Search Results (86)

AlCrFeNiSi high-entropy alloy (HEA) components were fabricated using digital light processing (DLP) 3D printing, followed by debinding under oxygen-rich and oxygen-deficient atmospheres and sintering at various temperatures. The influence of atmosphere on microstructural evolution, elemental redistribution, and mechanical consolidation was systematically investigated. Oxygen-rich debinding induced oxidation-driven gas formation and surface cracking, whereas oxygen-deficient debinding preserved residual carbon that reduced porosity and enabled earlier densification. The layered microstructure progressively vanished with temperature, and full consolidation was achieved at 1100 °C in oxygen-rich and 1050 °C in oxygen-deficient environments. Correspondingly, both processing conditions yielded similar maximum compressive strengths (~5 MPa), although the oxygen-deficient condition attained this strength at a lower temperature. These findings demonstrate that controlling oxygen exposure during debinding provides an effective pathway to reduce the sintering temperature while maintaining the mechanical performance of DLP-printed AlCrFeNiSi HEA components. Full article

The concept of heating the near-wellbore zone (NWZ) using activated aluminum alloys offers a novel approach to enhancing oil recovery. This article reviews research on the development of hydrocarbon-based solvent formulations for removing asphaltene–resin–paraffin deposits (ARPD) in the NWZ and restoring well productivity. A comprehensive analysis of ARPD composition enabled the selection of solvent systems tailored to specific deposit types. The efficiency of ARPD removal from the NWZ, downhole equipment, and oil gathering systems in heavy and highly viscous Kazakhstani crude oils was evaluated using hydrocarbon solvent blends (e.g., hexane–toluene, gasoline–o-xylene, o-xylene–hexane–1-hexene) with surfactants (polyoxyethylene sorbitan–maleic anhydride esters), atactic polypropylene (APP), and activated aluminum alloys. The developed formulations accelerated ARPD breakdown and reduced energy consumption. It has been established that the optimal concentration of APP (0.5 wt.%) provides up to 100% cleaning efficiency and increases dissolving capacity by 25–30% compared to traditional binary systems. Cleaning efficiency is driven by a thermochemical reaction between water and the aluminum alloy, 2Al + 6H₂O → 2Al(OH)₃ + 3H₂↑ + 17 kJ, which depends on the alloy’s microstructure, grain boundary condition, and additive distribution. The exothermic effect of the reaction leads to the formation of a hot gas–steam–hydrogen mixture, where atomic hydrogen actively breaks down ARPD and increases the reservoir permeability by 2 to 4.5 times. Results show that a composite formulation of hexane–toluene–alloy–H₂O₂ (46.5:15:0.25:38.25) reduces the treatment time of ARPD-3 from 60 to 10 min while maintaining high efficiency at the level of 98.3%. Full article

This work investigated the effect of high-nitrogen/low-hydrogen mixed atmosphere heat treatment on the electrochemical corrosion and wear resistance of plasma-sprayed FeCoNiCrAl high-entropy alloy (HEA) coatings. The HEA coatings were sequentially prepared through annealing at 400, 600, and 800 °C for 6 h. The heat treatment method was conducted in a vacuum tube furnace under 0.1 MPa total pressure, with gas flow rates set to 300 sccm N₂ and 100 sccm H₂. The XRD results indicated that the as-deposited coating exhibited α-Fe (BBC) and Al_0.9Ni_4.22 (FCC) phases, with an Fe_0.64N_0.36 nitride phase generated after 800 °C annealing. The electrochemical measurements suggested that an exceptional corrosion performance with higher thicknesses of passive film and double-layer capacitance can be detected based on the point defect model (PDM) and effective capacitance model. Wear tests revealed that the friction coefficient at 800 °C decreased by 3.84% compared to that in the as-sprayed state due to the formation of a dense nitride layer. Molecular orbital theory pointed out that the formation of bonding molecular orbitals, resulting from the overlap of valence electron orbitals of different atomic species in the HEA coating system, stabilized the structure by promoting atomic interactions. The wear mechanism associated with stress redistribution and energy balance from compositional synergy is proposed in this work. Full article

