Search Results (487)

The solid structure of industrial sinter comprises seven mineral associations (A, B, C, D, Ds, E, N) which have different relative abundances of key minerals, textures and spatial relationships to micro-macropores and hematite nuclei. Among the key characteristics of the mineral associations: (MA), MA-A comprises abundant SFCA-I microplates with hematite; MA-B consists of disseminated fine-grained magnetite in a network of SFCA-III microplates; MA-C is similar to MA-B but contains patches of dendritic SFCA-III with larnite and minor glass; MA-D comprises magnetite surrounded by coarse prisms of SFCA within glass; MA-Ds, a subtype of MA-D, includes SFCA with secondary skeletal hematite; MA-E consists of anhedral to skeletal magnetite or hematite in a matrix of glass; and MA-N comprises unmelted hematite nuclei from iron ore feedstock. SFCA-III and SFCA-I are dominant in MA-B and MA-A, respectively, whilst magnetite is the most common mineral in MA-C, MA-D/Ds and MA-E. Low-temperature sintering samples are largely of MA-A to MA-D (62 area %), which contain higher combined levels of SFCA-SFCA-III and lower levels of magnetite-dominant MA-E (12.6 area %), whereas high-temperature/magnetite sintering examples had high levels of magnetite-dominant MA-E (31.6 area %) and MA-D/Ds (52.1 area %) and low levels of MA-A to MA-C (8.9 area %). It is proposed that the formation of each MA is controlled by the peak sintering temperature attained, the dwell time at higher temperature which adversely allows fractional crystallisation to tie up more Fe in magnetite rather than forming SFCA phases during cooling, and especially a slower rate of cooling which promotes the formation of more SFCA family phases at lower temperatures. However, local variations in chemistry inherited from raw material granulation and assimilation during sintering of Si-rich gangue or ore nuclei are also important. Full article

Sliding bearing alloy layers must combine excellent tribological performance with reliable metallurgical bonding, but conventional fabrication methods often suffer from coarse grains, chemical segregation and poor interface adhesion. Annular coaxial laser wire-feed cladding, by providing more uniform heat input and rapid solidification, is expected to mitigate these deficiencies; however, systematic studies of this technique applied to tin-based Babbitt alloy layers remain limited. In this work, Babbitt layers produced by conventional casting and by annular coaxial laser wire-feed cladding were compared in terms of microstructure, phase constitution, hardness and tribological behavior. The results indicate that laser cladding can produce continuous, dense and well-bonded coatings and markedly refine the SnSb phase, reducing grain size from approximately 100 μm in the cast material to 10-20 μm. Hardness increased from 25.3 HB to 27.6 HB, while tribological performance improved substantially: the coefficient of friction decreased by about 38.19% and the wear volume was reduced by approximately 10.46%. These improvements are attributed mainly to the rapid solidification, low dilution and more uniform phase distribution associated with annular coaxial laser cladding, demonstrating the strong potential of this process for fabricating high-performance tin-based Babbitt bearing layers. Full article

In the present contribution, Hot-rolled and annealed ferritic stainless steel T4003 with three distinct Mo contents (0%, 0.1%, and 0.2%) served as the research subject. Weldability tests were implemented by means of gas metal arc welding. Coupled with microstructural characterization, mechanical property assessments, and electrochemical corrosion tests, the regulatory mechanism of Mo on the microstructure and properties of the HAZ was systematically elucidated. Results demonstrate that the influence of Mo content on the evolution of the coarse-grained region structure of heat affected zone becomes significant. The addition of 0.1% Mo refines the grains, increasing the fraction of lath martensite to 70–75% while limiting the maximum width of the coarse-grained zone to 0.64 mm. Meantime, the addition promotes the precipitation of (Nb, Ti, Mo) (C, N) composite carbonitrides, enhancing overall performance through synergistic grain refinement and second-phase strengthening. The sample with 0.1% Mo exhibits an average low-temperature impact energy of 16.3 J at −40 °C, with the highest Vickers hardness in the HAZ, favorable strength–plasticity synergy of the welded joint, and optimal corrosion resistance. The coarse-grained zone of the 0.2% Mo sample is dominated by coarse δ-ferrite and features a larger width, and the HAZ shows inferior mechanical properties and corrosion resistance. The precipitated phases in the 0.2% Mo segregate along the grain boundaries and distribute in a chain-like distribution, exacerbating the deterioration of material properties. These findings provide a technical reference for optimizing the composition design of T4003 ferritic stainless steel and ensuring its safe application in railway freight vehicles. Full article

