Search Results (94)

Friction Stir Processing (FSP) has emerged as an advanced solid-state surface engineering technique for tailoring high-performance surface architectures in metal matrix composites (MMCs). By combining localized thermo-mechanical deformation with controlled material flow, FSP enables grain refinement, homogeneous dispersion of reinforcement, and strong interfacial bonding without melting or altering bulk properties. This review critically examines the role of FSP in enhancing the mechanical, tribological, and corrosion performance of composites, with emphasis on process–structure–property relationships. Key strengthening mechanisms, including grain boundary strengthening, load transfer, particle pinning, and defect elimination, are systematically discussed, along with their implications for wear resistance, fatigue life, and durability. Special attention is given to corrosion and tribo-corrosion behavior, highlighting electrochemical mechanisms such as micro-galvanic interactions, passive film stability, and interfacial chemistry. Furthermore, the eco-efficiency, industrial viability, and sustainability advantages of FSP are evaluated in comparison with conventional surface modification techniques. The review concludes by identifying critical challenges and outlining future research directions for the scalable, multifunctional, and sustainable design of composite surfaces. Full article

Carbon nanotubes/2Al2 composites, due to their low density, high specific strength, and high elastic modulus, are representative lightweight structural materials for next-generation aerospace applications. Traditional processing methods are inefficient and have long production cycles, making them unsuitable for the demands of efficient, rapid, and intelligent manufacturing of complex structures. This article proposes the use of metal additive manufacturing technology to solve this problem. For the first time, a 22 mm high carbon nanotube/2Al2 composite was fabricated using additive friction stir deposition, and the changes in surface morphology, microstructure, mechanical properties, and corrosion resistance of the as-deposited composite were systematically studied. After additive manufacturing, the composite exhibited a continuous and defect-free, typical onion-like structure. The as-deposited microstructure consists of uniformly equiaxed grains with an average grain size of 1.23 μm to 1.62 μm and uniformly distributed Al₂Cu particles. The tensile strength and elongation of the as-deposited composite in both the transverse and processing directions are no less than 450 MPa and 15%, respectively, superior to those of the base material. After additive manufacturing, the as-deposited composite exhibited a corrosion current density of 0.19 μA cm⁻² in the transverse direction—only 4% of that of the base material. This enhanced corrosion resistance is attributed to the uniform distribution of precipitated phases achieved through additive manufacturing, which suppresses micro-galvanic corrosion, resulting in minimal, uniform corrosion. This study provides a research foundation and technical support for the additive manufacturing of aluminum-based composites. Full article

Mg-Zn alloys are a promising type of biodegradable material for orthopedic devices, combining the natural advantages of Mg with the properties provided by Zn. This study examines how temperature affects the behavior of three MgxZn alloys (x = 1.4: 6.1 and 7.8) obtained by induction levitation. Normal temperatures of 20–25 °C and 40 °C simulating fever conditions were selected. Microstructural characterization and microhardness tests were conducted to characterize the alloys. Corrosion behavior was analyzed by open circuit potential, linear polarization, and electrochemical impedance spectroscopy. The balance between matrix softening and intermetallic formation becomes more sensitive when the alloys are exposed to elevated temperatures when microstructural heterogeneities become more influential. Although higher Zn content can facilitate the formation of more stable Zn-rich films, excessive Zn content, as in the 7.8%Zn alloy, also promotes micro-galvanic corrosion through increased MgZn intermetallic phase content, meaning that temperature amplifies both the beneficial and detrimental effects of Zn. Full article

Grey cast iron brake discs are widely used in automotive applications due to their excellent thermal and mechanical properties. However, stricter environmental regulations such as Euro 7 demand improved surface durability to reduce particulate emissions and corrosion-related failures. This study evaluates multilayer coatings fabricated by Laser Metal Deposition (LMD) as a potential solution. Two multi-layer systems were investigated: 316L + (316L + WC) and 316L + (430L + TiC), which were primarily reinforced with ceramic additives to increase wear resistance, with their influence on corrosion being critically evaluated. Electrochemical tests in 5 wt.% NaCl solution (DIN 17475) revealed that the 316L + (316L + WC) coating exhibited the lowest corrosion current density and most stable passive behavior, consistent with the inherent passivation of the austenitic 316L matrix. In contrast, the 316L + (430L + TiC) system showed localized corrosion associated with micro-galvanic interactions, despite the chemical stability of TiC particles. Post-corrosion SEM and EDS confirmed chromium depletion and chloride accumulation at corroded sites, while WC particles exhibited partial dissolution. These findings highlight that ceramic reinforcements do not inherently improve corrosion resistance and may introduce localized degradation mechanisms. Nevertheless, LMD-fabricated multilayer coatings demonstrate potential for extending brake disc service life, provided that matrix–reinforcement interactions are carefully optimized. Full article

