Search Results (211)

In physiological environments, several metallic alloys, including titanium, stainless steel, cobalt–chromium, and emerging biodegradable systems such as magnesium (Mg), zinc (Zn), and iron (Fe), offer mechanical properties and biocompatibility suitable for load-bearing implants. With the rapid advancement of 3D printing technologies, these alloys can now be fabricated into patient-specific, complex geometries that enhance both structural performance and functional integration. Beyond serving as structural supports, 3D-printed alloys are increasingly engineered as localized drug-delivery platforms to release anti-inflammatory, antibacterial, anticancer, and osteogenic agents at the implant–tissue interface, addressing the dual clinical needs of site-specific therapy and mechanical stabilization. Nevertheless, this field remains underexplored because studies differ widely in alloy chemistry, surface topography, porosity, coating strategy, drug-loading methods, and release profiles, as well as in how material degradation or passivation interacts with pharmacokinetics. For the first time, this review consolidates drug-loading and elution strategies across 3D-printed alloy platforms, compares therapeutic categories in relation to alloy and coating types, and critically evaluates how the surface microstructure or alloy geometry influences release behavior. Full article

Intermetallic Fe₃Al-based alloys reinforced with Laves-phase precipitates are emerging as potential replacements for conventional high-alloy steels and possibly polycrystalline Ni-based superalloys in structural applications up to 700 °C. Their impressive mechanical properties, however, are offset by limited fabricability and poor machinability due to their severe brittleness. High tool wear during finish-machining, which is still required for components such as turbine blades, remains a key barrier to their broader adoption. In contrast to conventional manufacturing routes, additive manufacturing offers a viable solution by enabling near-net-shape manufacturing of difficult-to-machine iron aluminides. In the present study, laser powder bed fusion was used to produce an Fe-25Al-1.5Ta intermetallic containing strengthening Laves-phase precipitates, and the porosity, microstructure and phase composition were characterized as a function of the process parameters. The results showed that preheating the build plate to 650 °C effectively suppressed delamination and macrocrack formation, even though noticeable cracking still occurred at the high scan speed of 1000 mm/s. X-ray tomography revealed that samples fabricated with a lower scan speed (500 mm/s) and a higher layer thickness (0.1 mm) contained larger, irregularly shaped pores, whereas specimens printed at the same volumetric energy density (40 J/mm³) but with different parameter sets exhibited smaller fractions of predominantly spherical pores. All samples contained mostly elongated grains that were either oriented close to <001> relative to the build direction or largely texture-free. X-ray diffraction confirmed the presence of Fe₃Al and C14-type (Fe, Al)₂Ta Laves phase in all samples. Hardness values fell within a narrow range (378–398 HV10), with only a slight reduction in the specimen exhibiting higher porosity. Full article

This study presents the results of laser beam welding of dissimilar high-alloy super stainless steels. Differences in their thermal and mechanical properties pose significant challenges in manufacturing processes. The present work demonstrates the potential advantages of using 309L filler material in laser welding of high-alloy materials with different properties. The research focuses on a comparative evaluation of the effects of 309L filler metal on the TP904L—TP347 joint in terms of joint strength and microstructure. The analysis of the joints provides insight into the role of the filler metal in improving joint properties. The obtained results show that both welds exhibit a similar microstructure composed of pillar, cellular, and equiaxed dendrites; however, they differ in dendrite growth orientation, calculated ferrite number (FN), the G/R ratio, and dendrite arm spacing, indicating a lower thermal gradient in the joint welded with filler metal. The results also reveal the presence of precipitates in the welds near the TP904L steel fusion line, most likely Cr₂₃C₆ type. Mechanical properties evaluation, based on standard and miniaturized tensile tests as well as hardness measurement, shows that the use of 309L filler metal improves both the joint strength and ductility, although it does not significantly affect the material hardness. Full article

