Search Results (134)

The dispersion behavior of ceramic particles in aluminum alloys during rapid solidification critically affects the resulting microstructure and mechanical performance. In this study, we investigated the nucleation and growth of Al₃(Sc,Zr) on TiB₂ surfaces in a 2TiB₂/Al–8Ni–0.6Sc–0.1Zr alloy, fabricated via wedge-shaped copper mold casting and laser surface remelting. Thermodynamic calculations were employed to optimize alloy composition, ensuring sufficient nucleation driving force under rapid solidification conditions. The results show that the formation of Al₃(Sc,Zr)/TiB₂ composite interfaces is highly dependent on cooling rate and plays a pivotal role in promoting uniform TiB₂ dispersion. At an optimal cooling rate (~1200 °C/s), Al₃(Sc,Zr) nucleates heterogeneously on TiB₂, forming core–shell structures and enhancing particle engulfment into the α-Al matrix. Orientation relationship analysis reveals a preferred (111)α-Al//(0001)TiB₂ alignment in Sc/Zr-containing samples. A classical nucleation model quantitatively explains the observed trends and reveals the critical cooling-rate window for composite interface formation. This work provides a mechanistic foundation for designing high-performance aluminum-based composites with uniformly dispersed reinforcements for additive manufacturing applications. Full article

Aluminum–air batteries are highly promising energy storage systems due to their high theoretical energy density, environmental friendliness, and cost-effectiveness. However, the self-corrosion of aluminum anodes in alkaline electrolytes remains a critical issue that significantly limits their practical application and commercialization. This review paper comprehensively examined various advanced strategies aimed at suppressing the self-corrosion of anodes in Al–air batteries. We summarized the fundamental principles of these approaches, their advantages and disadvantages, and provided an in-depth analysis of their effectiveness, supported by experimental and theoretical evidence. Specifically, this review systematically analyzes six major strategies for suppressing anode self-corrosion: anode alloying, electrolyte additives, novel electrolytes, anode surface treatment, battery structural design, and computer-aided investigation. Furthermore, we proposed the challenges and future research directions in this field. Overall, this review aimed to offer valuable insights and guidance for the development of high-performance, long-lasting Al–air batteries. Full article

With the development of industrialization, the demand for high-performance metal materials has increased, and copper and its alloys have been widely used. The microstructure of these materials significantly affects their performance. To address the issues of subjectivity, low efficiency, and limited quantitative capability in traditional metallographic analysis methods, this paper proposes a deep learning-based approach for segmenting the second phase in Cu-Fe alloys. The method is built upon the YOLO11 framework and incorporates a series of structural enhancements tailored to the characteristics of the secondary-phase microstructure, aiming to improve the model’s detection accuracy and segmentation performance. Specifically, the EIEM module enhances the C3K2 structure to improve edge perception; the CSPSA module is optimized into C2CGA to strengthen multi-scale feature representation; and the RepGFPN and DySample techniques are integrated to construct the GDFPN neck network. Experimental results on the Cu-Fe alloy metallographic image dataset demonstrate that YOLO11 outperforms mainstream semantic segmentation models such as U-Net and DeepLabV3+ in terms of mAP (85.5%), inference speed (208 FPS), and model complexity (10.2 GFLOPs). The improved YOLO11 model achieves an mAP of 89.0%, a precision of 84.6%, and a recall of 81.0% on this dataset, showing significant performance improvements while effectively balancing inference speed and model complexity. Additionally, a quantitative analysis software system for secondary phase uniformity based on this model provides strong technical support for automated metallographic image analysis and demonstrates broad application prospects in materials science research and industrial quality control. Full article

