Search Results (2,344)

This study presents a comparative investigation of the microstructure, phase composition, microhardness, tribological behavior, and corrosion resistance of heterogeneous coatings deposited on St3 steel by twin-wire electric arc spraying (TWEAS). Three wire combinations were examined: ER309LSi + Steel 70, Sv-08G2S + Steel 70, and 30KhGSA + ER309LSi. The coatings were characterized using X-ray diffraction (XRD), scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS), Vickers microhardness testing, ball-on-disc tribological measurements, and potentiodynamic polarization in 3.5 wt.% NaCl solution. All coatings exhibited a characteristic lamellar structure with a thickness of 340–360 μm and hardness values significantly higher than those of the steel substrate. The 30KhGSA + ER309LSi coating demonstrated the highest cross-sectional microhardness (532 ± 13 HV) and the lowest specific wear rate (0.411 × 10⁻⁴ mm³/(N·m)), which was more than five times lower than that of the substrate. The enhanced wear resistance was associated with the formation of the Cr₇C₃ and Cr₂₃C₆ carbide phases, as identified by XRD. The Sv-08G2S + Steel 70 coating exhibited the lowest corrosion rate among the investigated coatings due to its more homogeneous ferritic structure and reduced electrochemical contrast between lamellae. The results demonstrate that the phase composition and distribution of alloying elements play a decisive role in determining the functional properties of heterogeneous TWEAS coatings. Full article

Quaternary β-Ti-xTa-xZr-xNb (TTZN) alloys (x = 10, 20, and 30 wt%) were surface-modified by plasma electrolytic oxidation (PEO) to improve their surface properties. This treatment promotes the incorporation of bioactive ions, such as Ca and P, and favors the formation of a porous anodic surface resulting from the oxidation of the precursor metals. This study investigated how the addition of alloying elements (Zr, Ta, and Nb) influences oxide formation, PEO-induced pore morphology, wettability, and coating hardness. The surfaces were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS), Vickers microhardness testing, and wettability analysis. XRD analysis revealed that the TTZN10 alloy exhibited crystalline TiO₂ phases in the form of anatase and rutile. In contrast, the TTZN20 and TTZN30 alloys exhibited only cubic ZrO₂ diffraction peaks, while no TiO₂ peaks were detected within the detection limits of the XRD technique. Micrographs showed micrometric pores on all alloy surfaces. The TTZN20 alloy exhibited the highest porosity (31.8%), which correlated with lower hydrophilicity (θ = 79°) and high surface free energy (67 mJ/m²). After PEO treatment, all surfaces exhibited high hardness values ranging from 491 to 561 HV. The highest hardness was observed for TTZN10, attributed to the mixed anatase/rutile TiO₂ phase composition. Full article

Single-crystal diamond (SCD) is an ideal substrate material for semiconductor devices due to its extremely wide bandgap and exceptionally high thermal conductivity. However, diamond’s extreme hardness and chemical inertness pose challenges for the fabrication of ultra-smooth surfaces. Traditional polishing processes are not only inefficient but also prone to introducing subsurface defects, which severely degrade device performance. To address the above issues, this study proposes a hybrid polishing process combining reactive ion etching (RIE) surface modification with chemical mechanical polishing (CMP), which enables low-loss atomic-level processing of SCD. The study found that RIE treatment induces lattice disorder on the diamond surface, forming a sp²-hybridized amorphous carbon-modified layer. Compared to the sp³ structure of native diamond, this modified layer has lower hardness and is easier to remove. We conducted the verification of the optimized process using high-quality single-crystalline diamond (SCD) samples with an initial surface roughness Ra of 0.68 nm. Under the optimized RIE parameters (substrate bias power: 200 W, etching time: 600 s, gas flow ratio of Ar:O₂:CF₄ = 40:50:10), the surface roughness Ra was reduced to as low as 0.35 nm after 2 h of CMP treatment. Furthermore, systematic characterization of the SCD’s as-received surface, RIE-modified surface, and CMP-treated surface was performed using Raman spectroscopy and X-ray photoelectron spectroscopy (XPS), elucidating the “etching modification–mechanical removal” polishing mechanism. Full article

