Search Results (4,504)

Physics-based constitutive modelling remains a cornerstone for predicting ductile damage and fracture in metallic materials, particularly where microstructural mechanisms govern macroscopic response. Over the past two decades, a wide range of crystal plasticity, porous plasticity, and void-based fracture models have been proposed to capture deformation localisation, void growth, and coalescence under complex loading paths. However, these developments are often presented in isolation, obscuring their shared physical assumptions and limiting their transferability across material systems and length scales. This article provides a microstructure-sensitive perspective on the constitutive modelling of ductile damage and fracture, with particular emphasis on crystal plasticity-based frameworks, void growth and coalescence mechanisms, and interface-driven fracture. Rather than attempting an exhaustive review, this review highlights the unifying concepts, modelling trade-offs, and recurring challenges related to parameter identifiability, scale bridging, and predictive robustness. It further clarifies how physics-based constitutive descriptions can be systematically integrated into modern fatigue and fracture assessments and situates these developments relative to emerging data-assisted and machine-learning-enhanced modelling strategies. By reframing established constitutive models within a coherent physical narrative, this perspective aims to support more transparent model selection, improve interpretability, and guide future developments in the multiscale damage and fracture modelling of metallic materials. While these frameworks offer enhanced microstructure sensitivity, their parameter richness and experimental calibration demand currently limit widespread industrial deployment, motivating ongoing work on reduced-order and data-assisted variants. Full article

Silica-supported zinc (II)–Schiff-base complexes were prepared through a simple and high-yield immobilization strategy and evaluated as heterogeneous catalysts for the ring-opening polymerization (ROP) of lactide. Silica gel and silica nanoparticles were employed as supports to assess the influence of support morphology and textural properties on catalytic performance. Comprehensive characterization by AAS, BET, SEM, and SEM–EDS confirmed effective anchoring of the Zn complexes, homogeneous metal distribution, and support-dependent textural modifications. The supported catalysts were active in the bulk ROP of racemic and enantiopure lactide, affording PLA with high conversions and moderate dispersities. Silica-gel-supported systems exhibited high and reproducible activity over a wide range of conditions, whereas catalysts supported on silica nanoparticles showed a stronger dependence on reaction time and ligand electronic effects, highlighting the key role of the support in modulating active site accessibility and chain growth. Microstructural and thermal analyses confirmed the formation of atactic PLA from rac-lactide and stereoregular PLLA from L-lactide. Overall, this study demonstrates that silica-supported zinc(II)–Schiff-base complexes constitute an effective and versatile heterogeneous platform for lactide ROP and underscore the importance of support properties in the rational design of sustainable catalysts for biodegradable polyester synthesis. Full article

Metal packaging materials remain fundamental across food, beverage, pharmaceutical, cosmetic, and technical sectors owing to their combination of mechanical robustness, total light and gas barrier performance, thermal resistance, and established recyclability. Aluminum alloys, tinplate, tin-free steel (TFS/ECCS), stainless steels, metal–matrix composites (MMCs), and metal–polymer or metal–paper laminates define distinct metal-based packaging architectures whose metallurgical and interfacial design governs forming behaviour, corrosion and migration pathways, coating integrity, and mechanical reliability. In this review, these architectures are examined from a materials- and systems-oriented perspective, linking composition, microstructure, processing routes, and surface engineering to functional performance across rigid, semi-rigid, and flexible formats. The analysis also considers the ongoing transition from bisphenol A (BPA)-based epoxy linings to BPA-free and hybrid coating chemistries, the use of nano-structured metallic and metal-oxide surfaces, and the role of composite laminates in which thin metallic foils are combined with polymeric or paper-based structural layers. These material and architectural aspects are discussed together with safety, regulatory, and circularity considerations that increasingly influence the design and selection of metal-based packaging. Ion migration, coating degradation, and corrosion under realistic storage environments are considered in relation to EU, FDA, ISO, and sector-specific requirements, while attention is also paid to the contrast between well-established closed-loop recycling infrastructures for aluminum and steel and the more complex end-of-life management of coated metals and multilayer laminates. The review provides a unified framework connecting materials selection, metallurgical design, processing, performance, regulatory compliance, and sustainability in metal-based packaging systems. Applications spanning consumer goods, pharmaceuticals, cosmetics, and advanced electronics are integrated to support an overall understanding of how metallic and hybrid metal-based architectures underpin functional reliability and life-cycle sustainability. Full article

