Search Results (1,383)

This study investigates the influence of design factors and key process parameters—including explosive welding (EXW), rolling, and laser processing—on the formation, microstructure, and tribological properties of Ti–Cu–Ni intermetallic coatings. A combined manufacturing approach was employed, starting with the EXW of an MN19 cupronickel alloy to a VT1-0 titanium substrate, followed by multi-pass rolling to achieve a cladding thickness of approximately 0.3 mm. Subsequently, laser surface remelting was performed to facilitate controlled mass transfer and homogenization within the reaction zone. Numerical simulation using COMSOL Multiphysics v. 5.4 was utilized to optimize the thermal cycles and determine the ideal energy density (42 J/mm²) for phase formation. The results demonstrate that the primary structural components of the coatings produced under optimal conditions are solid solutions based on the ternary-modified titanium cuprides Ti₂Cu(Ni) and TiCu(Ni). The transition from a layered bimetal to a finely dispersed intermetallic structure significantly enhances the surface characteristics. This specific phase composition provides a sustained microhardness of ~5 GPa across the coating cross-section. Comparative wear tests against fixed abrasive revealed that the wear resistance of the Ti–Cu–Ni coatings is 2.5 times higher at room temperature and 1.5 times higher at 600 °C than that of the base VT1-0 titanium. Full article

In order to explore the outstanding problems, such as poor mechanical performance, of recycled aggregate from construction waste in the application of backfills, this study innovatively used accelerated carbonation treatment technology to pretreat the recycled aggregates, and systematically investigated the evolution of mechanical properties in carbonated recycled aggregate-based cemented paste backfill (CPB). By carbonizing the waste recycled concrete aggregate (RCA), carbonation recycled concrete aggregates (CRCA) were obtained, and coal gangue was replaced as the filling aggregate at 50% and 100% for mine paste filling. The mechanical properties of the CPB were measured, and the mechanism was analyzed in combination with the changes in the microstructure. The results showed that the physical properties of RCA were significantly improved by carbonation treatment compared with untreated raw RCA: the apparent density of C₆₀d-RCA increased by 2.88% relative to non-carbonated RCA, while its crushing value decreased by 51.45%, resulting in a more stable aggregate structure. In terms of mechanical properties, the compressive strengths of the 28day carbonated backfills with 50% and 100% CRCA contents (denoted as C₂₈d-RCA-50 and C₂₈d-RCA-100) reached 6.38 MPa and 5.32 MPa, representing increases of 61.52% and 46.33%, respectively, compared to the control group. Microstructure and phase composition analysis showed that the carbonation reaction not only produced calcium carbonate (CaCO₃) crystals to effectively fill the internal pores and reduce the total porosity of the matrix, but also promoted the generation of monocarboaluminate and provided abundant nucleation sites for calcium silicate hydrate (C-S-H) gel hydration, which significantly optimized the structure of the interfacial transition zone (ITZ) and improved its microhardness. Among all test groups, the CRCA-50 group showed the most optimized microstructure and the best mechanical properties. This study provides a theoretical reference for the resource utilization of this type of 30-year service life RCA in mine filling. Full article

To address the accumulation of construction and demolition waste (W&D), this study recycled it into regenerated fine aggregate and prepared 3D-printed mortars with replacement ratios ranging from 0% to 100%. The mechanical properties of hardened specimens were tested, and the degradation mechanisms of mechanical performance were investigated through SEM, MIP, and microhardness analysis. The carbon emissions of the materials were evaluated. The results indicated that while the 3D-printed mortar exhibited excellent buildability, its compressive strength, flexural strength, and interlayer bond strength gradually decreased with increasing replacement ratio. MIP results showed that as the replacement ratio of the W&D increased from 0% to 100%, the total porosity of the 3D-printed specimens significantly increased from 14.7433% to 27.5903%. SEM and microhardness images confirmed severe ITZ deterioration, and the average ITZ width increased from 31 to 79 μm. As the W&D replacement ratio increased from 0% to 100%, the total GWP decreased from 0.4043 to 0.3800 kg CO₂-eq/kg mortar. Maximizing the utilization of W&D is key to achieving efficient utilization of solid waste. Considering printability, mechanical performance, interlayer behavior, microstructural characteristics, and environmental impact in a comprehensive manner, the 80% W&D replacement ratio can be regarded as a relatively balanced and promising selection. This work not only suggests the technical feasibility of recycling W&D in 3D printing mortar, but also proposes a sustainable pathway to reduce carbon emissions in construction. Full article