In this study, manual welding electrodes with varying niobium (Nb) contents (0, 0.05, and 0.1 wt%) were developed for 960 MPa grade low-alloy high-strength steel, and deposited metals were produced through multilayer multipass welding. Microstructural characterization and mechanical testing were performed using scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), electron backscatter diffraction (EBSD), and a universal testing machine to investigate the influence of Nb content and elucidate the strengthening mechanisms. The results demonstrate that under identical welding conditions, multipass thermal cycles induced a primary microstructural transformation from martensite to tempered martensite in all deposited metals, which predominantly comprised tempered martensite with minor fractions of bainite and second-phase particles. Increasing Nb content led to significant grain refinement. The second-phase particles exhibited sizes of 0.158 μm, 0.176 μm, and 0.168 μm, respectively, with volume fractions of 5.69%, 5.82%, and 5.90%. Nb addition substantially enhanced hardness and strength while causing a noticeable reduction in low-temperature impact toughness, though the values remained within acceptable limits. The deposited metal containing 0.05 wt% Nb exhibited optimal comprehensive mechanical properties, with a hardness of 386.7 HV, tensile strength of 1060 MPa, yield strength of 962 MPa, and Charpy impact energies of 41.95 J and 33.17 J at −40 °C and −60 °C, respectively. Theoretical calculations revealed that the dislocation strengthening contribution in martensite increased from 526 MPa to 600 MPa with increasing Nb content, representing the dominant strengthening mechanism, while grain refinement strengthening increased from 135.5 MPa to 157.6 MPa. Full article

Ti–6Al–4V is the primary titanium alloy for aerospace, biomedical, and additive manufacturing applications; however, the high cost of powders produced by atomization limits their widespread adoption. This study aims to develop a cost-effective method for producing chemically homogeneous pre-alloyed Ti–6Al–4V powders from titanium sponge. A combined process is proposed, involving the hydrogenation of titanium sponge, mechanical alloying of the hydride phase with Al and V powders, and subsequent vacuum dehydrogenation. The formation of the brittle δ-TiH₂ phase facilitated intensive material comminution and effective distribution of the alloying elements. According to laser diffraction data, the median particle size decreased from 450 to 30–35 µm. X-ray diffraction (XRD) analysis confirmed the sequential α-Ti → δ-TiH₂ transition and the formation of a stable α + β two-phase structure characteristic of Ti–6Al–4V following dehydrogenation. SEM observations demonstrated that the final powders predominantly consist of individual fractured particles with limited hard agglomeration, favorable for powder flowability and compaction behavior. EDS analysis indicated a relatively homogeneous microscale distribution of Al and V without observable large-scale segregation. The synthesized powders exhibited low impurity levels, with O < 0.07 wt.% and H < 0.02 wt.%. The developed approach represents a promising and economical alternative to expensive atomization techniques for powder metallurgy and additive manufacturing. Full article

High Velocity Oxy-Fuel (HVOF) thermal spraying enables the deposition of dense coatings with low porosity, high hardness, and good fracture resistance. Tungsten carbide–cobalt (WC-Co) coatings are widely used in industrial and aerospace applications due to their excellent wear resistance; however, improving crack resistance and coating–substrate adhesion remains a key challenge. In this study, WC-Co+Ni composite coatings were deposited on ductile cast iron, with emphasis on the role of Ni addition in controlling microstructure development under HVOF conditions. Microstructural characterization was performed using optical, scanning, and transmission electron microscopy (OM, SEM, TEM), while phase composition and chemical analysis were determined by X-ray diffraction (XRD) and energy-dispersive spectroscopy (EDS). The coatings exhibited a dense, low-porosity microstructure composed of fine WC and W₂C carbides embedded in a Co–Ni binder, with locally nanocrystalline regions. XRD analysis confirmed WC and W₂C as the dominant phases, with weak reflections corresponding to the η-phase (Co₆W₆C), indicating local decarburization. The addition of Ni increases the fraction of the transient liquid phase during particle flight, enhancing carbide dissolution and mass transport in the binder, which accelerates decarburization kinetics and promotes η-phase formation. Simultaneously, Ni modifies the binder into a more ductile Co–Ni matrix, reducing the detrimental effect of brittle η-phase on coating integrity. Mechanical and tribological testing (instrumented indentation and scratch testing) demonstrated improved crack resistance, wear resistance, and adhesion. The results show that Ni addition enables process-driven microstructural tailoring of HVOF-sprayed WC-Co coatings, leading to enhanced performance despite the presence of η-phase. Full article