The development of stable, non-toxic electrolytes is essential for electrodepositing large-area coatings. This study presents a novel low-cyanide electrolyte, offering a viable alternative to traditional cyanide-based solutions for the electroplating of gold–copper alloys. Compared to conventional baths, the new formulation offers safer handling and environmental compatibility without compromising performance. Electrolyte compositions were optimized via cyclic voltammetry, and coatings were deposited using direct current, pulse current, and reverse pulse current methods. The novel low-cyanide electrolyte system achieved a 99.1% reduction in cyanide use compared with the commercial formulation. Coatings produced with pulse current and reverse pulse current deposition exhibited structural, morphological, and mechanical properties comparable to those obtained from cyanide-based electrolytes. Overall, the low-cyanide electrolyte represents a safer, high-performance alternative to traditional cyanide-based systems. Full article

This study signifies the development and characterization of a composite material with a metallic matrix of aluminum reinforced with a steel mesh, utilizing centrifugal casting technology. An evaluation was conducted to ascertain the influence of the formulation process and the presence of the insert on the mechanical behavior with regard to tensile strength. The aluminum matrix was obtained from commercial and scrap alloys, elaborated by advanced methods of degassing and chemical modification. Meanwhile, the steel mesh reinforcement was cleaned, copper plated, and preheated to optimize wetting and, consequently, adhesion. The structural characterization was performed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy analyses (EDX), which highlighted a well-defined interface and uniform copper distribution. The composite was produced by means of horizontal-axis centrifugal casting in a fiberglass mold, followed by cold rolling to obtain flat specimens. A total of eight tensile specimens were examined, with measured ultimate tensile strengths ranging from 78.5 to 119.8 (MPa). A thorough examination of the fractured specimens revealed a brittle fracture mechanism, devoid of substantial plastic deformation. The onset of failures was frequently observed at the interface between the aluminum matrix and the steel mesh. The use of SEM and EDX investigations led to the confirmation of the uniformity of the copper coating and the absence of significant porosity or interfacial defects. A bimodal distribution of tensile strength values was observed, a phenomenon that is likely attributable to variations in mesh positioning and local differences in solidification. A correlation was established between the experimental results and an analytical polynomial model, thereby confirming a reasonable fit. In sum, the present study provides a substantial foundation for the development of metal matrix composites with enhanced performance, specifically designed for challenging structural applications. This method also demonstrates potential for recycling aluminum scrap into high-performance composites with controlled microstructure and mechanical integrity. Full article

Babbitt alloys are among the most commonly used materials for sliding bearings. However, with the high speeds and heavy loads of modern machinery, as well as the demands of extreme working conditions, the temperature resistance, strength, and hardness of traditional Babbitt alloys are often insufficient to meet these requirements. To address this issue, it is essential to improve the properties of Babbitt alloys, particularly their performance at high temperatures. The present study explored a technical approach for incorporating copper powder to improve the high-temperature performance of Babbitt alloys. Copper powder was added to the traditional Babbitt alloy in mass percentages of 1, 2, 3, and 4%. After fabrication, the samples were examined using metallographic structure analysis, high-temperature compression testing, and friction and wear testing. The experiments investigated the effects of copper powder addition on the properties of the Babbitt alloy and determined the optimal amount of copper powder required to enhance its performance. Full article

In response to the performance requirements of ship conductive rings in the coupled environment of high salt spray, high humidity, and mechanical wear in the ocean, a Cu-TiC composite coating was prepared on the surface of 7075 aluminum alloy by using the high-speed laser cladding (HLC) technology. The influence laws of the scanning speed (86.4–149.7 mm/s) on the microstructure, tribological properties, and corrosion resistance of the coating were explored. The results show that the scanning speed significantly changes the phase composition and grain morphology of the coating by regulating the thermodynamic behavior of the molten pool. At a low scanning speed (86.4 mm/s), the CuAl₂ phase is dominant, and the grains are mainly columnar crystals. As the scanning speed increases to 149.7 mm/s, the accelerated cooling rate promotes an increase in the proportion of Cu₂Al₃ phase, refines the grains to a coexisting structure of equiaxed crystals and cellular crystals, and improves the uniformity of TiC particle distribution. Tribological property analysis shows that the high scanning speed (149.7 mm/s) coating has a 17.9% lower wear rate than the substrate due to grain refinement and TiC interface strengthening. The wear mechanism is mainly abrasive wear and adhesive wear, accompanied by slight oxidative wear. Electrochemical tests show that the corrosion current density of the high-speed cladding coating is as low as 7.36 × 10⁻⁷ A·cm⁻², and the polarization resistance reaches 23,813 Ω·cm². The improvement in corrosion resistance is attributed to the formation of a dense passivation film and the blocking of the Cl diffusion path. The coating with a scanning speed of 149.7 mm/s exhibits optimal wear-resistant and corrosion-resistant synergistic performance and is suitable for the surface strengthening of conductive rings in extreme marine environments. This research provides theoretical support for the process performance regulation and engineering application of copper-based composite coatings. Full article

