Search Results (11,102)

The typical microstructure and mechanical properties of twin-roll cast (TRC) 2139 aluminum alloy were investigated and compared with mold casting (MC) 2139 alloy. This work pioneers the application of TRC to produce 2139 Al-Cu-Mg alloy, a material that is challenging for rapid solidification. The TRC process resulted in a denser dendritic structure, with the composition of intermetallic compounds, primarily Al₂Cu and Al₂CuMg, remaining largely stable throughout the casting process. After solution treatment, the recrystallized grains in the MC sheets were uniformly distributed, while the TRC sheets exhibited a more localized and refined recrystallized microstructure, particularly within coarse second-phase regions. Following heat treatments, the TRC sheets showed a significant increase in the Ω phase after T6, with a slight growth in size and a uniform distribution, while the Ω phase in T8 showed an increased density and smaller size, which diffused evenly across the material. The TRC process uniquely refines the microstructure and enhances Ω phase precipitation, yielding a 10%+ improvement in strength and ductility over conventional casting. The mechanical properties of the TRC sheets improved significantly: tensile and yield strengths increased by over 10% after T6, compared to MC sheets, with elongation slightly higher in TRC. T8 treatment further enhanced the mechanical properties of the TRC sheets, achieving an improvement in strength with only a minor trade-off in elongation. This establishes TRC as a superior industrial route for high-performance aluminum sheets, offering a promising industrial route, delivering substantial improvements in both strength and ductility over conventional casting methods. Full article

High-quality hole machining of Ti-6Al-4V is critical for precision aerospace components but remains challenging due to the alloy’s poor machinability. In this study, the influence of cutting parameters on milling force, burr formation and the hole quality of Ti-6Al-4V was investigated. The mechanical properties and microstructure of the milled holes were analyzed. The research results show that milling depth is the primary factor governing variations in milling force and burr formation. The minimum milling force of 3.61 N is achieved at a milling depth of 60 μm, a feed per tooth of 2 μm/z and a cutting speed of 31 m/min. Compared to pre-optimization parameters, the milling force is decreased by 91.74%. Correspondingly, entrance burr width and hole-axis deviation were substantially reduced, indicating marked improvement in hole quality and geometrical accuracy. Microstructural observations show no deleterious phase transformations or excessive work-hardening under the optimized regime. The results deliver quantitative guidelines for parameter selection and tool application in micro-hole milling of Ti-6Al-4V and provide a foundation for further process modelling and optimization for aerospace manufacturing. Full article

In physiological environments, several metallic alloys, including titanium, stainless steel, cobalt–chromium, and emerging biodegradable systems such as magnesium (Mg), zinc (Zn), and iron (Fe), offer mechanical properties and biocompatibility suitable for load-bearing implants. With the rapid advancement of 3D printing technologies, these alloys can now be fabricated into patient-specific, complex geometries that enhance both structural performance and functional integration. Beyond serving as structural supports, 3D-printed alloys are increasingly engineered as localized drug-delivery platforms to release anti-inflammatory, antibacterial, anticancer, and osteogenic agents at the implant–tissue interface, addressing the dual clinical needs of site-specific therapy and mechanical stabilization. Nevertheless, this field remains underexplored because studies differ widely in alloy chemistry, surface topography, porosity, coating strategy, drug-loading methods, and release profiles, as well as in how material degradation or passivation interacts with pharmacokinetics. For the first time, this review consolidates drug-loading and elution strategies across 3D-printed alloy platforms, compares therapeutic categories in relation to alloy and coating types, and critically evaluates how the surface microstructure or alloy geometry influences release behavior. Full article

In this study, the influence of post-processing heat treatment on microstructure and mechanical properties of Ti-6Al-2Sn-4Zr-2Mo (Ti-6242) alloy fabricated by laser powder bed fusion (L-PBF) was investigated. The mechanical properties of the as-built and heat-treated samples with various temperatures (600–850 °C) were evaluated using a tensile test at room temperature. After heat treatments, both yield strength (YS) and ultimate tensile strength (UTS) gradually decreased, while the tensile elongation tended to increase as the heat treatment temperature increased. These variations were closely related to the microstructural evolution caused by heat treatment. Specifically, the decomposition of α′ martensite into the α + β lamellar structure and subsequent coarsening were promoted with increasing temperature, leading to stress relief and improved dislocation storage capability, which resulted in the variation in mechanical properties. Notably, although the mechanical strength was reduced after heat treatment with increasing temperatures, the lowest yield strength and ultimate tensile strength were measured as 1086.4 ± 16.5 and 1135.0 ± 15.0 MPa, respectively, which are comparable to or higher than those of conventionally processed Ti-6242. As a result, the post-processing heat treatment could be an effective approach to achieve desirable performance for targeted applications. Full article