This study investigates the influence of an austenitic buffer layer on the microstructure, hardness, and abrasive wear resistance of Fe–Cr–C hardfacing applied to high-chromium white cast iron (HCWCI) hammer tips used in sugarcane shredders. Hardfacing was performed by shielded metal arc welding with two Fe–Cr–C layers deposited directly on the HCWCI substrate and with an austenitic buffer layer followed by an Fe–Cr–C hardfacing layer. Microstructural characterization was carried out using optical microscopy, scanning electron microscopy with energy-dispersive X-ray spectroscopy, while hardness profiles were determined by micro-Vickers testing. Abrasive wear behavior was evaluated using a dry sand–rubber wheel test according to ASTM G65. The non-buffered hardfacing layer exhibited a hypereutectic Fe–Cr–C microstructure consisting of coarse primary chromium carbides, resulting in high hardness values of approximately 840 HV. In contrast, the buffered sample showed an austenite-rich matrix with finer eutectic carbides and reduced hardness of around 600 HV. Abrasive wear tests of the non-buffered sample showed a lower mass loss, whereas the buffered sample exhibited a substantially higher mass loss. These results demonstrate that Fe–Cr–C hardfacing without a buffer layer provides superior wear resistance. Full article

The mineralogical characteristics of low-grade hard-rock uranium ore from the Zoujiashan deposit were systematically investigated via multiple analytical techniques, including chemical analysis, X-ray fluorescence (XRF) spectrometry, uranium occurrence analysis, 3D X-ray micro-computed tomography (CT), an automated mineral identification and characterization system (AMICS), and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDS). The results revealed that the uranium grade of the ore was only 0.202%, among which 65.87% existed in the form of independent uranium minerals, while the remaining 34.13% existed in a dispersed ionic state. Except for quartz, most uranium minerals and gangue minerals were finely disseminated and closely intergrown. The pre-concentration of the ore is therefore necessary to separate uranium-rich particles from barren particles at a coarse particle size. Ore density analysis demonstrated that the feed particle size exerted a significant impact on the separation performance, and the optimum feed particle size was determined to be 20 mm. Subsequently, dense medium cyclone (DMC) separation tests were conducted. The experimental results indicated that fine grains were prone to report to low-density products (tailings) during mixed-size beneficiation. Under a tailings yield of 54%, for the −20 + 8 mm coarse fraction, the tailings uranium grade was 0.025% and the uranium recovery of the concentrate was 88.05%. Therefore, classified separation can effectively promote separation efficiency. To reveal the density control mechanism of the particle separation behavior inside the DMC, computational fluid dynamics (CFD) simulations were implemented with the Eulerian–Eulerian multiphase model in ANSYS-Fluent (version 2020R2). The simulation results suggested that a density difference of 8.6% realized effective separation. This work achieved the effective treatment of low-grade hard-rock uranium ore via DMC separation, providing a novel technical route for uranium ore pre-concentration. Full article

Welding aluminum (Al) to titanium (Ti) is particularly challenging because of the large differences in their melting points and the tendency to form cavities and brittle intermetallic compounds. Such issues can be mitigated in friction stir welding (FSW) by understanding the underlying mechanisms of microstructural evolution and tensile fracture behavior. In the present study, FSW was carried out on commercially pure Al and commercially pure Ti. X-ray micro-computed tomography results show that the distribution of Ti fragments depends on their morphology, with fine particles (volume 10³–10⁴ µm³) being distributed homogeneously, while large flakes (10⁷–10⁹ µm³) are concentrated near the joint interface. A three-dimensional analysis of Ti fragment distribution was performed to clarify material flow and particle dispersion within the weld nugget. EDS (Energy-Dispersive Spectroscopy) and EPMA (Electron Probe Microanalysis) composition mapping confirmed the formation of AlTi and Al₃Ti intermetallic phases, with Al₃Ti as the dominant phase (consistent with its lower Gibbs free energy of formation). Because Al is the primary element in the matrix and undergoes the highest degree of deformation, its microstructural evolution in Al was examined using Electron Backscatter Diffraction (EBSD). Grain refinement in Al was attributed to continuous dynamic recrystallization (CDRX). Mechanical mixing and intermetallic formation increased the hardness of the weld, while the tensile response corresponded to a joint efficiency of approximately 77%, alone with an 11% improvement in elongation over base Al. The study further establishes a correlation among Ti particle distribution, local microstructural evolution, and the tensile response of the joint. Fractographic analysis indicates a bimodal fracture mechanism, and failure occurred away from the joint interface, indicating a strong joint. To interpret this behavior, a spring-based model was proposed to relate the fracture location and tensile deformation to the spatial variation in microstructure across the welded zones. This approach provides a conceptual framework that is extendable to other dissimilar material systems with spatially varying microstructures. Full article

