Search Results (80)

The lack of new materials with desired processability and functional characteristics remains a challenge for metal additive manufacturing (AM). Therefore, in this work, a new promising AISI 316L-based alloy with better performance compared to the commercially available one is developed via the laser powder bed fusion (L-PBF) process. Moreover, establishing process–structure–properties linkages is a critical point that should be evaluated carefully before adding newly developed alloys into the AM market. Hence, the current study investigates the influences of various process parameters on the as-built quality and microstructure of the newly developed alloy. The results revealed that increasing laser energy density led to reduced porosity and surface roughness, likely due to enhanced melting and solidification. Microstructural analysis revealed a uniform distribution of copper within the austenite phase without forming any agglomeration or secondary phases. Electron backscatter diffraction analysis indicated a strong texture along the build direction with a gradual increase in Goss texture at higher energy densities. Grain boundary regions exhibited higher local misorientation and dislocation density. These findings suggest that changing the process parameters of the L-PBF process is a promising method for developing tailored microstructures and chemical compositions of commercially available AISI 316L stainless steel. Full article

This study develops a comprehensive artificial neural network (ANN) model for predicting the mechanical properties of carbon–manganese cast steel, specifically, the yield strength (YS), tensile strength (TS), elongation (El), and reduction of area (RA), based on the chemical composition (16 alloying elements) and heat treatment parameters. The neural network model, employing a 20-44-44-4 architecture and trained on 400 samples from an industrial dataset of 500 samples, achieved 90% of test predictions within a 5% deviation from actual values, with mean prediction errors of 3.45% for YS and 4.9% for %EL. A user-friendly graphical interface was developed to make these predictive capabilities accessible, without requiring programming expertise. Sensitivity analyses revealed that increasing the copper content from 0.05% to 0.2% enhanced the yield strength from 320 to 360 MPa while reducing the ductility, whereas niobium functioned as an effective grain refiner, improving both the strength and ductility. The combined effects of carbon and manganese demonstrated complex synergistic behavior, with the yield strength varying between 280 and 460 MPa and the tensile strength ranging from 460 to 740 MPa across the composition space. Optimal strength–ductility balance was achieved at moderate compositions of 1.0–1.2 wt% Mn and 0.20–0.24 wt% C. The model provides an efficient alternative to costly experimental trials for optimizing C-Mn steels, with prediction errors consistently below 6% compared with 8–20% for traditional empirical methods. This approach establishes quantitative guidelines for designing complex multi-element alloys with targeted mechanical properties, representing a significant advancement in computational material engineering for industrial applications. Full article

This study signifies the development and characterization of a composite material with a metallic matrix of aluminum reinforced with a steel mesh, utilizing centrifugal casting technology. An evaluation was conducted to ascertain the influence of the formulation process and the presence of the insert on the mechanical behavior with regard to tensile strength. The aluminum matrix was obtained from commercial and scrap alloys, elaborated by advanced methods of degassing and chemical modification. Meanwhile, the steel mesh reinforcement was cleaned, copper plated, and preheated to optimize wetting and, consequently, adhesion. The structural characterization was performed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy analyses (EDX), which highlighted a well-defined interface and uniform copper distribution. The composite was produced by means of horizontal-axis centrifugal casting in a fiberglass mold, followed by cold rolling to obtain flat specimens. A total of eight tensile specimens were examined, with measured ultimate tensile strengths ranging from 78.5 to 119.8 (MPa). A thorough examination of the fractured specimens revealed a brittle fracture mechanism, devoid of substantial plastic deformation. The onset of failures was frequently observed at the interface between the aluminum matrix and the steel mesh. The use of SEM and EDX investigations led to the confirmation of the uniformity of the copper coating and the absence of significant porosity or interfacial defects. A bimodal distribution of tensile strength values was observed, a phenomenon that is likely attributable to variations in mesh positioning and local differences in solidification. A correlation was established between the experimental results and an analytical polynomial model, thereby confirming a reasonable fit. In sum, the present study provides a substantial foundation for the development of metal matrix composites with enhanced performance, specifically designed for challenging structural applications. This method also demonstrates potential for recycling aluminum scrap into high-performance composites with controlled microstructure and mechanical integrity. Full article