Cu-Fe in situ composites often face challenges in achieving high strength during cold rolling due to the inefficient transformation of partial Fe phases into fibrous structures. To uncover the underlying mechanisms, this study systematically investigates the co-deformation behavior of Cu and Fe phases in a Cu-10Fe alloy subjected to cold rolling at various strains. Through microstructure characterization, texture analysis, and mechanical property evaluation, we reveal that the Cu matrix initially accommodates most applied strain (ε_vm < 1.0), forming shear bands, while Fe phases (dendrites and spherical particles) exhibit negligible deformation. At intermediate strains (1.0 < ε_vm < 4.0), Fe phases begin to deform: dendrites elongate along the rolling direction, and spherical particles evolve into tadpole-like morphologies under localized shear. Concurrently, dynamic recrystallization occurs near Fe phases in the Cu matrix, generating ultrafine grains. Under high strains (ε_vm > 4.0), Fe dendrites progressively transform into filaments, whereas spherical Fe particles develop long-tailed tadpole-like structures. Texture evolution indicates that Cu develops a typical copper-type rolling texture, while Fe forms α/γ-fiber textures, albeit with sluggish texture development in Fe. The low efficiency of Fe fiber formation is attributed to the insufficient strength of the Cu matrix and the elongation resistance of spherical Fe particles. To optimize rolled Cu-Fe in situ composites, we propose strengthening the Cu matrix (via alloying/precipitation) and suppressing spherical Fe phases through solidification control. This work provides critical insights into enhancing Fe fiber formation in rolled Cu-Fe systems for high-performance applications. Full article

Cu–Zn alloys are widely used engineering materials with well-known industrial applications. However, studies on their electrical and thermal conductivities have primarily relied on experimental measurements, while theoretical investigations remain limited. In this work, eight crystal structure models were constructed to represent three phase configurations (α single phase, α + β′ dual phase, and β′ single phase) of Cu–Zn alloys with Zn concentrations ranging from 0 to 50 at.%. Based on the first-principles calculations combined with the Boltzmann transport equation, the electrical and thermal conductivities of these models were computed, and the electronic structure of the α-phase configurations was further analyzed. The results show that both electrical and thermal conductivities exhibit a non-monotonic trend with increasing Zn content, initially decreasing and then increasing. This trend is in strong agreement with available experimental data. Further analysis of the electronic structure reveals that, in the α-phase region, the density of states near the Fermi level is mainly contributed by Cu d-orbitals. As Zn content increases, the effective DOS near the Fermi level decreases, leading to reduced electron transport capability. For thermal conductivity, both the Wiedemann–Franz law and the first-principles calculations were employed, yielding results consistent with experimental trends. In summary, this study systematically investigates the variation of electrical and thermal conductivities of Cu–Zn binary alloys with Zn content and explores the underlying physical mechanisms from the perspective of electronic structure. The findings provide valuable theoretical support for understanding and optimizing the transport properties of complex alloy systems. Full article