The development of lightweight aluminum matrix composites with improved mechanical performance and thermal stability using sustainable reinforcement materials remains a significant challenge in structural materials engineering. Although ceramic-reinforced aluminum composites exhibit enhanced strength and thermal resistance, the potential of bio-derived snail shell particles as environmentally sustainable reinforcements remains insufficiently explored. In this study, snail-shell-reinforced AA6061 aluminum matrix composites were fabricated by stir casting to investigate their microstructural characteristics, mechanical behavior, phase composition, and thermal stability. Snail shell particles, predominantly composed of CaCO₃, were processed to particle sizes of 50–75 µm before incorporation into the molten aluminum matrix. Characterization was performed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), tensile and hardness testing, thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). The results revealed relatively uniform particle dispersion and satisfactory matrix–reinforcement interfacial compatibility. The tensile strength increased from 155 ± 5 MPa for the unreinforced alloy to 211 ± 4.8 MPa for the reinforced composite, corresponding to an improvement of approximately 36%, while elongation increased from 2.4 ± 0.2% to 4.6 ± 0.4% (92%). XRD analysis confirmed the presence of Al, CaCO₃, Mg₂Si, and minor CaO phases, indicating successful reinforcement incorporation and strengthening phase formation. Thermal analysis demonstrated enhanced thermal stability, increased residual mass retention, and improved resistance to thermal degradation. This work demonstrates that bio-derived snail shell particles are viable and environmentally sustainable reinforcements for lightweight aluminum matrix composites intended for structural engineering applications. Full article

Ultra-High Molecular Weight Polyethylene (UHMWPE), the standard base material in ski manufacturing, offers excellent gliding performance but exhibits limited mechanical and scratch resistance on hard and icy snow conditions. In this work, stainless steel is proposed as a mechanically robust alternative, and its inherently higher friction against snow is addressed through surface engineering. The snow friction behavior of 301H stainless steel surfaces decorated with fishbone-like microstructures combined with Laser-Induced Periodic Surface Structures (LIPSSs) was investigated using a custom-built snow tribometer. Several pattern designs, with different pitch distances and depths, were engraved using femtosecond laser pulse irradiation. We conducted morphological, physical, and chemical investigations through microscopy, static contact angle measurements, and X-ray Photoelectron Spectroscopy analyses. Results indicate that the gliding performance is not directly related to the modifications in surface chemistry and wetting behavior of the samples but is affected by the geometry and orientation with respect to the sliding direction of the specific micro- and nano-features. Overall, we achieved friction coefficient values comparable to those found in UHMWPE with a fast and economically sustainable single-step laser-texturing process. This approach allows the industrial up-scaling of the fishbone-texture design to real-size alpine ski prototypes. Full article

Black-hole accretion systems exhibit a characteristic coexistence of activities: broad-band X-ray variability, hot coronae, wide-angle winds, and both steady and discrete jets. This coexistence suggests a persistently time-dependent magnetic background in which noisy fluctuations and explosive release are both essential. In this paper, we connect them all to the storage, organization, and intermittent reconnection-mediated release of magnetic energy, and we propose a Synchronized Spin Model (SSM) in which multiple local dynamos in a rotating accretion flow are represented as interacting macro-spins. Their synchronization, partial synchronization, excursion, and reversal define a compact set of collective variables that organize both timing statistics and large-scale morphology. In this picture, multiscale magnetic reconnection converts stored magnetic energy into coronal heating, flares, intermittent outflows, and discrete jet activity, while the same synchronization dynamics produce amplitude modulation and demodulation, providing a route to 1/f-like variability, rms–flux/Taylor-like scaling, and approximately log-normal statistics of the demodulated envelope. We further argue that, although the continuous flux distribution in black-hole systems is more naturally discussed in multiplicative or log-normal terms, broader event-catalog statistics remain useful for describing suitably defined burst hierarchies, particularly by analogy with solar and stellar flare systems. The hard/soft cycle of X-ray binaries is then interpreted as motion through magnetic state space. Full article