The efficiencies of additive manufacturing (AM) over conventional processes have enabled the rapid production of aluminum (Al) alloys with AM. Because laser beam powder bed fusion (LB-PBF) parts do not offer the surface quality and geometrical accuracy for direct use, the functional surfaces of LB-PBF parts are usually machined by subtractive machining. The machinability of LB-PBF AlSi10Mg was studied in dry, MQL (used corn oil), and cryo-LN₂ cutting environments across distinct speed–feed combinations using CVD-AlTiN-coated carbide inserts, and surface integrity and tool life were quantified in terms of surface roughness (Ra) and flank wear (Vb), respectively. The lowest Ra (0.98–1.107 μm) was obtained with cryo-LN₂, followed by MQL and dry cutting environments, because the trends observed were consistent with the surface mechanisms observed in 3D topography and bearing curves. Similarly, the tool wear results mirrored the Ra results, lowest with LN₂ (0.087–0.110 mm), due to improved thermal management, reduced adhesion and abrasion, and shorter contact length. Cryo-LN₂ provided the best surface finish and tool life among all tested environments. To enable data-driven prediction, the limited dataset was augmented using SMOTE, and machine learning (ML) models were trained to predict Ra and Vb. CatBoost was found to yield the best Ra predictions (R² = 0.9090), while Random Forest and XGBoost yielded the best Vb predictions (R² ≈ 0.878). Full article

The rapid growth of the hydrogen industry, driven by global decarbonization efforts, has intensified the need for safe and large-capacity storage systems. Although hydrogen is one of the most abundant elements on Earth, its storage remains technically challenging due to its chemical reactivity and stringent containment requirements. Previous research has primarily emphasized the material-level behavior of polymer liners, composites, and metal alloys because chemical compatibility plays a critical role in aboveground high-pressure tanks. However, for underground storage systems, long-term structural stability is governed not only by material performance but also by the geo-mechanical behavior of deep rock masses. This study proposes a seismic design approach for Lined Rock Caverns (LRCs), a deep underground storage concept capable of sustaining high internal pressure. The method incorporates ground-induced deformation and evaluates the additional influence of internal pressure on lining behavior. Numerical analyses demonstrate that internal pressure has a significant stabilizing effect on the structural response by reducing ovalization and suppressing nonlinear deformation mechanisms. The results highlight that internal pressure is not a secondary load but a key design parameter that must be integrated into the seismic evaluation of LRC-based hydrogen storage facilities. Full article

AlCoCrFeNi high-entropy alloys (HEAs) are promising materials due to their exceptional mechanical properties and thermal stability. This study employs first-principles calculations based on density functional theory (DFT) to investigate the phase stability and electronic properties of AlCoCrFeNi HEA. The atomic size difference (δ) was determined to be 5.44%, while the mixing enthalpy (ΔH_mix) was found to be −14.24 kJ/mol, and the valence electron concentration (VEC) was measured at 7.2, indicating a dual-phase structure consisting of the BCC and B2 phases. The formation energies indicated that the BCC phase exhibits the highest stability under typical conditions. The elastic properties were assessed, revealing Young’s modulus of 250 GPa, a shear modulus of 100 GPa, and a bulk modulus of 169 GPa, which suggest high stiffness. The alloy demonstrated a Poisson’s ratio of 0.25 and a G/B ratio of 0.59, indicating relatively brittle behavior. Microhardness simulations predicted a value of 604 HV0.2, which closely aligns with experimental measurements of 602 HV0.2 at 1300 W laser power, 532 HV0.2 at 1450 W, and 544 HV0.2 at 1600 W. The electronic structure analysis revealed metallic behavior, with the d-orbitals of Co, Fe, and Ni contributing significantly to the electronic states near the Fermi level. These findings offer valuable insights into the phase behavior and mechanical properties of AlCoCrFeNi HEA, which are crucial for the design of high-performance materials suitable for extreme engineering applications. Full article