High-performance copper alloys are crucial for integrated circuit lead frames due to their high density, multifunctionality, and low cost. High-performance copper alloys typically address the competing issues of high strength and high electrical conductivity through alloying and processing control methods. However, the traditional methods for developing these alloys are time-consuming, expensive, and complex processes. This study utilizes Explainable AI by employing machine learning (ML) and deep learning (DL) techniques to predict the hardness (HRC) and electrical conductivity (mS/m) based on the alloy composition, including Cr, Zr, Ce, and La, and the processing parameters, namely the aging time, of Cu-Cr-Zr alloys. A comprehensive dataset of 47 experimental Cu-Cr-Zr alloy samples, derived from prior experimental studies, was analyzed using feature engineering, correlation analysis, and explainability methods such as SHapley Additive exPlanations (SHAP). Various ML models, including ensemble methods like XGBoost, CatBoost, and AdaBoost, were evaluated for their predictive performance. The feature importance analysis revealed that the aging time and Zr content significantly influence the hardness, followed by Ce content, while Cr and La contents reveal a weak contribution to hardness values. Electrical conductivity is predominantly controlled by aging time, with a weak negative influence of the alloying elements. These findings align well with metallurgical principles, where microstructural refinement and precipitation behavior dictate the hardness and conductivity of Cu-Cr-Zr alloys. Hyperparameter tuning and model stacking further enhanced the predictive accuracy, with the final stacked models achieving R² scores of 0.8762 for hardness within a training time of 1.739 s and 0.8132 for electrical conductivity within a training time of 1.091 s. These findings demonstrate the effectiveness of ML-driven approaches in material property predictions, providing valuable insights for material design and property processing parameter optimization. Full article

The increasing restriction of lead in industrial alloys, particularly in copper–zinc-based materials such as CuZn40Pb2, necessitates the development of environmentally safer alternatives. ZnAl15Cu1Mg (ZEP1510), a zinc-based wrought alloy composed of 15% aluminum, 1% copper, 0.03% magnesium, with the remainder being zinc, has emerged as a promising candidate for lead-free applications due to its favorable forming characteristics and corrosion resistance. This study investigates the performance of ZEP1510 compared to conventional leaded copper alloys and galvanized steel. Corrosion behavior was evaluated using neutral salt spray testing, cyclic climate chamber exposure, and electrochemical potential analysis in chloride- and sulfate-containing environments. ZEP1510 exhibited corrosion resistance comparable to brass and significantly better performance than galvanized steel in neutral and humid atmospheres. Combined with its low processing temperature and high recyclability, ZEP1510 presents itself as a viable and sustainable alternative to brass with lead for applications in sanitary, automotive, and electrical engineering industries. Full article

The selection of a suitable plasma-facing material (PFM) that must protect the divertor, cooling systems, and structural components is an important challenge in the design of advanced fusion reactors and requires careful consideration. Material degradation due to melting and evaporation may lead to plasma contamination, which must be strictly avoided. Among the candidate materials, tungsten (W) is the most promising because of its thermo-mechanical and physical properties, which allow it to endure repeated exposure to extremely harsh conditions within the reactor. The plasma spraying (PS) technique is gaining increasing interest for the deposition of tungsten (W) coatings to protect heat sink materials, due to its relatively low cost, high deposition rates, and capability to coat complex-shaped surfaces and fix damaged coatings in situ. This review aims to provide a systematic assessment of tungsten (W) coatings produced by PS techniques, evaluating their suitability as PFMs. It discusses W-based materials, plasma spraying technologies, the role of the interface in joining W coating and metallic substrates such as copper alloys and steels, and the main issues related to coating surface erosion under steady-state and transient heat loads associated with advanced fusion reactor operation modes and off-normal events. Quantitative data available in the literature, such as porosity, oxygen content, thermal conductivity of the coatings, residual stresses accumulated in the coating–substrate interface, surface temperature, and material loss following heat load events, were summarized and compared to bulk W ones. The results demonstrate that, following optimization of the fabrication process, PS-W coatings exhibit excellent performance. In addition, previously mentioned advantages of PS technology make PS-W coatings an attractive alternative for PFM fabrication. Full article