The Zn-3Mg alloy fabricated by laser powder bed fusion (LPBF) additive manufacturing is widely used in biomedical implants due to its excellent biocompatibility and favorable mechanical strength. However, its application is hindered by limited ductility and a relatively rapid degradation rate. This study investigated the influence of annealing heat treatment on the microstructure, mechanical properties, and degradation behavior of LPBF-fabricated Zn-3Mg porous implants. A systematic analysis of various annealing parameters revealed the evolution mechanisms of the microstructure, including grain coarsening and the precipitation and distribution of secondary phases Mg₂Zn₁₁ and MgZn₂. The results indicated that appropriate annealing conditions (such as 250 °C for 1 h) significantly enhanced the compressive strain by 10%, while maintaining a high compressive strength of 24.72 MPa. In contrast, excessive annealing temperatures (e.g., 365 °C) promoted the formation of continuous brittle phases along grain boundaries, leading to deterioration in mechanical performance. The degradation behavior analysis illustrated a substantial increase in the corrosion rates from 0.6973 mm/year to 1.00165 mm/year after annealing at 250 °C for 0.5 h and 365 °C for 1 h, which can be attributed to the micro-galvanic effect induced by the presence of fine or coarse secondary phases that promoted localized corrosion. This study demonstrated synergistic regulation of mechanical properties and degradation behavior in the Zn-3Mg porous structures through optimized heat treatment, thereby providing essential theoretical and experimental supports for the clinical application of biodegradable zinc-based implants. Full article

Many special structures such as pipeline, revolving gears, and tanks suffer from biofouling used in marine environment, which could induce serious results in the ship system such as blockage and stuck, consequently lead to failure of the mechanical system and power system. Generally, coatings with antifouling agents are used for protecting metal structures from biofouling, but coatings are not conveniently applicable in the high velocity flowing seawater and narrow space. Electrochlorination and electrolysis of copper and aluminum anode are usually used in these circumstances, but the electric power will lead to stray current corrosion to the component. For the sake of convenience and safety, Cu-Ti pseudo alloy antifouling anode was proposed in this work for antifouling in pipeline and other narrow spaces without external electric power. Four Cu-Ti pseudo alloy antifouling anodes with different Ti contents (mass fraction) of 0 wt.%, 5 wt.%, 10 wt.%, and 15 wt.% were investigated with computational method, and a 15 wt.% Ti content Cu-Ti pseudo alloy antifouling anode was prepared by cold spray, and the microstructure and composition of the anode were observed by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). Electrochemical tests were conducted to obtain the corrosion potential, potentiodynamic polarization curve, and micro zone electrochemical information in natural seawater, and the Cu ions releasing behavior were analyzed using inductively coupled plasma (ICP). The results indicated that in natural seawater, copper particles, and titanium particles on the surface of anode samples can form micro galvanic couples. With the increase in Ti mass fraction, the number of micro primary cells composed of copper particles and titanium particles increases, and the corrosion rate of Cu particles increased. When the Ti mass fraction is 15%, the corrosion rate is the fastest, and the copper ion release rate increases by nearly ten times, reaching 147 μg/(cm²·d). This method can effectively accelerate the releasing rate of Cu ions in Cu-Ti pseudo alloy anode and promote the antifouling effect. Full article

In this study, Al-5Cu-0.3Sc nanocomposites reinforced with 0–20 wt.% B₄C were successfully fabricated using a combined melt-spinning, mechanical alloying, and sintering route. The rapid solidification achieved during melt spinning suppressed elemental segregation and refined the microstructure, producing a nanocrystalline Al-Cu-Sc matrix that served as a uniform host for B₄C particles. X-ray diffraction confirmed the coexistence of Al, Al₂Cu, Al₃Sc, and B₄C phases, indicating a dual-strengthening mechanism consisting of precipitation strengthening from Al₂Cu/Al₃Sc and particle strengthening from B₄C. Increasing B₄C content increased hardness from 44.9 HV to 188.2 HV (≈319%) via effective load transfer, interfacial dislocation accumulation, and particle–matrix interlocking. The wear rate decreased from 3.81 × 10⁻³ mm³/m to 6.29 × 10⁻³ mm³/m (≈98.35%), corresponding to a nearly 60-fold increase in wear resistance due to the formation of a stable ceramic tribofilm and the protective effect of embedded B₄C particles. Conversely, the corrosion rate increased from 0.117 mm/year to 6.136 mm/year (≈52-fold) due to intensified microgalvanic interactions among B₄C, Al₂Cu, and the Al matrix. Generally, the incorporation of B₄C reinforcement provides a great improvement in mechanical and tribological properties at the expense of corrosion resistance, highlighting a performance trade-off relevant for lightweight structural and surface critical applications. 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