Tightness of homogeneous embankment dams is often ensured by means of upstream water barriers, such as bituminous concrete facings, concrete slabs, shotcrete membranes, metallic sheets, geomembranes, and cement blankets. The stability analysis of these dams, especially in areas with high seismicity, must include the hydraulic and mechanical effects resulting from an extensive, sudden cracking of the impervious facing. To this purpose, in this paper, simple, original analytical solutions are proposed to estimate the position of the exit point on the downstream slope of the dam, the maximum height of the saturation front at the downstream face, and the time required for the saturation front to reach the downstream face. These variables generally depend on several factors, such as the geometry of the dam, homogeneity or heterogeneity, the permeability coefficient of the dam body materials, and resistance laws to describe the seepage flow. The high number of these factors requires the development of advanced 2D/3D FEM analyses, often computationally heavy and complex to implement. Although approximate, the proposed solutions may however allow us to define the role of the various factors and their interaction, to quickly deduce the main, preliminary design indications. Full article

Coarse-grained soil is a commonly used filling material in foundation engineering, and its static shear characteristics are significantly affected by the initial stress state. For coarse-grained soils, clearly defining the drainage conditions and improving the accuracy of pore water pressure measurements are crucial in static shear tests. Based on GDS dynamic and static true triaxial equipment, this paper systematically conducts static shear tests on coarse-grained soil under three-dimensional initial isotropic, three-dimensional initial anisotropic, and plane strain states. The effects of initial mean principal stress, initial generalized shear stress, initial intermediate principal stress coefficient, and water content on the stress–strain relationship, strength, modulus, and friction angle of coarse-grained soil are analyzed. The research shows that under the same initial mean principal stress, the peak strength under a plane strain state is the largest, and that under a three-dimensional initial anisotropic state is the smallest. The peak strength of coarse-grained soil with optimal water content is generally higher than that under a saturated state; under a three-dimensional initial anisotropic state, the peak strength decreases with an increase in the initial generalized shear stress and increases with an increase in the initial intermediate principal stress coefficient. The research results provide a theoretical basis for the analysis of mechanical behavior of coarse-grained soil in foundation engineering. Full article

The typical microstructure and mechanical properties of twin-roll cast (TRC) 2139 aluminum alloy were investigated and compared with mold casting (MC) 2139 alloy. This work pioneers the application of TRC to produce 2139 Al-Cu-Mg alloy, a material that is challenging for rapid solidification. The TRC process resulted in a denser dendritic structure, with the composition of intermetallic compounds, primarily Al₂Cu and Al₂CuMg, remaining largely stable throughout the casting process. After solution treatment, the recrystallized grains in the MC sheets were uniformly distributed, while the TRC sheets exhibited a more localized and refined recrystallized microstructure, particularly within coarse second-phase regions. Following heat treatments, the TRC sheets showed a significant increase in the Ω phase after T6, with a slight growth in size and a uniform distribution, while the Ω phase in T8 showed an increased density and smaller size, which diffused evenly across the material. The TRC process uniquely refines the microstructure and enhances Ω phase precipitation, yielding a 10%+ improvement in strength and ductility over conventional casting. The mechanical properties of the TRC sheets improved significantly: tensile and yield strengths increased by over 10% after T6, compared to MC sheets, with elongation slightly higher in TRC. T8 treatment further enhanced the mechanical properties of the TRC sheets, achieving an improvement in strength with only a minor trade-off in elongation. This establishes TRC as a superior industrial route for high-performance aluminum sheets, offering a promising industrial route, delivering substantial improvements in both strength and ductility over conventional casting methods. Full article

Torrential flows are hazardous hydro-geomorphological phenomena characterized by sudden water discharge and intense sediment transport. They occur in mountainous areas where hydrometeorological monitoring is often limited or absent. The lack of such data hinders the identification of flow types and sediment transport conditions, reducing the effectiveness of mitigation measures. To address this issue, the current study focuses on geomorphic characteristics of torrential watersheds and identifies indirect indicators of torrential activity. The sedimentological and geomorphic signatures of torrential flows in the lower Damdere River catchment (Eastern Rhodopes Mountains, southern Bulgaria) were characterized. To capture inter-annual variability in torrential activity and differences between the Damdere and its tributary the Duandere, we sampled riverbed deposits. We also sampled areas upstream and downstream of the check dam to assess its influence. Samples were analyzed for grain size distribution, petrography, and mineralogy (X-ray diffraction). Results show contrasting controls on sediment supply and transport: the Duandere delivers relatively coarse material, whereas the Damdere attains higher transport capacity during torrential events. The check dam is largely infilled and exerts only local effects by trapping finer sediments upstream. Downstream, the channel retains its torrential character. Inter-annual comparison upstream of the structure shows sediment fining linked to lower flows. Petrographic and XRD data point to mechanically driven erosion and rapid sediment transfer. The results underline the importance of geological–geomorphological indicators in the lack of long-term monitoring in similar mountain catchments and can support flood risk management. Full article

