Search Results (34)

This study focuses on realistic modeling of forming load and microstructural evolution during hot metal extrusion, emphasizing the effects of friction models and hydraulic press behavior. Rather than merely predicting load magnitudes, the objective is to replicate actual press operation by integrating a load limit response into finite element modeling (FEM). By applying Coulomb and shear friction models under both constant and hydraulically controlled press conditions, the resulting impact on grain size evolution during deformation is examined. The hydraulic press simulation features a maximum load threshold that dynamically reduces die velocity once the limit is reached, unlike constant presses that sustain velocity regardless of load. P91 steel is used as the material system, and the predicted grain size is validated against experimentally measured data. Incorporating hydraulic control into FEM improves the representativeness of simulation results for industrial-scale extrusion, enhancing microstructural prediction accuracy, and ensuring forming process reliability. Full article

: Predicting the mechanical response of industrial alloys is crucial for optimizing manufacturing processes and improving material performance. Traditional, solely experimental approaches, though effective, are inefficient as they are resource-intensive, requiring extensive laboratory testing and the iterative calibration of processing conditions. These costs can be avoided through computational/virtual experiments based on a multiscale hierarchical framework that integrates macroscopic approaches, mesoscale modelling as well as atomic level and advanced thermodynamical simulations to study and predict the mechanical response of metallic systems. In the context of this work, a framework for studying the effect of forming on metallic materials is proposed, applied, and validated on the hot extrusion of AA6063. Coupling thermodynamic simulations (including Phase Field) results with literature data establishes a microstructurally accurate representative volume element (RVE) design. This way, the phase fraction and the grain size of the RVE are determined by thermodynamic simulations (ThermoCalc, MICRESS), which can be validated via microstructure characterization. It is known that the mechanical properties of the individual phases affect the macroscopical properties of the material. Using atomic level simulations (i.e., molecular dynamics), the dislocation density of the material is calculated and utilized as an input for a Crystal Plasticity Fast Fourier Transformation simulation. This iterative process can be applied to match all stages of manufacturing processes. The hierarchical and systematic integration of these computational methodologies enables a rigorous analysis of the effect that processing parameters have on the microstructure. This work contributes to the broader effort of creating experiment-free workflows for designing materials and processes by leveraging a multiscale modeling approach. Coupled with experimental data, the predictive accuracy of the mechanical behavior can be further enhanced. Full article

Artificial intelligence methods, especially artificial neural networks (ANNs), have increasingly been utilized for the mathematical description of physical phenomena in (metallic) material processing. Traditional methods often fall short in explaining the complex, real-world data observed in production. While ANN models, typically functioning as “black boxes”, improve production efficiency, a deeper understanding of the phenomena, akin to that provided by explicit mathematical formulas, could enhance this efficiency further. This article proposes a general framework that leverages ANNs (i.e., Conditional Average Estimator—CAE) to explain predicted results alongside their graphical presentation, marking a significant improvement over previous approaches and those relying on expert assessments. Unlike existing Explainable AI (XAI) methods, the proposed framework mimics the standard scientific methodology, utilizing minimal parameters for the mathematical representation of physical phenomena and their derivatives. Additionally, it analyzes the reliability and accuracy of the predictions using well-known statistical metrics, transitioning from deterministic to probabilistic descriptions for better handling of real-world phenomena. The proposed approach addresses both aleatory and epistemic uncertainties inherent in the data. The concept is demonstrated through the hot extrusion of aluminum alloy 6082, where CAE ANN models and predicts key parameters, and ChatGPT explains the results, enabling researchers and/or engineers to better understand the phenomena and outcomes obtained by ANNs. Full article

Zn-Ag-Cu alloys have recently attracted attention as alloy candidates for biomedical applications, but, to date, they have not achieved the required mechanical properties. To improve the mechanical properties of Zn-Ag-Cu-base alloys, in this work, the effects of the presence of increasing amounts of Ag and Cu as alloying elements on the properties of four 0.05% Mg-micro-alloyed Zn-Ag-Cu base alloys are explored. The alloys were manufactured in an electric furnace with a protective atmosphere using increasing amounts of Ag and Cu as alloying agents, and were cast in a metallic mold. The samples obtained were thermomechanically processed by hot extrusion. Three of the four alloys under study presented increasing amounts of the second phase (Ag, Cu)Zn₄, high mechanical properties, a microstructure and mechanical behavior characteristic of heteromaterials with a heterogeneous lamella-structure, and met the requirements of the mechanical properties, corrosion rate, antibacterial properties against S. aureus, and the cytotoxicity required for biomedical applications. It seems possible to tune the properties of the ZnAgCu-0.05% Mg alloys by changing the Ag and Cu contents. Full article