The Er-Zr-Sc-modified Al-Mg alloys produced by additive manufacturing (AM) exhibit good formability and excellent mechanical properties, and present great potential for applications in the fields of aerospace and automotive fields. In this work, the preparation process of Al-4.5Mg-0.7Er-0.5Zr-0.3Sc high-strength aluminum alloy powder for additive manufacturing by vacuum induction melting gas atomization (VIGA) was investigated. With the goal of obtaining excellent sphericity and higher powder yield in the particle size range of 15~53 μm, a new type atomizer with optimized convergence angle and tube extension length was designed based on finite element numerical simulation and experimental research, and the optimal atomization processing parameters were determined. The results revealed that when the convergence angle was 32° and the extension length was 5 mm, the large negative pressure and suction force at the tube outlet could facilitate the smooth flow of the melt and a refined powder particle size; when the melt temperature was 800 °C and the atomization pressure was 3.25 Mpa, the melt had low viscosity and the atomization gas could fully interact with the melt. Meanwhile, the melt droplets had suitable cooling conditions, avoiding the generation of irregular powders and improving the powder sphericity. Under the above optimal processing parameters, the prepared powders were spherical or nearly spherical with fine particle size and a high yield of about 39.45%. Full article

Zr₄₈Cu_47.5Al₄Co_0.5 bulk amorphous alloy composites were prepared by selective laser melting (SLM) technology under different processing conditions and their non-isothermal crystallization behaviors were systematically investigated. The results show that the crystallization phases are Cu₁₀Zr₇ and CuZr₂ for both gas-atomized powder and SLMed samples. The dependence of volume fraction of Cu₁₀Zr₇ and CuZr₂ on laser energy density can be fitted by an exponential function. The crystalline sizes of Cu₁₀Zr₇ and CuZr₂ linearly increase with increasing energy density. The thermal stability is larger for the gas-atomized powders than for the SLMed bulk samples. It is interestingly found that there is an exponential relationship between the crystallization enthalpy ΔH_x and the amorphous content. In addition, the glass transition is more difficult for the gas-atomized powders than for the SLMed bulk samples. The crystallization procedure is more difficult for the SLMed bulk samples than for the gas-atomized powders. The local activation energy E_α decreases with increasing α for the gas-atomized powder and the SLMed bulk samples. In addition, the E_α is larger for the SLMed bulk samples than for the gas-atomized powder at the corresponding crystallization fraction α. The dependence of the local Avrami exponent n(α) on the α is similar for both the gas-atomized powders and the SLMed bulk samples at studied heating rates. The crystallization mechanism is also discussed. Full article

The interrelationships between the topological features, such as surface roughness deduced from atomic force microscopy (AFM), and wettability properties expressed by the contact angle of a water droplet on the surface of nanostructured wide bandgap oxide films prepared by spray pyrolysis are investigated for a wide range of compositions. A direct relationship between the surface roughness and the value of the contact angle was found for nanocomposite (In₂O₃)_1−x(MgO)_x, (In_1−xGa_x)₂O₃, and Zn_1−xMg_xO films, for which both the surface roughness and the contact angle increase with the increasing x-value. On the other hand, in ITO films doped with Ga, it was found that the surface roughness increases by increasing the Ga doping, while the contact angle decreases. Both the surface roughness and the contact angle proved to increase in Ga₂O₃ films when they were alloyed with Al₂O₃, similar to other nanocomposite films. An inverse relationship was revealed for a nanocomposite formed from Ga₂O₃ and SnO₂. The contact angle for a (Ga₂O₃)_0.75(SnO₂)_0.25 film was larger as compared to that of the Ga₂O₃ film, while the surface roughness was lower, similar to ITO films. The highest value of the contact angle equal to 128° was found for a (In₂O₃)_1−x(MgO)_x film with an x-value of 0.8, and the largest RMS roughness of 20 nm was showed by a Ga_1.75Al_0.25O₃ film. The optical properties of the prepared films were also analyzed from optical absorption spectroscopy, demonstrating their bandgap variation in the range of (4 to 4.85) eV, corresponding to the middle ultraviolet spectral range. Full article