Nano-titanium dioxide ceramic coatings exhibit excellent wear resistance, corrosion resistance, and self-cleaning properties, showing great potential as multifunctional protective materials. This study proposes a synergistic reinforcement strategy by encapsulating micron-sized Al₂O₃ particles with nano-TiO₂. A core-shell structured nanocomposite coating composed of 65 wt% nano-TiO₂ encapsulating 30 wt% micron-Al₂O₃ was precisely designed and fabricated via a slurry dip-coating method on Q235 steel substrates. The microstructure and surface morphology of the coatings were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD). Comprehensive performance evaluations including densification, adhesion strength, wear resistance, and thermal shock resistance were conducted. Optimal coating properties were achieved under the conditions of a binder-to-solvent ratio of 1:15 (g/mL), a heating rate of 2 °C/min, and a sintering temperature of 400 °C. XRD analysis confirmed the formation of multiple crystalline phases during the 400 °C curing process, including titanium pyrophosphate (TiP₂O₇), aluminum phosphate (AlPO₄), copper aluminate (Cu(AlO₂)₂), and a unique titanium phosphate phase (Ti₃(PO₄)₄) exclusive to the 2 °C/min heating rate. Adhesion strength tests revealed that the coating sintered at 2 °C/min exhibited superior interfacial bonding strength and outstanding performance in wear resistance, hardness, and thermal shock resistance. The incorporation of nano-TiO₂ into the 30 wt% Al₂O₃ matrix significantly enhanced the mechanical properties of the composite coating. Mechanistic studies indicated that the bonding between the nanocomposite coating and the metal substrate is primarily achieved through mechanical interlocking, forming a robust physical interface. These findings provide theoretical guidance for optimizing the fabrication process of metal-based ceramic coatings and expanding their engineering applications in various industries. Full article

W-Cu composites are widely used in the fields of switch contact materials and electronic packages because of their high hardness, high plasticity, and excellent thermal conductivity, while the traditional W-Cu composite preparation process is often accompanied by problems such as a long production cycle, difficulties in the processing of shaped parts, and difficulties in guaranteeing the uniformity. Therefore, this work developed a chemical plating technique to prepare W-20 wt.% Cu composite powder with a core–shell structure and used this powder as a raw material for powder metallurgy to solve the problem of inhomogeneity in the production of W-Cu composite by the conventional solution infiltration method. Moreover, the work also developed a high-temperature-resistant photosensitive resin, which was used as a raw material to prepare injection molds using photocuring to replace traditional steel molds. Compared to steel molds, which take about a month to prepare, 3D printed plastic molds take only a few hours, greatly reducing the production cycle. At the same time, 3D printing also provides the feasibility of the production of shaped parts. The injection molded blanks were degreased and sintered under different sintering conditions. The results show that the resultant chemically plated W-Cu composite powder has a uniform Cu coating on the surface, and the Cu forms a dense and uniform three-dimensional network in the scanning electron microscope images of each subsequent sintered specimen, while the photocuring-prepared molds were used to prepare the W-Cu shaped parts, which greatly shortened the production cycle. This preparation method enables rapid preparation of tungsten–copper composite-shaped parts with good homogeneity. Full article

