Search Results (779)

Cr/Ti bilayer coatings were deposited on 7050 aluminum alloy via magnetron sputtering at substrate temperatures of room temperature (RT), 150 °C, and 300 °C to investigate temperature effects on microstructure, hardness, and corrosion resistance. All coatings exhibited Cr(110) and Ti(002) phases. Temperature significantly modulated corrosion resistance by altering pore density, grain boundary density, and passivation film composition. Increasing temperature from RT to 150 °C raised corrosion rates primarily due to increased pore density. Further increasing to 300 °C reduced corrosion rates mainly through decreased grain boundary density, while passivation film composition changes altered electrochemical reaction kinetics. Substrate-coating interface defect density primarily influenced hardness with minimal effect on corrosion. Consequently, the RT-deposited coating, despite lower hardness, demonstrated optimal corrosion resistance: polarization resistance (7.17 × 10⁴ Ω·cm²), charge transfer resistance (12,400 Ω·cm²), and corrosion current density (2.47 × 10⁻⁷ A/cm²), the latter being two orders of magnitude lower than the substrate. Full article

The corrosion of high-strength steel wires is a key factor impacting the durability and reliability of cable-stayed bridges. In this study, the corrosion pit features on a high-strength steel wire, which had been in service for 27 years, were extracted and modeled using three-dimensional point cloud data obtained through 3D surface scanning. The Otsu method was applied for image binarization, and each corrosion pit was geometrically represented as an ellipse. Key pit parameters—including length, width, depth, aspect ratio, and a defect parameter—were statistically analyzed. Results of the Kolmogorov–Smirnov (K–S) test at a 95% confidence level indicated that the directional angle component (θ) did not conform to any known probability distribution. In contrast, the pit width (b) and defect parameter (Φ) followed a generalized extreme value distribution, the aspect ratio (b/a) matched a Beta distribution, and both the pit length (a) and depth (d) were best described by a Gaussian mixture model. The obtained results provide valuable reference for assessing the stress state, in-service performance, and predicted remaining service life of operational stay cables. Full article

Subsea pipelines, operating in high-pressure and high-salinity conditions, face ongoing risks of leakage. Pipeline leaks can pollute the marine environment and, in severe cases, cause safety incidents, endangering human lives and property. Regular integrity inspections of subsea pipelines are critical to prevent corrosion-related leaks. This study develops a magnetic flux leakage (MFL)-based pig for detecting corrosion in subsea pipelines. Using a three-dimensional finite element model, this study analyzes the effects of defect geometry, lift-off distance, and operating speed on MFL signals. It proposes a defect estimation method based on axial peak-to-valley values and radial peak spacing, with inversion accuracy validated against simulation results. This study establishes a theoretical and practical framework for subsea pipeline integrity management, providing an effective solution for corrosion monitoring. Full article

This study systematically investigated the corrosion evolution and protective mechanisms of X80 pipeline steel in Xinjiang’s saline soil environments under freeze–thaw cycling conditions. Combining regional soil characterization with laboratory-constructed corrosion systems, we employed electrochemical impedance spectroscopy, potentiodynamic polarization, and surface analytical techniques to quantify temporal–spatial corrosion behavior across 30 freeze–thaw cycles. Experimental results revealed a distinctive corrosion resistance pattern: initial improvement (cycles 1–10) attributed to protective oxide layer formation, followed by accelerated degradation (cycles 10–30) due to microcrack propagation and chloride accumulation. Synchrotron X-ray diffraction analyses identified sulfate–chloride ion synergism as the primary driver of localized corrosion disparities in heterogeneous soil matrices. A comparative evaluation of asphalt-coated specimens demonstrated a 62%–89% corrosion rate reduction, with effectiveness directly correlating with coating integrity and thickness (200–500 μm range). Molecular dynamics simulations using Materials Studio revealed atomic-scale ion transport dynamics at coating–substrate interfaces, showing preferential Cl⁻ permeation through coating defects. These multiscale findings establish quantitative relationships between environmental stressors, coating parameters, and corrosion kinetics, providing a mechanistic framework for optimizing protective coatings in cold-region pipeline applications. Full article

Over the past 20 years, laser beam–electric arc hybrid welding has gained popularity, enabling high quality and efficiency standards needed for steel welds in structures subjected to severe working conditions. This process enables single-pass welding of thick components, overcoming issues concerning the individual use of traditional processes based on an electric arc or laser beam. Therefore, thorough knowledge of both processes is necessary to combine them optimally in terms of efficiency, reduced presence of defects, corrosion resistance, and mechanical and metallurgical features of the welds. This article aims to review the technical and metallurgical aspects of hybrid welding reported in the scientific literature mainly of the last decade, outlining possible choices for system configuration, the inter-distance between the two heat sources, as well as the key process parameters, considering their effects on the weld characteristics and also taking into account the consequences for solidification modes and weld composition. Finally, a specific section has been reserved for hybrid welding of clad steel plates. Full article