Aiming at the high-value application of rare earth elements lanthanum (La), an Al-50% La alloy was selected and prepared in a vacuum medium-frequency induction furnace. The geometric characteristics of the Al-50% La alloy powders were compared and studied, with the powders prepared by two different methods: mechanical pulverization and gas atomization. The results showed that an Al-49.09% La master alloy was obtained, and the only intermediate phase containing La in the experimental alloy was Al₁₁La₃. From the perspectives of chemical and phase composition, La has a high yield. Additionally, an Al-La alloy with controllable rare earth intermediate phases can be obtained. The Al-La alloy powders prepared by the mechanical pulverization method are irregular in shape, but the particle size is relatively small, ranging from 0.25 to 66.9 μm. Submicron powders were obtained, with 4.38% of the powders having an equivalent particle size of less than 1 μm. Considering the characteristic of the selective laser melting (SLM) process forming micro-melt pools, a small amount of submicron Al-La alloy powders prepared by the mechanical pulverization method can be used as a trace additive for SLM preparation of CP-Ti. The powders prepared by gas atomization have good sphericity, with a particle size range of 1.65 to 76.0 μm. Among them, the powders with a size of 2–10 μm account for 75.52%, and this part of the powders can be used for the powder metallurgy preparation of composite materials. Full article

The substitution of aluminum powder with highly reactive ultrafine aluminum-based metal fuels has a significant impact on the energy release of aluminum-containing energetic materials because of their excellent energy density and combustion performances. A series of ultrafine spherical Al-Mg alloy fuels with different contents of magnesium were prepared by close-coupled gas atomization technology. The properties of Al-Mg alloy powders of 13~15 μm were tested by SEM, TG-DSC, and laser ignition experiments. Results show that alloying with magnesium can significantly enhance thermal oxidation and combustion performance, leading to more oxidation weight gains and higher combustion heat release. HMX-based castable explosives with the same content of Al and the novel Al-Mg alloy were made and tested. Results show that the detonation performances of HMX/Al-Mg alloy/HTPB are better than HMX/Al/HTPB. Compared to the HMX/Al/HTPB explosive, the detonation heat of HMX/ Al-Mg alloy/HTPB was increased by 200 kJ/kg, the energy release efficiency was enhanced from 80.55% to 83.19%, the detonation velocity was increased by 114 m/s, and the shock wave overpressure at 5 m was increased by 83%. This research provides a new type of composite metal fuel for improving the combustion performance of Al powder. Full article

The paper focuses on material characterization and technology properties of a new Ti-12Al-42Nb spherical powder alloy for additive manufacturing of personal medical implants. The electrode induction melting inert gas atomization (EIGA) method was used to produce the powder alloy. The powder sphericity coefficient (PSC) was 1.02. Image J software was used to calculate the spherical degree by processing images sets from scanning electron microscopy (SEM) and optical microscopy (OM). SEM of particles cross-sections indicated internal thermal-induced porosity (TIP) with a 2.3 μm pore diameter. Particle size distribution was in the range from 15.72 μm (d10) to 64.48 μm (d100) as measured by laser particle analyzer. It was indicated that flowability and powder bulk density were 196 sec and 2.79 g/cm³, respectively. XRD analysis confirmed the beta phase of the powder alloy with no additional phases. X-ray fluorescence spectrometry confirmed the alloyed composition. Reducing and oxidative melting methods of analysis showed a slight amount of impurities: oxygen (0.0087 wt.%), nitrogen (0.03 wt.%), hydrogen (0.0012 wt.%), sulfur (0.0016 wt.%), and carbon (0.022 wt.%). Simultaneous thermal analysis (STA) was performed to indicate weight growth and losses and thermal effects in argon, nitrogen, and air as well as the oxidation of Al₂O₃, TiO₂, and Nb₂O₅ on the surface layer of Ti-12Al-42Nb powder alloy particles. Different phase transformations of γAl₂O₃ $\to$ θAl₂O₃ $\to$ αAl₂O₃ and TiO₂ rutile $\to$ TiO₂ anatase phase transformation were detected by STA in the oxidative layer. Full article

