Search Results (949)

To ensure the sustainability of alloy-based strategies, both compositional design and processing routes must be simplified. Metal additive manufacturing (AM), with its exceptionally rapid, non-equilibrium solidification, offers a unique platform to produce tailored microstructures in simple alloys that deliver superior mechanical properties. In this study, we employ laser powder bed fusion (LPBF) to fabricate 1080 plain carbon steel, a binary alloy comprising only iron and carbon. Deviating from conventional process optimization focusing primarily on density, we optimize LPBF parameters for mechanical performance. We systematically varied key parameters (laser power and scan speed) to produce batches of tensile specimens, which were then evaluated on a high-throughput mechanical testing platform (HTP). Using response surface methodology (RSM), we developed predictive models correlating these parameters with yield strength (YS) and elongation. The RSM models identified optimal and suboptimal parameter sets. Specimens printed under the predicted optimal conditions achieved YS of 1543.5 MPa and elongation of 7.58%, closely matching RSM predictions (1595.3 MPa and 8.32%) with deviations of −3.25% and −8.89% for YS and elongation, respectively, thus validating model accuracy. Comprehensive microstructural characterization, including metallographic analysis and fracture surface examination, revealed the microstructural origins of performance differences and the underlying strengthening mechanisms. This methodology enables rapid evaluation and optimization of LPBF parameters for 1080 carbon steel and can be generalized as an efficient framework for robust LPBF process development. Full article

Although cemented carbides have been manufactured by the powder metallurgy (P/M) technology for over a century now, systematic developmental efforts are still underway. In the present study, tool life improvements in metal grooving applications are the key objective. Four PVD-coated cemented carbides compositions, dedicated to groove steel, stainless steel, cast iron, and aluminium alloys, have been newly designed, along with their manufacturing conditions. Physical, mechanical and chemical characteristics—such as sintered density, modulus of elasticity, hardness, fracture toughness, WC grain size, and the chemical composition of the substrate material, as well as the chemical composition, microhardness, structure, and thickness of the coatings—have been studied. A series of grooving tests have also been conducted to assess whether modifications to the thus far marketed tool materials, tool geometries, and coatings can improve cutting performance. In order to compare the laboratory and application properties of the investigated materials with currently produced by reputable companies, commercial inserts have also been tested. The experimental results obtained indicate that the newly developed grooving inserts exhibit excellent microstructural characteristics, high hardness, fracture toughness, and wear resistance and that they show slightly longer tool life compared to the commercial ones. Full article

TiAl alloy offers advantages including low density, high specific strength and stiffness, and excellent high-temperature creep resistance. It is widely used in the aerospace, automotive, and chemical sectors, as well as in other fields. However, at temperatures of 800 °C and above, it forms a porous oxide film predominantly composed of TiO₂, which fails to provide adequate protection. Applying high-temperature protective coatings is therefore essential. Oxides demonstrating protective efficacy at elevated temperatures include Al₂O₃, Cr₂O₃, and SiO₂. The Pilling–Bedworth Ratio (PBR)—defined as the ratio of the volume of the oxide formed to the volume of the metal consumed—serves as a critical criterion for assessing oxide film integrity. A PBR value greater than 1 but less than 2 indicates superior film integrity and enhanced oxidation resistance. Among common oxides, Al₂O₃ exhibits a PBR value within this optimal range (1−2), rendering aluminum-based compound coatings the most extensively utilized. Aluminum coatings can be applied via methods such as pack cementation, thermal spraying, and hot-dip aluminizing. Pack cementation, being the simplest to operate, is widely employed. In this study, a powder mixture with the composition Al:Al₂O₃:NH₄Cl:CeO₂ = 30:66:3:1 was used to aluminize γ-TiAl intermetallic compound specimens via pack cementation at 600 °C for 5 h. Subsequent isothermal oxidation at 900 °C for 20 h yielded an oxidation kinetic curve adhering to the parabolic rate law. This treatment significantly enhanced the high-temperature oxidation resistance of the γ-TiAl intermetallic compound, thereby broadening its potential application scenarios. Full article