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article

Underwater inspection images of hydraulic structures often suffer from haze, severe color distortion, low contrast, and blurred textures, impairing the accuracy of automated crack, spalling, and corrosion detection. However, many existing enhancement methods fail to preserve structural details and suppress noise in turbid environments. To address these limitations, we propose a compact image enhancement framework called Wavelet Fusion with Sobel-based Weighting (WWSF). This method first corrects global color and luminance distributions using multiscale Retinex and gamma mapping, followed by local contrast enhancement via CLAHE in the L channel of the CIELAB color space. Two preliminarily corrected images are decomposed using discrete wavelet transform (DWT); low-frequency bands are fused based on maximum energy, while high-frequency bands are adaptively weighted by Sobel edge energy to highlight structural features and suppress background noise. The enhanced image is reconstructed via inverse DWT. Experiments on real-world sluice gate datasets demonstrate that WWSF outperforms six state-of-the-art methods, achieving the highest scores on UIQM and AG while remaining competitive on entropy (EN). Moreover, the method retains strong robustness under high turbidity conditions (T ≥ 35 NTU), producing sharper edges, more faithful color representation, and improved texture clarity. These results indicate that WWSF is an effective preprocessing tool for downstream tasks such as segmentation, defect classification, and condition assessment of hydraulic infrastructure in complex underwater environments. Full article

Austenitic stainless steel inevitably undergoes deformation during application, and it is necessary to study the properties of deformed steel. This article investigates the evolution of microstructure, mechanical properties, and corrosion resistance of plastic-deformed 304 steel, the evolution law of structure and properties of steel is revealed. As a result, it was found that with the increase in deformation, the grains of 304 steel were destroyed, and many small subgrains were generated internally, resulting in a significant decrease in grain size. At the same time, the content of martensitic transformation in stainless steel increased significantly. The characteristics of the surface passivation film of stainless steel also change during the deformation process. Meanwhile, with the increase in deformation, the nanohardness and wear resistance of 304 steel gradually increase, but its corrosion resistance gradually decreases. Analysis suggests that microstructural changes such as grain size and phase transformation in stainless steel lead to an improvement in its mechanical properties, while the generation of defects during deformation and changes in surface passivation film characteristics result in a deterioration of its corrosion resistance. This study can provide a reference for the forming and performance optimization of metals and has high theoretical significance and practical value. Full article

In response to the challenges associated with weld treatment during the on-site corrosion protection of hydraulic steel gates, this paper proposes a method utilizing a magnetic adsorption climbing robot to perform corrosion protection operations. Firstly, a magnetic adsorption climbing robot with a multi-wheel independent drive configuration is proposed as a mobile platform. The robot body consists of six joint modules, with the two middle joints featuring adjustable suspension. The joints are connected in series via an EtherCAT bus communication system. Secondly, the kinematic model of the climbing robot is analyzed and a PID trajectory tracking control method is designed, based on the kinematic model and trajectory deviation information collected by the vision system. Subsequently, the proposed kinematic model and trajectory tracking control method are validated through Python3 simulation and actual operation tests on a curved trajectory, demonstrating the rationality of the designed PID controller and control parameters. Finally, an intelligent software system for weld defect detection based on computer vision is developed. This system is demonstrated to conduct defect detection on images of the current weld position using a trained model. Full article

Background and Objectives: Magnesium (Mg)-based materials, such as the WE43 alloy, show potential in biomedical applications owing to their advantageous mechanical properties and biodegradability; however, their quick corrosion rate and hydrogen release restrict their general clinical utilization. This study aimed to develop a novel Mg-Zn-Ca alloy system based on WE43 alloy, evaluating the influence of Zn and Ca additions on microstructure, mechanical properties, cytocompatibility, and electrochemical behavior for potential use in biodegradable orthopedic applications. Materials and Methods: The WE43-Zn-Ca alloy system was developed by alloying standard WE43 (Mg–Y–Zr–RE) with 1.5% Zn and Ca concentrations of 0.2% (WE43_0.2Ca alloy) and 0.3% (WE43_0.3Ca alloy). Microstructural analysis was performed utilizing scanning electron microscopy (SEM) in conjunction with energy-dispersive X-ray spectroscopy (EDS), while the chemical composition was validated through optical emission spectroscopy and X-ray diffraction (XRD). Mechanical properties were assessed through tribological tests. Electrochemical corrosion behavior was evaluated using potentiodynamic polarization in a 3.5% NaCl solution. Cytocompatibility was assessed in vitro on MG63 cells using cell viability assays (MTT). Results: Alloys WE43_0.2Ca and WE43_0.3Ca exhibited refined, homogeneous microstructures with grain sizes between 70 and 100 µm, without significant structural defects. Mechanical testing indicated reduced stiffness and an elastic modulus similar to human bone (19.2–20.3 GPa), lowering the risk of stress shielding. Cytocompatibility tests confirmed non-cytotoxic behavior for alloys WE43_0.2Ca and WE43_0.3Ca, with increased cell viability and unaffected cellular morphology. Conclusions: The study validates the potential of Mg-Zn-Ca alloys (especially WE43_0.3Ca) as biodegradable biomaterials for orthopedic implants due to their favorable combination of mechanical properties, corrosion resistance, and cytocompatibility. The optimization of these alloys contributed to obtaining an improved microstructure with a reduced degradation rate and a non-cytotoxic in vitro outcome, which supports efficient bone tissue regeneration and its integration into the body for complex biomedical applications. 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

