Search Results (67)

This study evaluates the applicability and accuracy of coarse-grain modeling (CGM) in discrete-element method (DEM)–based simulations, focusing on particle-mixing efficiency in five representative industrial mixers: the tumbling V mixer, ribbon-blade mixer, paddle-blade mixer, vertical-blade mixer, and conical-screw mixer. Although the DEM is widely employed for particulate system simulations, the high computational cost associated with fine particles significantly hinders large-scale applications. CGM addresses these issues by scaling up particle sizes, thereby reducing particle counts and allowing longer simulation timesteps. We utilized the Lacey mixing index (LMI) as a statistical measure to quantitatively assess mixing uniformity across various CGM scaling factors. Based on the results, CGM significantly reduced computational time (by over 90% in certain cases) while preserving acceptable accuracy levels in terms of LMI values. The mixing behaviors remained consistent under various CGM conditions, based on both visually inspected particle distributions and the temporal LMI trends. Although minor deviations occurred in early-stage mixing, these discrepancies diminished with time, with the final LMI errors remaining below 5% in most scenarios. These findings indicate that CGM effectively enhances computational efficiency in DEM simulations without significantly compromising physical accuracy. This research provides practical guidelines for optimizing industrial-scale particle-mixing processes and conducting computationally feasible, scalable, and reliable DEM simulations. Full article

The conventional manufacturing of refractory complex concentrated alloys (RCCAs) for high-temperature applications is complicated, particularly when material costs and high melting points of the materials processed are considered. Additive manufacturing (AM) could provide an effective alternative. However, the extreme temperatures involved represent significant challenges for manufacturing defect-free alloys using this approach. To address this issue, we investigated the preparation of a CrNbTiZr quaternary complex concentrated alloy from an equimolar blend of elemental powders using commercially available powder-blown L-DED technology. Initially, the alloys exhibited some defects owing to the internal stress caused by the temperature gradients. This was subsequently resolved by optimizing the deposition strategy. SEM, XRD and EDS were used to analyze the alloy in the as-deposited condition, revealing a BCC phase and a secondary Laves phase. Furthermore, Vickers hardness testing demonstrated a correlation between the hardness and the volume fraction of the Laves phase. Finally, successfully performed compression tests confirmed that the prepared material exhibits high-temperature strength and therefore is promising for high-temperature application under extreme conditions. Full article

Titanium alloys, especially Ti6Al4V, are widely used in biomedical implants due to their biocompatibility and mechanical strength. However, their high elastic modulus (>100 GPa), compared to that of human bone (10–30 GPa), often causes stress shielding, reducing implant lifespan. To address this, titanium alloys with lower elastic modulus are under development. In this study, Ti-based multi-element alloy with 16 wt.% Nb samples were fabricated using laser powder bed fusion (L-PBF) from a premixed powder blend of Ti6Al4V and Nb-Hf-Ti. Processing high-melting Nb-based alloys via L-PBF poses challenges, which were mitigated through optimized parameters, including a maximum laser power of 100 W. Eleven parameter sets were employed to evaluate printability, microstructure, and mechanical properties. Microstructural analysis revealed Widmanstätten structures composed of α and β phases, along with isolated spherical pores. Reduced hatch spacing and slower laser speed led to increased hardness. The highest hardness (~43 HRC) was observed at the highest energy density (266 J/mm³), while the lowest (~28 HRC) corresponded to 44 J/mm³. Elastic modulus values ranged from 30 to 35 GPa, closely matching that of bone. These results demonstrate the potential of the developed Ti-based alloy containing 16 wt.% Nb as a promising candidate for load-bearing biomedical implants. Full article

