Search Results (554)

As a new type of alloy system composed of five or more principal components, high-entropy alloys demonstrate outstanding comprehensive performance in the field of friction and wear through the synergistic effects of the high-entropy effect, lattice distortion effect, hysteresis diffusion effect and cocktail effect. This paper systematically reviews the research progress on the friction and wear properties of high-entropy alloys. The mechanisms of metal elements such as Al, Ti, Cu and Nb through solid solution strengthening, second-phase precipitation and oxide film formation were analyzed emphatically. And non-metallic elements such as C, Si, and B form and strengthen the regulation laws of their tribological properties. The influence of working conditions, such as high temperature, ocean, and hydrogen peroxide on the friction and wear behavior of high-entropy alloys by altering the wear mechanism, was discussed. The influence of test conditions such as load, sliding velocity and friction pair matching on its friction coefficient and wear rate was expounded. It is pointed out that high-entropy alloys have significant application potential in key friction components, providing reference and guidance for the further development and application of high-entropy alloys. Full article

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological parameters of the laser irradiation process are characterized, which determine the range of laser processing modes within which no oxidation and crack formation occur, and a high-quality composite with specified geometrical parameters is formed. It has been proven that composites consisting of synthetic diamond grains and a metal bond do not lose strength under the condition that the temperature during laser heating does not exceed 1600 °C and the exposure time is 0.3 s. Electron microscopy and X-ray diffractometry were used for experimental studies of the microstructure and phase composition of the sintered layers. A new design and manufacturing method for a drum-type abrasive tool with replaceable diamond inserts for grinding large-sized aircraft and shipbuilding products are proposed. Components of a laser technological complex for the implementation of the process of sintering the diamond-containing layer of the abrasive inserts of the drum have been developed. Full article

In this work, the development of Al-based metal matrix composites (MMCs) is achieved using hybrid SiC and ZrO₂ reinforcement particles for automotive applications. Powder metallurgy (PM) is employed with various combinations of important process parameters for the fabrication of MMCs. MMCs were characterized using scanning electron microscopy (SEM), X-ray diffractometry (XRD), and a microhardness study. All XRD graphs adequately exhibit Al, SiC, and ZrO₂ peaks, indicating that the hybrid MMC products were satisfactorily fabricated with appropriate mixing and sintering at all the considered fabrication conditions. Also, no impurity peaks were observed, confirming high composite purity. MMC products in all the XRD patterns, suitable for the desired applications. According to the SEM investigation, SiC and ZrO₂ reinforcement components are uniformly scattered throughout Al matrix in all produced MMC products. The occurrence of Al, Si, C, Zr, and O in EDS spectra demonstrates the effectiveness of composite ball milling and sintering under all manufacturing conditions. Moreover, an increase in interfacial bonding of fabricated composites at a higher sintering temperature indicated improved physical properties of the developed MMCs. The highest microhardness value is 86.6 HVN amid all the fabricated composites at 7% silica, 14% zirconium dioxide, 500° sintering temperature, 90 min sintering time, and 60 min milling time. An integrated Particle Swarm Optimization–Support Vector Machine (PSO-SVM) model was developed to predict microhardness based on the input parameters. The model demonstrated strong predictive performance, as evidenced by low values of various statistical metrics for both training and testing datasets, highlighting the PSO-SVM model’s robustness and generalization capability. Specifically, the model achieved a coefficient of determination of 0.995 and a root mean square error of 0.920 on the training set, while on the testing set, it attained a coefficient of determination of 0.982 and a root mean square error of 1.557. These results underscore the potential of the PSO-SVM framework, which can be effectively leveraged to optimize process parameters for achieving targeted microhardness levels for the developed Al-SiC-ZrO₂ Composites. Full article

The weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical properties compared to the results for casting. However, the high cost of forging can limit its economic feasibility. Low pressure forging (LPF) combines the benefits of casting and forging, employing controlled pressure to fill the mold cavity and improve metal purity. This study investigates the effectiveness of the LPF process in optimizing the mechanical properties of AlSi7Mg aluminum alloy by evaluating the influence of three different magnesium content levels. The specimens underwent T6 heat treatment (solubilization treatment followed by artificial aging), with varying aging times and temperatures. Microstructural analysis and tensile tests were conducted to determine the optimal conditions for achieving superior mechanical strength, contributing to the design of lightweight, high-performance components for advanced automotive applications. The most promising properties were achieved with a T6 treatment consisting of solubilization at 540 °C for 6 h followed by aging at 180 °C for 4 h, resulting in mechanical properties of σ_y 280 MPa, σ_m 317 MPa, and A% 3.5%. Full article

The prediction of microstructure evolution during thermal processing plays a crucial role in tailoring the mechanical properties of metallic components. Therefore, this work presents a comprehensive, multiscale modelling approach to simulating phase transformations in large-diameter steel rings during cooling. A finite-element-based thermal model was first used to simulate transient temperature distributions in a large-diameter ring under different cooling conditions, including air and water quenching. These thermal histories were subsequently employed in two complementary phase transformation models of different levels of complexity. The Avrami model provides a first-order approximation of the evolution of phase volume fractions, while a complex full-field cellular automata approach explicitly simulates the nucleation and growth of ferrite grains at the microstructural level, incorporating local kinetics and microstructural heterogeneities. The results highlight the sensitivity of final grain morphology to local cooling rates within the ring and initial austenite grain sizes. Simulations demonstrated the formation of heterogeneous microstructures, particularly pronounced in the ring’s surface region, due to sharp thermal gradients. This approach offers valuable insights for optimising heat treatment conditions to obtain high-quality large-diameter ring products. Full article

The concept of “material effort” appears in continuum mechanics wherever the response of a material to the currently existing state of loads and boundary conditions loses its previous, predictable character. However, within the material, which still descriptively remains a continuous medium, new physical structures appear and new previously unused physical features of the continuum are activated. The literature is dominated by a simplified way of thinking, which assumes that all these states can be characterized and described by one and the same measure of effort—for metals it is the Huber–Mises–Hencky equivalent stress. Quantitatively, perhaps 90% of the literature is dedicated to this equivalent stress. The remaining authors, as well as the author of this paper, assume that there is no single universal measure of effort that would “fit” all operating conditions of materials. Each state of the structure’s operation may have its own autonomous measure of effort, which expresses the degree of threat from a specific destruction mechanism. In the current energy sector, we are increasingly dealing with “low-cycle thermal fatigue states”. This is related to the fact that large, difficult-to-predict renewable energy sources have been added. Professional energy based on coal and gas units must perform many (even about 100 per year) starts and stops, and this applies not only to the hot state, but often also to the cold state. The question arises as to the allowable shortening of start and stop times that would not to lead to dangerous material effort, and whether there are necessary data and strength characteristics for heat-resistant steels that allow their effort to be determined not only in simple states, but also in complex stress states. Do these data allow for the description of the material’s yield surface? In a previous publication, the author presented the results of tension and compression tests at elevated temperatures for two heat-resistant steels: St12T and 26H2MF. The aim of the current work is to determine the properties and strength characteristics of these steels in a pure torsion test at elevated temperatures. This allows for the analysis of the strength of power turbine components operating primarily on torsion and for determining which of the two tested steels is more resistant to high temperatures. In addition, the properties determined in all three tests (tension, compression, torsion) will allow the determination of the yield surface of these steels at elevated temperatures. They are necessary for the strength analysis of turbine elements in start-up and shutdown cycles, in states changing from cold to hot and vice versa. A modified testing machine was used for pure torsion tests. It allowed for the determination of the sample’s torsion moment as a function of its torsion angle. The experiments were carried out at temperatures of 20 °C, 200 °C, 400 °C, 600 °C, and 800 °C for St12T steel and at temperatures of 20 °C, 200 °C, 400 °C, 550 °C, and 800 °C for 26H2MF steel. Characteristics were drawn up for each sample and compared on a common graph corresponding to the given steel. Based on the methods and relationships from the theory of strength, the yield stress and torsional strength were determined. The yield stress of St12T steel at 600 °C was 319.3 MPa and the torsional strength was 394.4 MPa. For 26H2MH steel at 550 °C, the yield stress was 311.4 and the torsional strength was 382.8 MPa. St12T steel was therefore more resistant to high temperatures than 26H2MF. The combined data from the tension, compression, and torsion tests allowed us to determine the asymmetry and plasticity coefficients, which allowed us to model the yield surface according to the Burzyński criterion as a function of temperature. The obtained results also allowed us to determine the parameters of the Drucker-Prager model and two of the three parameters of the Willam-Warnke and Menetrey-Willam models. The research results are a valuable contribution to the design and diagnostics of power turbine components. Full article