Additive friction stir deposition (AFSD) is a solid-state additive manufacturing process that enables the fabrication of fully dense metallic components without common fusion-related defects. Inconel 718, widely used in aerospace and energy sectors, requires high structural reliability; therefore, evaluating its response to AFSD is essential for advanced applications. This study investigates the effects of AFSD on IN718 by comparing the mechanical properties and microstructure of the as-deposited material with the feedstock condition. Tensile testing showed that the ultimate tensile strength (UTS) increased by 5% along the traverse direction, whereas elongation was reduced compared to the feedstock. In contrast, build-direction tensile specimens exhibited lower UTS and substantially reduced elongation, revealing mechanical anisotropy. Microhardness increased by 20%, consistent with substantial grain refinement from 11 µm to 3 µm due to dynamic recrystallization during deposition. X-ray diffraction (XRD) revealed no clearly detectable secondary phase formation after AFSD within the resolution limits of conventional XRD, suggesting that the increased hardness and traverse-direction strength can be partly explained by grain refinement. Elemental mapping detected oxygen-enriched Al/Ti regions at interlayer boundaries, which may contribute to the reduced build-direction ductility. Overall, AFSD refined the microstructure, enhanced hardness, and improved traverse-direction strength, while build-direction tensile testing revealed anisotropic mechanical behavior. Full article

This study aimed to optimize the nitriding parameters for Plasma Immersion Ion Implantation (PIII) of stainless steels. UNS S32750 super duplex stainless steel, widely employed in the petrochemical industry, was subjected to PIII under varying nitriding atmospheres (mixtures of H₂ and N₂) and treatment pressures. The fixed PIII nitriding parameters included a temperature of 300 °C, a duration of 3 h, a bias voltage of approximately −10 kV, a frequency of 500 Hz, and a pulse width of 30 μs. Following the treatments, the phases were characterized by X-ray diffraction (XRD), while the hardness and elastic modulus of the modified surfaces were evaluated via nanoindentation. Regarding the nitriding atmosphere, gas mixtures approaching a 60% N₂/40% H₂ (vol.) ratio yielded a higher volume fraction of nitrogen-rich expanded phases in solid solution. Furthermore, higher treatment pressures promoted the formation of these expanded phases, consequently enhancing the surface hardness up to 2.7 times the hardness value of the untreated sample. These findings stand in contrast to those found for low-energy plasma nitriding (PN) processes. Full article

This study aims to compare the structural, mechanical, tribological, and corrosion properties of gradient and bilayer Al₂O₃/Cr₂O₃ coatings obtained by detonation spraying on 316L stainless steel. The coatings were characterized using X-ray diffraction, scanning electron microscopy, energy-dispersive spectroscopy, instrumental indentation, scratch testing, ball-on-disk tribological testing, and potentiodynamic polarization in a 3.5% NaCl solution. The results showed that the gradient Al₂O₃/Cr₂O₃ coating had a denser and more homogeneous structure than the bilayer coating. Quantitative SEM image analysis showed that the apparent porosity decreased from 1.285% for the bilayer coating to 0.934% for the gradient coating. Instrumental indentation revealed an increase in hardness from approximately 401 HV to 462 HV and an increase in elastic modulus from about 173 GPa to 183 GPa. The gradient coating also demonstrated higher critical loads during scratch testing, indicating improved resistance to crack initiation and coating failure. Tribological tests showed a lower and more stable coefficient of friction for the gradient coating, decreasing from approximately 0.58–0.60 to 0.52–0.55. Potentiodynamic polarization measurements showed that the corrosion current density decreased from 0.50540 to 0.24155 µA/cm², while the corrosion rate decreased from 0.00894 to 0.00428 mm/year. These results demonstrate that the gradient coating architecture improves the performance of Al₂O₃/Cr₂O₃ coatings by reducing porosity, increasing structural integrity, and promoting an improved structural integrity and reduced defect-related stress concentration through the coating thickness. Therefore, gradient Al₂O₃/Cr₂O₃ coatings obtained by detonation spraying are promising for applications requiring enhanced wear and corrosion resistance. Full article