for producing high-purity, spherical particles tailored for advanced material applications. Recent developments in USP synthesis leverage the continuous transport of aerosols from an ultrasonic generator to a high-temperature furnace, with nanopowders collected efficiently using an electrostatic precipitator. This study explored the use of USP for titanium oxysulfate and aluminum nitrate solutions derived from the aluminum industry, focusing on resource recovery and waste reduction. Titanium oxysulfate was synthesized by leaching slag, generated during the reduction of red mud, with sulfuric acid under oxidizing, high-pressure conditions. After purification, the titanium oxysulfate solution was processed using USP in a hydrogen reduction atmosphere to yield spherical titanium dioxide (TiO₂) nanopowders. The hydrogen atmosphere enabled precise control over the nanoparticles’ morphology and crystallinity, enhancing their suitability for use in applications such as photocatalysis, pigments, and advanced coatings. In parallel, both synthetic and laboratory solutions of aluminum nitrate [Al(NO₃)₃] were prepared. The laboratory solution was prepared by leaching aluminum hydroxide oxide (AlOOH) with hydrochloric acid to form aluminum chloride (AlCl₃), followed by a conversion to aluminum nitrate through the addition of nitric acid. The resulting aluminum nitrate solution was subjected to USP, producing highly uniform, spherical alumina (Al₂O₃) nanopowders with a narrow size distribution. The resulting nanopowders, characterized by their controlled properties and potential applicability, represent an advancement in oxide powder synthesis and resource-efficient manufacturing techniques. Full article