Spray forming is a manufacturing process that enables the production of high-performance metallic materials with exceptional properties. Due to its rapid solidification nature, spray forming can produce materials that exhibit fine, uniform, and equiaxed microstructures, with low micro-segregation, high solubility, and excellent workability. Al-Zn-Mg-Cu alloys have been widely used in the aerospace field due to their excellent properties, i.e., high strength, low density, and outstanding machinability. The alloy manufactured by spray forming has a combination of better impact properties and higher specific strength, due to its higher cooling rate, higher solute concentration, and lower segregation. In this manuscript, the recent development of spray-formed Al-Zn-Mg-Cu alloys is briefly reviewed. The influence of hot working, i.e., hot extrusion, hot forging, and hot rolling, as well as different heat treatments on the property and microstructure of spray-formed Al-Zn-Mg-Cu alloys is introduced. The second phases and their influence on the microstructure and mechanical properties are summarized. Finally, the potential in high-temperature applications and future prospects of spray-formed aluminum alloys are discussed. Full article

A magnesium-based metal matrix composite, Mg-5Se-2Zn-2SiO₂, was synthesized using the Disintegrated Melt Deposition (DMD) method followed by hot extrusion. Elemental analysis revealed that the material experienced selenium loss which was attributed to the evaporation of selenium at high temperatures. Superior damping characteristics were exhibited while retaining similar Young’s modulus, and significant grain refinement also resulted in decisively superior mechanical properties such as hardness (32% increase), fracture strain (39% increase), as well as yield and ultimate compressive strength (157% and 54% increase, respectively). These were a consequence of SiO₂ addition as well as presence of Mg₂Si (and MgSe) intermetallic phases which were detected by X-ray characterization. Furthermore, while the material had lower corrosion resistance than pure magnesium, it retained acceptable corrosion resistance as well as structural integrity after the full immersion duration of 28 days. Overall, the material exhibits promising potential for applications in the biomedical field, especially in development of smaller and lighter implants where mechanical properties are paramount, with key lessons learned for the synthesis of Mg-materials containing selenium for the future. Full article

Wood–plastic composites (WPCs) are some of the most common modern composite materials for interior and exterior design that combine natural waste wood properties and the molding possibility of a thermoplastic polymer binder. The addition of reinforcing elements, binding agents, pigments, and coatings, as well as changes to the microstructure and composition, can all affect the quality of WPCs for particular purposes. To improve the properties, hybrid composite panels of WPCs with 30 wt. % and 40 wt. % of wood content and reinforced with one or three metal grid layers were prepared sequentially by extrusion and hot pressure molding. The results show an average 20% higher moisture absorption for composites with higher wood content. A high impact test (HIT) revealed that the absorbed energy of deformation increased with the number of metal grid layers, regardless of the wood content, around two times for all samples before water immersion and around ten times after water absorption. Also, absorbed energy increases with raised wood content, which is most pronounced in three-metal-grid samples, from 21 J to 26 J (before swelling) and from 15 J to 24 J (after swelling). Flexural tests follow the trends observed by HIT, indicating around 65% higher strength for samples with three metal grid layers vs. samples without a metal grid before water immersion and around 80% higher strength for samples with three metal grid layers vs. samples without a grid after water absorption. The synthesis route, double reinforcing (wood and metal), applied methods of characterization, and optimization according to the obtained results provide a WPC with improved mechanical properties ready for an outdoor purpose. Full article