Compared with a traditional distribution transformer with silicon steel sheet as the core material, the no-load loss of an amorphous alloy transformer is greatly reduced due to its core using iron-based amorphous metal material, which has been applied in many countries. However, due to the brittleness of its amorphous strip, an amorphous alloy transformer is prone to debris in the process of production, transportation and work. The charge and migration characteristics of these debris will reduce the insulation strength of the transformer oil and endanger the safe operation of the transformer. In this paper, a charge measurement platform of amorphous alloy debris is set up, and the charging characteristics of amorphous alloy core debris under different flow velocities, particle radius and plate electric field strength are obtained. The results show that with an increase in pipeline flow velocity, the charge-to-mass ratio of the debris increases first and then decreases. With an increase in electric field strength, the charge-to-mass ratio of the debris increases; with an increase in the number of debris, the charge-to-mass ratio of the debris decreases; with an increase in debris size, the charge-to-mass ratio of the debris increases. The debris with different charge-to-mass ratios and types obtained from the above experiments are added to the simulation model of an amorphous alloy transformer. The lattice Boltzmann method (LBM) coupled with the discrete element method (DEM) is used to simulate the migration process of metal particles in an amorphous alloy transformer under the combined action of gravity, buoyancy, electric field force and oil flow resistance under electrothermal excitation boundary. The results show that the trajectory of the debris is related to the initial position, electric field strength and oil flow velocity. The LBM–DEM calculation model and charge measurement platform proposed in this paper can provide a reference for studying the charge mechanism and migration characteristics of amorphous alloy core debris in insulating oil. Full article

As the world increasingly gravitates towards green, environmentally friendly and low-carbon lifestyles, wind power has become one of the most technologically established renewable energy sources. However, with the continuous increase in their output power and height, wind turbine towers are subjected to higher-intensity alternating wind loads. This makes critical components more prone to fatigue failure, potentially leading to major accidents such as tower buckling or turbine collapse. High-strength bolts play a vital role in supporting towers but are susceptible to fatigue crack initiation under long-term cyclic loading, necessitating regular inspection. Types of wind turbine bolts mainly include high-strength bolts, stainless steel bolts, anchor bolts, titanium alloy bolts, and adjustable bolts. These bolts are distributed across different parts of the turbine and perform distinct functions. Among them, high-strength bolts in the tower are particularly critical for structural support, demanding prioritized periodic inspection. Compared to destructive offline inspection methods requiring bolt disassembly, non-destructive testing (NDT) has emerged as a trend in defect detection technologies. Therefore, this review comprehensively examines various types of NDT techniques for wind turbine towers’ high-strength bolts, including disassembly inspection techniques (magnetic particle inspection, penetration inspection, intelligent torque inspection, etc.) and non-disassembly inspection techniques (ultrasonic inspection, radiographic inspection, infrared thermographic inspection, etc.). For each technique, we analyze the fundamental principles, technical characteristics, and limitations, while emphasizing the interconnections between the methodologies. Finally, we discuss potential future research directions for bolt defect NDT technologies. Full article

During machining, most of the mechanical energy is converted into heat. A substantial part of this heat is transferred to the cutting tool, causing a rapid rise in tool temperature. Excessive thermal loads accelerate tool wear and lead to displacement of the tool center point, reducing machining accuracy and workpiece quality. This challenge is particularly pronounced when machining titanium alloys. Due to their low thermal conductivity, titanium alloys impose significantly higher thermal loads on the cutting tool compared to conventional carbon steels, making the process more difficult. To reduce temperatures in the cutting zone, cutting fluids are widely employed in titanium machining. They have been shown to significantly extend tool life. Cutting fluids are broadly categorized into cutting oils and water-based cutting fluids. Owing to their distinct thermophysical properties, these fluids exhibit notably different cooling and lubrication performance. However, current research lacks comprehensive cross-comparative studies of different cutting fluid types, which hinders the selection of optimal cutting fluids for process optimization. This study examines the influence of three cutting fluids—emulsion, cutting oil, and synthetic oil-free fluid—on tool wear, temperature, surface quality, and energy consumption during flood-cooled end milling of Ti-6Al-4V. A novel experimental setup incorporating embedded thermocouples enabled real-time temperature measurement near the cutting edge. Tool wear, torque, and surface roughness were recorded over defined feed lengths. Among the tested fluids, emulsion achieved the best balance of cooling and lubrication, resulting in the longest tool life with a feed travel path of 12.21 m. This corresponds to an increase of approximately 200% compared to cutting oil and oil-free fluid. Cutting oil offered superior lubrication but limited cooling capacity, resulting in localized thermal damage and edge chipping. Water-based cutting fluids reduced tool temperatures by over 300 °C compared to dry cutting but, in some cases, increased notch wear due to higher mechanical stress at the entry point. Power consumption analysis revealed that the cutting fluid supply system accounted for 60–70% of total energy use, particularly with high-viscosity fluids like cutting oil. Complementary thermal and CFD simulations were used to quantify heat partitioning and convective cooling efficiency. The results showed that water-based fluids achieved heat transfer coefficients up to 175 kW/m²·K, more than ten times higher than those of cutting oil. These findings emphasize the importance of selecting suitable cutting fluids and optimizing their supply to enhance tool performance and energy efficiency in Ti-6Al-4V machining. Full article