This study investigates the development of sustainable PVC-based composites filled with surface-modified wood flour for potential use in modern, energy-efficient building systems. The aim was to enhance the mechanical performance, thermal stability, and interfacial compatibility of PVC plastisols by incorporating fine- and coarse-grained coniferous wood flour modified with silane and surfactants. Composites were formulated using emulsion PVC (Vinnolit E-2059), bis(2-ethylhexyl) adipate as a plasticizer, and MARK-17 MOK as a thermal stabilizer, and were gelled under pressure at 150 °C. Their physical, mechanical, structural, and thermal characteristics were evaluated using density and hardness measurements, SEM, thermomechanical analysis, DMA, and TGA. The results demonstrated that composites containing fine-grained, silane-treated wood flour (Lignocel C-120) exhibited the most advantageous balance of stiffness, elasticity, and thermal resistance, attributable to improved polymer–wood interfacial adhesion. The findings confirm the potential of modified wood flour as an effective bio-based filler enabling the design of durable, thermally stable coating and insulating materials with reduced environmental impact. The proposed composites may serve as protective, bonding, or insulating layers in sustainable construction, supporting the development of innovative, wood-based materials for low-carbon building applications. Full article

In this study, a multiphysics coupling numerical model was developed to investigate the thermal-fluid dynamics and microstructure evolution during the laser metal deposition of AlCoCrFeNi high-entropy alloy (HEA) coatings on 430 stainless steel substrates. The model integrated laser-powder interactions, temperature-dependent material properties, and the coupled effects of buoyancy and Marangoni convection on melt pool dynamics. The simulation results were compared with experimental data to validate the model’s effectiveness. The simulations revealed a strong bidirectional coupling between temperature and flow fields in the molten pool: the temperature distribution governed surface tension gradients that drove Marangoni convection patterns, while the resulting fluid motion dominated heat redistribution and pool morphology. Initially, the Peclet number (Pe_T) remained below 5, indicating conduction-controlled heat transfer with a hemispherical melt pool. As the process progressed, Pe_T exceeded 50 at maximum flow velocities of 2.31 mm/s, transitioning the pool from a circular to an elliptical geometry with peak temperatures reaching 2850 K, where Marangoni convection became the primary heat transfer mechanism. Solidification parameter distributions (G and R) were computed and quantitatively correlated with scanning electron microscopy (SEM)-observed microstructures to elucidate the columnar-to-equiaxed transition (CET). X-ray diffraction (XRD) analysis identified body-centered cubic (BCC), face-centered cubic (FCC), and ordered B2 phases within the coating. The resulting hierarchical microstructure, transitioning from fine equiaxed surface grains to coarse columnar interfacial grains, synergistically enhanced surface properties and established robust metallurgical bonding with the substrate. Full article

The hierarchical structure and multifunctional properties of bio-based cellular materials, particularly cellulose, hemicellulose, and lignin, have attracted increasing attention and interest due to their sustainability and versatility. Recent advances in computational modeling and machine learning strategies have provided transformative insights into the molecular, mechanical, thermal, and electronic behaviors of these biopolymers. This review categorizes the conducted studies based on key material properties and discusses the computational methods utilized, including quantum mechanical approaches, atomistic and coarse-grained molecular dynamics, finite element modeling, and machine learning techniques. For each property, such as structural, mechanical, thermal, and electronic, we have analyzed the progress made in understanding inter- and intra-molecular interactions, deformation mechanisms, phase behavior, and functional performance. For instance, atomistic simulations have shown that cellulose nanocrystals exhibit a highly anisotropic elastic response, with axial elastic moduli ranging from approximately 100 to 200 GPa. Similarly, thermal transport studies have shown that the thermal conductivity along the chain axis (≈5.7 W m⁻¹ K⁻¹) is nearly an order of magnitude higher than that in the transverse direction (≈0.7 W m⁻¹ K⁻¹). In recent years, this research area has also experienced rapid advancement in data-driven methodologies, with the number of machine learning applications for biopolymer systems increasing more than fourfold over the past five years. By bridging multiscale modeling and data-driven approaches, this review aims to illustrate how these techniques can be integrated into a unified framework to accelerate the design and discovery of high-performance bioinspired materials. Eventually, we have discussed emerging opportunities in multiscale modeling and data-driven discovery to outline future directions for the design and application of high-performance bioinspired materials. This review aims to bridge the gap between molecular-level understanding and macroscopic functionality, thereby supporting the rational design of next-generation sustainable materials. Full article