Rare earth-rich NaZn₁₃-type La-Fe-Si-based alloys are promising candidates for near-room-temperature magnetocaloric applications. However, their poor corrosion resistance limits practical applications. The microstructure, corrosion behavior and magnetic entropy change of La_0.8Ce_0.2Fe_9.2Co_0.6Si_1.2 alloys after annealing were systematically investigated. Annealing treatments were conducted at 1423 K for durations of 4–24 h. As annealing time increased, the α-Fe phase content decreased monotonically from ~7.81wt% to ~2.92wt%, accompanied by significant microstructural evolution. For the 4 h-annealed sample, extensive and large corroded spots were observed, attributed to micro-galvanic corrosion where the α-Fe phase (cathode) and 1:13 matrix phase (anode) formed active electrochemical pairs. Prolonged annealing reduced the corrosion current density by ~50%, directly correlating with the α-Fe phase reduction and improved microstructural homogeneity. Notably, corrosion exhibited a negligible effect on the magnetic entropy change of the alloys. This study confirms that optimizing annealing time to decrease α-Fe content and enhance microstructural uniformity represents an effective strategy to improve corrosion resistance without compromising magnetocaloric performance. Full article

Corrosion is a complex, surface-initiated process that demands nanoscale, real-time characterization to understand its initiation and propagation. Atomic force microscopy (AFM) and scanning Kelvin probe force microscopy (SKPFM) have emerged as powerful tools in corrosion science, enabling high-resolution imaging and electrochemical mapping under realistic conditions. This review, inspired by pioneering work at KTH by Professors Christofer Leygraf and Jinshan Pan, highlights advanced analytical strategies that extend the capabilities of AFM and SKPFM beyond traditional line-profile analysis. Techniques such as power spectral density (PSD) analysis, multimodal Gaussian histogram fitting, statistical roughness quantification, and deconvolution methods are discussed in the context of case studies on aluminum alloys, stainless steels, magnesium alloys, biomedical implants, and protective coatings. By integrating in situ imaging, electrochemical mapping, and statistical data processing, these approaches provide deeper insights into localized corrosion, micro-galvanic coupling, and surface reactivity. Future directions include coupling AFM-based methods with high-speed imaging, machine learning, and spectro-electrochemical techniques to accelerate the development of corrosion-resistant materials and enable probabilistic diagnostics of corrosion initiation susceptibility. Full article

With the electrification of generator sets, electric locomotives, new energy vehicles, and other industries, AC motors subject bearings to an electric field environment, leading to galvanic corrosion due to the use of variable frequency power supply drives. The phenomenon of bearing discharge breakdown in subway traction motors is a critical issue in understanding the relationship between shaft current strength and the extent of bearing damage. This paper analyzes the mechanism of impulse discharge that leads to galvanic corrosion damage in bearings at a microscopic level and conducts electric thermal coupling simulations of the traction motor bearing discharge breakdown process. It examines the temperature rise associated with lubricant film discharge breakdown during the dynamic operation of the bearing and investigates how breakdown channel parameters and operational conditions affect the temperature rise in the micro-region of bearing lubrication. Ultimately, the results of the electric thermal coupling simulation are validated through experimental tests. This study revealed that in an electric field environment, the load-bearing area of the outer ring experiences significantly more severe corrosion damage than the inner ring, whereas non-bearing areas remain unaffected by electrolytic corrosion. When the inner ring reaches a speed of 4500_rpm, the maximum widths of electrolytic corrosion pits for the outer and inner rings are measured at 89 um and 51 um, respectively. Additionally, the highest recorded temperatures for the breakdown channels in the outer and inner rings are 932 °C and 802 °C, respectively. Furthermore, as the inner ring speed increases, both the width of the electrolytic corrosion pits and the temperature of the breakdown channels rise. Specifically, at inner ring speeds of 2500_rpm, 3500_rpm, and 4500_rpm, the widths of the electrolytic pits in the outer ring raceway load zone were measured at 34 um, 56 um, and 89 um, respectively. The highest temperatures of the lubrication film breakdown channels were recorded as 612 °C, 788 °C, and 932 °C, respectively. This study provides a theoretical basis and data support for the protective and maintenance practices of traction motor bearings. Full article

This study synthesized two eco-friendly inhibitors—a chitosan–copper metal–organic framework (CS@Cu MOF) and chitosan–Schiff base–Cu complex (Schiff–CS@Cu)—for Q345 steel protection in 3.5% NaCl/1M HCl. Electrochemical and weight loss analyses demonstrated exceptional corrosion inhibition: untreated specimens showed a 25.889 g/(m²·h) corrosion rate, while 100 mg/L of CS@Cu MOF and Schiff–CS@Cu reduced rates to 2.50 g/(m²·h) (90.34% efficiency) and 1.67 g/(m²·h) (93.56%), respectively. Schiff–CS@Cu’s superiority stemmed from its pyridine–Cu²⁺ chelation forming a dense coordination barrier that impeded Cl⁻/H⁺ penetration, whereas CS@Cu MOF relied on physical adsorption and micro-galvanic interactions. Surface characterization revealed that Schiff–CS@Cu suppressed pitting nucleation through chemical coordination, contrasting with CS@Cu MOF’s porous film delaying uniform corrosion. Both inhibitors achieved optimal performance at 100 mg/L concentration. This work establishes a molecular design strategy for green inhibitors, combining metal–organic coordination chemistry with biopolymer modification, offering practical solutions for marine infrastructure and acid-processing equipment protection. Full article