The development of metal salts-based nanocomposites is highly desired for the Fenton or Fenton-like reaction-based chemodynamic therapy of cancer. Manganese sulfate (MnSO₄)-dispersed nanoparticles (NPs) were fabricated with a hot-melt extrusion (HME) system for the chemodynamic therapy of colorectal cancer in this study. MnSO₄ was homogeneously distributed in polyethylene glycol (PEG) 6000 (as a hydrophilic polymer) with the aid of surfactants (Span 80 and Tween 80) by HME processing. Nano-size distribution was achieved after dispersing the pulverized extrudate of MnSO₄-based composite in the aqueous media. The distribution of MnSO₄ in HME extrudate and the interactions between MnSO₄ and pharmaceutical additives were elucidated by Fourier-transform infrared, X-ray diffractometry, X-ray photoelectron spectroscopy, and scanning electron microscopy analyses. Hydroxyl radical generation efficiency by the Fenton-like chemistry capability of Mn²⁺ ion was also confirmed by catalytic assays. By using the intrinsic H₂O₂ in cancer cells, MnSO₄ NPs provided an elevated cellular reactive oxygen species level, apoptosis induction capability, and antiproliferation efficiency. The designed HME-processed MnSO₄ formulation can be efficiently used for the chemodynamic therapy of colorectal cancer. Full article

Inconel 718 is a widely used superalloy, due to its unique corrosion resistance and mechanical strength properties at very high temperatures. Hot metal extrusion is the most widely used forming technique, if the manufacturing of slender components is required. As the current scientific literature does not comprehensively cover the fundamental aspects related to the process–structure relationships, in the present work, a combined numerical and experimental approach is employed. A finite element (FE) model was established to answer three key questions: (1) predicting the required extrusion force at different extrusion speeds; (2) evaluating the influence of the main processing parameters on the formation of surface cracks using the normalized Cockcroft Latham’s (nCL) damage criterion; and (3) quantitatively assessing the amount of recrystallized microstructure through Avrami’s equation. For the sake of modeling validation, several experimental investigations were carried out under different processing conditions. Particularly, it was found that the higher the initial temperature of the billet, the lower the extrusion force, although a trade-off must be sought to avoid the formation of surface cracks occurring at excessive temperatures, while limiting the required extrusion payload. The extrusion speed also plays a relevant role. Similarly to the role of the temperature, an optimal extrusion speed value must be identified to minimize the possibility of surface crack formation (high speeds) and to minimize the melting of intergranular niobium carbides (low speeds). Full article

In this paper, an axle sleeve is formed through a combined cross wedge rolling (CWR) and hot extrusion process, and the combined forming process is simulated via finite element analysis software Deform-3D. The forming mechanism is revealed by analyzing the stress and strain distribution, the temperature variation and the metal flow law of the workpiece during CWR and hot extrusion. Combined with CWR and hot extrusion forming experiments, the feasibility of a combined rolling and extrusion process to produce an axle sleeve is verified. It has been proven that the outer steps of the axle sleeve produced through the rolling extrusion composite process are well formed, the flange extrusion cavity is full, the metal streamline is continuous, the axis of the inner hole does not easily deviate, the product quality is good and the production efficiency is high. Full article

Recent research has focused on sheet shear cutting operations. However, little research has been conducted on bar shear cutting. The main objective of the present investigation is to study bar shear cutting with numerical and experimental analysis. Bar shear cutting is an important operation because it precedes bulk metalworking processes for instance machining, extrusion and hot forging. In comparison to sheet shear cutting, bar shear cutting needs thermomechanical modelling. The variational formulation of the model is presented to predict damage mechanics in the bar shear cutting of aluminium alloys. Coupled thermomechanical modelling is required to analyse the mechanical behaviour of bulk workpieces, in which the combined effect of strain and temperature fields is considered in the shear cutting process. For this purpose, modified hardening and damage Johnson–Cook laws are developed. Numerical results for sheet and bar shear cutting operations are presented. The comparison between numerical and experimental results of shearing force/tool displacement during sheet and bar shear cutting operations proves that the use of a thermomechanical model in the case of the bar shear cutting process is crucial to accurately predict the mechanical behaviour of aluminium alloys. The analysis of the temperature field in the metal bar shows that the temperature can reach T = 388 °C on the sheared surface. The current model accurately predicts the shear cutting process and shows a strong correlation with experimental tests. Two values of clearance (c₁ = 0.2 mm) and (c₂ = 1.2 mm) are assumed for modeling the bar shear cutting operation. It is observed that for the low shear clearance, the burr is small, the quality of the sheared surface is better, and the fractured zone is negligible. Full article