Porous intermetallic compounds have the properties of porous materials as well as a combination of covalent and metallic bonds, and they exhibit high porosity, structural stability, and corrosion resistance. In this work, a porous TiNi₃ intermetallic compound was fabricated through reactive synthesis of elemental powders. Next, detailed studies of its phase composition and pore structure characteristics at different sintering temperatures, as well as its corrosion behavior against an alkaline environment, were carried out. The results show that the as-prepared porous TiNi₃ intermetallic compound has abundant pore structures, with an open porosity of 56.5%, which can be attributed to a combination of the bridging effects of initial powder particles and the Kirkendall effect occurring during the sintering process. In 1 M KOH solution, a higher positive corrosion potential (−0.979 V_SCE) and a lower corrosion current density (1.18 × 10⁻⁴ A∙cm⁻²) were exhibited by the porous TiNi₃ intermetallic compound, compared to the porous Ni, reducing the thermodynamic corrosion tendency and the corrosion rate. The corresponding corrosion process is controlled by the charge transfer process, and the increased charge transfer resistance value (713.9 Ω⋅cm²) of TiNi₃ makes it more difficult to charge-transfer than porous Ni (204.5 Ω⋅cm²), thus decreasing the rate of electrode reaction. The formation of a more stable passive film with the incorporation of Ti contributes to this improved corrosion resistance performance. Full article

In recent years, recovering precious and base metals such as silver and copper from end-of-life products has become a fundamental factor in the sustainable development of many countries. This not only supports environmental goals but is also a profitable economic activity. Therefore, in this study, we investigate the recovery of silver and copper from an end-of-life photovoltaic panel powder using an alternative leaching system containing sulfuric acid and ferric sulfate instead of nitric acid-based leaching systems, which are susceptible to producing hazardous gases such as NO_x. To obtain this goal, a series of experiments were designed with the Central Composite Design (CCD) approach using Response Surface Methodology (RSM) to evaluate the effect of reagent concentrations on the leaching rate. The leaching results showed that high recovery rates of silver (>85%) and copper (>96%) were achieved at room temperature using a solution containing only 0.2 M sulfuric acid and 0.15 M ferric sulfate. Analysis of variance was applied to the leaching data for silver and copper recovery, resulting in two statistical models that predict the leaching efficiency based on reagent concentrations. Results indicate that the models are statistically significant due to their high R² (0.9988 and 0.9911 for Ag and Cu, respectively) and the low p-value of 0.0043 and 0.0003 for Ag and Cu, respectively. The models were optimized to maximize the dissolution of silver and copper using Design Expert software. Full article

Although Zn (II)-(−)-Epigallocatechin gallate (EGCg) complex (Zn-EGCg) is known for its promising bioactivities, little attention has been paid to its incorporation into daily green tea consumption. In this study, we aimed to incorporate Zn (II) into green tea extract to promote the formation of Zn-EGCg complex within the tea matrix. We then investigated how the formation of Zn-complexed green tea extract (Zn-GTE) influences the gut microbiota in a Western diet (WD)-fed mouse model. Structural analyses using ultraviolet–visible spectroscopy (UV–Vis), Fourier-transform infrared spectroscopy (FT-IR), proton nuclear magnetic resonance (¹H NMR), and powder X-ray diffraction (PXRD) suggested that Zn (II) interacted with hydroxyl groups of polyphenols within the extract, consistent with Zn-EGCg formation, although the complex could not be unequivocally identified. Under intake levels equivalent to daily consumption, Zn-GTE administration restored WD-induced reductions in alpha-diversity and resulted in a distinct microbial composition compared to treatment with green tea extract (GTE) or Zn alone, as shown by beta-diversity analysis. Linear discriminant analysis Effect Size (LEfSe) analysis revealed increased abundances of bacterial taxa belonging to o_Clostridiales, o_Bacteroidales, and f_Rikenellaceae, and decreased abundances of g_Akkermansia in the Zn-GTE group compared to the GTE group. These findings highlight that Zn-GTE, prepared via Zn (II) supplementation to green tea, may exert distinct microbiota-modulating effects compared to its individual components. This study provides new insights into the role of dietary metal–polyphenol complexes, offering a food-based platform for studying metal–polyphenol interactions under physiologically relevant conditions. Full article

In the framework of hydrogen production and storage for clean energy generation, the resistance to hydrogen embrittlement of a newly developed austenitic stainless steel is presented. Gas-atomized metal powders prepared from secondary-sourced metals were employed to manufacture test specimens with Laser Powder Bed Fusion (LPBF) technology. After machining and exposure to a controlled, pressurized hydrogen atmosphere at high temperature, the effect of hydrogen charging on the mechanical performance under static and dynamic conditions was investigated. The stabilizing effect of the optimized chemical composition is reflected in the absence of degradation effects on Yield Stress (YS), Ultimate Tensile Stress (UTS), and fatigue life observed for specimens exposed to hydrogen. Moreover, despite a moderate reduction in the elongation at fracture observed by increasing the hydrogen charging time, ductility loss calculated as Relative Reduction of Area (RRA) remains substantially unaffected by the duration of exposure to hydrogen and demonstrates that the austenitic steel is capable of resisting hydrogen embrittlement (HE). Full article

