Search Results (161)

Wittichenite (Cu₃BiS₃) was synthesized by mechanical alloying (MA) followed by hot pressing (HP), and its phase evolution, thermal stability, charge transport behavior, and thermoelectric performance were systematically examined. X-ray diffraction analysis of the MA powders revealed broadened diffraction peaks, indicating reduced crystallinity and refined crystallite size. After HP consolidation, a well-defined single-phase orthorhombic wittichenite structure was obtained. These results demonstrate that the mechanically induced solid-state synthesis was effectively initiated during MA and subsequently completed through crystallization, defect relaxation, and densification during HP. The MA–HP processed specimens exhibited high relative densities of 94–98% of the theoretical value and a homogeneous microstructure without detectable compositional segregation or grain-boundary enrichment, confirming the formation of a structurally and chemically stable single-phase bulk material. Thermal analysis identified a reversible polymorphic phase transition from P2₁2₁2₁ to Pnma at low temperature, followed by structural relaxation and the onset of partial decomposition at higher temperatures, indicating that Cu₃BiS₃ retains structural integrity below 700 K, which defines the relevant operating window for thermoelectric evaluation. The samples exhibited p-type semiconducting behavior, with electrical conductivity increasing with temperature due to thermally activated hole transport and showing an additional enhancement across the structural transition region. The Seebeck coefficient remained positive over the entire temperature range and decreased gradually with increasing temperature, consistent with semiconductor transport characteristics. The thermal conductivity remained low at 0.30–0.38 W·m⁻¹·K⁻¹, with a negligible electronic contribution, confirming that heat transport is dominated by lattice phonon scattering. As a result of the combined increase in electrical conductivity and intrinsically low thermal conductivity, the dimensionless figure of merit (ZT) increased continuously with temperature and reached 0.17 at 673 K. These results demonstrate that the MA–HP route provides an effective and scalable strategy for producing phase-pure Cu₃BiS₃ with controlled microstructure and reproducible thermoelectric performance. Full article

The modernization of global energy infrastructure within the Industry 5.0 framework requires the use of high-strength steels and reliable joining technologies to ensure safe, sustainable pipeline transport. This study focuses on the analysis of heterogeneous welded joints formed between high-strength alloy steel (34KhN2MA/EN 34CrNiMo6) and an austenitic welded seam (ER 307). While austenitic welds mitigate the risk of cold cracking, they introduce significant structural and mechanical heterogeneity. To address this, the research proposes and validates a material homogeneity criterion (MHC) derived from the LM-hardness methodology. By analyzing the statistical dispersion of macrohardness (HRC) through indicators such as the Weibull homogeneity coefficient (m) and the coefficient of variation (ν), the study establishes a quantitative approach to assess material degradation and structural uniformity across key weld zones. Results demonstrate that macrohardness profiling effectively distinguishes between structurally heterogeneous regions near the weld axis characterized by low homogeneity coefficients (m = 4.04 < 10, A_m = 0.742 < 0.878), elevated variability (ν = 29.68% > 11.6%), and high technological damageability (D = 0.92 > 0.81, j_D = 11.87 > 4.38) with pronounced step-like variation in macrohardness (HRC ∈ [12.6; 47]), on the one hand, and stabilized homogeneous zones in the base material, where m = 24.89 > 10, A_m = 0.947 > 0.878, ν = 4.39% < 11.6%, D = 0.52 ⟶ 0, j_D = 1.09 ⟶ 0, and characteristic range of HRC = 47–55, on the other hand. This methodology provides a robust, quasi-non-destructive tool for enhancing predictive maintenance, digital twins, and the overall integrity management of “smart” pipeline systems. Full article

