Search Results (355)

The optical floating zone technique was utilized to purify chromium and a single-phase chromium–silicon alloy in this work. The impurity content (carbon, nitrogen, and oxygen) can be reduced by decreasing the withdrawal speed of samples during the zone refining process, and the coarsening of grains was also observed. The effect of the impurities on mechanical properties was determined by hardness measurements at room temperature, and the hardness of both chromium and the chromium–silicon alloy decreased with lower concentrations of nitrogen and oxygen. In contrast, brittle material behavior is observed in samples prepared by arc melting process with higher concentrations of impurities. To use chromium–silicon alloys for future high-temperature applications, their brittle behavior must be improved, which can be achieved by reducing their carbon, nitrogen, and oxygen concentrations. Full article

To address the poor thermal shock resistance and high brittleness of traditional ceramic tools, a novel Si₃N₄/Sc₂W₃O₁₂ (SNS) composite ceramic material was developed via in situ synthesis using WO₃ and Sc₂O₃ as precursors and consolidated by spark plasma sintering. Sc₂W₃O₁₂ with negative thermal expansion was introduced to compensate for matrix shrinkage and modulate interfacial stress. The effects of varying Sc₂W₃O₁₂ content on thermal expansion, residual stress, microstructure, and mechanical properties were systematically investigated. Among the compositions, SNS3 (12 wt.% Sc₂W₃O₁₂) exhibited the best overall performance: relative density of 98.8 ± 0.2%, flexural strength of 712.4 ± 30 MPa, fracture toughness of 7.5 ± 0.3 MPa·m^1/2, Vickers hardness of 16.3 ± 0.3 GPa, and an average thermal expansion coefficient of 2.81 × 10⁻⁶·K⁻¹. The formation of a spherical chain-like Sc-W-O phase at the grain boundaries created a “hard core–soft shell” interface that enhanced crack resistance and stress buffering. Cutting tests showed that the SNS3 tool reduced workpiece surface roughness by 32.91% and achieved a cutting distance of 9500 m. These results validate the potential of this novel multiphase ceramic system as a promising candidate for high-performance and thermally stable ceramic cutting tools. Full article

This work explores the physical properties of the MAX-phase material Cr₃AlC₂ through the application of density functional theory (DFT). The refined lattice parameters were determined through the minimization of the total energy. In order to explore the electronic properties and bonding features, we carried out computations on the band structure and charge density distribution. The calculated elastic constants (C_ij) validated the mechanical stability of Cr₃AlC₂. To assess the material’s ductility or brittleness, we calculated Pugh’s ratio, Poisson’s ratio, and Cauchy pressure. The hardness was determined. This study examined the anisotropic behavior of Cr₃AlC₂ using directional analyses of its elastic properties and by computing relevant anisotropy indicators. We examined several key properties of Cr₃AlC₂, including the Grüneisen parameter, acoustic characteristics, Debye temperature, thermal conductivity, melting point, heat capacity, Helmholtz free energy, entropy, and internal energy. Phonon dispersion spectra were analyzed to assess the dynamic stability of Cr₃AlC₂. Full article

Choosing the appropriate cutting tool material is essential for enhancing machining processes because it directly affects product quality, surface finish, dimensional accuracy, tool longevity, and overall efficiency. Different materials are used for cutting tools, i.e., for cutting inserts. Due to their high hardness and high temperature resistance, ceramics cutting inserts allow for increased cutting speeds, resulting in shorter manufacturing times and reduced costs, despite being pricier than traditional cemented carbide and facing certain technical challenges due to their brittleness. Alumina-based ceramics dominate the market, accounting for about two-thirds of usage, followed by silicon nitride and zirconia. This paper provides a comprehensive overview of recent advances in alumina ceramic materials used as cutting inserts, focusing on research conducted in the last five years to optimize static and dynamic mechanical and thermal properties, wear resistance, density, etc. They ways in which the properties are altered through the incorporation of whiskers, nanoparticles, or nanotubes; the modification of the structure; the optimization of sintering parameters; and the application of advanced sintering techniques are demonstrated. The paper also addresses sustainability, environmental impact, and the management of critical raw materials associated with cutting inserts, which pertains to the future development of cutting insert materials. Full article

