Search Results (487)

Secondary hypereutectic Al-Si alloys are attractive for sustainable manufacturing, yet their application is often limited by low strength and electrical conductivity due to impurity-induced microstructural defects. Achieving a balance between mechanical and conductive performance remains a significant challenge. In this work, nickel-coated carbon nanotubes (Ni-CNTs) were introduced into secondary Al-20Si alloys to tailor the microstructure and enhance properties through interfacial engineering. Composites containing 0 to 0.4 wt.% Ni-CNTs were fabricated by conventional casting and systematically characterized. The addition of 0.1 wt.% Ni-CNTs resulted in the best combination of properties, with a tensile strength of 170.13 MPa and electrical conductivity of 27.60% IACS. These improvements stem from refined α-Al dendrites, uniform eutectic Si distribution, and strong interfacial bonding. Strengthening was achieved through grain refinement, Orowan looping, dislocation generation from thermal mismatch, and the formation of reinforcing interfacial phases such as AlNi₃C₀.₉ and Al₄SiC₄. At higher Ni-CNT contents, property degradation occurred due to agglomeration and phase coarsening. This study presents an effective and scalable strategy for achieving strength–conductivity synergy in secondary aluminum alloys via nanoscale interfacial design, offering guidance for the development of multifunctional lightweight materials. 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

Diverging from conventional dephosphorization approaches, this study employs a novel pre-reduction and smelting separation (PR-SS) to efficiently co-recover iron and phosphorus from high-phosphorus oolitic iron ore, directly yielding Fe–P alloy, and the Fe–P alloy shows potential as feedstock for high-phosphorus weathering steel or wear-resistant cast iron, indicating promising application prospects. Using oolitic magnetite concentrate (52.06% Fe, 0.37% P) as feedstock, optimized conditions including pre-reduction at 1050 °C for 2 h with C/Fe mass ratio of 2, followed by smelting separation at 1550 °C for 20 min with 5% coke, produced a metallic phase containing 99.24% Fe and 0.73% P. Iron and phosphorus recoveries reached 99.73% and 99.15%, respectively. EPMA microanalysis confirmed spatial correlation between iron and phosphorus in the metallic phase, with undetectable phosphorus signals in vitreous slag. This evidence suggests preferential phosphorus enrichment through interfacial mass transfer along the pathway of the slag phase to the metal interface and finally the iron matrix, forming homogeneous Fe–P solid solutions. The phosphorus migration mechanism involves sequential stages: apatite lattice decomposition liberates reactive P₂O₅ under SiO₂/Al₂O₃ influence; slag–iron interfacial co-reduction generates Fe₃P intermediates; Fe₃P incorporation into the iron matrix establishes stable solid solutions. Full article

Residual stresses generated during the casting process significantly affect the reliability of the final product, making accurate prediction and analysis of these stresses crucial. In particular, to minimize the difference between simulation results and actual measurements, it is essential to develop predictive simulations that incorporate microstructural characteristics. Therefore, in this study, residual stress prediction simulations were conducted for aluminum components manufactured by high-pressure die casting (HPDC), and measurement locations were selected based on the simulation results. Subsequently, the microstructural characteristics at each location (Si and intermetallic compounds) were quantitatively analyzed, and significant factors affecting residual stress were identified through design of experiments (DOE). As a result, Si sphericity (p-value ≤ 0.05) was observed to be the most significant factor among Si area fraction, IMC area fraction, and Si sphericity, and the residual stress and Si sphericity showed a positive interaction due to the rapid cooling rate and inhomogeneous microstructure distribution. Furthermore, the study demonstrated the effectiveness of DOE in clearly distinguishing the significance of variables with strong interdependencies. Full article

The present study examines the structure, properties and use of complex-alloyed hypereutectic aluminium-silicon alloys, emphasising the control of the morphology of primary silicon via treatment with various modifiers as well as their effects on its shape and distribution. Furthermore, this study reviews the experimental work related to the simultaneous modification of primary and eutectic silicon, which leads to the conclusion that favourable results can be obtained by complex modification treatment involving first- and second-type modifiers. After being cast, the AlSi18Cu3CrMn and AlSi18Cu5Mg non-standardised piston alloys are subjected to T6 heat treatment intended to enhance their mechanical performance, harnessing the full potential of the alloying elements. A microstructural analysis of the shape and distribution of both primary and eutectic silicon crystals following heat treatment was employed to determine their microhardness. Full article

The weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical properties compared to the results for casting. However, the high cost of forging can limit its economic feasibility. Low pressure forging (LPF) combines the benefits of casting and forging, employing controlled pressure to fill the mold cavity and improve metal purity. This study investigates the effectiveness of the LPF process in optimizing the mechanical properties of AlSi7Mg aluminum alloy by evaluating the influence of three different magnesium content levels. The specimens underwent T6 heat treatment (solubilization treatment followed by artificial aging), with varying aging times and temperatures. Microstructural analysis and tensile tests were conducted to determine the optimal conditions for achieving superior mechanical strength, contributing to the design of lightweight, high-performance components for advanced automotive applications. The most promising properties were achieved with a T6 treatment consisting of solubilization at 540 °C for 6 h followed by aging at 180 °C for 4 h, resulting in mechanical properties of σ_y 280 MPa, σ_m 317 MPa, and A% 3.5%. Full article

With the ongoing development of lightweight automobiles, research on new aluminum alloys and welding technology has gained significant attention. Friction stir welding (FSW) is a solid-state joining technique for welding aluminum alloys without melting. In this study, novel squeeze-cast Al-Si-Mg-Fe-Zn alloys with different Zn contents (0, 3.4, 6.5, and 8.3 wt%) were friction stir welded (FSWed) at a translational speed of 200 mm/min and a rotational speed of 800 rpm. These parameters were chosen based on the observations of visually sound welds, defect-free and fine-grained microstructures, homogeneous secondary phase distribution, and low roughness. Zn can affect the microstructure of Al-Si-Mg-Fe-Zn alloys, including the grain size and the content of secondary phases, leading to different mechanical and corrosion behavior. Adding different Zn contents with Mg forms the various amount of MgZn₂, which has a significant strengthening effect on the alloys. Softening observed in the weld zones of the alloys with 0, 3.4, and 6.5 wt% Zn is primarily attributed to the reduction in Kernel Average Misorientation (KAM) and a decrease in the Si phase and MgZn₂. Consequently, the mechanical strengths of the FSWed joints are lower as compared to the base material. Conversely, the FSWed alloy with 8.3 wt% Zn exhibited enhanced mechanical properties, with hardness of 116.3 HV_0.2, yield strength (YS) of 184.4 MPa, ultimate tensile strength (UTS) of 226.9 MP, percent elongation (EL%) of 1.78%, and a strength coefficient exceeding 100%, indicating that the joint retains the strength of the as-cast one, due to refined grains and more uniformly dispersed secondary phases. The highest corrosion resistance of the FSWed alloy with 6.5%Zn is due to the smallest grain size and KAM, without MgZn₂ and the highest percentage of {111} texture (24.8%). Full article

Interpenetrating phase composites (IPCs) have demonstrated tremendous potential across various fields, particularly those based on triply periodic minimal surface (TPMS) structures, whose uniquely interwoven lattice architectures have attracted widespread attention. However, current research on the dynamic mechanical properties of such IPC remains limited, and their impact resistance and damage mechanisms are yet to be thoroughly understood. In this study, a novel design of two volume fractions of IPCs based on the TPMS IWP configuration is developed using Python-based parametric modeling, with the Ti6Al4V alloy TPMS scaffolds fabricated via selective laser melting (SLM) and the AlSi12 reinforcing phase through infiltration casting. The influence of Ti alloy volume fraction and strain rate on the dynamic mechanical behavior of the Ti/Al IPC is systematically investigated using a split Hopkinson pressure bar (SHPB) experimental setup. Microscopic characterization validates the effectiveness and reliability of the proposed IPC fabrication method. Results show that the increasing Ti alloy volume fraction significantly affects the dynamic mechanical properties of the IPC, and IPCs with different Ti alloy volume fractions exhibit contrasting mechanical behaviors under increasing strain rates, attributed to the dominance of different constituent phases. This study enhances the understanding of the dynamic behavior of TPMS-based IPCs and offers a promising route for the development of high-performance energy-absorbing materials. Full article