Single-phase Cu₄Bi₄Se₉ was successfully synthesized through a simple and rapid process combining mechanical alloying (MA) and hot pressing (HP). The phase formation behavior, microstructural evolution, charge transport characteristics, and thermoelectric properties were systematically investigated. X-ray diffraction analysis as a function of MA time confirmed that all powders crystallized into a single orthorhombic phase with space group Pnma. No decompositions or secondary phases were observed after HP sintering, indicating high phase stability. Thermogravimetric and differential scanning calorimetric analyses revealed distinct endothermic peaks at 714–717 K for all samples, corresponding to the onset of the decomposition of Cu₄Bi₄Se₉. Microstructural observations showed that the relative density decreased with increasing HP temperature (>573 K), accompanied by grain growth and pore formation, reflecting the competition between Cu–Se interdiffusion and pore coarsening during high-temperature sintering. Hall effect measurements indicated p-type conduction for all samples, with carrier concentrations on the order of 10¹⁷ cm⁻³ and carrier mobilities of approximately 10² cm² V⁻¹ s⁻¹. With increasing temperature, the electrical conductivity increased monotonically, while the Seebeck coefficient gradually decreased, resulting in a maximum power factor of 0.12 mW m⁻¹ K⁻² at 573 K. The total thermal conductivity remained extremely low, ranging from 0.33 to 0.48 W m⁻¹ K⁻¹, with the electronic contribution accounting for less than 10%, indicating that lattice thermal transport is dominant. The suppressed lattice thermal conductivity is attributed to the combined effects of Cu atomic rattling, asymmetric bonding induced by Bi 6s² lone-pair electrons, and strong anharmonic phonon scattering arising from the complex crystal structure. Consequently, Cu₄Bi₄Se₉ achieved a peak dimensionless figure of merit ZT of 0.19 in the temperature range of 573–623 K, demonstrating that the MA–HP process enables stable phase formation and competitive thermoelectric performance without post-annealing. Full article

The alloy with a chemical composition of 64 at. % Fe and 36 at. % Ni is known as Invar36 and is characterized by a coefficient of thermal expansion (CTE) less than 2 × 10⁻⁶ °C⁻¹ below Curie temperature (about 250 °C). The conventional method of obtaining Invar36 alloys consists of melting and casting, followed by a series of heat treatments. In recent years, research has focused on unconventional technologies for Invar36 preparation such as the sintering of Fe and Ni elemental powders. Also, Invar36 in powder form can be synthesized by mechanical alloying (MA). The aim of this paper is the characterization of Invar36 compacts obtained by conventional sintering of mechanically alloyed Fe and Ni elemental powders. MA was performed in a high-energy planetary ball mill (Ar atmosphere). Mechanically alloyed powders were densified by conventional sintering (simple and double). The sintering parameters used are those specific to the sintering of ferrous parts. After simple sintering, the relative density was 74%. Re-pressing and double sintering lead to an increase in the relative density to 78.6%. The microstructure of Invar36 compacts consists of two phases. The coefficient of thermal expansion (CTE) was determined for Invar36 compacts obtained by both simple and double sintering at 1120 °C in endogas. The CTE values of Invar36 simple sintered (α = 0.6 × 10⁻⁶ °C⁻¹) and double sintered (α = 0.5 × 10⁻⁶ °C⁻¹) are very low, up to 195 and 225 °C, respectively. HV_0.05 values of the Invar-ss sample are lower than the values of the Invar-ds sample. Thus, the HV_0.05 value in areas where the γ phase predominates increases from 203 to 218, while in areas where the α phase is predominant it increases from 257 to 271. The results of this study have potential applicability in obtaining Invar parts by sintering under the specific conditions used for ferrous parts, without requiring any modification of the production flow. Full article

Models are described for calculating the crack initiation times for Alloy 600 and Type 304 SS in PWR and BWR primary coolant circuits, respectively. In PWRs, initiation is defined in terms of the grain boundary oxidation concept of Scott and Le Calvar, whereas in BWRs, cracks are envisioned to nucleate from corrosion pits. In contrast, in BWRs, we envision cracks to nucleate from corrosion pits, with the difference in the two systems being primarily due to electrochemical factors. Thus, in BWR primary coolant and the absence of hydrogen water chemistry (HWC), the oxidizing conditions due to the radiolytic production of H₂O₂ cause the ECP to be significantly more positive than the critical pitting potential. Accordingly, the nucleation and growth of pits due to passivity breakdown and the establishment of differential aeration between the pit nucleus’s internal and external environments, which results in growth of pits to the critical size necessary to satisfy the Kondo criteria for transition of a pit into a crack, is judged to be a realistic scenario. Contrariwise, in PWR primary coolant, the ECP is so negative [≈−1.0 V_she] due to the large amount of pressurizing H₂ present in the circuit [20–60 cm³(STP)/kg H₂O] that the nucleation and growth of pits is not possible. However, Totsuka and Smialowska found that MA Alloy 600 suffers hydrogen-induced cracking (HIC) at an ECP < −0.85 V_she, demonstrating that, in service with a high hydrogen concentration, brittle fractures will occur. The initiation sites were not identified. The crack initiation models for Alloy 600 in PWRs and Type 304 SS in BWRs reproduce the effects of the following independent variables: applied stress, temperature, cold work, grain boundary segregations, water chemistry, pH, and electrochemical potential. The origins of the observed scatter in experimentally measured crack initiation times are discussed, and the challenges of developing a more general crack initiation model (GCIM) are identified. From a mathematical viewpoint, the most significant challenge arises from the nested distributions involving the many parameters and expressions within the GCIM that are either distributed because of an imprecise definition or because some experimentally determined input parameters are experimentally scattered. Additionally, the evolution of semi-elliptical surface cracks resulting from the electrochemical crack length (ECL) being shorter than the classical mechanical crack length (MCL) must be incorporated if the GCIM is to find utility in the water-cooled nuclear power industry where semi-elliptical surface cracks are normally observed. Full article