Zn-Fe-Cr coatings were successfully deposited on sintered Nd-Fe-B matrix through the addition of the complexing agent etidronic acid (HEDP) to the plating solution; the electrodeposited process of the metal elements and the corrosion behavior of the coatings were also investigated. Through cyclic voltammetry (CV) tests, it was observed that the reduction potential difference between the metal elements was reduced by the addition of HEDP, which contributed to a more feasible electrodeposited process. The surface of Zn-Fe-Cr coating was covered by a chromate conversion film, and its microstructure was identified as the solid solution of Fe and Cr in Zn matrix. Compared with Zn and Zn-Fe coatings, the corrosion current density (J_corr) of Zn-Fe-Cr coating was decreased to 0.28 × 10⁻⁶ A·cm⁻², and the corrosion potential (E_corr) was increased to −1.01 V. Compared with the Zn and Zn-Fe coatings, the corrosion rate of the Zn-Fe-Cr coating has decreased by 90% and 98%, respectively. The corrosion resistance of coatings was further analyzed by neutral salt spray tests (NSS), and the analysis results showed that a composite oxide layer, composed of ZnO and Cr₂O₃, was formed in the corroded area of Zn-Fe-Cr coating during the corrosion process, which is capable of effectively inhibiting the expansion of the corrosion area. This research provides a promising strategy for ensuring the long-term service integrity of sintered Nd-Fe-B materials in marine environments. Full article

The newly identified greisen-hosted Nb-Ta mineralization in the Qidashan iron deposit, Liaoning Province, China, offers a unique opportunity to explore how hydrothermal processes contribute to the enrichment of critical metals. In this study, an integrated analytical approach of petrographic observation and scanning electron microscopy–energy-dispersive spectrometer (SEM-EDS), electron probe microanalyzer (EPMA), and laser ablation inductively coupled plasma mass spectrometer (LA-ICP-MS) U-Pb dating of columbite-group minerals (CGMs) were employed to systematically decipher the paragenetic sequence, micro-structure, elemental composition and mineralization age of CGMs, aiming at the genesis of greisen-hosted Nb-Ta mineralization. The mineralization is characterized by the abundant occurrence of CGMs. Three generations of CGMs and two mineralization stages are distinguished: stage I contains CGM Is and CGM IIs, with Nb₂O₅ ranging from 25.7 to 69.56 wt.% and Ta₂O₅ from 5.8 to 52.5 wt.%; stage II contains CGM IIIs, with Nb₂O₅ between 59.5 and 71.5 wt.% and Ta₂O₅ between 3.5 and 16.2 wt.%. CGM Is consist of euhedral, homogeneous crystals of more than 100 μm, exhibit low Ta/(Nb + Ta) ratios (0.05–0.06) and high Mn/(Fe + Mn) ratios (0.19–0.26), and belong to columbite-Fe. CGM IIs generally overgrow on CGM Is with hydrothermal overprinting textures, and show significant compositional gaps compared to CGM Is, exhibiting higher Ta/(Nb + Ta) ratios (0.13–0.55) and restricted Mn/(Fe + Mn) ratios (0.15–0.18), with some belonging to columbite-Fe and others to tantalite-Fe, which reveals a transition from magma to “hydrosilicate fluid”. CGM IIIs are mainly anhedral and homogeneous, with a grain size of less than 50 μm. However, some CGM IIIs overgrow on CGM IIs and/or CGM Is with patchy textures indicative of subsequent hydrothermal overprinting of hydrosilicate fluid, forming a coarse-grain size over 100 μm. CGM IIIs are characterized by lower Ta/(Nb + Ta) ratios (0.03–0.14) and variable Mn/(Fe + Mn) ratios (0.08–0.26), and they belong to columbite-Fe. LA-ICP-MS U-Pb dating yields weighted mean ²⁰⁶Pb/²³⁸U ages of 2646 ± 15 Ma for stage I and 2500 ± 28 Ma for stage II, indicating two-stage Nb-Ta mineralization. The early mineralization may correlate with the partial melting of volcanic–sedimentary rocks due to the geothermal anomalies associated with ~2.7 Ga submarine volcanism, and the late mineralization formed by the magmatic hydrothermal activities related to emplacement of the Qidashan granite in 2.5 Ga. We therefore propose that the two-stage greisen-hosted Nb-Ta mineralization probably widely occurred in these sedimentary–metamorphic iron deposits in the Anshan–Benxi area and even in the northern edge of the North China Craton, and it may provide new insights for evaluating the Nb-Ta resource potential in similar Algoma-type iron deposits globally. Full article