The friction surfacing (FS) process has emerged over the past few years as a method for joining both similar and dissimilar materials, for volume damage repair of defective components, and for corrosion protection. The possibility to produce a metallic coating by FS, without melting the material, classifies this technique as distinct from other standard methods. This unconventional deposition method is based on the severe plastic deformation that appears on a rotating metallic rod (consumable material) pressed against the substrate under an axial load. The present study aims to investigate the tribological properties and corrosion resistance provided by the aluminum-based FS coatings deposited onto a structural S235 steel substrate and further modified by plasma electrolytic oxidation (PEO). During the PEO treatment, the formation of a ceramic film is enabled, while the hardness, chemical stability, corrosion, and wear resistance of the modified surfaces are considerably increased. The morpho-structural characteristics and chemical composition of the PEO-modified FS coatings are further investigated using scanning electron microscopy combined with energy dispersive spectroscopy analysis and X-ray diffraction. Dry sliding wear testing of the PEO-modified aluminum-based coatings was carried out using a ball-on-disc configuration, while the corrosion resistance was electrochemically evaluated in a 3.5 wt.% NaCl solution. The corrosion rates of the aluminum-based coatings decreased significantly when the PEO treatment was applied, while the wear rate was substantially reduced compared to the untreated aluminum-based coating and steel substrate, respectively. Full article

Laser cladding, a cutting-edge surface modification technique for metals, offers a novel approach to enhancing the wear and corrosion resistance of substrates due to its rapid heating and cooling capabilities, precise control over coating thickness and dilution rates, and non-contact processing characteristics. However, disparities in the physical properties between the coating material and the substrate, coupled with the improper utilization of process parameters, can lead to coating defects, thereby compromising the quality of the coating. This paper examines the effects of material systems and process parameters on laser cladding composite coatings and shows that cracking is mainly caused by thermal and residual stresses. This article summarizes the methods for crack improvement and prevention in five aspects: the selection of processes in the preparation stage, the application of auxiliary fields in the cladding process, heat treatment technology, the use of auxiliary software, and the search for new processes and new structural materials. Finally, the future development trends of laser cladding technology are presented. Full article

This study systematically investigates the degradation and failure prediction of pipeline materials in sulfur-containing environments, with a particular focus on X52 pipeline steel exposed to high-sulfur environments. Through uniaxial tensile tests to assess mechanical properties, it was found that despite surface corrosion and a reduction in overall structural load-bearing capacity, the intrinsic mechanical properties of X52 steel did not exhibit significant degradation and remained within standard ranges. The Johnson–Cook constitutive model was developed to accurately capture the material’s plastic behavior. Subsequently, a genetic algorithm-optimized backpropagation (GABP) neural network was employed to predict the failure pressure of defective pipelines and the corrosion rate in acidic environments, with prediction errors controlled within 5%. By integrating the GABP model with NACE standard methods, a framework for predicting the remaining service life for in-service pipelines operating in sour environments was established. This method provides a novel and reliable approach for pipeline integrity assessment, demonstrating significantly higher accuracy than traditional empirical models and finite element analysis. Full article

The production of AISI 304 stainless steel (a corrosion-resistant alloy prone to solidification defects from high alloy content) particularly benefits from twin-roll strip casting—a short-process green technology enabling sub-rapid solidification (the maximum cooling rate exceeds 1000 °C/s) control for high-performance steels. However, the internal phenomena within its molten pool remain exceptionally challenging to monitor. This study developed a multiscale numerical model to simulate coupled fluid flow, heat transfer, and solidification in AISI 304 stainless steel twin-roll strip casting. A quarter-symmetry 3D model captured macroscopic transport phenomena, while a slice model resolved mesoscopic solidification structure. Laboratory experiments had verified that the deviation between the predicted temperature field and the measured average value (1384.3 °C) was less than 5%, and the error between the solidification structure simulation and the electron backscatter diffraction (EBSD) data was within 5%. The flow field and flow trajectory showed obvious recirculation zones: the center area was mainly composed of large recirculation zones, and many small recirculation zones appeared at the edges. Parameter studies showed that, compared with the high superheat (110 °C), the low superheat (30 °C) increased the total solid fraction by 63% (from 8.3% to 13.6%) and increased the distance between the kiss point and the bottom of the molten pool by 154% (from 6.2 to 15.8 mm). The location of the kiss point is a key industrial indicator for assessing solidification integrity and the risk of strip fracture. In terms of mesoscopic solidification structure, low superheat promoted the formation of coarse columnar crystals (equiaxed crystals accounted for 8.9%), while high superheat promoted the formation of equiaxed nucleation (26.5%). The model can be used to assist in the setting of process parameters and process optimization for twin-roll strip casting. Full article