This study investigates the effects of aluminum (Al) and titanium (Ti) additions on the porosity, microstructure, and corrosion performance of Hastelloy C276-based coatings fabricated via laser cladding on nodular cast iron substrates. Nickel-based alloy powders blended with varying Ti (1–10 wt.%) and Al (0.5–2.5 wt.%) contents were deposited under optimized laser parameters. Microstructural characterization revealed that Ti addition refined the grain structure and promoted the formation of TiC phases, while Al addition dispersed eutectic networks into isolated island-like structures. Both elements effectively suppressed porosity by reducing gas entrapment during solidification. However, excessive Ti (10 wt.%) induced brittle fracture due to TiC agglomeration, and Al addition caused interfacial cracks owing to Al₂O₃ formation. Electrochemical tests in a 3.5 wt.% NaCl solution indicated that Al/Ti additions enhanced initial passivation but reduced corrosion resistance due to weakened oxide film stability. XPS analysis revealed that Al-enriched coatings formed Al₂O₃ and Al(OH)₃, whereas Ti-modified coatings developed TiO₂ and TiC, both influencing the passivation behavior. These findings provide critical insights into tailoring laser-clad coatings for marine applications by balancing porosity suppression and corrosion resistance. Full article

As a rarefied metallic element, strontium (Sr) is susceptible to significant environmental radioactive contamination risks during industrial mining and refining processes. In this study, NaA molecular sieves were prepared by alkali excitation using synthetic powders, which were homogeneously blended with the polyacrylonitrile (PAN) matrix, and nanoscale TiO₂ reinforcing phases were introduced. Finally, composite separation membranes (TiO₂-NaA@PANMs) with stable adsorption properties were constructed by electrostatic spinning technology. The micro-morphology and interfacial properties were characterized by SEM, XRD, and FT-IR systems. The adsorption experiments demonstrated that the equilibrium adsorption capacity of the system for Sr²⁺ reached 55.00 mg/g at the optimized pH = 6.0, and the theoretical saturated adsorption capacity at 298 K was 80.89 mg/g. The isothermal process conformed to the Langmuir’s model of monomolecular layer adsorption, and the kinetic behavior followed the quasi-secondary kinetic equation. Following three cycles of regeneration by elution with a 0.3 mol/L sodium citrate solution, the membrane material exhibited 81.60% Sr²⁺ removal efficacy. The composite membrane passages exhibited remarkable potential for utilization in engineering applications involving the treatment of complex nuclear wastewater. Full article

The growing demand for passenger comfort and environmental protection, as well as reducing fuel consumption and exhaust emissions, drives the search for new, high-performance materials. Composite leaf springs, applied as part of elastic suspension systems and with the advantages of being strong and lightweight, with a high load-carrying capacity, are a possible method with which to achieve those goals. In this study, an epoxy thermoset was blended with 10–50 wt.% polysulfide rubber and reinforced with 10 wt.% alumina powder. The characteristics of the copolymer composite blend were studied by performing ASTM mechanical tests, including tensile strength, impact strength, hardness, and damping ratio tests. The experimental outcomes showed that increasing the proportion of polysulfide rubber caused a reduction in the maximum tensile strength, modulus at fracture, natural as well as damped frequency, and hardness, whereas a significant improvement was observed in impact strength, logarithmic decrement, and the damping ratio. Reinforcement with alumina powder caused a meaningful increase in the maximum tensile strength and natural frequency, with a good improvement in deformation strength. Impact strength and the damping ratio were maximized when alumina powder was increasingly added. This increase was contrary to what occurred for the hardness, which decreased upon reinforcement. Statistical methods, altering the design of the experiments, and linear regression were used to optimize the composite mixture for manufacturing leaf springs. Finally, the model was validated using analysis of variance and probability plots (normal distribution). The regression equations of tensile and impact strength, hardness, and damping ratio test results proved composite suitability for the application of leaf springs under representative loading and operating conditions. Finite element analysis of the composite material was performed using SolidWorks Simulation 22 Mechanical software. ANSYS 2022 R1 was used to study the mechanical properties of the leaf spring model fabricated from the proposed composite material. The finite element analysis results showed a significant reduction in the weight of leaf springs, with very good mechanical properties, including the tensile and impact strength, hardness, and damping ratio, when using the proposed copolymer-reinforced composite material. Full article