Part segmentation can be used to overcome limitations of additive manufacturing (AM) processes such as Direct Energy Deposition of Metals (DED). In this case subparts of soft martensitic steel 1.4313 produced by conventional manufacturing (CM) and AM are joined by laser welding. This paper reports the difference in thermal conductivity of conventional and additive manufactured parts. The thermal conductivity was calculated from the thermal diffusivity, the specific heat, and the bulk density. Furthermore, the temperature was measured during welding and the microstructure analyzed. The far field temperature was measured using eight K-type thermocouples and the microstructure was analyzed by metallography and light microscopy. The results showed that the thermal conductivity of AM material is 8% lower and therefore the heating rate 5% lower compared to CM material. The lower thermal conductivity is explained in the literature by its higher dislocation density, unfavorable alloying element distribution and a lower rest austenite content. AM introduces structural complexity that hampers electron and phonon transport, thereby reducing the thermal conductivity despite similar base chemical compositions. The heat-affected zone is only clearly visible on the CM side due to carbide formation. In DED parts, it comes to different phases in non-equilibrium states, which complicates the identification of carbides and the HAZ. The findings are important for the design of hybrid components to improve the the joint integrity and functionality of hybrid parts. Full article

This paper presents the results of wear tests of two types of commercial low-carbon, low-alloy martensitic abrasion-resistant steels, Hardox 450 and XAR 450, which belong to the hardness class 450 HBW. These steels, due to their increased resistance to the abrasive wear mechanism, are used for machine parts for applications in intensive abrasion environments such as construction, mining, and agriculture. The scope of work included microstructure analysis on an optical microscope, chemical composition analysis, Vickers hardness measurements at different loads (HV0.2, HV1 and HV2), and wear testing. Wear tests were carried out by the standard method “dry sand—rubber wheel”, and tests on the Taber abrader device. Microstructure analysis revealed that both steels have a similar non-oriented, homogenous, fine-grained martensitic microstructure. The results of HV2 hardness measurements showed a similar trend for both steels in all examined sections of the plates. For both tested steels, the hardness values of HV0.2 and HV1 are slightly higher than HV2, but the scattering of the results is also greater. Abrasion resistance testing using the standard “dry sand—rubber wheel” method showed that Hardox 450 steel has a lower volume loss of about 8%, but a greater scattering of the results compared to XAR 450 steel. The results of the abrasion resistance test on the Taber abrader device confirmed approximately the same behavior. For both steels, a prediction model was established for a reliable assessment of the wear intensity concerning the grain size. Although examined steels belong to the same hardness class, Hardox steel seems to be a more appropriate choice for the manufacture of machine components exposed to abrasive wear. Full article

In a recent investigation the corrosion-fighting potential of five benzaldehyde derivatives were explored: 4-Formylbenzonitrile (BA1), 4-Nitrobenzaldehyde (BA2), 2-Hydroxy-5-methoxy-3-nitrobenzaldehyde (BA3), 3,5-Bis(trifluoromethyl)benzaldehyde (BA4), and 4-Fluorobenzaldehyde (BA5). Benzaldehyde derivative (BA-2) showed a maximum inhibition efficiency of 93.3% at 500 ppm. Several techniques were used to evaluate these compounds’ ability to protect mild steel from corrosion in a 1 M HCl solution, including potentiodynamic polarization (PDP), electrochemical impedance spectroscopy (EIS), adsorption isotherms, and computational methods. Supporting techniques Fourier transform infrared spectroscopy (FTIR) and ultraviolet–visible (UV-Vis) spectroscopy were also employed to validate the results. Despite sharing a common benzene ring, the molecules differ in their substituents, allowing for a comprehensive examination of the substituents’ impact on corrosion inhibition. PDP analysis disclosed that the inhibitors exhibited mixed-type inhibition behavior, interacting with anodic as well as cathodic reactions, influencing the corrosion process. EIS analysis revealed that benzaldehyde derivatives formed a protective passive film on the metal, exhibiting high corrosion resistance by shielding the alloy from corrosive attacks. The benzaldehyde inhibitors followed the Langmuir adsorption isotherm, with high R² values near one, indicating a monolayer adsorption mechanism. DFT results indicate that BA 2 is the most effective inhibitor. FTIR and UV-vis spectroscopy revealed the molecular interactions between metal and benzaldehyde derivative molecules, providing insight into the binding mechanism. Experimental results support the outcomes obtained from the molecular dynamic (MD) simulations. Full article