The continuous demand for advanced composite materials with superior mechanical and electrical properties has driven the exploration of copper matrix composites for high-performance applications. The Cu–2Zr–0.6B (wt.%) powder mixtures were mechanically alloyed (MA) using two different ball-to-powder weight ratios (BPR: 10:1 and 15:1) to investigate the influence of milling conditions on the final composite material’s properties. MA powders milled with BPR 15:1 exhibited the highest values of dislocation densities, which induce higher hardness of Cu–ZrB₂ bulk materials. The MA powders were consolidated using three different methods: conventional cold pressing followed by sintering (CPS), hot pressing (HP), and spark plasma sintering (SPS). The in situ forming of ZrB₂ (3.5 vol.%) reinforcements during consolidation processes in Cu matrix proved to have a major impact on enhancing the hardness and structural stability, while the use of SPS and HP offered superior control over grain growth and porosity reduction compared to CPS. Main findings related to electrical and mechanical properties showed similar values for SPS (~38% IACS, ~173 HV1) and HP compacts (~39% IACS, ~155 HV1) but proved to be much higher compared to values of CPS compacts (~21% IACS, ~80 HV1). Full article

This work aims to develop a controlled ball milling strategy for preparing FeCoCrNiCu high-entropy alloy (HEA) powders with improved compositional homogeneity while maintaining limited oxygen uptake. Specifically, a novel two-step combined ball milling strategy integrating gradient ball-size configurations with a sequential milling procedure is proposed and systematically evaluated. Compared with conventional single-step milling, the mixed-ball and two-step configurations enhance mechanical alloying (MA) efficiency and promote the formation of more stable FCC and BCC dual-phase structures, as confirmed by X-ray diffraction (XRD) analysis. Compositional standard deviation derived from energy-dispersive X-ray spectroscopy (EDS) measurements indicates improved macroscopic uniformity, while oxygen/nitrogen/hydrogen (ONH) analysis verifies that oxygen incorporation remains limited within the tested processing window. Systematic comparison of jar filling degrees and sampling interruptions further reveals the coupled influence of collision energy distribution and exposure frequency on oxidation behavior. The results demonstrate that controlled energy distribution and minimized atmospheric disturbance are critical for balancing alloying efficiency and oxygen control in FeCoCrNiCu powders. Full article

A microalloyed (MA) steel, combined with titanium diboride (TiB₂), was utilised to create a unique steel matrix composite (SMC), enhancing the modulus of the MA steel while also improving its strength. Through thermomechanical processing stages, including hot rolling and plane-strain compression (PSC) testing, followed by various final cooling methods, a cooling rate of 0.1 °C/s was identified as the most effective for achieving a ferrite–pearlite microstructure, which is suitable for toughness and ductility. With TiB₂ reinforcement successfully incorporated via Fe-Ti and Fe-B additions during vacuum induction melting (VIM), it was observed that the TiB₂ particles were homogeneously dispersed in both 5% and 7.5% nominal volume fraction additions, exhibiting faceted and hexagonal morphology. TiB₂ was found to exert a grain-pinning effect on recrystallised austenite at 1050 °C, as evidenced by the retention of grain orientation from hot rolling, in contrast to the MA steel deformed without the composite reinforcement. Increasing the volume fraction of TiB₂ improved the stiffness and strength of both composite alloys, verified through mechanical testing. Full article

