Search Results (5,824)

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

This article presents the results of the tribological performance of 20MnCr5 (1.7147) tool steel countersamples produced by Direct Metal Laser Sintering (DMLS), as a potential material for inserts or working layers of sheet metal forming tools. Tribological tests were performed using a roller-block tribotester. The samples were sheet metals made of materials with significantly different properties: Inconel 625, titanium-stabilised stainless steel 321, EN AW-6061 T0 aluminium alloy, and pure copper. The samples and countersamples were analysed in terms of their wear resistance, coefficient of friction (COF), changes in friction force during testing, and surface morphology after tribological contact under dry friction conditions. The tests were performed on DMLSed countersamples in the as-received state. The largest gain of countersample mass was observed for the 20MnCr5/EN AW-6061 T0 friction pair. The sample mass loss in this combination was also the largest, amounting to 19.96% of the initial mass. On the other hand, in the 20MnCr5/Inconel 625 friction pair, no significant changes in the mass of materials were recorded. For the Inconel 625 sample, a mass loss of 0.04% was observed. The basic wear mechanism of the samples was identified as abrasive wear. The highest friction forces were observed in the 20MnCr5/Cu friction pair (COF = 0.913) and 20MnCr5/EN AW-6061 T0 friction pair (COF = 1.234). The other two samples (Inconel 625, 321 steel) showed a very stable value of the friction force during the roller-block test resulting in a COF between 0.194 and 0.213. Based on the changes in friction force, COFs, and mass changes in friction pair components during wear tests, it can be concluded that potential tools in the form of inserts or working layers manufactured using 3D printing technology, the DMLS method, without additional surface treatment can be successfully used for forming sheets of 321 steel and Inconel 625. Full article

The interface between high-performance thermoelectric materials and electrodes critically governs the conversion efficiency and long-term reliability of thermoelectric generators under high-temperature operation. Here, we propose Al_xCoCrFeNi high-entropy alloys (HEA) as barrier layers to bond Cu-W electrodes with p-type skutterudite (p-SKD) thermoelectric materials. The HEA/p-SKD interface exhibited excellent chemical bonding with a stable and controllable reaction layer, forming a dense, defect-free (Fe,Ni,Co,Cr)Sb phase (thickness of ~2.5 μm) at the skutterudites side. The interfacial resistivity achieved a low value of 0.26 μΩ·cm² and remained at 7.15 μΩ·cm² after aging at 773 K for 16 days. Moreover, the interface demonstrated remarkable mechanical stability, with an initial shear strength of 88 MPa. After long-term aging for 16 days at 773 K, the shear strength retained 74 MPa (only 16% degradation), ranking among the highest reported for thermoelectric materials/metal joints. Remarkably, the joint maintained a shear strength of 29 MPa even after 100 continuous thermal cycles (623–773 K), highlighting its outstanding thermo-mechanical stability. These results validate the Al_xCoCrFeNi high-entropy alloys as an ideal interfacial material for thermoelectric generators, enabling simultaneous optimization of electrical and mechanical performance in harsh environments. Full article

To our knowledge, no magnetic B2 phase in the Al–Mn system of near-equiatomic compositions has been reported so far. Here, we investigate the structural and magnetic characteristics of Al₄₅Mn_41.8X_13.2 (X = Fe, Co or Ni) alloys. We demonstrate that adding 13.2 atomic percent magnetic 3d metal to AlMn stabilizes a ferromagnetic B2 structure, where Al and X occupy different sublattices. We employ density functional theory calculations and experimental characterizations to underscore the role of the late 3d metals for the phase stability of the quasi-ordered ternary systems. We show that these alloys possess large local magnetic moments primarily due to Mn atoms partitioned to the Al-free sublattice. The revealed magneto-chemical effect opens alternative routes for tailoring the magnetic properties of B2 intermetallic compounds for various magnetic applications. 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