The low-temperature toughness of a coarse-grained heat-affected zone (CGHAZ) is a critical factor governing the service safety of welded joints in X70 pipeline steel. This study systematically investigated the influence of nitrogen content (ranging from 0.0018 to 0.0120 wt%) on the microstructure and low-temperature impact toughness of the CGHAZ in X70 pipeline steel using welding thermal simulation tests with a heat input of 12.5 kJ/cm. The results indicate that the CGHAZ microstructure predominantly comprises lath bainite (LB) and minor martensite–austenite (M/A) constituents. With increasing nitrogen content, the austenite-to-ferrite transformation start temperature (Ar₃) increased while the transformation finish temperature (Ar₁) decreased, resulting in coarsening of the lath bainite packet structure. The M/A volume fraction rose from 2.11% to 5.23%, the average particle size grew from 0.17 to 0.71 μm, and the high-angle grain boundary (HAGB > 15°) fraction declined from 67.5% to 52.2%. These microstructural alterations collectively caused the Charpy impact energy of the CGHAZ to decrease from 269 J to 48 J. The deterioration in toughness is primarily attributed to blocky M-A constituents lowering the resistance to crack nucleation and the reduced HAGB fraction diminishing the resistance to crack propagation. This work provides a theoretical foundation for optimizing the performance of X70 pipeline steel welded joints, and it is recommended that the nitrogen content in the base metal be strictly maintained below 0.005 wt% to ensure superior CGHAZ toughness. Full article

The global population explosion and accelerated industrialization have led to an increasing shortage of fossil fuels and environmental contamination, underscoring the urgent need to develop innovative energy storage technologies to improve energy utilization efficiency. As pivotal components in thermal energy storage (TES) systems, phase change materials (PCMs) enable spatiotemporal matching between thermal energy supply and demand through latent heat absorption and release during phase transitions. Organic PCMs are considered ideal candidates for thermal energy storage due to their high energy storage density, stable phase transition temperature, low supercooling, and negligible phase separation. However, inherent drawbacks such as low thermal conductivity, liquid leakage, limited light absorption, and lack of functionality have hindered their widespread application in advanced thermal management systems. Herein, we systematically summarize cutting-edge functionalization strategies for PCMs, progressing from conventional methods like thermal conductive particle blending and microencapsulation to the emerging design of 3D porous thermally conductive skeletons, including metal foams, boron nitride aerogels, carbon-based aerogels, and MXene aerogels. These frameworks not only enhance thermal transport via continuous conductive pathways and impart shape stability through capillary encapsulation but also, when integrated with photo-thermal, electro-thermal, and magneto-thermal conversion properties, enable broad applications in solar photo-thermal/photo-thermo-electric conversion, thermal management of electronics and batteries, building efficiency, and wearable thermal regulation. The review further addresses current challenges and future directions, highlighting scalable 3D framework fabrication, the shift to active thermal management, and innovative applications beyond conventional domains. By establishing a microstructure–property–application correlation, this work provides valuable insights for developing next-generation high-performance multifunctional phase change composites. Full article