This study’s novelty lies in providing first-time insights into the isolated role of Friction Stir Processing (FSP) travel speed on microstructure evolution and mechanical performance (micro-hardness, tensile properties, impact energy, and wear behavior) specifically in hypoeutectic as-cast Al-5 wt.% Si alloys, addressing a critical unaddressed gap in previous works (typically on near-eutectic compositions of Si > 6.5 wt.%). FSP, a solid-state technique, is highly effective for enhancing the properties of cast materials. The FSP was conducted at a fixed rotational speed of 1330 rpm and various travel speeds (26, 33, 42, and 52 mm/min). The FSP improves the mechanical properties of as-cast Al-5Si alloy by refining its grain structure. This leads to higher hardness, ultimate tensile strength (UTS), yield strength (YS), and strain at fracture and toughness compared to the as-cast condition. The specimen processed at 26 mm/min achieved the highest values of YS, UTS, toughness, and wear resistance. The fracture surfaces of the tensile and impact test specimens were examined using scanning electron microscopy (SEM) and discussed. Results indicated that the fracture surfaces revealed a transition from predominantly brittle fracture in the as-cast alloy to ductile fracture at 26 mm/min, changing to a mixed fracture mode at 52 mm/min. These findings underscore the critical importance of optimizing FSP travel speed to significantly tailor and enhance the mechanical performance of as-cast hypoeutectic Al-5Si alloys for industrial applications. Full article

This study investigates the effects of B₄C content (2.5, 5, 7.5, and 10 wt.%) on the microstructure and wear resistance of laser cladding 316 stainless steel coatings on a 2Cr12MoV steel substrate. The coating was prepared by laser cladding technology. The phase composition, microstructure evolution, microhardness, and tribological properties of the coating were analyzed. The results show that the decomposition of B₄C particles is complete, and the phase composition of the coating includes Austenite, Fe₂₃ (B₃C₃), Cr₂₃ (B_1.5C_4.5), and a Fe-Ni solid solution. The increase in B₄C content significantly increased the microhardness of the material from 206 HV_0.2 (substrate) to 829 HV_0.2 (10 wt.% B₄C) by 4.02 times. Wear resistance also improved, with the 10 wt.% coating exhibiting the lowest wear rate (10 × 10⁻⁸ mm³/N·m) due to fine-grained and dispersion strengthening mechanisms. However, excessive B₄C (10 wt.%) induced cracks from increased brittleness, resulting in higher friction coefficients. The wear mechanism consists of fatigue wear, adhesive wear, and oxidative wear, and the degree of wear decreases with the increase in B₄C content. This work demonstrates that the addition of B₄C effectively improves the hardness and wear resistance of 316 stainless steel coatings, providing practical insights into surface engineering in high wear applications. Full article

Multi-principal element alloys (MPEAs) exhibit distinct characteristics compared to conventional single-principal element-based metallic materials, primarily due to their unique design, resulting in intricate microstructural features. Currently, a comprehensive understanding of the fabrication processes, compositional design, and microstructural influence on the tribological and corrosion behavior of multi-component alloys remains limited. While the hardness of MPEAs generally correlates positively with wear resistance, with higher hardness typically associated with improved wear resistance and reduced wear rates, quantitative relationships between these properties are not well established. In this study, the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was selected as a model system. A homogeneous Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was successfully synthesized via mechanical alloying followed by spark plasma sintering (SPS). To further investigate the correlation between hardness and wear rate, varying concentrations of alumina nanoparticles were incorporated into the alloy matrix as a reinforcing phase. The results revealed that the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy exhibited a single-phase face-centered cubic (FCC) structure, which was maintained with the addition of alumina nanoparticles. The hardness of the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy without nano-alumina was 727 HV, with a corresponding wear rate of 2.9 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The incorporation of nano-alumina increased the hardness to 823 HV, and significantly reduced the wear rate to 1.6 × 10⁻⁴ mm³·N⁻¹·m⁻¹, representing a 45% reduction. The Al₂O₃ nanoparticles effectively mitigated alloy wear through crack passivation and matrix strengthening; however, excessive addition reversed this effect due to the agglomeration-induced brittleness and thermal mismatch. The quantitative relationship between hardness (HV) and wear rate (W) was determined as W = 2348 e^(−0.006HV). Such carefully bounded empirical relationships, as demonstrated in studies of cold-formed materials and dental enamel, remain valuable tools in applied research when accompanied by explicit scope limitations. Full article