The paper presents the results of oxidation tests on the alloy based on the intermetallic phase, Fe40Al5Cr0.2TiB, in the air at 700–1000 °C temperature. The kinetics of corrosion processes were determined, the surface condition after oxidation was assessed, and the type and morphology of the oxides formed were determined. In addition, the paper presents the possibility of applying the technology of surfacing Fe40Al5Cr0.2TiB alloy on the surface of steel grade S235JR as a protective coating that is resistant to high temperatures. The process was carried out using the TIG method by direct current (DC). After the surfacing, the structure of the surfacing weld made of the tested material on the base of structural steel grade S235JR was determined. It was found that a protective Al₂O₃ oxide layer is formed on the surface of the oxidized alloy based on the intermetallic phase from the FeAl system, and the oxidation kinetics have a parabolic course. Moreover, it was found that the morphology of the oxides formed on the surface varies depending on the oxidation temperature, which clearly indicates a different mechanism of oxide layer formation. The formation of a stable α-Al₂O₃ oxide variety on the surface of the Fe40Al5Cr0.2TiB alloy protects the material from further corrosion, which favors the application of this alloy on structures and fittings operating at elevated temperatures. The aim of the research was to use the Fe40Al5Cr0.2TiB alloy with very good oxidation resistance as a layer overlay on ordinary quality S235JR steel. In this way, conditions were created that fundamentally changed the surface condition (structure and physicochemical properties) of the system: steel as a substrate—intermetallic phase Fe40Al5Cr0.2TiB as a surfacing layer, in order to increase resistance to high-temperature corrosion and erosion (in the environment of gases and solid impurities in gases) often occurring in corrosive environments, especially in the power industry (boilers, pipes, installation elbows) and the chemical industry (fittings). At the same time, the surfacing method used is one of the cheapest methods of changing the surface properties of the material and regenerating or repairing the native material with a material with better properties, especially for applications in high-temperature corrosion conditions. Full article

Objective: The increasing number of aging patients with total hip arthroplasties (THA) causes an increased incidence of periprosthetic fractures (PPF). The study aimed to evaluate the impacts of two different materials in the same-sized cemented stems on PPF in bone models. Methods: This study compared the maximum rotational torque leading to PPF when stems made of cobalt–chromium–molybdenum (Co–Cr–Mo) alloy and stainless use steel (SUS) were implanted using simulated bone models (Sawbones, 3403). The maximum destruction torque was compared statistically for each material (Co–Cr–Mo alloy vs. SUS stainless steel) in this model, and fracture patterns were examined. Results: The PPF occurred with a spiral propagation from the proximal femur towards the diaphysis, with breakage occurring near the distal end of the stem. There were no significant differences in the destruction torque values between the Co–Cr–Mo alloy (103.0 ± 14.9 Nm) and SUS (98.7 ± 15.1 Nm) samples (p = 0.575). The fractures using the bone models exhibited similar patterns in all specimens, resembling clinical PPF fracture types clinically, specifically Vancouver classification B2. Conclusions: The comparison of the maximum destruction torques of the Co–Cr–Mo alloy and SUS cemented stems in simulating PPF showed no significant differences. The results suggest that the materials of the cemented stems might not significantly affect the occurrence of PPF in THA. Full article

An experimental campaign based on multiaxial tests is carried out to characterize the ductile behavior of 17-4PH steel and a Ti6Al4V titanium alloy, and to calibrate numerical ductile damage models, accordingly. This study aimed to identify a minimal set of four specimen types to ensure the robust tuning of the damage models, using only a conventional uniaxial machine for testing. Two different shear–tension candidate geometries are identified, modified, and used together with cylindrical and notched bar specimens to evaluate material plastic strain at fracture under several stress states, characterized by different triaxialities and Lode angles. Finite element analysis and digital image correlation techniques are used to identify local data not directly measured from the tests. Three recent ductile damage models are calibrated using the experimental data. The accuracy of the proposed approach is validated and presented for the two alloys, by comparing the results with calibrations performed on the same materials using more conventional multiaxial tests. It is shown that the new methodology is effective, and how either one of the two shear–tension geometries in addition to tensile tests could replace, with the same level of accuracy, typical more complex calibration procedures involving tests that require dedicated facilities. Full article