The conventional manufacturing of refractory complex concentrated alloys (RCCAs) for high-temperature applications is complicated, particularly when material costs and high melting points of the materials processed are considered. Additive manufacturing (AM) could provide an effective alternative. However, the extreme temperatures involved represent significant challenges for manufacturing defect-free alloys using this approach. To address this issue, we investigated the preparation of a CrNbTiZr quaternary complex concentrated alloy from an equimolar blend of elemental powders using commercially available powder-blown L-DED technology. Initially, the alloys exhibited some defects owing to the internal stress caused by the temperature gradients. This was subsequently resolved by optimizing the deposition strategy. SEM, XRD and EDS were used to analyze the alloy in the as-deposited condition, revealing a BCC phase and a secondary Laves phase. Furthermore, Vickers hardness testing demonstrated a correlation between the hardness and the volume fraction of the Laves phase. Finally, successfully performed compression tests confirmed that the prepared material exhibits high-temperature strength and therefore is promising for high-temperature application under extreme conditions. Full article

Parametric changes in the first coordination shell (FCS) of a vitreous metallic Pd_42.5Cu₃₀Ni_7.5P₂₀ alloy are analysed, aiming to confirm the identification of the glass transition temperature (T_g) via processing of XRD patterns utilising radial and pair distribution functions (RDFs and PDFs) and their evolution with temperature. The Wendt–Abraham empirical criterion of glass transition and its modifications are confirmed in line with previous works, which utilised the kink of the temperature dependences of the minima and maxima of both the PDF and the maxima of the structure factor S(q). Massive fluctuations are, however, identified near the T_g of the derivatives of the minima and maxima of the PDF and maxima of S(q), which adds value to understanding the glass transition in the system as a true second-order-like phase transformation in the non-equilibrium system of atoms. Full article

As a new type of alloy system composed of five or more principal components, high-entropy alloys demonstrate outstanding comprehensive performance in the field of friction and wear through the synergistic effects of the high-entropy effect, lattice distortion effect, hysteresis diffusion effect and cocktail effect. This paper systematically reviews the research progress on the friction and wear properties of high-entropy alloys. The mechanisms of metal elements such as Al, Ti, Cu and Nb through solid solution strengthening, second-phase precipitation and oxide film formation were analyzed emphatically. And non-metallic elements such as C, Si, and B form and strengthen the regulation laws of their tribological properties. The influence of working conditions, such as high temperature, ocean, and hydrogen peroxide on the friction and wear behavior of high-entropy alloys by altering the wear mechanism, was discussed. The influence of test conditions such as load, sliding velocity and friction pair matching on its friction coefficient and wear rate was expounded. It is pointed out that high-entropy alloys have significant application potential in key friction components, providing reference and guidance for the further development and application of high-entropy alloys. Full article

Mg-Li-based dissoluble metal is a promising material for preparing dissoluble magnesium alloy wires. However, there are few reports on the development of Mg-Li dissoluble magnesium alloy wires so far. In this paper, the mechanical properties and dissoluble properties of as-drawn and annealed LA141-0.5Cu wires were investigated in detail. It was found that the tensile strength of the LA141-0.5Cu wires decreased from 160 MPa to 127 MPa and the elongation increased from 17% to 22% after annealing. The difference in corrosion rates (93 °C/3% KCl solution) between the as-drawn wires and annealed wires is not significant, with values of 5.1 mg·cm⁻²·h⁻¹ and 4.5 mg·cm⁻²·h⁻¹, respectively. This can be explained as follows: after annealing, the number of dislocations in the wire decreases, the strength decreases, and the plasticity increases. The reason why the wires have a significant corrosion rate is that there is a large potential difference between the Cu-containing second phase and the magnesium matrix, which forms galvanic corrosion. The decrease in dislocation density after annealing leads to a slight reduction in the corrosion rate of the wires. This work provides a qualified material for fabricating temporary blocking knots for the exploitation of unconventional oil and gas resources. Full article