Oxide dispersion-strengthened (ODS) alloys demonstrate enhanced mechanical properties at elevated temperatures and show potential as next-generation powder materials for additive manufacturing. These alloys can mitigate defects such as micropores and cracks by regulating solidification and grain growth behaviors during the additive manufacturing process. This study investigates the fabrication technology for ODS Ti-6Al-2Sn-4Zr-2Mo (Ti6242) alloy powder to achieve uniform oxide distribution within the alloy powders. Thermodynamic calculations were employed to determine the optimal Ti6242–Y₂O₃ composition for in situ gas atomization, ensuring complete dissolution of the oxide in the Ti6242 molten metal and subsequent reprecipitation upon cooling. A rod-shaped ingot was produced via vacuum arc melting, resulting in coarse Y₂O₃ precipitating along the grain boundaries. The powder was fabricated through an electrode induction gas atomization method, and the ODS Ti6242 powder exhibited a spherical shape and a smooth surface. Cross-sectional analysis revealed the uniform distribution of Y₂O₃ oxide particles, measuring several tens of nanometers in size, within the alloy powder. This research demonstrates the successful synthesis of oxide-integrated ODS Ti6242 alloy powder through the in situ gas atomization method, potentially advancing the field of additive manufacturing for high-temperature applications. Full article

Gallium oxide (Ga₂O₃) has gained considerable attention due to its wide bandgap, the availability of native substrates, and its excellent properties for solar-blind photodetectors, transparent electronics, and next-generation power devices. However, the expensive Ga₂O₃ native substrates have restricted its widespread adoption. To reduce costs and further the development of β-Ga₂O₃-based devices, there is a need for bandgap-tunable oxide films with high crystal quality for deep-ultraviolet (DUV) photodetectors and high-breakdown-field power devices. This study introduces a Thermal Interdiffusion Alloying method to address these requirements. It focuses on developing deep ultraviolet (DUV) photodetectors using β-Ga₂O₃ thin films on sapphire substrates by promoting the diffusion of aluminum (Al) atoms from the substrate into the film, resulting in the formation of aluminum gallium oxide (β-(Al_xGa_1−x)₂O₃). The aluminum content is controlled by adjusting the process temperature, allowing for tunable detection wavelengths and enhanced DUV sensing capabilities. Radio frequency (RF) sputtering optimizes the film’s quality by adjusting the sputtering power and the argon/oxygen (Ar/O₂) flow ratio. Material analysis indicates that this method expands the optical bandgap and shifts the response wavelength to 210 nm, significantly boosting the performance of the fabricated photodetectors. This research presents considerable potential for advancing DUV photodetectors across various disinfection applications. Full article