During the cold metal transfer (CMT) arc additive manufacturing process of steel/copper bimetallic materials, interfacial penetration cracks have been observed due to the significant differences in thermal and physical properties between steel and copper. To mitigate the occurrence of these penetration cracks and enhance the interfacial elemental diffusion at the steel/copper junction, this study aims to fabricate high-performance steel/copper bimetallic materials with a uniform microstructure using CMT arc additive manufacturing techniques. A reciprocating additive sequence was adopted, with steel deposited first, followed by copper. Four different interlayer compositions, Cu-Ni, Fe-Ni, Cu-Cr, and Ni-Cr, were applied to the steel surface before the deposition of aluminum bronze. These interlayers served as a transition between the steel and copper materials. The manufacturing process then continued with the deposition of aluminum bronze to achieve the desired bimetallic structure. After the addition of interlayers, all four sets of samples exhibited excellent macroscopic formability, with clear and smooth interlayer contours and no visible cracks or collapse defects at the junction interfaces. The mechanical properties of the composite walls were enhanced following the addition of the interlayers, with an increase in tensile strength observed across the samples. The sample with the Fe-Ni interlayer showed the most significant improvement, with a 52% increase in impact energy absorption. Furthermore, the sample with the Fe-Ni interlayer demonstrated a higher average hardness level than the other groups, which was associated with the distribution and content of the iron-rich phase and the β′ phase. Full article

The quality, reproducibility, and reliability of additive-manufactured parts strongly depend on optimizing printing parameters and post-processing treatments. This study evaluates the effects on the microstructure and corrosion resistance properties of solution annealing and aging heat treatments performed on 17-4 PH stainless steel samples fabricated with different build-up orientations using a material extrusion technology: the Bound Metal Deposition^TM. The chemical composition and microstructures were determined using X-ray diffraction, chemical etching, optical microscopy, and scanning electron microscopy. The corrosion resistance properties in neutral sodium chloride electrolytes were investigated through cyclic potentiodynamic polarization and open circuit potential monitoring and analysis. The findings demonstrated that the solution annealing heat treatment remarkably enhanced the overall corrosion resistance properties of the samples. The improvement was attributed to the growth of the ferritic phase along the grain boundaries of the martensitic matrix and a finer dispersion of copper precipitates. The aging heat treatment performed after solution annealing enhanced the ferritic phase development, resulting in a further improvement of the localized corrosion resistance properties. Full article

The copper-based steel backing material is prepared using a combination of mechanical alloying and secondary sintering methods. The effect of Y₂O₃ content on the microstructure, hardness, and tribological properties of the copper-based self-lubricating layer is investigated. The results demonstrate that the addition of Y₂O₃ enhances the strength of the copper-based self-lubricating layer. Graphite and Y₂O₃ act synergistically to form a three-dimensional supporting framework, thereby boosting the overall strength of the copper-based composite material and increasing its Brinell hardness by 27%. Additionally, the incorporation of Y₂O₃ effectively improves the tribological properties of the composite material, significantly reducing wear during the friction process and decreasing the wear rate by 77%. Under the experimental conditions, the optimal Y₂O₃ content is determined to be 1 wt%. Full article

Fused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–metal composite feedstock and proceeds through three primary stages, namely shaping (i.e., printing), debinding, and sintering. As critically discussed in the present review, the final quality of metal FFF parts is influenced by the characteristics of the composite feedstock, such as the metal loading, polymer backbone, and presence of additives, as well as by the processing conditions. The literature shows that a diverse array of metals, including steel, copper, titanium, aluminium, nickel, and their alloys, can be successfully used in metal FFF. However, the formulation of appropriate polymer binders represents a hurdle to the adoption of new material systems. Meanwhile, intricate geometries are difficult to fabricate due to FFF-related surface roughness and sintering-induced shrinkage. Nonetheless, the comparison of metal FFF with other common metal AM techniques conducted herein suggests that metal FFF represents a convenient option, especially for prototyping and small-scale production. Whilst providing insights into the functioning mechanisms of metal FFF, the present review offers valuable recommendations, facilitating the broader uptake of metal FFF across various industries. Full article