Novel pure Zn and Zn-3Ag-xFe (x = 0, 1, 3, 5) (wt.%) nanocrystalline powders were synthesized for potential use as implants and stent materials by the mechanical alloying (MA) technique. The morphological and structural alterations of the powders milled for 5, 10, and 20 h were examined. SEM research revealed that during MA, the original elemental powder particles were subjected to a cold-welding process, subsequently fracturing in a brittle manner. The EDX spectra of the powders milled for 20 h indicated a uniform distribution of components. Laser diffraction particle size examination proved that the Zn-3Ag-1Fe alloy had the smallest particle size at 58.8 µm. XRD examination indicates the existence of AgZn₃ and Fe₃Zn₁₀ intermetallic phases. The crystallite size diminishes with prolonged milling time, decreasing from 130 nm to 30 nm. The porosity rose from 11.62% for pure Zn to 15.35% in the Zn-3Ag-5Fe alloy, suggesting that the incorporation of Ag and the higher Fe ratio diminished the compressibility of the milled powders, as evidenced by density tests. The Zn-3Ag-5Fe alloy exhibited the maximum corrosion current density of 164.65 µA/cm², attributed to the microgalvanic effect and reduced relative density induced by the Fe₃Zn₁₀ phase, which escalated with higher Fe doping. The hardness of the Zn-3Ag-5Fe alloy rose from 34.5 ± 2.8 HV to 132.2 ± 4.6 HV compared to the pure Zn sample, while the wear coefficient decreased from 0.029 ± 0.003 mm³/Nm to 0.005 ± 0.001 mm³/Nm, corresponding with the hardness test results. In contrast to S. aureus, which exhibited an 87.8% susceptibility to antibacterial activity from 3% silver and iron additions, E. coli demonstrated over 85% susceptibility to antibacterial activity from silver addition alone. The Zn-3Ag and Zn-3Ag-1Fe samples demonstrated high biocompatibility, attaining cell survival rates of 99.2% ± 3.01% and 99.2% ± 4.02% for the 12.5% extract, respectively. This study demonstrates that the newly developed Zn-Ag-xFe alloys have exceptional mechanical properties and excellent biocompatibility. Furthermore, the variable biodegradation rate dependent on alloy type presents an avenue for further research. Full article

Two Ni-AlSi12 coatings were prepared using mechanical alloying (MA) and mechanical alloying followed by laser cladding (LC), respectively. Phase composition and microstructure variations caused by powder weight ratio and laser-specific energy were thoroughly analyzed in this study. Mechanical properties and oxidation behavior are markedly improved by subsequent laser cladding. The MA-LC coating, characterized by high densification and crack-free properties, presents a homogeneous microstructure with refined features. Microhardness testing reveals a marked superiority of the MA-LC coating over the conventional MA coating. The nano-hardness of MA-LC coating is 9.79 GPa, exhibiting that it is 6.84 times the nano-hardness of the MA sample. Owing to metallurgical bonding, the MA-LC coating possesses excellent scratch bonding performance. The MA-LC coating shows favorable oxidation behavior, due to the following three reasons: Firstly, oxygen diffusion can be effectively blocked by the compact Al₂O₃ oxide layer developed on the MA-LC coating surface, which reduces the oxidation velocity. Secondly, the coating’s mean grain dimensions demonstrate an increasing tendency after oxidation, which reduces the grain boundary serving as the oxygen diffusion channel. This enhancement significantly improves the coating’s oxidation resistance. Thirdly, analysis of the coating’s respective kernel average misorientation (KAM) map revealed a significant release of internal stress following 100 h oxidation, which can improve the coating’s resistance to spallation. Full article

End-stage temporomandibular joint (TMJ) disorders often necessitate total joint replacement, and the selection of biomaterial directly impacts long-term outcomes. Ti6Al4V and CoCrMo are commonly used alloys, yet their biomechanical performance in patient-specific prostheses remains insufficiently compared. This study aimed to evaluate the mechanical response of custom TMJ prostheses fabricated from these alloys using finite element analysis (FEA). A three-dimensional mandibular model was created from computed tomography data, and a patient-specific prosthesis was designed in SolidWorks (Dassault Systèmes, SolidWorks Corp., Waltham, MA, USA) and analyzed in ANSYS Workbench 2022 R1 (Ansys Inc., Canonsburg, PA, USA). Physiological loading was simulated by applying forces at the insertion sites of the temporalis, masseter, and medial pterygoid muscles. In the Ti6Al4V model, maximum von Mises stresses reached 192.18 MPa on the mandibular component and 92.004 MPa on the fossa prosthesis, whereas the CoCrMo model demonstrated higher stresses of 204.31 MPa and 94.182 MPa, respectively. Both alloys exhibited similar stress distributions, but Ti6Al4V generated lower stress magnitudes, indicating more favorable load transfer and a reduced risk of mechanical overload on articulating components. These findings underscore the significance of alloy selection in optimizing TMJ prostheses and demonstrate the value of FEA as a tool for guiding future patient-specific designs. Full article