The wet chemical auto-combustion technique was used to synthesize barium zirconate ceramic (BaZrO₃). Many strategies were applied to regulate the functional properties of the perovskite-structured sample which was calcinated at 800 °C for 9 h. A Fourier-transform IR spectrometer, an X-ray diffractometer, a scanning electron microscope (SEM)-EDAX, an LCR meter, and a UV–visible spectrometer were employed to study the structural, morphological, optical, and electrical properties of the prepared barium zirconate sample. Using data derived from XRD, the perovskite phase was confirmed, and the average value of the crystallite size was found to be 17.68 nm. The lattice constant, crystallinity, unit cell volume, tolerance factor, and X-ray density were also calculated. SEM-EDAX confirmed the elemental composition of the product and verified that it contained only the major constituents (Ba, Zr, and O). The vibrational modes of the prepared sample were investigated using FTIR in wavelengths ranging from 400 to 4000 cm⁻¹. Energy bandgap was observed using Tauc’s plot, where a graph was prepared for photon energy (hυ) and (αhυ)². The powder sample was blended with PVA and made into pellets of 13 mm diameter using a pelletizer to explore dielectric parameters like the dielectric constant, while the loss factor was recorded at a frequency ranging from 100 Hz to 4 MHz at room temperature. With its high dielectric constant and low dielectric loss factor, barium zirconate ceramic stands as an excellent material for several microwave applications. Full article

For the first time, the refractory high-entropy alloys with equiatomic compositions, HfNbTaTiZr and HfNbTiZr, were synthesized directly from a blend of elemental powders through ten revolutions of high-pressure torsion (HPT) at room temperature. This method has demonstrated its effectiveness and simplicity not only in producing solid bulk materials but also in manufacturing refractory high-entropy alloys (RHEAs). Unlike the melting route, which typically results in predominantly single BCC phase alloys, both systems formed new three-phase alloys. These phases were defined as the Zr-based hcp1 phase, the α-Ti-based hcp2 phase, and the Nb-based bcc phase. The volume fraction of the phases was dependent on the accumulated plastic strain. The thermal stability of the phases was studied by annealing samples at 500 °C for one hour, which resulted in the formation of a mixed structure consisting of the new two hexagonal and cubic phases. Full article

Despite the large number of studies devoted to different compositions of polymer binders for PIM technology, the actual task is still a comparative analysis of the properties of different types of binders to determine their advantages and disadvantages and optimize the compositions used. In this regard, this study aims at the identification and comparative analysis of the rheological properties of the most demanded feedstocks with binders based on polyoxymethylene and a wax–polyolefin mixture under the condition of using identical steel powder filler. The rate of change in the volume fraction of the liquid phase of the binder in the compared feedstocks with temperature change was determined by the calculation–experimental method. As shown, the temperature dependence of the viscosity of feedstocks with a binder based on a polymer blend depends on factors with variable power, i.e., the viscosity change with temperature occurs by different mechanisms with their relaxation spectra. Thus, the principle of temperature–time superposition for feedstocks with multicomponent binders is not applicable, and the study of the viscosity of such materials should involve a wide range of shear rates and temperatures using experimental methods. Capillary rheometry was used to measure the flow curves of feedstocks based on polyoxymethylene and wax–polyolefin binders. The analysis of flow curves of feedstocks showed that feedstocks with a binder of solution–thermal type of debinding have significantly lower viscosity, which is an advantage for molding thin-walled products. However, their difference of 1.5 times sensitivity to the shear rate gradient leads to their lower resistance to “jets” and liquation of components because of shear rate gradients when molding products with elements of different cross-sectional areas. Full article