In the present work, chemical and ion beam surface treatments were performed in order to modify the electrochemical behavior of industrial austenitic–martensitic steel VNS-5 in 3.5 wt. % NaCl. Immersion for 140 h in a solution containing 0.05 M potassium dichromate and 10% phosphoric acid promotes formation of chromium hydroxides in the outer surface layer. By means of a new type of ion source, based on a high-current pulsed magnetron discharge with injection of electrons from vacuum arc plasma, ion implantation with Ar⁺ and Cr⁺ ions of the VNS-5 steel was performed. It has been found that the ion implantation leads to formation of an Fe- and Cr-bearing oxide layer with advanced passivation ability. Moreover, the ion beam-treated steel exhibits a lower corrosion rate (by ~7.8 times) and higher charge transfer resistance in comparison with an initial (mechanically polished) substrate. Comprehensive electrochemical and XPS analysis has shown that a Cr₂O₃-rich oxide film is able to provide an improved corrosion performance of the steel, while the chromium hydroxides may increase the specific conductivity of the surface layer. A scheme of a charge transfer between the microgalvanic elements was proposed. Full article

Titanium (Ti) and its alloys have attracted more interest, as they are widely employed as biomaterials due to their great biocompatibility, excellent strength ratio, and lightweight. However, corrosion occurs slowly due to an electrochemical reaction once the Ti material has been placed in the human body, contributing to infection and failure of implants in medical applications. Thus, the corrosion phenomenon has caused great concern in the biomedical field. It is desirable to make the surface modification to provide better corrosion resistance. The fabrication techniques of the coatings fabricated onto Ti and/or Ti alloy surfaces have been reported, including sol–gel, annealing, plasma spraying, plasma immersion ion implantation, physical vapor deposition, chemical vapor deposition, anodization, and micro-arc oxidation. This review first describes the corrosion types, including localized corrosion (both pitting and crevice corrosion), galvanic corrosion, selective leaching, stress corrosion cracking (SCC), corrosion fatigue (CF), and fretting corrosion. In the second part, the effects of corrosion on the human body were discussed, and the primary cause for clinical failure and allergies has been identified as the excessive release of poisonous and dangerous metal ions (Co, Ni, and Ti) from corroded implants into bodily fluids. The inclusion and exclusion criteria during the selection of literature are described in the third section. In the last section, we emphasized the current research progress of Ti alloy (particularly Ti6Al4V alloy) coatings in biomaterials for medical applications involving dental, orthopedic, and cardiovascular implants for anticorrosive applications. However, there are also several problems to explore and address in future studies, such as the release of excessive metal ions, etc. This review will draw attention to both researchers and clinicians, which could help to increase the coatings fabricated onto Ti and/or Ti alloy surfaces for anticorrosive applications in biomaterials for medical applications. Full article

The advancement of additive manufacturing (AM) technologies, particularly laser powder bed fusion (LPBF), has enabled the production of complex components with enhanced mechanical properties and shorter lead times compared to conventional manufacturing processes. This study focuses on the characterization of maraging steel (EOS MS1) fabricated by LPBF technology using an EOS M 290 system. Three material groups were investigated: a conventionally manufactured tool steel (95MnWCr5) serving as a reference, LPBF-produced maraging steel in the as-built condition, and LPBF-produced maraging steel subjected to post-processing heat treatment. The samples were thoroughly examined using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), glow discharge optical emission spectroscopy (GDOES), electrochemical corrosion analyses in a 3.5% NaCl solution, and Vickers microhardness measurements. Electrochemical tests revealed that heat-treated LPBF maraging steel samples exhibited slightly increased corrosion current densities relative to their as-built counterparts, attributed to the formation of Ti-rich and Ni-rich precipitates during aging, creating localized microgalvanic cells. Despite the increased corrosion susceptibility, hardness measurements clearly demonstrated enhanced hardness and mechanical properties in heat-treated samples compared to the as-built state and conventional tool steel reference. The findings underscore the importance of optimized LPBF parameters and controlled post-processing heat treatments in balancing mechanical performance and corrosion resistance. Consequently, LPBF-produced maraging steels hold considerable promise for tooling and industrial applications where high strength, dimensional stability, and acceptable corrosion behavior are required. Full article