The increasing demand for the development of environmentally friendly alternatives to petroleum-derived materials has increased research efforts on sustainable polymer composites. This study systematically examined the effect of nano-biochar derived from agricultural wastes such as olive pulp on the mechanical and thermal properties of epoxy-resin-based composites. First, the biochar from olive pulp was produced by pyrolysis at 450 °C and turned to nano-biochar using ball milling. Composite samples containing nano-biochar at different rates between 0 and 10% were prepared. The nano-biochar and composite samples were characterized by using different techniques such as SEM-EDS, BET, FTIR, XRD, Raman, TGA, and DMA analyses. Also, the tensile strength, elastic modulus, Shore D hardness, thermal stability, and static toughness of the composite samples were evaluated. The best performance was observed in the sample containing 6% nano-biochar; the ultimate tensile strength increased from 17.37 MPa to 23.46 MPa compared to pure epoxy, and the elastic modulus and hardness increased. However, a decrease in brittleness and toughness was observed at higher additive rates. FTIR and DMA analyses indicated that the nano-biochar interacted strongly with the epoxy matrix and increased its thermal stability. The results showed that the olive-pulp-derived nano-biochar could be used to improve the structural and thermal properties of the epoxy composites as an inexpensive and environmentally friendly filler. As a result, this study contributes to the production of new polymer-based materials that will encourage the production of environmentally friendly composites with nano-scale biochar obtained from olive waste, which is an easily accessible, renewable by-product. Full article

Sintered Neodymium–iron–boron (NdFeB) exhibits high hardness and brittleness, resulting in low electrical discharge machining (EDM) efficiency. The study on the interaction effect of parameters on the material removal rate (MRR) of sintered NdFeB processed by EDM-milling is carried out to improve machining efficiency. The interaction significance of parameters on the MRR is analysed based on the interaction curve of two parameters. Meanwhile, the variation of MRR caused by the change in △_y(x), △_{y x}, and the sum and product of △_y(x) are obtained by calculation. The interaction significance of parameters on MRR is obtained by comparing the sum and product of △_y(x), while the significance of each parameter on MRR is obtained by comparing △_y(x) and △_{y x}. The reasons for the variation of interaction significance are revealed by analysing the differences in crater diameters and discharge waveforms. It is concluded that different levels of interactions exist between the processing parameters. The interaction between pulse on time and pulse off time affects the MRR most significantly, and current affects the MRR most significantly among single factors. The interaction of parameters can affect processes such as dielectric breakdown, discharge channel expansion, discharge energy and its utilisation, dielectric deionisation, significantly affecting the MRR of sintered NdFeB processed by EDM-milling. Full article

The structural, mechanical, dislocation, and electronic properties of the Sc₃AlC MAX phase under applied pressure are investigated in detail using first-principles calculations. Key parameters, including lattice parameter ratios, elastic constants, Young’s modulus, bulk modulus, shear modulus, brittle-to-ductile behavior, Poisson’s ratio, anisotropy, Cauchy pressure, yield strength, Vickers hardness, and energy factors, are systematically analyzed as a function of applied pressure. The results demonstrate that the Sc₃AlC MAX phase exhibits remarkable mechanical stability within the pressure range of 0 to 60 GPa. Notably, applied pressure markedly improves its mechanical properties, such as resistance to elastic, bulk, and shear deformations. The B/G ratio suggests a tendency toward ductile behavior with increasing pressure, and the negative Cauchy pressure indicates the directional characteristics of interatomic bonding in nature. Vickers hardness and yield strength increase under pressures of 0 to 10 GPa and then decrease sharply above 50 GPa. High pressure suppresses dislocation nucleation due to the increased energy factors, along with twinning deformation. Furthermore, electronic structure analysis confirms that high pressure enhances the interatomic bonding in the Sc₃AlC MAX phase, while the enhancement effect is not substantial. This study offers critical insights for designing MAX phase materials for extreme environments, advancing applications in aerospace and electronics fields. Full article