Nanostructured metallic materials are widely applied in various fields due to their excellent comprehensive properties. Enhancing mechanical properties through microstructure design has emerged as a novel strengthening strategy. In this contribution, the microscopic mechanical behavior of coarse-grained and gradient-structured nanocrystalline NiCoAl alloys during tensile deformation was investigated via molecular dynamics simulations. Based on the investigation of compositional effects, the Ni₆₀Co₃₀Al₁₀ alloy composition was selected, exhibiting a yield strength of 4.92 GPa. The results indicate that increasing Al content reduces the material’s strength, Young’s modulus, and work hardening effect. Furthermore, by introducing a gradient structure with grain sizes gradually varying from 1.8 nm to 6.5 nm into the alloy, the yield strength reaches 1.8 GPa and the flow stress reaches 3.35 GPa, demonstrating a significant improvement compared to the uniform coarse-grained structure. Upon introducing the gradient structure into the alloy, it was observed that geometrically necessary dislocations (GNDs) nucleate in the coarse-grained region during deformation and gradually extend towards the fine-grained region. The increased grain boundary density effectively impedes dislocation motion and enhances dislocation pinning capability, thereby inducing continuous strain hardening and improving plasticity. By promoting the accumulation and interaction of grain boundary dislocations, the gradient structure achieves further strengthening and strain hardening in the alloy, providing a theoretical basis and simulation foundation for designing high-performance advanced alloys. Full article

Phase-change materials (PCMs) are capable of storing or releasing a substantial amount of thermal energy within a small volume through the latent heat of fusion during phase transitions of melting and solidification, i.e., from solid to liquid or vice versa, in a near isothermal process. However, commonly used organic PCMs, such as paraffin wax, exhibit very low thermal conductivity, contributing to an adverse increase in overall thermal resistance and, thus, a slow thermal response. This limitation often becomes a bottleneck for the system from a thermal performance standpoint. To mitigate this issue, the present work explores the fabrication of heat sinks incorporating nano-structured graphitic foams, including carbon foam (CF) and expanded graphite (EG), as well as micro-structured metal foams such as open-cell copper foam (OCCF), all impregnated with a paraffin-based PCM with a melting temperature near 37 °C. This study focuses on applying passive thermal management strategies to design efficient heat sinks capable of maintaining the temperatures of battery modules and electronic circuits within an acceptable thermal safety threshold for small satellites and spacecrafts, exemplified by the OPTIMUS and Pumpkin battery modules designed for CubeSats with a nominal cross-sectional area of almost 4″ × 4″. Temperature responses and average overall thermal resistances for fabricated heat sinks are accordingly assessed and compared in a vacuum chamber to simulate space conditions. Furthermore, the impact of operating pressure on the thermal performances of various heat sinks will be investigated by executing the same tests in both atmospheric and vacuum conditions. The findings demonstrate a superior thermal performance of composite heat sinks integrating carbon foam and copper foam into the paraffin PCM compared to the baseline PCM heat sink under both vacuum and atmospheric operating pressure conditions. Full article