This paper presents a theoretical study of the structural, electronic, and elastic properties of gallium-doped CuInSe₂ using the GGA exchange-correlation functional with the Hubbard correction for five Ga compositions: 0, 0.25, 0.5, 0.75, and 1. The found lattice parameters decrease with gallium composition and obey Vegard’s law. Traditional DFT calculations fail to explain the band structure of Copper Indium Gallium Selenide compounds (CIGS). The use of Hubbard corrections of d-electrons of copper, indium, gallium, and p-electrons of selenium opens the gap, showing a semiconductor’s behavior of CuInGaSe2 alloys in the range 1.04 eV to 1.88 eV, which are in good agreement with available experimental data and current theory using an expensive hybrid exchange-correlation functional. The obtained formation energies for the different gallium compositions are close to −1 eV/atom, and the phonon spectra indicate the thermodynamic stability of these alloys. The values of the elastic constant satisfy the Born elastic stability conditions, suggesting that these compounds are mechanically stable. Moreover, we compute the bulk modulus (B), shear modulus (G), Young’s modulus (E), Poisson ratio (p), Pugh’s ratio (r), and average Debye speed ($v$), and the Debye temperature (${\mathsf{\Theta }}_{\mathrm{D}}$) with the Ga composition. There is a symmetry between our results and the experimental data, as well as earlier simulation results. Full article

The growing demand for miniature mechanical components has increased the importance of ultra-precision micro machine tools and real-time monitoring. This study examines acoustic emission (AE) sensing for the intelligent control of an ultra-precision micro lathe. AE signals were measured while brass and aluminum alloys were turned with cermet and diamond tools at different spindle speeds and cutting depths. Finite element simulations were performed to clarify the AE generation mechanisms. The AE waveform amplitude changed stepwise corresponding to tool–workpiece contact, elastoplastic deformation, and chip formation, enabling precise contact detection at the 0.1 μm level. The AE amplitude increased with increasing spindle speed and increasing depth of cut except during abnormal conditions (e.g., workpiece adhesion). Frequency analysis revealed a dominant peak near 0.2 MHz during normal cutting, as well as high-frequency (>1 MHz) components linked to built-up edge formation. Simulations confirmed that these AE features reflect variations in the strain rate in the shear zone and on the rake face. They also confirmed that cutting force spectra under high friction reproduce the experimentally observed high-frequency peaks. These findings demonstrate the feasibility of using AE sensing to identify the cutting state and support the development of self-optimizing micro machine tools. Full article

The 6xxx-series Al alloys have been used for decades because of their favorable strength-to-weight ratio, corrosion resistance, and fatigue performance. However, conventional welding techniques often induce localized weakening, as thermal effects modify the microstructure and compromise structural integrity. For nearly 70 years, AA4043 welding wire has been the primary choice for joining 6xxx-series Al alloys. Nevertheless, microstructural and mechanical property mismatches between the base metal and weld region remain key factors contributing to premature failure, while welding-induced defects further increase rupture susceptibility. Microalloying has emerged as an effective strategy for enhancing both the mechanical and thermal properties of aluminum alloys. In this study, rare-earth (RE) elements La and Ce were introduced into the AA4043 system to exploit their grain refining and mechanical strengthening capabilities. In addition, the effects of Sr modification were examined and compared with La-Ce addition. This work aims to elucidate the strengthening mechanisms associated with La-Ce-Ti microalloying in AA4043 welding wire, a topic that has rarely been systematically investigated. With 0.019Ti-0.02La-0.03Ce additions, the modified wire exhibited significant performance improvements, achieving an UTS of 204 MPa and a YS of 191 MPa—representing increases of 10.3% and 18.6%, respectively. Full article

The 5083 aluminum alloy is widely used in marine engineering due to its excellent corrosion resistance and weldability. To address microstructural defects that may arise during hot rolling, homogenization annealing is employed as a critical post-processing step to enhance mechanical and processing properties. This study systematically investigates the effects of different homogenization annealing temperatures (held for 1 h) on the microstructure, corrosion behavior, and mechanical properties of hot-rolled 5083 aluminum alloy. The microstructural characteristics, phase composition, and corrosion morphology were characterized using scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), polarized light microscopy (POM), electron backscatter diffraction (EBSD), and electrochemical tests. Microhardness was measured using a Vickers hardness tester. The results indicate that the annealing temperature markedly influences the type, morphology, and distribution of precipitated secondary phases and significantly affects grain refinement. The alloy treated at 350 °C (5083–350 °C) exhibited optimal corrosion resistance, as evidenced by electrochemical impedance spectroscopy showing the highest charge transfer resistance and surface morphology analysis revealing minimal and shallow corrosion pits. Simultaneously, this treatment achieved significant stress relief and secondary phase precipitation strengthening, resulting in a peak microhardness of 78.8 HV. The study demonstrates that 350 °C homogenization annealing synergistically improves both the corrosion resistance and mechanical properties of hot-rolled 5083 aluminum alloy, providing valuable insights for optimizing its heat treatment process. Full article