To improve the surface properties of 40Cr steel, Ni45/Y₂O₃ laser-cladded coatings (L-CCs) were fabricated on the surface of 40Cr steel. The effects of Y₂O₃ addition (0.5%, 1.0%, and 1.5%) on the microstructure, microhardness, residual stress, wear resistance, and corrosion resistance of the L-CCs were systematically investigated. The results indicate that Y₂O₃ has a significant effect on enhancing the corrosion resistance and suppressing the residual stress of the L-CCs, whereas its contribution to the improvement of microhardness and wear resistance is relatively limited. Compared with the single Ni45 L-CC, the L-CC containing 1.0% Y₂O₃ exhibited a 45.9% reduction in corrosion current density and a 79.3% reduction in residual stress. At a Y₂O₃ addition of 0.5%, the microhardness increased by 4.0%, while the average friction coefficient and wear mass loss decreased by 4.8% and 2.6%, respectively, relative to the single Ni45 L-CC. Excessive Y₂O₃ addition reduces the fluidity of materials in the molten pool and deteriorates the microstructural uniformity, thereby weakening or even impairing the surface properties of the L-CCs. Full article

Laser shock peening (LSP) is a surface treatment technique focused on improving the mechanical performance of metal components by inducing compressive residual stresses. This research evaluated the effects of LSP on a Ti-6Al-4V alloy, an α + β titanium alloy manufactured by wrought and additive manufacturing used in biomedical and aerospace applications. Samples manufactured by conventional processes and additive manufacturing were treated under the following conditions: Pulse width of 6 ns, wavelength of 1064 nm, scan density of 2500 pulses/cm², pulse energy of 0.750 J, and repetition frequency of 10 Hz. The mechanical response was evaluated in terms of residual stress, microhardness, and microstructure before and after treatment. The results showed significant improvements, reaching compressive residual stress fields of up to −800 MPa and a 22% increase in microhardness, and grain refinement from 18.16 μm to 5.54 μm. These results confirm the effectiveness of LSP in improving the surface integrity and mechanical behavior of Ti64 components, regardless of their manufacturing method. Full article

The efficient fabrication of high-quality Ni60-WC composite coatings with low dilution and defect density remains a challenge for wear-critical tunneling cutters. In this study, a plasma–laser hybrid cladding (PLHC) strategy was developed to fabricate Ni60-40 wt% WC composite coatings, and their microstructures and properties were systematically compared with those produced by plasma cladding (PC) and laser cladding (LC). The PLHC coatings exhibit a low dilution rate of 10.7% and an ultra-low porosity of 0.2%, indicating improved metallurgical integrity. Microstructural analysis reveals that the hybrid energy input effectively suppresses WC dissolution and promotes a refined, uniformly distributed hard-phase network within the Ni-based matrix. As a result, the PLHC coatings achieve a high average microhardness of 1187.83 HV_1.0 and superior wear resistance, with a wear volume of 24.69 × 10⁻³ mm³ under a 200 N load, representing reductions of 53.6% and 20.9% compared with PC and LC coatings, respectively. These results demonstrate the effectiveness of plasma–laser hybrid cladding in tailoring the microstructure–property relationship of WC-reinforced composite coatings. Full article