Conventional rock mechanical testing approaches encounter significant limitations when applied to deeply buried fractured formations, constrained by formidable sampling difficulties, prohibitive costs, and intricate specimen preparation demands. This investigation pioneers an innovative nanoindentation-based multiscale methodology (XRD–ED–SEM integration) that revolutionizes the mechanical characterization of dolostone through drill cuttings analysis, effectively bypassing conventional coring requirements. Our integrated approach combines precision surface polishing with advanced indenter calibration protocols, enabling the continuous stiffness method to achieve unprecedented measurement accuracy in determining micromechanical properties—notably an elastic modulus of 119.47 GPa and hardness of 5.88 GPa—while simultaneously resolving complex indentation size effect mechanisms. The methodology reveals three critical advancements: remarkable 92.7% dolomite homogeneity establishes statistically significant elastic modulus–hardness correlations (R² > 0.89), while residual imprint analysis uncovers a unique brittle–plastic interaction mechanism through predominant rhomboid plasticity (84% occurrence) accompanied by microscale radial cracking (2.1–4.8 μm). Particularly noteworthy is the identification of load-dependent property variations, where surface hardening effects and defect interactions cause 28.7% parameter dispersion below 50 mN loads, progressively stabilizing to <8% variance at higher loading regimes. By developing a micro–macro bridging model that correlates nanoindentation results with triaxial test data within a 12% deviation, this work establishes a groundbreaking protocol for carbonate reservoir evaluation using minimal drill cutting material. The demonstrated methodology not only provides crucial insights for optimizing hydraulic fracture designs and wellbore stability assessments, but it also fundamentally transforms microstructural analysis paradigms in geomechanics through its successful application of nanoindentation technology to complex geological systems. Full article

To address the critical applications of heterogeneous structures involving nickel-based superalloys (IN718) and copper alloys (CuSn10) under extreme operating conditions, and to address the limitations of traditional joining techniques in terms of interfacial brittleness and geometric constraints, this study employs Laser Powder Bed Fusion (LPBF) technology, specifically multi-material LPBF (MM-LPBF). By precisely melting IN718 and CuSn10 powders layer by layer, the study directly fabricates multi-material IN718/CuSn10 joint specimens, thereby simplifying the complexity of traditional joining processes. The research systematically investigates the interfacial microstructure and mechanical property evolution laws and underlying mechanisms. It reveals that sufficient element diffusion and hardness gradients are present at the IN718/CuSn10 interface, indicating good metallurgical bonding. However, due to significant differences in thermophysical properties, cracks inevitably appear at the interface. Mechanical property tests indicate that the strength of the IN718/CuSn10 joint specimens falls between that of IN718 and CuSn10, but with lower elongation, and fractures primarily occur at the interface. This research provides theoretical support for establishing a process database for LPBF formed of nickel–copper heterogeneous materials, advancing the manufacturing technology of aerospace multi-material components. Full article