Shape memory alloys (SMAs) are functional materials with a wide range of applications, from the aerospace sector to the biomedical field. Nowadays, there is a worldwide interest in developing SMAs through powder metallurgy like additive manufacturing (AM), which allows innovative building processes. However, producing SMAs using AM techniques is particularly challenging because of the microstructure required to obtain optimal functional properties. This aspect is critical in the case of Cu–Al–based SMAs, due to their high elastic anisotropy, making them brittle in polycrystalline form. In this work, we approached the processing of a Cu–Al–Ni SMA following a specific powder metallurgy route: gas atomization of a pre-alloyed melt; compaction of the atomized powders through hot isostatic pressing; and a final hot rolling plus thermal treatments. Then, the microstructure of the material was characterized by electron microscopy showing a specific [001] texture in the rolling direction that improved the functional behavior. The successive processing steps produce an increase of about 40 °C in the martensitic transformation temperatures, which can be well controlled and reproduced through the developed methodology. The thermomechanical functional properties of superelasticity and shape memory were evaluated on the final SMA. Outstanding, fully recoverable superelastic behavior of 4.5% in tension, as well as a ±5% full shape memory recovery in bending, were reported for many cycles. These experiments demonstrate the enhanced mechanical and functional properties obtained in polycrystalline Cu–Al–Ni SMAs by powder metallurgy. The present results pave the road for producing this kind of SMA with the new AM technologies, which always produce polycrystalline components and can improve their processes taking the powder metallurgy SMA, here produced, as reference material. Full article

In this work, the effect of high-entropy alloy powder preparation on the coatings deposited via high-velocity oxygen fuel sprayings was studied. The powders of FeNiCoCrMo_0.5Al_1.3 composition were prepared by milling and gas atomization. The structures, porosity, phase composition, and microhardness of the coatings produced from mechanically alloyed and gas-atomized powders were compared. The influence of milling parameters on the powder phase composition and morphology was studied. Milling at 600 rpm for 1.5 h allowed the production of mechanically alloyed powder with a homogeneous distribution of Fe, Ni, and Al and thin lamellas enriched with Co, Cr, and Mo. Despite the difference in the feedstock powders’ phase compositions, the phase compositions of the coatings deposited from mechanically alloyed and gas-atomized powders are the same consisting of BCC, FCC solutions, and oxide. The amount of FCC solutions and oxide in the coating depends on the size distribution of the sprayed powder. It was found that the phase composition and the properties of the coatings deposited from the mechanically alloyed and gas-atomized powders of similar sizes are similar. Full article

Hexagonal boron nitride (h-BN) is recognized as a 2D wide bandgap material with unique properties, such as effective photoluminescence and diverse lattice parameters. Nitride alloys containing h-BN have the potential to revolutionize the electronics and optoelectronics industries. The energy band structures of three boron-containing nitride alloys—B_xAl_1−xN, B_xGa_1−xN, and B_xIn_1−xN—were calculated using standard density functional theory (DFT) with the hybrid Heyd–Scuseria–Ernzerhof (HSE) function to correct lattice parameters and energy gaps. The results for both wurtzite and hexagonal structures reveal several notable characteristics, including a wide range of bandgap values, the presence of both direct and indirect bandgaps, and phase mixing between wurtzite and hexagonal structures. The hexagonal phase in these alloys is observed at very low and very high boron concentrations (x), as well as in specific atomic configurations across the entire composition range. However, cohesive energy calculations show that the hexagonal phase is more stable than the wurtzite phase only when x > 0.5, regardless of atomic arrangement. These findings provide practical guidance for optimizing the epitaxial growth of boron-containing nitride thin films, which could drive future advancements in electronics and optoelectronics applications. Full article

Leveraging the liquid-phase immiscibility effect and phase diagram calculations, a sequence of alloy powders with varying Fe content was designed and fabricated utilizing the gas atomization method. Microstructural characterizations, employing SEM, EDS, and XRD analyses, revealed the successful formation of an incomplete shell on the surfaces of Al-Bi-Fe powders, obviating the need for Sn doping. This study systematically investigated the microstructure, hydrolysis performance, and hydrolysis process of these alloys in deionized water. Notably, Al-10Bi-7Fe exhibited the highest hydrogen production, reaching 961.0 NmL/g, while Al-10Bi-10Fe demonstrated the peak conversion rate at 92.99%. The hydrolysis activation energy of each Al-Bi-Fe alloy powder was calculated using the Arrhenius equation, indicating that a reduction in activation energy was achieved through Fe doping. Full article