This study systematically investigates the influence of CeO₂ content (0–0.6 wt.%) on the microstructure and mechanical properties of Stellite6/WC composite coatings fabricated by plasma spray welding. The phase composition and microstructure of the coatings were characterized using X-ray diffraction (XRD) and scanning electron microscopy (SEM), while microhardness and tribological performance were evaluated using a semi-automatic Vickers microhardness tester and a ball-on-disk tribometer. The results indicate that the coating with 0.4 wt.% CeO₂ exhibits the optimal combination of mechanical and tribological properties, achieving a maximum microhardness of 1107.62 HV_0.3—a 50.5% improvement over the unmodified coating—and a minimum wear mass loss of 1.4 mg, corresponding to a 78.1% reduction compared to the CeO₂-free counterpart. These findings demonstrate that appropriate CeO₂ addition significantly enhances both the microhardness and wear resistance of Stellite6/WC coatings, offering an effective strategy to mitigate surface degradation and extend the service life of 45 steel substrates under demanding operating conditions. Full article

To obtain ultrahigh strength Cu alloy strip for board-to-board connectors, a CuNiSiMgMn multi-element high-solute alloy was designed, and high-temperature short-time solid solution was utilized to optimize the properties of this alloy. The evolution in microstructure and properties of the cold-rolled CuNiSiMgMn alloy strip during high-temperature short-time solid solution, aging, and further cold-rolling are investigated. The results reveal that there are high-density Ni_xSi precipitates and deformation defects in the original cold-rolled CuNiSiMgMn alloy strip. During a solid solution at 1000 °C, recrystallization primarily occurs between 15 and 30 s, while precipitate decomposition starts at a solid solution time of ~30 s and is almost complete 10 s later. With further increase in the solid solution time, the grain size of the alloy grows rapidly, but the residual precipitate particles exhibit little change. Upon aging at 500 °C for 2 h and a further 80% cold-rolling, nano-sized precipitates are formed, yielding high-strength alloy strips. The 80% cold-rolling increases the microhardness by 12% and decreases the electrical conductivity by 3% IACS. The strip solid solution-treated for 35 s exhibits the maximum strength, with a tensile strength of >950 MPa and a conductivity of >30% IACS. Further extension of the solid solution time decreases both the tensile strength and elongation. This work clarifies the critical time of recovery, recrystallization, and precipitate decomposition of the CuNiSiMgMn alloy during high-temperature solid solution and provides guidance for industrial production. Full article

To enhance the utilization rate and mechanical performance of recycled sand (RS) in extrusion-based 3D printing, this study investigates the influence of varying incorporation ratios of RS across two particle size fractions: 0.075–1.18 mm (RS01) and 1.18–2.36 mm (RS12). The RS utilization rate was determined via the material balance method, while microstructural mechanisms were analyzed using scanning electron microscopy and Vickers microhardness testing. The results indicate that: a combination of 75% RS01 and 25% RS12 achieves the maximum RS utilization rate of 84.3%. At an RS12/RS01 ratio of 1:3, the printed specimens exhibit the smallest tilt angles in bidirectional buildability tests, measuring 7.6° and 7.2°, with corresponding tan θ values of 0.066 and 0.063. Compared to mortar with 100% RS01, this optimized mixture yields average increases of 36.5% in compressive strength, 40.7% in flexural strength, and 6.8% in interlayer splitting strength. Analysis of variance indicates that different particle size combinations have a significant effect on the mechanical properties. Microhardness analysis reveals that the combination of 75% RS01 and 25% RS12 achieves a minimum interfacial transition zone width of 46 µm. Utilizing larger-particle-size RS in 3D printing effectively enhances its utilization rate while maintaining satisfactory printability and mechanical properties. Full article

High-speed laser cladding (HLC) technology can provide high cooling rates and low dilution rates for the preparation of metastable Fe-based amorphous phases. In this work, the effects of Ta content on the microstructure, mechanical properties, and soft magnetic performance of Fe-based amorphous alloys were systematically investigated. The results indicated that Ta remained uniformly dispersed within the FeSiB amorphous powder, and no new phases were formed after mechanical ball milling. The higher mixing enthalpy of Ta and its atomic radius difference from other elements (such as Fe, Si, B) were beneficial in improving glass-forming ability (GFA), and with an increase in Ta element content from 0% to 2%, 4% and 6%, the amorphous phase content was 48.6%, 51.5%, 60.4% and 54.8%, respectively. The average microhardness of the coating with a Ta content of 4% was 1310 HV_0.2, which was 50HV_0.2 higher than before; in addition, the wear rate reduced from 2.21 × 10⁻⁴ mg·N⁻¹·m⁻¹ to 2.06 × 10⁻⁴ mg·N⁻¹·m⁻¹. Also, corrosion tests showed that the coating with a Ta content of 4% displayed superior corrosion resistance compared to that before the Ta addition. However, because the element Ta could alter the local electronic environment and enhance the local magnetic anisotropy of FeSiB, the saturation magnetic flux density (Ms) decreased from 1.64 T to 1.56 T, and the coercivity (Hc) increased from 0.9 A/m to 1.3 A/m, which caused degradation of the soft magnetic properties. Full article