A fiber Bragg grating (FBG)-based ocean temperature and depth sensor structure is proposed. The pressure sensing section employs a secondary sensitization design comprising a piston and the polycarbonate buffer, while the temperature sensing section utilizes an FBG encapsulated within a metal silver tube, accompanied by a temperature compensation structure. Simulation analyses verify the enhanced sensitivity of the proposed configuration. By selecting suitable materials for the piston, metal tube, and polymer, and optimizing the dimensions of key components, the sensitivity of the bare FBG sensor is significantly improved through the combined effects of the piston, polymer, and metal tube. After optimization, the sensor exhibits a pressure sensitivity of 1.33 nm/MPa and a temperature sensitivity of 102.77 pm/°C, meeting the high-precision detection requirements for ocean temperature and depth sensing. The experimental results show that the temperature sensitivity is 109.9 pm/°C within the temperature range of −5~35 °C, and that the pressure sensitivity is 1.63 nm/MPa within the pressure range of 1~10 MPa. These results confirm that the sensor is well-suited for high-precision ocean temperature and depth measurements. Full article

The conventional spent lithium-ion batteries (LIBs) recycling method suffers from complex processes and excessive chemical consumption. Hence, this study proposes an electrochemical strategy for achieving reductant-free leaching of high-valence transition metals and efficient separation of valuable components from spent cathode sheets (CSs). An innovatively designed sandwich-structured electrochemical reactor achieved efficient reductive dissolution of cathode materials (CMs) while maintaining the structural integrity of aluminum (Al) foils in a dilute sulfuric acid system. Optimized current enabled leaching efficiencies exceeding 93% for lithium (Li), cobalt (Co), manganese (Mn), and nickel (Ni), with 88% metallic Al foil recovery via cathodic protection. Multi-scale characterization systematically elucidated metal valence evolution and interfacial reaction mechanisms, validating the technology’s tripartite innovation: simultaneous high metal extraction efficiency, high value-added Al foil recovery, and organic removal through single-step electrochemical treatment. The process synergized the dissolution of CM particles and hydrogen bubble-induced physical liberation to achieve clean separation of polyvinylidene difluoride (PVDF) and carbon black (CB) layers from Al foil substrates. This method eliminates crushing pretreatment, high-temperature reduction, and any other reductant consumption, establishing an environmentally friendly and efficient method of comprehensive recycling of battery materials. Full article

With the continuous advancement of electromagnetic protection technologies, the development of lightweight electromagnetic wave-absorbing materials with excellent absorption performance has become a critical challenge in the field. In this study, commercially available hollow glass microspheres (HGMs) were employed as templates, and Ni²⁺/Co²⁺ metal ions were used to catalyze the polymerization of dopamine (PDA), forming HGM@Ni_xCo_y/PDA precursors. Subsequent high-temperature pyrolysis yielded lightweight composite absorbing materials, denoted as HGM@Ni_xCo_y/C. This material integrates dielectric loss, conductive loss, magnetic loss, and resonance absorption mechanisms, exhibiting outstanding electromagnetic wave absorption properties. The absorption performance can be effectively tuned by adjusting the Ni-to-Co ratio, with the optimal performance observed at an atomic ratio of 2:3. At a filler loading of 20 wt.%, HGM@Ni₂Co₃/C achieved an effective absorption bandwidth (EAB) of 6.83 GHz (ranging from 10.53 to 17.36 GHz) and a minimum reflection loss (RL_min) of −27.26 dB. These results demonstrate that the synergistic combination of hollow glass bubbles and carbon-based magnetic components not only significantly reduces the material density and required filler content but also enhances overall absorption performance, highlighting its great potential in the development of lightweight and high-efficiency electromagnetic wave absorbers. Full article