Al-xSi-35Ge (x = 4, 6, 8, 10, 12, wt.%) filler metals were prepared to vacuum braze 6061 aluminum alloy. The wettability of filler metals was studied. A thermodynamics model of the Al-Si-Ge ternary alloy was established to analyze the mechanism and impact of Si in the microstructure of the brazed joint. The findings indicated that Si addition had a slight effect on the melting point of Al-xSi-35Ge filler metals. Great molten temperature region of fillers was responsible for the loss of Ge during the wetting process, making residual filler metal difficult to melt. The microstructure of the joint was characterized by a multilayer structure that was primarily composed of three zones: two transition regions (Zone I) and a filler residual region (Zone II). There was liquidation of filler metal for Al-Si-35Ge filler metals during brazing, resulting in holes and cracks in joints. Increasing the Si content in fillers could alleviate the liquidation of filler metal, owing to diminishing difference of chemical potential of Ge (μ_Ge) in fillers and 6061 substrates, hindering the diffusion of Ge from filler metal to substrates. Full article

Aluminium alloy foams have been widely used due to their excellent strength-to-weight ratio, low density, and outstanding properties such as high energy absorption and effective noise and heat insulation. In this study, aluminium machining chips have been used for foam production as a potential recycling method. The process has involved solution heat treatment followed by artificial ageing. Researchers have been analysing the microhardness of both the foam and the bulk material, as well as examining their microstructures. The maximum microhardness value of the bulk material has been found to be 158 ± 2 HV1 at an ageing temperature of 175 ± 1 °C for 2 ± 0.02 h. For the foams, the highest microhardness of 150 ± 2 HV1 has been achieved after ageing at 150 ± 1 °C for 9 ± 0.02 h. Experimental planning has been carried out using Design Expert software. The optimisation process has identified 150 ± 1 °C for 2 ± 0.02 h as the optimum condition for artificial ageing. Full article

The anode assembly, as a key component in the electrolytic aluminum process, is composed of steel claws and aluminum guide rods. The connection quality between the steel claws and guide rods directly affects the current conduction efficiency, energy consumption, and operational stability of equipment. Achieving high-quality joining between the aluminum alloy and steel has become a key process in the preparation of the anode assembly. To join the guide rods and steel claws, this work uses Cold Metal Transfer (CMT) technology to clad aluminum on the steel surface and employs machine vision to detect surface forming defects in the cladding layer. The influence of different currents on the interfacial microstructure and mechanical properties of aluminum alloy cladding on the steel surface was investigated. The results show that increasing the cladding current leads to an increase in the width of the fusion line and grain size and the formation of layered Fe₂Al₅ intermetallic compounds (IMCs) at the interface. As the current increases from 90 A to 110 A, the thickness of the Al-Fe IMC layer increases from 1.46 μm to 2.06 μm. When the current reaches 110 A, the thickness of the interfacial brittle phase is the largest, at 2 ± 0.5 μm. The interfacial region where aluminum and steel are fused has the highest hardness, and the tensile strength first increases and then decreases with the current. The highest tensile strength is 120.45 MPa at 100 A. All the fracture surfaces exhibit a brittle fracture. Full article

Primary teeth play a crucial role in a child’s development, particularly in maintaining space for permanent teeth. The premature loss of a primary tooth can lead to orthodontic issues, making the use of space maintainers essential to ensure proper growth and development of permanent teeth. To preserve space, the fabrication of a space maintainer is necessary. Since conventional space maintainers do not restore masticatory function, this study presents an innovative solution for space preservation following the extraction of the first primary molar through the design of the functional space maintainer KOS&MET (Key Orthodontic System and Materials Enhanced Therapy). The space maintainer was designed using the 3Shape Dental Designer 2023 version software tool and manufactured via additive 3D printing, utilizing a metal alloy with high resistance to masticatory forces. The crown is supported by the primary canine, while an intraoral window is created to monitor the eruption of the successor tooth. This design does not interfere with occlusion and enables bilateral chewing. Masticatory performance was assessed using two-color chewing gum, and the results showed improvement after cementing the space maintainer. This innovative approach not only preserves space for permanent teeth but also enhances masticatory function, contributing to the proper growth and development of the jaws and teeth. Full article