Foundry aluminum-silicon (Al-Si) alloys, especially those containing Cu and/or Mg, are widely used in casting processes for fabricating lightweight parts. This study focuses on the optimization of the solution heat treatment parameters within the T6 heat treatment of an innovative AlSi7Cu0.5Mg0.3 secondary alloy, aiming at achieving energy savings and reducing the environmental impact related to the production of foundry components for the automotive industry. Different combinations of solution times and temperatures lower than those typically adopted in industrial practice were evaluated, and their effects on tensile properties were investigated on samples machined from as-cast and T6-treated castings produced by pouring the alloy into a steel permanent mold. Thermal analysis (TA) and differential thermal analysis (DTA) were performed to monitor the solidification sequence of microstructural phases as well as their dissolution on heating according to the proposed solution heat treatments. Microstructural analysis by light microscopy (LM) and scanning electron microscopy (SEM), together with Brinell hardness testing, was also carried out to assess the effects of heat treatment parameters. The results suggested that a shorter solution heat treatment set at a temperature lower than that currently adopted for the heat treatment of the studied alloy can still ensure the required mechanical properties while improving productivity and reducing energy consumption. Full article

The application fields of high-temperature titanium alloys are mainly concentrated in the aerospace, defense and military industries, such as the high-temperature parts of rocket and aircraft engines, missile cases, tail rudders, etc., which can greatly reduce the weight of aircraft while resisting high temperatures. However, traditional high-temperature titanium alloys containing multiple types of elements (more than six) have a complex impact on the solidification, deformation, and phase transformation processes of the alloys, which greatly increases the difficulty of casting and deformation manufacturing of aerospace and military components. Therefore, developing low-component high-temperature titanium alloys suitable for hot processing and forming is urgent. This study used data augmentation (Gaussian noise) to expedite the development of a novel quinary high-temperature titanium alloy. Utilizing data augmentation, the generalization abilities of four machine learning models (XGBoost, RF, AdaBoost, Lasso) were effectively improved, with the XGBoost model demonstrating superior prediction accuracy (with an R² value of 0.94, an RMSE of 53.31, and an MAE of 42.93 in the test set). Based on this model, a novel Ti-7.2Al-1.8Mo-2.0Nb-0.4Si (wt.%) alloy was designed and experimentally validated. The UTS of the alloy at 600 °C was 629 MPa, closely aligning with the value (649 MPa) predicted by the model, with an error of 3.2%. Compared to as-cast Ti1100 and Ti6242S alloy (both containing six elements), the novel quinary alloy has considerable high-temperature (600 °C) mechanical properties and fewer components. The microstructure analysis revealed that the designed alloy was an α+β type alloy, featuring a typical Widmanstätten structure. The fracture form of the alloy was a mixture of brittle and ductile fracture at both room and high temperatures. Full article

In this study, lanthanum (La), a rare earth element, was added at concentrations of 0.25 wt.%, 0.5 wt.%, and 0.75 wt.% to an Al–10%Si–2%Cu-based alloy prepared by die casting. The effects of solution and aging heat treatment conditions on the mechanical properties and corrosion resistance were investigated. Microstructural changes, hardness, and corrosion behavior were analyzed as functions of La content and heat treatment parameters. The optimal hardness was achieved at a solution treatment temperature of 500 °C or higher and an aging time of 2 h. In particular, the addition of 0.5 wt.% La led to significant refinement of the α-Al grains, enhancing hardness through the Hall–Petch strengthening mechanism. Furthermore, the combined effects of aging treatment and La addition promoted the formation of a fine, uniform microstructure and stable dispersion of precipitates, resulting in improved mechanical performance. Electrochemical polarization tests revealed that the alloy containing 0.5 wt.% La exhibited the best corrosion resistance. This enhancement was attributed to the formation of the LaCu₂Al₄Si intermetallic compound, which has a lower electrochemical potential than the Al₂Cu phase, thereby reducing corrosion susceptibility within the microstructure. Full article