Friction stir welding (FSW) of dissimilar aluminium alloys often results in non-uniform microstructure and hardness distributions due to asymmetric temperature fields and material flow. The objective of this study is to establish a quantitative relationship between thermal history, microstructural evolution, and hardness distribution in dissimilar AA5052-H32/AA6061-T6 FSW joints by combining experimental characterisation with validated thermal modelling. AA5052-H32 and AA6061-T6 plates were welded under five different parameter sets. A thermal finite element model was developed in COMSOL Multiphysics to simulate temperature evolution during welding and was validated using embedded thermocouple measurements, with predicted peak temperatures ranging from 455 °C to 641 °C. Optical microscopy, scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to characterise grain structure and dynamic recrystallisation (DRX) behaviour, while Vickers microhardness mapping was used to evaluate the local mechanical response. The results show that DRX occurred in the nugget zone (NZ), leading to significant grain refinement, with a minimum grain diameter of 6.07 µm, representing an approximately eightfold reduction compared with the base material AA5052-H32. In contrast, the thermo-mechanically affected zone (TMAZ) experienced limited recrystallisation due to insufficient plastic deformation and temperature. The lowest hardness was observed in the TMAZ on the AA5052-H32 side, with the hardness reduction of 22% primarily caused by work hardening loss. Hardness was also reduced by 34% on the AA6061-T6 side due to decreased precipitation strengthening caused by high temperatures. This combined experimental–numerical study provides a systematic thermal–microstructure–hardness framework for understanding and predicting local property variations in dissimilar FSW joints. Full article

Cr₂O₃-based ceramic coatings are widely used in wear-critical applications; however, their tribological performance under dry sliding conditions can be limited by brittleness and frictional instability. In heavy-duty vehicles, the king pin–bushing contact operates under severe dry sliding conditions, motivating the investigation of composite Cr₂O₃–nTiO₂ coatings as a potential surface engineering solution. In this study, Cr₂O₃–TiO₂ coatings containing 0, 10, 20, 30, and 40 wt% TiO₂ were deposited by atmospheric plasma spraying (APS) from mechanically mixed powders. Phase composition was analyzed by X-ray diffraction using an X’Pert PRO MRD diffractometer, while microstructure and elemental distribution were examined by scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS) on a FEG Quattro C microscope. Mechanical properties were evaluated by Vickers microhardness, instrumented indentation and scratch testing, while dry sliding wear behavior was assessed by pin-on-disc tests performed on a CETR UMT-2 tribometer against a bronze counterbody, with continuous monitoring of the coefficient of friction (COF). The results show that plasma spraying produces lamellar composite coatings with intrinsic porosity and locally modified phase composition. Cr₂O₃-rich coatings exhibit higher hardness (1198 HV2 compared with 877 HV2 for Cr₂O₃–40TiO₂ corresponding to an increase of approximately 36%) and improved resistance to indentation, reflected by lower penetration depths and higher elastic modulus values (134 GPa for S0 compared with 77 GPa for S2). These coatings also exhibit a more stable friction response and reduced material transfer from the bronze counterbody, as confirmed by the lower mass loss of the pins (0.0295 g for S0 compared with 0.0473 g for S4, corresponding to a reduction of about 38%). Increasing TiO₂ content leads to changes in friction stability and wear behavior associated with microstructural heterogeneity. These findings indicate that the sliding wear performance of Cr₂O₃–nTiO₂ coatings is governed by elastic–plastic stability under localized contact loading and support their applicability for dry sliding king pin–bushing systems in heavy-duty vehicles. Full article