In this paper, two kinds of copper-containing steels with copper contents of 2.31 and 6.01 wt.% were designed. By comparing with commercial Q355, the bactericidal properties of copper in seawater containing sulfate-reducing bacteria (SRB) and its influence on the corrosion process of steel were revealed. The corrosion rate, morphology of products, and bactericidal action of copper were tracked by scanning electron microscopy, X-ray diffraction, confocal microscopy, and electrochemical analysis techniques. It was found that the resistance of copper-containing steel to bacterial corrosion was obviously better than that of non-copper-containing steel. At 28 days, the weight loss rates in the SRB environment for 0Ni2Cu6 samples increased by merely 5.43%, which was nearly half that of Q355 of 9.75%. Cu-containing steels exhibited potent antibacterial action, with the ε-Cu phase altering the corrosion byproduct composition from brittle flakes to robust particles and inhibiting the production of H₂S. The killed bacteria adhered to the surface of the steel and slowed down the corrosion of the steel. The confocal laser scanning microscope and electrochemical experiments showed that a dense CuFeO₄ film formed on the substrate, impeding corrosive ion penetration, and an upsurge in Cu content markedly enhanced the material’s anti-corrosion and antimicrobial attributes. Full article

In this study, we fabricated Ti-Cu-based friction composites containing waste-metal (Ti, CuZn, stainless steel (SSt), MgAl), Al₂O₃ due to improving properties and its good compatibility with copper and graphene nanoplatelets as reinforcement and lubricant component, using planetary ball mill and technique based on Spark Plasma Sintering (SPS). Understanding the wear behaviour of such engineered friction composites is essential to improve their material design and safety, as these materials could have the potential for use in public and industrial transportation, such as high-speed rail trains and aircraft or cars. This is why our study is focused on wear behaviour during friction between function parts of devices. We investigated the composite materials designed by us in order to clarify their microstructural state and mechanical properties. Using different loading conditions, we determined the Coefficient of Friction (COF) using a ball-on-disc tribological test. We analysed the state of the samples after the mentioned test using a Scanning Electron Microscope (SEM), then Energy-Dispersive X-ray Spectroscopy (EDS), and confocal microscopy. Also, a comparative analysis of friction properties with previously studied materials was performed. The results showed that friction composites with different compositions, despite the same conditions of their compaction during sintering, can be defined by different wear characteristics. Our study can potentially have a significant contribution to the understanding of wear mechanisms of Ti-Cu-based composites with incorporated metal-waste and to improving their material design and performance. Also, it can give us information about the possibilities of reusing metal-waste from different machining operations. Full article

Modules (or parts) of a car are a complex functional material combination used to deliver a specified task for a car. Recovering all materials, energy, etc., into high-grade materials at their end of life (EoL) is impossible. This is dictated by the second law of thermodynamics (2LT) and thence economics. Thus, recyclability cannot be conducted with simplistic mass-based approaches void of thermodynamic considerations. We apply, in this paper, a process simulation model to estimate the true recyclability of various SEAT (Volkswagen Group) car parts within the EU H2020 TREASURE project. This simulation model is developed with 190 reactors and over 310 feed components with over 1000 reaction species in the 880 streams of the flowsheet. The uniqueness of the work in this paper is to apply the full material declaration (FMD) and bill of materials (BOM) of all 310 materials in the parts as a feed to the process simulation model to show the parts’ true recyclability. We classified all parts into categories, i.e., copper-rich, steel-rich and plastic-rich, to maximally recover metals at the desired material quality, as well as energy. Recyclability is understood to create high-grade products that can be applied with the same functional quality in these parts. In addition, disassembly strategies and related possible redesign show how much recyclability can be improved. Process simulation permits the creation of alloys, phases, materials, etc., at a desired quality. The strength of the simulation permits any feed from any End-of-Life part to be analyzed, as long as the FMD and BOM are available. This is analogous to any mineral and metallurgical engineering process simulation for which the full mineralogy must be available to analyze and/or design flowsheets. This paper delivers a wealth of data for various parts as well as the ultimate recovery of materials, elements, and energy. The results show clearly that there is no one single recycling rate for elements, materials, and alloys. It is in fact a function of the complexity and material combinations within the parts. The fact that we use a thermochemical-based process simulator with full compositional detail for the considered parts means full energy balances as well as exergy dissipation can be evaluated. This means that we can also evaluate which parts, due complex mixtures of plastics, are best processed for energy recovery or are best for material and metal recovery, with thermochemistry, reactor technology and integrated flowsheets being the basis. Full article