The metallurgical industry has been constantly changing over the past decades. On the one hand, there has been the modernization and improvement of production efficiency, and on the other hand, we have seen a reduction in the negative impact on the environment. The possibility of using alternative materials and the circular economy is significant in this area. In the present work, research was carried out to determine the usefulness of biomass in the form of fruit seeds for the recycling processes of metal-bearing raw materials, including slags from copper production processes, which are characterized by a much higher metal content than ores of this metal. The main carbon-bearing material/reducer used in the process is metallurgical coke. The transformation of the European metal industry has been observed in recent years. To carry out the physicochemical characterization of the tested material, a research methodology was adopted using tools to determine the stability of behavior at high temperatures, chemical composition, and volatile components. Thermodynamic analysis was carried out, indicating the theoretical course of reactions of individual system components and thermal effects, allowing a determination of whether the assumed reactions are endothermic or exothermic. The planned research ends with the reduction process in conditions similar to those carried out in industrial conditions. Enforced by the guidelines for reducing CO₂ emissions, it contributes to a significant reduction in the demand for coke. This paper addresses the issue of determining the feasibility of using selected bioreducers, including cherry stones, to verify their suitability in the process of reducing copper oxides. The study used copper slag with a composition similar to slags generated at the copper production stage in a flash furnace. The results obtained in reducing copper content above 98 wt. % indicate the great potential of this type of bioreducer. It should be noted that, unlike conventional fossil fuels, the use of cherry stones to reduce copper slag can be considered an environmentally neutral method of carbon offset. The resulting secondary slag is a waste product that can be stored and disposed of without harmful environmental effects due to its low lead content. An additional advantage is the relatively wide availability of cherry stones. Full article

Studying the fatigue performance of metallic components and optimizing their design from the perspectives of structure, microstructure, and service conditions has long been a critical research focus. In this study, a comprehensive analysis was conducted on the sealing performance and fatigue behavior of W-shaped metallic sealing rings with varying microstructures. A novel simulation approach is proposed that replaces explicit gradient definitions with temperature conduction to address the issue of stress concentration at interfaces in the finite element modeling of gradient structures. Based on this method, a macroscopic finite element model was developed to simulate the plastic strain accumulation and springback of the sealing ring in service. Then, taking the stress evolution at the trough position of the sealing ring during service as a boundary condition, the evolution of stored-energy density and fatigue life of rings with different microstructures, including both homogeneous and gradient configurations, was quantitatively evaluated. The findings of this work provide valuable insights for the design of structural parameters and the optimization of forming process parameters in high-performance sealing-ring applications. Full article

Solid oxide fuel cells (SOFCs) have been considered as alternative energy conversion devices because of their high energy conversion efficiency, fuel flexibility, and cost efficiency without precious metal catalysts. In current SOFCs, the cermet anode consists of nickel and ion-conducting ceramic materials, and solid oxide electrolytes and ceramic cathodes have been used. SOFCs normally operate at high temperatures because of the lower ion conductivity of ceramic components at low temperatures, and they have weaknesses in terms of mechanical strength and durability against thermal shock originating from the properties of ceramic materials. To solve these problems, metal-supported solid oxide fuel cells (MS-SOFCs) have been designed. SOFCs using metal substrates, such as Ni-based and Cr-based alloys, provide significant advantages, such as a low material cost, ruggedness, and tolerance to rapid thermal cycling. In this article, SOFCs are introduced briefly, and the types of metal substrate used in MS-SOFCs, as well as the advantages and disadvantages of each metal support, are reviewed. Full article