A blend of only commercial powders, including Ni625, CoCrF75, and 316L, were used as the raw material for fabricating non-equiatomic CoCrFeNiMo_xNb_y high entropy alloys (HEAs) through laser powder bed fusion (PBF-LB/M) via in situ alloying, instead of using pure elemental powders, thus reducing the raw materials cost. The rapid cooling inherent in the PBF-LB/M process facilitated the dissolution of Mo and Nb, resulting in a single FCC phase characterized by high relative densities. High-temperature tensile tests were conducted at room temperature, 700 °C, 800 °C, and 900 °C, revealing mechanical properties that surpassed those reported in existing HEA literature. The remarkable strength of the HEAs developed in this study primarily stemmed from the incorporation of Mo and Nb, leading to the precipitation of Mo and Nb-rich lave phases at elevated temperatures. While constraining elongation when confined to grain boundaries, these precipitates enhanced strength without compromising elongation when distributed throughout the matrix. This work is a feasibility study to explore the usage of commodity compositions from the market to develop HEAs using PBF-LB/M, which opens the possibility of using scraps to further the development of new materials. Consequently, this study presents a rapid and cost-effective approach for HEA development, improving efficiency and sidestepping the direct utilization of critical raw metals for sustainable manufacturing. Moreover, this work also underscores the outstanding mechanical performance of these HEAs at high temperatures, paving the way for the design of innovative alloys for future high-temperature applications. Full article

Printed circuit boards (PCBs) are the main components of e-waste. In order to reduce the negative impact of waste PCBs on human health and the environment, they must be properly disposed of. A new method is demonstrated for recycling waste PCBs. It is referred to as the high-temperature thermo-mechano-chemical gasification (TMCG) of PCBs by the detonation-born gasification agent (GA), which is a blend of H₂O and CO₂ heated to a temperature above 2000 °C. The GA is produced in a pulsed detonation gun (PDG) operating on a near-stoichiometric methane–oxygen mixture. The PDG operates in a pulsed mode producing pulsed supersonic jets of GA and pulsed shock waves possessing a huge destructive power. When the PDG is attached to a compact flow reactor filled with waste PCBs, the PCBs are subject to the intense thermo-mechano-chemical action of both strong shock waves and high-temperature supersonic jets of GA in powerful vortical structures established in the flow reactor. The shock waves grind waste PCBs into fine particles, which undergo repeated involvement and gasification in the high-temperature vortical structures of the GA. Demonstration experiments show full (above 98%) gasification of the 1 kg batch of organic matter in a setup operation time of less than 350 s. The gaseous products of PCB gasification are mainly composed of CO₂, CO, H₂, N₂, and CH₄, with the share of flammable gas components reaching about 45 vol%. The solid residues appear in the form of fine powder with visible metal inclusions of different sizes. All particles in the powder freed from the visible metal inclusions possess a size less than 300–400 μm, including a large fraction of sizes less than 100 μm. The powder contains Sn, Pb, Cu, Ni, Fe, In, Cd, Zn, Ca, Si, Al, Ti, Ni, and Cl. Among these substances, Sn (10–20 wt%), Pb (5–10 wt%), and Cu (up to 1.5 wt%) are detected in the maximum amounts. In the powder submitted for analysis, precious elements Ag, Au, and Pt are not detected. Some solid mass (about 20 wt% of the processed PCBs) is removed from the flow reactor with the escaping gas and is partly (about 10 wt%) trapped by the cyclones in the exhaust cleaning system. Metal inclusions of all visible sizes accumulate only in the flow reactor and are not detected in powder samples extracted from the cyclones. The gasification degree of the solid residues extracted from the cyclones ranges from 76 to 91 wt%, i.e., they are gasified only partly. This problem will be eliminated in future work. Full article

Mushrooms, due to their basic composition and the presence of numerous mycochemicals, can be used to improve various food matrices. The objective of this study was to determine the impact of replacing wheat flour (2%, 4%, 6% w/w) with mushroom lyophilisates from cultivated mushrooms—A. bisporus and P. ostreatus—on the technological quality, basic nutritional and elemental composition, antioxidant activity (ABTS, FRAP), total polyphenol content (TPC), and sensory evaluation of shortbread cookies. The functional properties of blended flours were also determined, such as bulk density (BD), water- and oil-holding capacity (WHC, OHC), swelling capacity (SW), and water solubility index (WSI). The results show that the amounts of protein, fiber, and ash were higher in cookies enriched with mushrooms than in control cookies. The enriched products, depending on the amount of mushroom powder used and the mushroom species, had a higher content of zinc, iron, magnesium, potassium, and copper. The increase in the addition of mushroom powder resulted in a significant (p < 0.05) increase in the TPC content and antioxidant properties. The use of composite flours contributed to a significant increase in hardness (at 6% mushroom powder) and a change in color parameters, with lower whiteness and a greater ΔE recorded for cookies with A. bisporus lyophilisate. In the sensory evaluation, the samples enriched with P. ostreatus powder received higher scores compared with control samples, while the cookies with A. bisporus flour were evaluated lower than the control. Full article