Cracks were found at the gate of the 430Cb ferritic stainless steel exhaust system jet base produced by investment casting. In this paper, the cracks of failed stainless steel castings were comprehensively analyzed by means of macroscopic inspection, laser confocal microscopy, field emission scanning electron microscopy, electron backscatter diffraction, X-ray diffractometer, ProCAST (version 2018, ESI Group, Paris, France) simulation and Thermo-Calc (TCFE10 database, 2022a, Thermo-Calc Software AB, Solna, Sweden) thermodynamic calculation. It can be concluded that all the cracks originate from the gate on the surface of the casting, and the fracture surface shows brittle intergranular characteristics, which can be determined as cold cracks. The formation of cold cracks can be attributed to the fact that the local stress generated during cooling after the casting solidifies exceeds the strength limit of the material itself. As the gate is the final solidification zone, shrinkage is limited and stress is concentrated. The grains are coarse, and the microstructure defects such as shrinkage porosity, pores and needle-like NbC further weaken the plasticity of the grain boundaries, promoting the crack to propagate along the direction of the maximum principal stress. The uneven cooling rate and shell constraint during the investment casting process make it difficult to release stress, and the existence of microstructure defects are the fundamental causes of crack generation. Full article

Inconel 625 is widely employed in high-temperature and corrosive environments, where the integrity of welded joints critically influences component performance. This study systematically investigates how laser beam welding (LBW) heat input governs cooling behaviour, microstructure evolution, elemental segregation, and the mechanical performance of Inconel 625 weld joints aiming to become sustainable joints. A single-spot monochromatic non-contact type infrared pyrometer is used to monitor the thermal cycles of the molten weld pool and the cooling rate and melt pool lifetime were determined based on the thermal cycle data. The impact of cooling rate and melt pool lifetime on weld geometry, microstructure, micro-segregation, and mechanical properties were thoroughly investigated. The findings revealed that the fibre laser welding produced sound, defect-free joints across all experimental heat-input conditions and the weld quality was fairly dictated by cooling rate during solidification. Reducing heat input (by using faster laser scan speeds) increased the cooling rate (1.45 × 10³ to 3.65 × 10³ °C/s), resulting in a shortened melt-pool lifetime and altered weld bead geometry from hourglass to truncated-cone profiles. Eventually, the fusion-zone microstructure transitioned from coarse cellular/columnar dendrites at high heat inputs to refined dendrites at low heat inputs. The EDS analysis revealed pronounced Nb and Mo segregation in slowly cooled welds and Laves phase formation due to insufficient time for solute redistribution and γ-Ni matrixes were consistent noted with XRD-observed peaks. The presence of the brittle Laves phase adversely affects the microhardness and tensile strength of the weld joints. Mechanical testing confirmed that decreasing heat input (in faster laser scan speeds) enhanced micro-hardness and tensile strength due to grain refinement and solute entrapment in the γ matrix. The highest joint strength (989.3 ± 10.4 MPa) and elongation (40.3 ± 1.8%) approached those of the work material, and these findings establish processing parameter–structure–property relationships for the LBW of Inconel 625. The co-relation in the present manuscript can be used in the future for process monitoring and for controlling the mechanical properties of laser welding and may provide a practical guidance for optimizing weld quality in advanced industrial applications. Full article