In the field of metal matrix composites, it is a great challenge to improve the strength and elongation of magnesium matrix composites simultaneously. In this work, xTC4/AZ31 (x = 0.5, 1, 1.5 wt.%) composites were fabricated by spark plasma sintering (SPS) followed by hot extrusion. Scanning electron microscopy (SEM) showed that nano-TC4 (Ti-6Al-4V) was well dispersed in the AZ31 matrix. We studied the microstructure evolution and tensile properties of the composites, and analyzed the strengthening mechanism of nano-TC4 on magnesium matrix composites. The results showed that magnesium matrix composites with 1 wt.%TC4 had good comprehensive properties; compared with the AZ31 matrix, the yield strength (YS) was increased by 20.4%, from 162 MPa to 195 MPa; the ultimate tensile strength (UTS) was increased by 11.7%, from 274 MPa to 306 MPa, and the failure strain (FS) was increased by 21.1%, from 7.6% to 9.2%. The improvement in strength was mainly due to grain refinement and good interfacial bonding between nano-TC4 and the Mg matrix. The increase in elongation was the result of grain refinement and a weakened texture. Full article

Particle-reinforced Cu-based electrical contact materials prepared by traditional powder metallurgical methods suffer the same critical problem, where the agglomeration of the addition phases in the Cu matrix significantly deteriorates the performance of the composites and restricts their application. In this work, CdMoO₄/Cu matrix composites were fabricated by an in situ method and followed by a powder metallurgical process. Firstly, CdMoO₄/particles formed a nucleus and grew up based on the surfaces of Cu particles, realizing the controllable in situ synthesis of mixed powders with homogeneously dispersed CdMoO₄ nanoparticles via a one-step reaction. Secondly, the bulk CdMoO₄/Cu composites were fabricated by pressing and sintering and then densified by hot-extrusion and cold rolling processes. The microstructures and properties of the extruded and rolled specimens were characterized, respectively. The results indicated that the rolled CdMoO₄/Cu composite exhibited excellent comprehensive properties of electrical conductivity and mechanical properties for electrical contact materials. Moreover, the effects of the contact force on the static contact resistance of the extruded and rolled composites were evaluated in the closed state of the contact materials. It was found that the rolled CdMoO₄/Cu contact materials possessed a stable electrical contact characteristic with low and steady contact resistance. This work designed ternary CdMoO₄ particles to reinforce Cu-based composites with well-balanced performances by an in situ synthesis method and this strategy can be extended to the design of ternary oxide/metal composites utilized as electrical contact materials. Full article

Metal matrix nanocomposites are attracting attention because of their great potential for improved mechanical properties and possible functionalization. These hybrid materials are often produced by casting processes, but they can also develop their property profile after hot working, e.g., by forging or extrusion. In this study, a commercial cast magnesium alloy AM60 was enriched with 1 wt.% AlN nanoparticles and extruded into round bars with varied extrusion rates. The same process was carried out with unreinforced AM60 in order to determine the influences of the AlN nanoparticles in direct comparison. The influence of extrusion speed on the recrystallization behavior as well the effect of nanoparticles on the microstructure evolution and the particle-related strengthening are discussed and assessed with respect to the resulting mechanical performance. Full article

Direct solid-states, such as hot extrusion and equal channel angular pressing (ECAP), are alternative and efficient solid-state processes for use in recycling aluminium scrap. These processes utilise less energy and are eco-friendly. Ceramic particles such as ZrO₂ are suggested as alternatives in the production of metal composites. This study investigated and optimised the effects of various parameters of reinforced ZrO₂ nanoparticles on the mechanical and physical properties via response surface methodology (RSM). These parameters were the volume fraction (VF), preheating temperature (T), and preheating time (t). The effects of these parameters were examined before and after the heat treatment condition and ECAP. Each parameter was evaluated at varying magnitudes, i.e., 450, 500, and 550 °C for T, 1, 2, and 3 h for t, and 1, 3, and 5% for VF. The effect that process variables had on responses was elucidated using the factorial design with centre point analysis. T and VF were crucial for attaining the optimum ultimate tensile strength (UTS) and microhardness. Reducing VF increased the mechanical properties to 1 vol% of oxide. The maximum hardness of 95 HV was attained at 550 °C, 1.6 h, and 1 vol% ZrO₂ with a density of 2.85 g/cm³ and tensile strength of 487 MPa. UTS, density, and microhardness were enhanced by 14%, 1%, and 9.5%, respectively. Additionally, the hot extrusion parameters and ECAP followed by heat treatment strengthened the microhardness by 64% and density by 3%. Compression pressure and extrusion stress produced in these stages were sufficient to eliminate voids that increased the mechanical properties. Full article