Aluminum and its alloys are very versatile materials used in a wide range of applications due to the initial characteristics of pure aluminum and the combination of properties obtained from its blend with other elements. Considering that aluminum is the second-most-produced metal after steel, and that its production will increase over time based on the demand to produce products through conventional and additive methodologies, this will lead to an increase in the energy consumed as well as the footprint of carbon generated. It is for this reason that the generation of competitive aluminum alloys must be approached from secondary sources (recycling). To address these environmental issues, in this work, 2070 aluminum alloy (AA2070) samples were manufactured using secondary aluminum powder and compared with the primary aluminum source. The samples were compacted at 700 MPa and sintered at a different range of temperatures between 525 °C and 575 °C. The study includes thermodynamic modeling, microstructure, and mechanical characterization. Microstructure and phases characterization were carried out via scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis, respectively, whereas the mechanical characterization comprised relative density evaluation, hardness, and flexion tests. Results were compared with the calculation of phase stability using Thermo-Calc software 2020a. Based on the results obtained, it can be concluded that the secondary AA2070 optimal sintered temperature, where the components raised the highest mechanical properties and effective relative density range, is 575 °C. Furthermore, the recycled alloys have similar relative densities and flexural strengths than the corresponding alloys made from primary aluminum powder. Full article

TiNbZrTa alloys are promising for multidisciplinary applications, such as refractory and biomedical purposes, due to their high thermal stability and non-toxicity. Hardness and elastic modulus are among the key features for their adequate industrial applications. The influence of porosity and Ti/Ta ratio were investigated on TiNbZrTa alloys produced by three different processing routes, i.e., (i) blend element and posterior press and sintering (BE + P&S); (ii) mechanical alloying with press and sintering (MA + P&S); and (iii) arc melting and casting. Porosity decreased in the following order: casting < MA + P&S < BE + P&S. The total porosity of alloys increased with increasing Ta contents, i.e., by lowering the Ti/Ta ratio. However, the Ti/Ta ratio did not considerably affect the bonding energy or the elastic modulus. Hardness was increased significantly in dense alloys compared to porous ones. However, porosity and Ti/Ta ratio did not show a clear trend in hardness among the porous alloys. Full article

Additive manufacturing of Duplex Stainless Steels (DSS) and Super Duplex Stainless Steels (SDSS) has been successfully demonstrated using LPBF in recent years, however, both alloys feature an almost fully ferritic microstructure in the as-built condition due to the fast cooling rates associated with the Laser Powder Bed Fusion (LPBF) process. Blends of DSS and SDSS powders were formulated with austenitic stainless-steel 316L powder, aiming to achieve increased austenite formation during in the LPBF as-built condition to potentially minimize the post heat treatments (solution annealing and quenching). Powder characteristics were investigated and process parameters were optimized to produce near fully dense parts. Nanoindentation (NI) tests were conducted to measure, not only the local mechanical properties and correlate them with the as-built microstructure, but also to gain a deeper understanding in the deformation behavior of individual phases that cannot be studied directly by macroscopic tensile tests. Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD) were employed for microstructural analysis and phase quantification. The microstructural analysis and EBSD phase maps revealed an increase in austenite in the as-built microstructures. Blend 1 resulted in a duplex microstructure consisting of 10% austenite at the XY plane and 20% austenite at the XZ plane. The austenite content increased with increasing proportion of 316L stainless steel in the powder blends. The DSS blend required a much higher volumetric energy density for the fabrication of near fully dense parts. This imposed a slower solidification and a higher melt pool homogeneity, allowing for adequate diffusion of the austenite stabilizing elements. The presented workflow and findings from this study provide valuable insights into powder mixing for the development of custom alloys for rapid material screening in LPBF. Full article