The lubrication of mining reducer is subjected to the contamination of coal rock dust, and this contamination has extremely serious influence on the wear life of reducers. This paper examines the effects of coal dust and rock dust contamination on the wear of mine gearboxes, especially the wear mechanisms and particle characteristics under lubrication conditions of coal dust and rock dust mixtures of different particle sizes and contents. In the paper, 18CrNiMo7-6 alloy steel was used as the reducer gear material to simulate the actual working conditions, and friction and wear tests were conducted by CFT-1 comprehensive tester to analyze the wear particle characteristics under different contamination conditions. In the experiment, 80-mesh and 200-mesh coal dust and silica particles were used (80-mesh pore size is about 180 μm; 200-mesh pore size is about 75 μm), and different mass fractions of contaminant mixtures were set. The results show that under 80-mesh coal dust contamination, punctate pits, scratches and green halos appeared on the surface of wear particles, and the corrosion and abrasive effects were enhanced when the concentration increased, while 200-mesh coal dust contamination was characterized by black pits and green halos, and the abrasive effect was not obvious. Silica contamination showed significant cutting effects with red oxide wear particles. The synergistic effect of the two contaminants accelerated the wear of the material, and the wear particles were characterized by delamination, flaking and black pits. The study shows that the concentration and type of contaminants have a significant effect on the wear performance of the reducer. Full article

Springback is still one of the most challenging issues in sheet metal forming, especially in the automotive industry, where hundreds of pressings made of different types of materials are joined together by various methods. In this study, springback evaluation was conducted on three types of steel that are commonly used in the automotive industry. Transformation induced plasticity (TRIP), micro-alloyed and deep-drawing steel sheets were used in compression bending, which is largely used in bending hollow tubes. The impact of die diameter and anisotropy on the springback was studied and evaluated. A numerical prediction of springback was conducted using Simufact Forming 2022 software. Based on the experimental results, it was found that steels with higher yield and tensile strength experience more springback than steels with lower strength properties. Additionally, the use of larger die diameters (30 mm and 25.4 mm) in compression bending results in higher springback compared to smaller ones (10 mm and 15 mm). The impact of anisotropy on the springback was mostly evident in pressings made of deep-drawing steel. Full article

To meet the requirement of low magnetic permeability, which, in turn, lowers the ferrite content of castings, of special interest is 316 stainless steel, whose low ferrite content renders it suitable also for nuclear power applications. Therefore, the effects of the composition and cooling rate of 316 stainless steel castings on the ferrite content are investigated. Three 316 stainless steel continuous casting samples with different compositions (primarily differing in the Ni content) are studied, i.e., low-alloy type (L-316), medium-alloy type (M-316), and high-alloy type (H-316). The austenite-forming element nickel of three different industrial samples is 10%, 12%, and 14%, respectively. The effect of the cooling rate on the ferrite content and precipitation phases of the high Ni content of the 316 stainless steel casting (H-316) is studied by remelting experiments and different methods of quenching of liquid steel. In both cases, the ferrite content and the precipitate phases in the microstructure are analyzed using SEM and EBSD. The results indicate that compositional changes within the 316 stainless steel range lead to changes in the solidification mode. In the L-316 casting, solidified by the FA mode (ferrite–austenite mode), ferrite precipitates first from the liquid phase, followed by the formation of austenite, and the ferrite content is 11.2%. In contrast, the ferrite content in the M-316 and H-316 castings, solidified by the AF mode (austenite–ferrite mode), is 2.88% and 2.45%, respectively. The effect of the solidification mode on the ferrite content is more obvious than that of the composition. The microstructure of the L-316 casting is mainly composed of the austenitic phase and the ferritic phase. The microstructure of the M-316 casting is composed of austenite, ferrite, and a small amount of sigma phase, with a small amount of ferrite transformed into the sigma phase. The microstructure of the H-316 casting is basically composed of austenite and the sigma phase, with the ferrite has been completely transformed into sigma phase. Changes in composition have a greater influence on the precipitate phases, while the solidification mode has a lesser impact. In the remelting experiments, the ferrite content in the H-316 ingot obtained through furnace cooling and air cooling is 1.49% and 1.94%, respectively, and the cooling rates are 0.1 °C/s and 3.5 °C/s, respectively. Under oil- and water-cooling conditions, with cooling rates of 11.5 °C/s and 25.1 °C/s, respectively, the ferrite content in the ingot is controlled to below 1%. The effect of the cooling rate on the precipitation phase of the H-316L ingot is that the amount of precipitated phase in the ingot decreases with an increase in cooling rate, but, when the cooling rate exceeds a certain value (air cooling 3.5 °C/s), the change in cooling rate has little effect on the amount of the precipitated phase. Full article