The structural stability, electronic structure, and elastic properties of MgZn₂, Mg₃Zn₈Ce, and Mg₄Zn₇Ce have been investigated by adopting first-principles calculations methods based on density functional theory. The calculated lattice parameters agree well with experimental values and previous calculations. Formation enthalpy and binding energy calculations show that Mg₃Zn₈Ce has the highest alloying ability and structural stability. Electronic structure analysis suggests that Ce doping forms strong covalent bonds with Mg and Zn atoms, enhancing the stability of the system. Mechanical property calculations show that Mg₄Zn₇Ce exhibits the highest toughness, while Mg₃Zn₈Ce demonstrates the best shear resistance. Thus, Ce doping increases the stability and bonding strength of MgZn₂, reduces material brittleness, and enhances material ductility. This computational analysis provides theoretical support for predicting the properties of Mg-Zn-Ce alloys. Full article

This article presents a comparative study of mechanical properties and stress corrosion cracking (SCC) resistance of bare AW-5083 aluminum alloy and the same alloy coated by plasma electrolytic oxidation (PEO). Although Al–Mg alloys of the 5XXX series have been extensively studied with respect to SCC behavior, data concerning their performance after PEO treatment under mechanical loading in chloride-containing environments remain scarce. Prior to SCC testing, potentiodynamic polarization measurements were performed to assess the barrier properties of the PEO coating against general corrosion. The results demonstrate that the PEO coating significantly modifies the electrochemical response of the alloy and improves its resistance to corrosion processes in the presence of chloride ions. SCC tests revealed that the application of the PEO coating leads to enhanced resistance to stress-assisted degradation of the AW-5083 alloy, while distinct features of coating cracking under tensile loading were observed and discussed. The study provides new experimental insight into the combined mechanical and electrochemical behavior of PEO-coated AW-5083 alloy exposed to chloride environments. Full article

Background/Objectives: Biodegradable implants have emerged as a promising alternative to traditional metallic fixation devices in pediatric orthopedic surgery. Avoiding implant removal is especially advantageous in children, who would otherwise require a second operation with additional anesthetic and surgical risks. This study reviews the current use of poly(lactic-co-glycolic acid) (PLGA) implants in pediatric fracture fixation and evaluates how they address limitations associated with traditional hardware. Methods: A narrative review was conducted summarizing current evidence, clinical experience, and case examples involving PLGA-based devices used in pediatric trauma. Special emphasis was placed on the degradation mechanism of PLGA, its controlled hydrolysis profile, and the capacity of the material to provide temporary mechanical stability during bone healing before complete resorption. The review included studies of PLGA use in forearm, distal radius, ankle, and elbow fractures, comparing outcomes to those obtained with metallic implants. Results: Across multiple clinical reports and case series, PLGA implants demonstrated effective fracture healing, stable fixation, and complication rates comparable to traditional metallic devices. Patients treated with resorbable implants benefited from reduced postoperative morbidity, no requirement for implant removal, and improved imaging compatibility. Conclusions: PLGA-based bioabsorbable implants represent a safe and effective alternative to conventional metal fixation in children. Their favorable degradation kinetics and clinical performance support their growing use in pediatric trauma surgery, while ongoing advances in polymer design and bioresorbable alloys continue to expand future applications. Full article

Deep eutectic solvents (DES) have emerged as a versatile and sustainable medium for the green synthesis of nanomaterials, offering a viable alternative to conventional organic solvents and ionic liquids. Nanomaterials can be synthesised in DESs via multiple routes, including chemical reduction, solvothermal, and electrochemical methods. Among the different pathways, this review focuses on the electrochemical synthesis of nanomaterials in DESs, as it offers several advantages: low cost, scalability for large-scale production, and low-temperature processing. The size, shape, and morphology (e.g., nanoparticles, nanoflowers, nanowires) of the resulting nanostructures can be tuned by adjusting the concentration of the electroactive species, the applied potential, the current density, mechanical agitation, and the electrolyte temperature. The use of DES as an electrolytic medium represents an environmentally friendly alternative. From an electrochemical perspective, it exhibits high electrochemical stability, good solubility for a wide range of precursors, and a broad electrochemical window. Furthermore, their low surface tensions promote high nucleation rates, and their high ionic strengths induce structural effects such as templating, capping and stabilisation, that play a crucial role in controlling particle morphology, size distribution and aggregation. Despite significant progress, key challenges persist, including incomplete mechanistic understanding, limited recyclability, and difficulties in scaling up synthesis while maintaining structural precision. This review highlights recent advances in the development of metal, alloy, oxide, and carbon-based composite nanomaterials obtained by electrochemical routes from DESs, along with their applications. Full article