Thermal energy storage (TES) systems are widely employed in concentrated solar power (CSP) applications as a means of storing and dispatching energy. Typical thermal fluids used in TES systems include molten salts, such as solar salt (a KNO₃–NaNO₃ eutectic), as well as other inorganic salts currently under consideration. While these molten nitrate, chloride, sulfate, and carbonate salts offer favourable thermal properties, they can induce significant corrosion of metallic containment materials, leading to reduced system efficiency and component lifetime. Despite extensive post-exposure studies, in situ electrochemical understanding of corrosion mechanisms in molten solar salt remains limited, particularly for emerging alloys such as FeCrAl. In this study, the in situ corrosion behaviour of structural alloys in molten solar salt was investigated using electrochemical impedance spectroscopy (EIS). Complementary post-exposure characterization was performed using destructive techniques, including scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX), to assess microstructural and chemical changes. The materials evaluated were stainless steel SS316 and comparatively underexplored Kanthal FeCrAl alloys, exposed to molten solar salt (40 wt% KNO₃–60 wt% NaNO₃) at 545 °C. The electrochemical and microstructural analyses indicate that FeCrAl exhibits superior corrosion resistance associated with the formation of a more stable and protective oxide scale, compared to SS316 under the investigated conditions. This study provides new electrochemical evidence supporting the suitability of FeCrAl alloys for TES applications, while also indicating that SS316 may develop improved corrosion resistance over extended exposure durations, highlighting the importance of long-term performance assessment. Full article

Achieving natural esthetics has become essential for successful dental restorations and supports the use of modern non-metal materials. However, complexity in esthetic features of natural teeth, determined by both inherent color factors and hierarchical and gradient microstructures, makes recording, determination, and reproduction difficult. This often leads to misunderstanding during manufacturing and dissatisfaction with the final outcome, even when using advanced digital tools. The aim of this study was to investigate a new, easy-to-handle digital tool for determining the color of restorative materials. An industrial-level handheld color identifier, the NCS Colourpin SE, together with the corresponding NCS color system, was tested on three materials: dental resin nanocomposite, self-glazed zirconia (SGZ), and Decore zirconia pellets. The repeatability and impacts of geometrical contributions such as surface roughness and thickness on different colors were measured. The Colourpin SE offered promising repeatability. Decore zirconia showed more than 90% repeatability for most of the colors, independent of thickness. The NCS scanner showed slightly better repeatability than earlier in clinical trials with an intraoral scanner. The shades A3.5 and A3 had lower repeatability, varying from 50 to 90%. It identified effects of material thickness and surface roughness, where the thicker samples were identified with higher blackness levels, and surface roughness seemed to be coupled with a lower blackness level in color identification codes. Small but consistent differences between materials were detected, suggesting that material and manufacturing methods affect the final shade. The NCS Colourpin SE shows potential to be developed into an affordable and easy-to-handle scanner for the identification of a patient’s tooth color, enabling synchronization with digital workflows and improving the match between restoration and the patient’s natural teeth. Nevertheless, further research and development in customized applications for color identification in esthetic dentistry is still required through multidisciplinary collaboration. Full article

The increasing impact of climate change and resource scarcity demands energy-efficient and resource-conserving manufacturing strategies. Metal forming offers substantial potential for lightweight construction and material efficiency. Forming-induced ductile damage, particularly void nucleation and growth, is often neglected in component design. Industrial practice still relies mainly on macroscopic mechanical properties and safety factors, while microstructural damage evolution and its influence on fatigue performance are largely disregarded. This study investigates load-path-dependent fatigue behavior and damage mechanisms using axial and combined axial–torsional fatigue tests. Particular attention is given to the phase shift d between axial and torsional loading, which strongly affects fatigue life. The results indicate that axial loading dominates damage evolution, while load path interactions significantly change fatigue performance. A phase shift of d = 90° resulted in a significant increase in the number of cycles to failure, N_f, for different total strain amplitudes with the same rotational angle amplitude of θ = 10°. These findings highlight the importance of considering load-path-sensitive stress states in fatigue assessment of formed components. Fractographic analyses, AI-assisted 3D reconstruction, and confocal laser scanning microscopy support the experimental results. Full article