In this study, CuCr50Ni_X (X = 0, 0.1, 0.5, and 0.9 wt.%) coatings were successfully fabricated on a pure copper substrate via infrared-blue hybrid laser cladding. The effects of Ni addition on the microstructure, mechanical and electrical properties, and arc erosion resistance under 24 V/30 A conditions were systematically investigated. The results demonstrate that Ni refines the Cr phase and promotes the formation of a (Cr, Ni) solid solution and nanoscale Cr₇Ni₃ precipitates during non-equilibrium solidification. The coating with 0.5 wt.% Ni exhibits optimal comprehensive performance. It achieves a high microhardness of 174.2 HV_0.5, representing a 149% increase compared to the copper substrate (72 HV_0.5). Simultaneously, it maintains a good electrical conductivity of 29.8% IACS. Arc erosion morphology transforms from localized deep pits (CuCr50) to uniform, shallow characteristics (CuCr50Ni_0.5), accompanied by reduced cathode mass loss. This enhanced performance is attributed to the refined and dispersed Cr distribution, which facilitates dynamic arc root movement, together with improved phase boundary stability conferred by the (Cr, Ni) solid solution and Cr₇Ni₃ precipitates. This work provides a novel strategy for developing high-performance, long-life electrical contact components through surface alloying design and laser additive manufacturing. Full article

This paper investigates how the thickness of dogbone tensile specimens made from heat-treated Hastelloy-X alloy produced by Laser Powder Bed Fusion (LPBF) influences their mechanical properties and microstructure. The focus of the investigation is on surfaces in an “as-built” condition and considers a range of thickness from 3 to 1 mm. The “as-built” surfaces condition is a fundamental outcome, considering that LPBF technology’s key feature is the ability to produce intricate and complex geometries that are difficult to achieve with conventional manufacturing technologies. The specimens were fabricated according to ASTM E8/E8M-21 and were heat-treated in a vacuum furnace at 1150 °C for two hours. The microstructure of the material was evaluated through porosity, EBSD, and Microhardness analyses. The mechanical properties were evaluated through tensile tests conducted at room temperature on dogbone specimens fabricated both parallel and perpendicular to the building direction. The findings indicate a significant reduction in mechanical properties that could be correlated with the reduction in specimen thickness, reflecting a gradual decline from the baseline. Specifically, a 14% decrease in Ultimate Tensile Strength (from 612 to 528 MPa), an approximately 19% reduction in Young’s Modulus (from 190 GPa to 153 GPa), and a 32% decrease in Elongation at Break (from 59.2% to 40.0%) were observed. Furthermore, it was noted that the printing orientation of the specimens significantly affects their mechanical properties, regardless of thickness. Overall, the results suggest that applying standard heat treatment under specific conditions, such as with a thin, exposed wall of about 1mm with a striped strategy, may not lead to adequate material performance. Full article

In this study, a novel reverse friction stir processing (FSP) was adopted to investigate the effects of multi-pass reverse FSP on the microstructure, microhardness, bonding strength, and tribological properties of NiCrBSi coatings deposited on 6061-T6 aluminum alloy via atmospheric plasma spraying (APS). The results demonstrate that reverse FSP effectively eliminates pores, unmelted particles, and interlamellar defects in the as-sprayed coating without causing mechanical damage to the coating surface inside the processed zone. With an increase in processing passes, a micron-scale diffusion zone forms at the coating/substrate interface, transforming the bonding mechanism from mechanical interlocking to metallurgical bonding. Mechanical property tests reveal that compared with the as-sprayed state, the microhardness and tensile bonding strength of the three-pass FSPed coating are increased by 26.0% and 171.1%, respectively, indicating significantly improved mechanical properties. Tribological tests demonstrate that the main wear mechanism of the as-sprayed coating is severe abrasive wear. After multi-pass FSP, the wear mechanism of the coating transforms into a mixed wear mechanism. Among them, the FSP3 coating exhibits mild abrasive wear accompanied by local adhesive wear. Full article