This study addresses the issues of coarse primary austenite dendrites and uneven graphite distribution in hypoeutectic gray cast iron. High-energy mechanical activation technology was used to prepare high-energy activated SiC particles (EASiCp), and the regulatory mechanisms of trace additions (0–0.15 wt.%) on the solidification process and microstructure properties of hypoeutectic gray cast iron were systematically investigated. The results indicate that high-energy activation treatment reduced the average particle size of SiC particles from 26.53 μm to 9.51 μm and increased their specific surface area from 0.35 m²/g to 1.78 m²/g. X-ray diffraction (XRD) analysis revealed that the grain size was refined from 55.5 nm to 17.4 nm, with significant lattice distortion. The absorption rate of EASiCp in the melt stabilized between 68–72%, with particles predominantly dispersed within the grains (78.12%) and at grain boundaries (21.88%) in sizes ranging from 0.3 to 2 μm. The addition of EASiCp enhanced the solidification undercooling from 5.3 °C to 8.4 °C and reduced the latent heat of crystallization from 162.6 J/g to 99.96 J/g due to its endothermic reaction in the melt (SiC + Fe → FeSi + C) and heterogeneous nucleation effects. In terms of microstructure, the addition of 0.15 wt.% EASiCp increased the primary austenite dendrite content by 35.29%, reduced the secondary dendrite arm spacing by 57.98%, shortened the graphite length from 0.46 mm to 0.20 mm, and refined the eutectic colony size from over 500 μm to 180 μm. The final material achieved a tensile strength of 308 MPa, an improvement of 12.82% compared to the unadded group. Mechanistic analysis showed that EASiCp facilitated direct nucleation, reaction-induced “micro-area carbon enrichment,” and a synergistic effect in suppressing grain growth, thereby optimizing the solidification microstructure and enhancing performance. This study provides a new method for the efficient nucleation control of hypoeutectic gray cast iron. Full article

Graphite anodes are widely used as consumable electrodes in the high-temperature electrolytic production of rare earth metals within fluoride molten salts. However, their rapid and complex corrosion presents significant economic and operational challenges, including high consumption costs, process instability, greenhouse gas emissions, and product contamination. While the corrosion morphology of specific graphite types has been studied, a systematic investigation linking the intrinsic properties of diverse graphite materials to their microstructural and chemical evolution during corrosion is lacking. This study elucidates the corrosion mechanisms of three distinct graphite anodes—fine-grained, isostatically pressed graphite anodes (#1), medium-coarse-grained, extruded graphite anodes (#2), and recycled, extruded graphite anodes (#3) in industrial PrNdF₃–LiF molten salt electrolytes at 1050 °C. Through a multifaceted analytical approach encompassing SEM, EDS, XRD, Raman, and FT-IR, we investigated the macro- and microscale corrosion behaviors across multiple scales. The results revealed markedly different degradation patterns: the #1 anode exhibited intergranular corrosion with granular exfoliation; the #2 anode developed a protective but cracked resolidified salt layer; and the #3 anode suffered the most severe uniform and pitting corrosion. Postcorrosion analysis confirmed surface enrichment with fluorine, praseodymium, and neodymium, the formation of PrF₃ and NdF₃ phases, and substantial degradation of the graphitic structure. Raman spectroscopy specifically revealed a reduction in the crystallite size, introduction of in-plane point defects, and disruption of the interlayer stacking order. On the base of infrared spectroscopy analysis, all key characteristic absorption peaks of the graphite anodes undergo consistent attenuation after corrosion. This work provides critical insights for the informed selection and optimization of graphite anodes to increase the efficiency and sustainability of rare earth electrolysis. Full article

Competitive industrial farming of Tenebrio molitor L. requires strategies aimed at reducing production costs and improving overall efficiency. Among variable costs, feed is one of the most significant components. Previous research has mainly focused on the nutritional composition of diets, the use of agri-food by-products, and the optimization of multicomponent formulations, sometimes administered in pelleted form during bioassays. However, knowledge about the influence of the administration form is scarce. This study investigated the effects of different feed forms—finely ground (<0.5 mm), coarsely ground (0.5–2 mm), and assembled (pellets, cookies, and crumbles)—on both adult and larval performance. Three feeds (wheat bran, brewer’s spent grain, and chicken feed) were tested to assess adult productivity and larval growth. The results showed non-significant differences in adult survival between feed forms, whereas finely ground feed significantly increased adult productivity and the survival of newborn larvae. Furthermore, larvae in the growing phase (40–60 days old) were able to effectively utilize assembled feeds, with no significant differences in larval weight compared to those reared on ground diets. These findings suggest that pelleted formulations for T. molitor farming should include a fraction of finely ground material to support early larval stages, thereby optimizing survival and development. Moreover, the different influence of feed form provides useful information for planning evaluation trials of multicomponent assembled diets. Full article