To overcome the limitations of single-phase plasma-sprayed coatings, where ceramic coatings exhibit high hardness but poor toughness while metallic coatings possess good ductility but insufficient hardness, AT40/Al metal–ceramic composite coatings were prepared by atmospheric plasma spraying. In this study, Al₂O₃–40%TiO₂ (AT40) ceramic was used as the hard phase and aluminum as the ductile phase. The effects of Al content (10%, 20%, and 30%) and key spraying parameters, including arc power (36–40 kW), spraying distance (85–130 mm), and gun traverse speed (400–1200 mm s⁻¹), on the microstructure and mechanical properties of the coatings were systematically investigated. The coatings were characterized using SEM, XRD, and EDS, and grey relational analysis was employed to evaluate the influence of process parameters. The results show that the introduction of an appropriate amount of Al significantly improves coating densification. When the Al content is 10%, the coating porosity decreases to 3.2%, compared with 8.5% for the pure AT40 coating. The optimal spraying parameters were determined to be 38 kW arc power, 100 mm spraying distance, and 400 mm s⁻¹ traverse speed, under which the coating exhibits a microhardness of 519.68 HV and a 45.3% improvement in impact resistance compared with the pure AT40 coating. Phase analysis indicates that partial transformation of α-Al₂O₃ to γ-Al₂O₃ occurs during spraying, while interfacial reactions between Al and TiO₂ lead to the formation of Al₂TiO₅, enhancing the interfacial bonding strength. The improved performance of the composite coating is attributed to the combined effects of structural densification, interfacial strengthening, and the synergistic interaction between ceramic and metallic phases. Full article

High-entropy alloy (HEA) coatings are widely recognized for their excellent hardness and wear resistance. Heterogeneous cabled wire welding (HCWW) combined with gas metal arc welding (GMAW) has emerged as an efficient approach for fabricating HEA coatings; however, severe arc instability inherent to HCWW often deteriorates coating quality. In this study, the effects of axial magnetic fields (AMFs) with different orientations on the HCWW–GMAW process were systematically investigated. High-speed imaging revealed that the HCWW arc without magnetic assistance exhibits pronounced instability, characterized by asymmetric morphology and rotational behavior. The application of AMFs significantly altered arc dynamics. An upward axial magnetic field (N-AMF, 2 mT) effectively suppressed arc rotation, resulting in a stable bell-shaped arc and more uniform heat input, whereas a downward axial magnetic field (S-AMF) caused arc contraction and promoted dendrite coarsening. Consequently, the N-AMF condition led to a refined and homogeneous microstructure, yielding a high microhardness of 825 ± 15 HV. Tribological tests demonstrated that the wear rate of the N-AMF-assisted coating was reduced by 55% compared with that produced by conventional GMAW. These results highlight that magnetic-field-induced arc stabilization plays a critical role in achieving high-performance HEA surface coatings. Full article

Al₂O₃-Cu ceramic-metal composites containing 2.5 vol.% of a metallic phase were fabricated using the Pulse Plasma Sintering (PPS) method in order to evaluate the influence of sintering temperature on densification, microstructure, and mechanical performance. Consolidation was carried out at 1200 °C, 1250 °C, 1300 °C, and 1400 °C under uniaxial pressure with a short sintering time of 3 min. Regardless of the processing temperature, all composites exhibited very high relative densities exceeding 99% of the theoretical value, indicating the high efficiency of PPS in densifying Al₂O₃-Cu systems while suppressing copper leakage. X-ray diffraction confirmed the presence of only two phases, Al₂O₃ and Cu, with no secondary reaction products. Microstructural observations revealed irregular copper particles and areas of dispersed metallic phase, whose proportion decreased with increasing sintering temperature due to accelerated matrix densification and copper immobilization. Grain growth in the alumina matrix was strongly temperature-dependent, with the average equivalent grain diameter increasing from 0.49 µm at 1200 °C to 2.35 µm at 1400 °C. Hardness decreased from 19.5 ± 2.8 GPa to 12.2 ± 1.6 GPa with increasing temperature, whereas fracture toughness reached a maximum of 5.42 ± 0.65 MPa·m0.5 at 1400 °C. The highest strength under monotonic compression conditions was obtained for samples sintered at 1300 °C, indicating an optimal balance between densification and microstructural coarsening. These results demonstrate that PPS is an effective method for producing dense Al₂O₃-Cu composites with tailored microstructure and mechanical properties. Full article