Complex oxides with the general formula Gd₂(Ti_1−xZr_x)₂O₇ are promising candidates for radioactive waste immobilization due to their capacity to withstand radiation by dissipating part of the free energy driving defect creation and phase transitions. In this study, samples with varying zirconium content (xZr = 0.00, 0.15, 0.25, 0.375, 0.56, 0.75, 0.85, 1.00) were synthesized via the sol–gel method and thermally treated at 500 °C to obtain nanosized powders mimicking the defective structure of irradiated materials. Synchrotron-based techniques were employed to investigate their structural properties: High-Resolution X-ray Powder Diffraction (HR-XRPD) was used to assess long-range structure, while Pair Distribution Function (PDF) analysis and Extended X-ray Absorption Fine Structure (EXAFS) spectroscopy provided insights into the local structure. HR-XRPD data revealed that samples with low Zr content (xZr ≤ 0.25) are amorphous. Increasing Zr concentration led to the emergence of a crystalline phase identified as defective fluorite (xZr = 0.375, 0.56). Samples with the highest Zr content (xZr ≥ 0.75) were fully crystalline and exhibited only the fluorite phase. The experimental G(r) functions of the fully crystalline samples in the low r range are suitably fitted by the Weberite structure, mapping the relaxations induced by structural disorder in defective fluorite. These structural insights informed the subsequent EXAFS analysis at the Zr-K and Gd-L₃ edges, confirming the splitting of the cation–cation distances associated with different metal species. Moreover, EXAFS provided a local structural description of the amorphous phases, identifying a consistent Gd-O distance across all compositions. 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 lack of new materials with desired processability and functional characteristics remains a challenge for metal additive manufacturing (AM). Therefore, in this work, a new promising AISI 316L-based alloy with better performance compared to the commercially available one is developed via the laser powder bed fusion (L-PBF) process. Moreover, establishing process–structure–properties linkages is a critical point that should be evaluated carefully before adding newly developed alloys into the AM market. Hence, the current study investigates the influences of various process parameters on the as-built quality and microstructure of the newly developed alloy. The results revealed that increasing laser energy density led to reduced porosity and surface roughness, likely due to enhanced melting and solidification. Microstructural analysis revealed a uniform distribution of copper within the austenite phase without forming any agglomeration or secondary phases. Electron backscatter diffraction analysis indicated a strong texture along the build direction with a gradual increase in Goss texture at higher energy densities. Grain boundary regions exhibited higher local misorientation and dislocation density. These findings suggest that changing the process parameters of the L-PBF process is a promising method for developing tailored microstructures and chemical compositions of commercially available AISI 316L stainless steel. Full article

Thermally conductive polymer composites are essential for effective heat dissipation in electronic packaging, where both thermal management and mechanical reliability are critical. Although diglycidyl ether of bisphenol-A (DGEBA)-based epoxies exhibit favorable properties, their intrinsically low thermal conductivity limits broader applications. Incorporating conductive fillers, such as expanded graphite (EG) and metal powders, enhances heat transport but often compromises mechanical strength due to poor filler–matrix compatibility. In this study, we address this trade-off by employing a titanate coupling agent to surface-modify aluminum (Al) fillers, thereby improving interfacial adhesion and dispersion within the DGEBA matrix. Our results show that incorporating 10 wt% untreated Al increases thermal conductivity from 7.35 to 9.60 W/m·K; however, this gain comes at the cost of flexural strength, which drops to 18.29 MPa. In contrast, titanate-modified Al (Ti@Al) not only preserves high thermal conductivity but also restores mechanical performance, achieving a flexural strength of 35.31 MPa (at 5 wt% Ti@Al) and increasing impact strength from 0.60 to 1.01 kJ/m². These findings demonstrate that interfacial engineering via titanate coupling offers a compelling strategy to overcome the thermal–mechanical trade-off in hybrid composites, enabling the development of high-performance materials for advanced thermal interface and structural applications. Full article

This paper investigates the application of non-calcined metal tartrate as a novel alternative pore former to prepare functional ceramic composites to fabricate solid oxide fuel cells (SOFCs). Compared to carbonaceous pore formers, non-calcined pore formers offer high compatibility with various ceramic composites, providing better control over porosity and pore size distribution, which allows for enhanced gas diffusion, reactant transport and gaseous product release within the fuel cells’ functional layers. In this work, nanocrystalline gadolinium-doped ceria (GDC) and Ni-Gd-Ce-tartrate anode powders were prepared using a single-step co-precipitation synthesis method, based on the carboxylate route, utilising ammonium tartrate as a low-cost, environmentally friendly precipitant. The non-calcined Ni-Gd-Ce-tartrate was used to fabricate dense GDC electrolyte pellets (5–20 μm thick) integrated with a thin film of Ni-GDC anode with controlled porosity at 1300 °C. The dilatometry analysis showed the shrinkage anisotropy factor for the anode substrates prepared using 20 wt. The percentages of Ni-Gd-Ce-tartrate were 30 wt.% and 40 wt.%, with values of 0.98 and 1.01, respectively, showing a significant improvement in microstructural properties and pore size compared to those fabricated using a carbonaceous pore former. The results showed that the non-calcined pore formers can also lower the sintering temperature for GDC to below 1300 °C, saving energy and reducing thermal stresses on the materials. They can also help maintain optimal material properties during sintering, minimising the risk of unwanted chemical reactions or contamination. This flexibility enables the versatile designing and manufacturing of ceramic fuel cells with tailored compositions at a lower cost for large-scale applications. Full article