In this study, we optimized the traditional composition of AISI 8630 steel and evaluated its corrosion resistance through a series of tests. We conducted corrosion tests in a 3.5% NaCl solution and performed a 720 h fixed-load tensile test in accordance with the NACE TM-0177-2016 standard to assess sulfide stress corrosion cracking (SSCC). To analyze the corrosion products and the structure of the corrosion film, we employed X-ray diffraction and transmission electron microscopy. The corrosion rate, characteristics of the corrosion products, structure of the corrosion film, and corrosion resistance mechanism of the material were investigated. The results indicate that the optimized AISI 8630 material demonstrates excellent corrosion resistance. After 720 h of exposure, the primary corrosion products were identified as chromium oxide, copper sulfide, iron oxide, and iron–nickel sulfide. The corrosion film exhibited a three-layer structure: the innermost layer with a thickness of 200–300 nm contained higher concentrations of alloying elements and formed a dense, cohesive rust layer that hindered the diffusion of oxygen and chloride ions, thus enhancing corrosion resistance. The middle layer was thicker and less rich in alloying elements, while the outer layer, approximately 300–400 nm thick, was relatively loose. Full article

Metal composite parts are widely used in different industries owing to their significant improvement in material properties, such as mechanical strength, electrical conductivity, and corrosion resistivity, compared to traditional single metals. Such composite parts can be manufactured and processed in different ways to achieve the desired geometry and quality. Among various metal forming techniques, drawing is the most commonly used process to produce long composite wires or rods from raw single materials. During the drawing process of composite wires or rods, not only does the core radius ratio change, but the core or sleeve layer may also undergo necking or fracture due to excessive tensile stresses in the softer layer. In this paper, bimetallic rods with AISI-1006 low-carbon steel cores and C10100 oxygen-free electronic copper sleeves are modeled using the finite element software DEFORM. The simulation models are verified by drawing experiments. The effects of initial bonding conditions, the initial core ratio, reduction ratio, semi-die angle, drawing speed, and friction on the plastic deformation behavior of the bimetallic rods are investigated. The results indicate that the initial bonding conditions have a great impact on the deformation behavior of the billets in terms of strain distribution, material flow, residual stress, and the final core ratio. The permissible forming parameters for obtaining a sound product are investigated as well. With the aid of these analyses, the drawing process and the quality of the products can be controlled steadily. Full article

The development of multi-material filaments has enabled fused filament fabrication-based additive manufacturing to address demand for high-performance lightweight multifunctional components. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene based filaments with metallic reinforcements of magnetic iron (MI), stainless steel (SS), bronze (Br), copper (Cu), Bismuth (Bi), and Tungsten (W) were investigated to elucidate their complex processing–structure–property relationships. The microstructure of 3D-printed materials were characterized by microscopy and analyzed to determine the metal cross-sectional area percentage and the relationship between metal reinforcement, the polymer matrix, and porosity. Compression testing was conducted in directions parallel and perpendicular to the build direction in order to evaluate the effect of orientation and metal reinforcement on the mechanical properties. 3D-printed specimens experienced either fracture through print layers or layer-wise interfacial rupture for loads applied perpendicular and parallel to the print layers, respectively. A dependence of yield strength on loading orientation was observed for Br-PLA, Cu-PLA, SS-PLA, Bi-ABS, and W-ABS; however, MI-PLA and pure ABS specimens did not exhibit this sensitivity. Metal reinforcement also influenced the magnitude of compressive yield strength, with MI-PLA and SS-PLA demonstrating increased strength over Br-PLA and Cu-PLA, while ABS demonstrated increased strength over Bi-ABS and W-ABS. These results demonstrate the importance of considering orientation in printing and applications, the trade-off between various metallic reinforcements for added multifunctionality, and the potential of these tailored polymer composites for novel 3D-printed structures. Full article