The induction quenching–tempering process typically enhances the surface strength and core toughness of alloy steels by utilizing the skin effect. However, the impact of parameters like quenching current and heating time on the microstructure and mechanical property of 34CrNiMo6 steel crankshafts remains unclear. In this work, the microstructure of 34CrNiMo6 steel after induction quenching exhibits three distinct zones: a martensite hardened layer; a transition zone of martensite and tempered sorbite; and a matrix of tempered sorbite. As the induction current (400, 500, and 600 mA) and heating time (3, 5, and 7 s) increase, the hardened layer thickness enhances (up to 3.21 mm). Under the 600 mA and 7 s, the hardened layer reaches peak hardness and residual stress values of 521.48 HV and −330.12 MPa, showing a decreasing trend from surface to core. After tempering at 330 °C for 2 h, the hardened layer mainly consists of tempered martensite, and the surface hardness and residual stress decrease to 417.94 HV and −12.33 MPa. The temperature gradient from quenching balances after tempering, with martensitic phase transformation and stress redistribution reducing hardness and residual stress. Furthermore, the induction quenching–tempering process enhances the toughness of 34CrNiMo6 steel when compared to the untreated specimen, boosting its tensile yield strength, elongation, and tensile strength by 15.3%, 14.9%, and 19.5%, respectively. This work deepens the understanding of induction quenching–tempering process and provides valuable insights for designing alloy steels with excellent mechanical properties. Full article

Mechanical alloying (MA) has been proven to be an energy-efficient synthetic route for the development of high-performance thermoelectric (TE) materials. Higher Manganese Silicide (HMS) phases of the general formula Mn(Si_1−xAl_x)_1.75 (0 ≤ x ≤ 0.05) were prepared by MA implementing a short-time ball-milling process. Powder XRD and SEM analysis were carried out to validate the HMS phases, while small amounts of the secondary phase, MnSi, were also identified, especially for the Al-doped products. Electrical transport properties measurements showed that Al substitution causes an effective hole doping. A remarkable increase in electrical conductivity is observed for the Al-doped phases, while the corresponding reduction in the Seebeck coefficient is indicative of the increase in carrier density. Despite the small percentages of MnSi detected in Al-doped phases, an improvement in TE efficiency is achieved in the series Mn(Si_1−xAl_x)_1.75 (0 ≤ x ≤ 0.05). The 2.5% Al-doped phase exhibits a maximum figure-of-merit (ZT) of 0.43 at 773 K. Moreover, in an effort to utilize recycled silicon byproducts from photovoltaic (PV) manufacturing, Al-doped phases are developed by MA using two types of Si kerf. The two kerf-based products exhibit lower TE efficiencies, due to the increased amounts of the metallic MnSi phase. Full article

Electromigration (EM) is a critical reliability concern in electronic solder joints due to increasing current densities in modern electronic packaging. EM-induced failures often manifest as void formation and microstructural degradation, particularly at the cathode interface. To address this issue, composite solder joints with elemental additions have been explored to enhance performance under high current stress. This study investigates the effect of Zn addition on the electromigration behavior and mechanical performance of eutectic Sn-Bi solder joints on copper (Cu) and nickel-coated copper (Ni/Cu) substrates. The solder alloys 58Sn-42Bi and Zn-modified Sn-Bi were prepared and reflowed onto the substrates. Electromigration testing was performed under a constant current of 1000 mA at room temperature, with applied voltages of 5 V, 12 V, and 24 V over a 10-day period per sample. Shear tests were conducted at a crosshead speed of 0.1 mm/min to evaluate joint strength. The results revealed that Zn addition influenced the distribution of Bi within the solder matrix, reducing Bi depletion at the cathode and mitigating accumulation at the anode, suggesting improved EM resistance. Zn-containing solder joints also demonstrated enhanced shear strength compared to unmodified Sn-Bi joints. These findings highlight the potential of Zn as a beneficial alloying element for improving the reliability of lead-free solder joints and form a foundation for future studies incorporating phase analysis and predictive EM lifetime modelling. Full article

Pore defects are one of the most common defects in the aluminum alloy electron beam welding process. In this paper, research on the pore defects and related mechanisms of the electron beam welding of dissimilar aluminum alloys was carried out with 1060 and 2A12 aluminum alloys. Under the test conditions, the pore defects of the aluminum alloy joint were related to the penetration status, the porosity of the critically penetrated joint was low, and the porosity of the beam joint increased when it was slightly penetrated. When the welding speed changed from 300 mm/min to 1200 mm/min, the porosity in the critically penetrated joint first increased and then decreased. When the welding speed was set to 300 mm/min and the beam current was set to 26 mA, the porosity of the joints reached its minimum value at 0.23%. Based on the actual process of electron beam welding, a flow simulation model was established to study the aluminum alloy welding process. The stability of the keyhole was related to the electron beam energy density reaching the inner keyhole, so increasing the electron beam for the fully penetrated joints was advantageous for reducing the pore defects. Full article