High-temperature fuel cells and electrolyzers, particularly molten carbonate fuel cells (MCFCs) and Molten Carbonate Electrolyzers (MCEs), are expected to play a critical role in clean power generation, hydrogen production, and integrated CO₂ separation. Unfortunately, despite their potential, these technologies have not yet reached full commercialization. The main reason for this is material degradation. In particular, the corrosion of metallic components continues to be a leading cause of performance loss and system failure. This review provides a comprehensive assessment of degradation mechanisms in MCFC and MCE systems. It examines key metallic components, such as current collectors and bipolar plates, focusing on the performance of commonly used materials, including stainless steels and advanced alloys, under prolonged exposure to corrosive environments. To address degradation issues, this review evaluates current mitigation strategies and discusses material selection, protective coatings application, and the optimization of operational parameters. Advances in alloy development, coatings, surface treatments, and process controls have been compared in terms of effectiveness, scalability, and long-term stability. The review concludes with a synthesis of current best practices and future directions, emphasizing the need for integrated, multi-functional solutions to achieve the lifetimes required for full commercialization. By linking materials science, electrochemistry, and systems engineering, this review offers directions for the development of corrosion-resistant MCFC and MCE technologies in support of a hydrogen-based, carbon-neutral energy future. Full article

This study investigates the effects of destructive climatic factors on the mechanical and performance properties of various structural materials, encompassing both polymers and metals. Over recent decades, the growing adoption of synthetic polymers has revolutionized engineering applications, yet their susceptibility to environmental degradation poses significant challenges. This research emphasizes the need for comprehensive testing under both operational and environmental stressors, including extreme temperatures, UV radiation, and moisture, to assess material durability and performance. Mechanical tests were conducted at ambient (25 °C) and low temperatures (−50 °C) to evaluate the strength and strain responses of selected materials. Additionally, a 12-month accelerated aging process using UV radiation and elevated temperatures was performed to simulate long-term environmental exposure. Parameters such as Shore D hardness, gloss, and mass were measured at regular intervals to quantify material degradation. The results revealed significant differences in performance across material types. Among polymers, laser-extruded and milky plexiglass, as well as solid polycarbonate, exhibited satisfactory resistance to aging, with minimal changes in mechanical properties. However, high-impact polystyrene displayed substantial deformation and hardness loss after prolonged UV exposure. For metals, aluminum and stainless steel (304 and 316) demonstrated exceptional durability, retaining structural and aesthetic properties after 12 months of accelerated aging, whereas galvanized steel exhibited pronounced corrosion. The study highlights the critical interplay between mechanical loading and environmental factors, stressing the importance of material selection tailored to specific climatic conditions. It further underscores the value of integrating experimental findings with predictive models, such as finite element analysis, to enhance the design and longevity of engineering materials. The findings provide actionable insights for industries operating in temperate climates, where materials are subjected to diverse and cyclic environmental stressors. Recommendations are offered for selecting resilient materials suitable for protective housings and structural components. Full article

Red mud from bauxite processing is among the large-tonnage technogenic waste that poses a significant ecological threat. At the same time, red mud serves as a raw material source for expanding the resource base for obtaining iron, rare metals, and rare earth elements. Numerous studies on their utilization have shown that only through comprehensive processing, combining pyrometallurgical and hydrometallurgical methods, is it possible to maximize the extraction of all the useful components. This work addresses the first stage of a comprehensive technology for processing red mud through reduction smelting, separating iron in the form of pig iron, and producing slag. Studies were conducted on the reductive smelting of red mud using waste slurry from alumina production as the calcium-containing material, taken in proportions calculated to obtain a fluid slag with a hydraulic modulus of 0.55–0.8. The permissible mixing range of red mud with waste slurry was determined to be in the ratio of 0.56–1.2. In cases where the charge was prepared in violation of the required hydraulic modulus value, pig iron was not obtained during smelting. When the hydraulic modulus requirement was met, the temperature of the reductive smelting process was 1350–1400 °C. The total amount of recovered iron obtained as pig iron and fine fractions amounted to 99.5% of the original content. The low iron content (0.23–0.31%) in the non-magnetic slag fraction allows for the production of high-quality titanium oxide and rare earth element concentrates in the subsequent stages of the comprehensive hydrometallurgical processing of red mud, involving acid leaching. Based on the results of a phase analysis of the slag, pig iron, and melt, the reactions of the reductive smelting process were established, and their thermodynamic likelihood was determined. In fluid slags, the content of the sodium aluminosilicate phase is twice as high as that in slag with a higher hydraulic modulus. The reductive smelting of 100% red mud with the addition of calcium oxide, calculated to achieve a hydraulic module of 0.55 at a temperature of 1350–1400 °C, produced pig iron and slag with high alkali and iron contents. Full article