Conventional etchants for multi-metal/alloy stacked structures often suffer from nonuniform etching, residual layers, or undercutting, failing to meet high-generation production standards. This study presents a stable copper-molybdenum (Cu-Mo) etchant with extended bath life for thin film transistor liquid crystal display (TFT-LCD) applications, achieved through compositional optimization. Systematic investigations have been conducted on the effects of etching time, copper ion (Cu²⁺) loading (bath life) and storage time on the etch performance, alongside evaluations of sudden-eruption point and material compatibility. Results demonstrate that over-etching beyond the “detected endpoint” by 10% to 90% maintains critical dimension (CD) bias and taper angle of MoNiTi(MTD)/Cu/MTD three-layer and Cu/MTD two-layer within process specifications, as well as the difference between the CD bias of the three-layer and two-layer structures at the same over-etch time. The optimized formulation exhibits a 20% broader process window and 20% longer bath life compared to the process-of-record (POR) etchant. Shelf stability exceeds 15 days with minimal performance degradation, while maintaining compatibility with industrial equipment materials. These advancements address key challenges in high-precision etching for advanced TFT-LCD manufacturing, providing a scalable solution for next-generation display production. Full article

The high-temperature performance of 10CrNi2Mo3Cu2V steel is critically governed by the distribution of Cu-rich phases. This study systematically investigated the evolution of solute redistribution, Cu-rich phase precipitation, microstructural transformations, and mechanical properties in 10CrNi2Mo3Cu2V alloy under varying aging temperatures. Advanced characterization techniques, including atom probe tomography (APT) and transmission electron microscopy (TEM), were employed to analyze microstructural features and phase formation in both as-built and heat-treated specimens. The key findings reveal that copper atom segregation initiates at a tempering temperature of 350 °C. Upon increasing the temperature to 450 °C, extensive precipitation of nanoscale copper clusters is observed. Temperatures exceeding 450 °C trigger the formation of ε-Cu phases, which undergo subsequent coarsening. Notably, these copper clusters and Cu-rich precipitates act as dislocation pinning sites, promoting crack nucleation and propagation, thereby markedly degrading the alloy’s impact energy absorption capacity. The critical diameter for Orowan mechanism-governed strengthening by Cu-rich phases is determined to be ~6 nm, while the average diameter of matrix-penetrating Cu-rich particles is approximately 1.46 nm. Quantitative analysis demonstrated that the combined contributions of the Orowan bypass mechanism and particle-cutting mechanism yield a strength enhancement of ~219 MPa, which exhibits excellent agreement with experimentally measured strength increments. These results provide critical insights into the interplay between microstructural evolution and mechanical degradation in precipitation-strengthened steels under thermal exposure. Full article

In the current work, the distribution behaviors of irradiation-induced dislocation loops near the W-Cu interface (contains a thin W₂C transition layer) under self-interstitial atom diffusion-dominated conditions were investigated based on the comparative experiment of 3 MeV Fe ion and 100 keV He ion irradiation. The size distribution and number density of radiation-induced dislocation loops in both sides of the interface were characterized using Transmission Electron Microscopy with different two-beam conditions. The impact of the phase boundary on the dislocation loop distribution and the influence of He on this mechanism was discussed. The results showed that the phase boundary (PB) has a significant effect on the distribution of radiation-induced dislocation loops. In the Fe-irradiated sample, the proportion of b = 1/2<111> type dislocation loops near the phase boundary on the W side increases significantly, and b = 1/2<110> type dislocation loops dominate on the Cu side. He will significantly affect the loop distribution near the W/Cu phase boundary due to the strong binding of He with vacancies in W, which suppresses the recombination of SIA and vacancies and promotes the formation and growth of interstitial-type dislocations. Full article