One of the most effective methods of improving the properties of aluminium alloys is grain refining using Al-Ti-B master alloys. In contrast, zirconium is a key alloying element, used mainly in 2xxx and 7xxx series aluminium alloys, where it contributes to dispersion enhancement and reduces the rate of dynamic recrystallisation. However, even trace amounts of zirconium—just a few hundredths of ppm—significantly reduce the performance of Al-Ti-B grain refiners, a phenomenon known as ‘Zr poisoning’. This study investigates the impact of holding time and the level of Al-5Ti-1B addition on the microstructure and properties of an AlMgSi(Cu) alloy containing 0.15 wt.% Zr, cast as 7-inch DC billets. The structure and phase distribution were characterised using optical microscopy (OM), scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Grain size and morphology were evaluated through macrostructure analysis (etched cross-sections and polarised light microscopy), while chemical and elemental distributions were analysed via SEM-EDS and STEM-EDS mapping. Additionally, Brinell hardness measurements were conducted across the billet diameter to assess the correlation between grain size and mechanical properties. The results show that reducing holding time and increasing the Al-5Ti-1B addition improves grain refinement efficiency despite the presence of Zr. The finest grain structure (150–170 μm) and most homogeneous hardness distribution were achieved when the grain refiner was continuously fed during casting at 80 ppm B. These findings are supported by the literature and contribute to a deeper understanding of the Zr poisoning effect and its mitigation through optimized casting practice. Full article

The precision casting of nickel-based single-crystal superalloys imposes stringent requirements on the high-temperature stability and chemical inertness of ceramic shell face coats. To address the issue of traditional EC95 shells (95% Al₂O₃–5% SiO₂) being prone to react with the alloy melt at elevated temperatures, thereby inducing casting defects, this study proposes a lanthanide oxide-based ceramic face coat material. Three distinct powders—LaAlO₃ (LA), LaAlO₃/La₂Si₂O₇ (LAS), and LaAl₁₁O₁₈/La₂Si₂O₇/Al₂O₃ (LA11S)—are successfully prepared through solid-phase sintering of the La₂O₃-Al₂O₃-SiO₂ ternary system. Their slurry properties, shell sintering processes, and high-temperature performance are systematically investigated. The results demonstrate that optimal slurry coating effectiveness is achieved when LA powder is processed with a liquid-to-powder ratio of 3:1 and a particle size of 300 mesh. While LA shells show no cracking at 1300 °C, their face coats fail above 1400 °C due to the formation of a La₂Si₂O₇ phase. In contrast, LAS and LA11S shells suppress cracking through the La₂Si₂O₇ and LaAl₁₁O₁₈ phases, respectively, exhibiting exceptionally high-temperature stability at 1400 °C and 1500 °C. All three shells meet the high-temperature strength requirements for CMSX-4 single-crystal alloy casting. Interfacial reaction analysis and Gibbs free energy calculations reveal that Al₂O₃-forming reactions occur between the novel shells and alloy melt, accompanied by minor dissolution erosion without other chemical side reactions. This work provides a high-performance face coat material solution for investment casting of nickel-based superalloys. Full article

The topographical, microstructural, and mechanical surface properties of additively manufactured components depend on variations of several processing parameters. Most studies focus on a narrow range of parameter variations, with the surface and subsurface characteristics being determined for that limited set of conditions. This makes it difficult to optimize these properties for additively manufactured parts and the energy consumption of the additive-manufacturing (AM) process. Our study looks at the systematic variation of two key AM parameters over their full range using a commercial AM machine. The laser scanning speed (500–1700 mm/s) and the laser power (250–370 W) were the parameters used. We analyze and discuss how these two parameters affect the surface topography, roughness, porosity, microstructure and hardness, as well as their anisotropy for the top and side surfaces during powder bed fusion, using a single AM machine and printing strategy. The aluminum alloy AlSi10Mg was selected for the study. It is one of the most commonly used materials in die casting and has the potential to take advantage of AM technology, since these parts can be lightweight, have good mechanical properties and to be produced with complex shapes. Full article