Pyrometallurgical recycling of lithium-ion batteries presents distinct advantages including streamlined processing, simplified pretreatment requirements, and high throughput capacity. However, its industrial implementation faces challenges associated with high energy demands and lithium loss into slag phases. This investigation develops an integrated reduction smelting–chloridizing volatilization process for the comprehensive recovery of strategic metals (Li, Mn, Cu, Co, Ni) from spent ternary lithium-ion batteries; calcium chloride was selected as the chlorinating agent for this purpose. Thermodynamic analysis was performed to understand the phase evolution during reduction smelting and to design an appropriate slag composition. Preliminary experiments compared carbon and aluminum powder as reducing agents to identify optimal operational parameters: a smelting temperature of 1450 °C, 2.5 times theoretical CaCl₂ dosage, and duration of 120 min. The process achieved effective element partitioning with lithium and manganese volatilizing as chloride species, while transition metals (Cu, Ni, Co) were concentrated into an alloy phase. Process validation in an induction furnace with N₂-O₂ top blowing demonstrated enhanced recovery efficiency through optimized oxygen supplementation (four times the theoretical oxygen requirement). The recovery rates of Li, Mn, Cu, Co, and Ni reached 94.1%, 93.5%, 97.6%, 94.4%, and 96.4%, respectively. This synergistic approach establishes an energy-efficient pathway for simultaneous multi-metal recovery, demonstrating industrial viability for large-scale lithium-ion battery recycling through minimized processing steps and maximized resource utilization. Full article

Sawdust is receiving increasing attention as a promising green adsorbent. However, due to its powder nature, it is difficult to recover after adsorbing heavy metals and may even cause secondary pollution. To solve this problem, a novel sawdust/foamed geopolymer (SFG) adsorbent was prepared by using sawdust as a raw material, geopolymer as a binder, and hydrogen peroxide as a foaming agent. This study discussed the effect of SFG dosage, solution temperature, solution pH, contact time, and initial Cu²⁺ solution concentration on the adsorption capacity and removal rate. The results showed that a desirable SFG adsorbent with the SFG dosage of 0.5 g, temperature of 25 °C, pH of 5, contact time of 720 min, and initial Cu²⁺ solution concentrations of 90 mg/L is recommended, of which the adsorption capacity is 31.5 mg/g with the removal rate being 92.76%. In addition, the adsorption performance of the SFG adsorbent is superior to that of pure sawdust and similar to that of the foamed geopolymer adsorbent, and it has the characteristics of higher strength, lower cost, and more environmental friendliness. This study indicated that the SFG adsorbents are feasible as adsorbents; meanwhile, this work can provide a scientific reference for the development of new bio-composite adsorbent materials, especially in the field of the treatment of heavy metal ions in wastewater. Full article

The miniaturization of heat exchangers requires advanced manufacturing methods, as conventional techniques such as milling or casting are insufficient for producing complex microscale geometries. This study investigates the feasibility of using selective laser melting (SLM) with 316L stainless steel powder to fabricate compact heat exchangers with minichannels. The exchanger was designed using Autodesk Inventor 2023.3 software and produced under optimized process parameters. Measurements using a hydrostatic balance demonstrated that the applied process parameters resulted in a relative material density of 99.5%. The average microhardness in the core region of the SLM-fabricated samples was 255 HV, and the chemical composition of the final material differed only slightly from that of the feedstock material (stainless steel powder). Dimensional accuracy, surface quality, and internal structure integrity were assessed using computed tomography, optical microscopy, and contact profilometry. The fabricated component demonstrated high geometric fidelity and channel permeability, with local surface deformations associated with the absence of support structures. The average surface roughness (Ra) of the minichannels was 11.11 ± 1.63 µm. The results confirm that SLM technology enables the production of functionally viable heat exchangers with complex geometries. However, limitations remain regarding dimensional accuracy, powder removal, and surface roughness. These findings highlight the potential of metal additive manufacturing for heat transfer applications while emphasizing the need for further research on performance testing under real operating conditions, especially involving two-phase flow. Full article