Erosive wear of materials caused by solid particles leads to severe damage on the surface of structure materials and results in mechanical failures. Erosion has been extensively studied for many years in terms of mechanisms, material properties, and impact dynamics. Since the early 21st century, little progress has been made on the evaluation of surface erosive failure due to multiple impacts of particulate solids. The major difficulty is the enormous number of variables involved in the erosion process. However, the existing theories are only able to take a few of them and end up with many assumptions on the others. In summary, the influential factors on erosion can be classified as impact dynamics (such as velocity and angles), mechanisms of material failures (deformation, cutting, and cracking), and material properties of solids and the surface (hardness, toughness, ductility, and brittleness). In this paper, erosion mechanisms and progress from the existing theories have been reviewed critically, which gives a better understanding of the phenomenon. Based on the review of the influential factors in terms of contributions to the process, proper evaluation methods of the erosion process have been discussed, which leads to further thinking of better assessments. Full article

SiC_f/SiC ceramic matrix composite (CMC), a hard and brittle material, faces significant challenges in efficient and high-quality processing of small-sized shapes. To address these challenges, the nanosecond laser was used to process micro-holes in the SiC_f/SiC CMC using a two-step drilling method, including laser pre-drilling in air and laser final-drilling with a water jet. The results of the single-parameter variation and optimized orthogonal experiments reveal that the optimal parameters for laser pre-drilling in air to process micro-holes are as follows: 1000 processing cycles, 0.7 mJ single-pulse energy, −4 mm defocus, 15 kHz pulse-repetition frequency, and 85% overlap rate. With these settings, a micro-hole with an entrance diameter of 343 μm and a taper angle of 1.19° can be processed in 100 s, demonstrating high processing efficiency. However, the entrance region exhibits spattering slags with oxidation, while the sidewall is covered by the recast layer with a wrinkled morphology and attached oxides. These effects are primarily attributed to the presence of oxygen, which enhances processing efficiency but promotes oxidation. For the laser final-drilling with a water jet, the balanced parameters for micro-hole processing are as follows: 2000 processing cycles, 0.6 mJ single-pulse energy, −4 mm defocus, 10 kHz pulse-repetition frequency, 85% overlap rate, and a 4.03 m/s water jet velocity. Using these parameters, the pre-drilled micro-hole can be finally processed in 96 s, yielding an entrance diameter of 423 μm and a taper angle of 0.36°. Due to the effective elimination of spattering slags and oxides by the water jet, the final micro-hole exhibits a clean sidewall with microgrooves, indicating high-quality micro-hole processing. The sidewall morphology could be ascribed to the different physical properties of SiC fiber and matrix, with steam explosion and cavitation erosion. This two-step laser drilling may provide new insights into the high-quality and efficient processing of SiC_f/SiC CMC with small-sized holes. Full article

Potassium dihydrogen phosphate (KDP) crystals, vital for high-power laser systems, pose significant machining challenges due to their brittleness, low hardness, and hygroscopic properties. Achieving crack-free, high-precision surfaces is essential but complex. Single-point diamond fly-cutting (SPDF) is the primary method, yet it exposes tools to high mechanical stress and heat, accelerating wear. In dry cutting, worn tools develop adhesive layers that detach, causing scratches and degrading surface quality. Traditional wet cutting improves surface finish but leaves residual fluids that contaminate the surface with metal ions, leading to optical degradation and fogging. To address these issues, this study explores mixed-fat-based minimum quantity lubrication (MQL) as a sustainable alternative, comparing two lubricants: biodegradable-base mixed ester lubrication (BBMEL) and hydrocarbon-based synthetic lubricant (HCBSL). A comprehensive evaluation method was developed to analyze surface roughness, tool wear, and subsurface damage under dry cutting, MQL-BBMEL, and MQL-HCBSL conditions. Experimental results show that MQL-BBMEL significantly enhances machining performance, reducing average surface roughness by 27.77% (Sa) and 44.77% (Sq) and decreasing tool wear by 25.16% compared to dry cutting, outperforming MQL-HCBSL. This improvement is attributed to BBMEL’s lower viscosity and higher proportion of polar functional groups, which form stable lubricating films, minimizing friction and thermal effects. Structural analyses confirm that MQL-BBMEL prevents KDP crystal deliquescence and surface fogging. These findings establish MQL-BBMEL as an eco-friendly, high-performance solution for machining brittle optical materials, offering significant advancements in precision machining for high-power laser systems. Full article