Search Results (15,135)

T6 aging, involving solution treatment and artificial aging, is a widely adopted strengthening method for magnesium alloys due to its proven effectiveness. However, the integration of three or more sequential thermal treatments has been explored only sparingly, primarily due to the challenges associated with optimizing such multi-parameter processing systems. This study demonstrates that integrating a 12 h deep cryogenic treatment (DCT) before aging in a Mg–Al–Ca–Mn alloy optimizes mechanical performance, achieving a tensile strength of 343 MPa and 27.3% elongation. Microstructural analysis, based on electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM), reveals that the strength enhancement results from ~29 nm precipitate refinement, elevated dislocation density, and nanoscale sub-grain formation, while the ductility gains stem from the activation of non-basal slip systems and the suppression of microcrack propagation. These synergistic mechanisms enable superior strain accommodation, providing a clear framework for DCT-enabled sequential heat treatment design in high-performance magnesium alloys. Full article

This study presents a comparative evaluation of injection-moulded PA12 composites reinforced with AlSi10Mg and 304 SS fillers, with emphasis on microstructure–property correlations linking powder morphology, mechanical performance, thermal stability, and tribological behaviour. Powder characterization revealed distinct morphologies—fine spherical AlSi10Mg particles (D50 ≈ 32 µm) dispersed uniformly in the matrix—while SS particles (D50 ≈ 245 µm) tended to agglomerate, leading to interfacial voids. Tensile testing showed that the elastic modulus of neat PA12 (0.95 GPa) increased by 20% and 28% with 20 wt% AlSi10Mg and SS, respectively. However, tensile strength decreased from 35.04 MPa (PA12) to 32.18 MPa (20 wt% AlSi10Mg) and 31.03 MPa (20 wt% 304 SS), consistent with stress concentrations around particle clusters. Hardness values remained nearly unchanged at 96–98 Shore D across all composites. Thermal analysis indicated that AlSi10Mg promoted crystallization, increasing crystallinity from 31% (PA12) to 34% and raising Tm by 2 °C. In contrast, 304 SS reduced crystallinity to 28% but significantly improved thermal stability, shifting Tonset from 405 °C (PA12) to 426 °C at 20 wt%. Tribological tests demonstrated substantial improvements: the coefficient of friction decreased from 0.42 (PA12) to 0.34 (AlSi10Mg) and 0.29 (304 SS), while wear rates dropped by 40% and 55%, respectively. SEM confirmed smoother worn surfaces in AlSi10Mg composites and abrasive grooves in 304 SS composites. The findings show that AlSi10Mg is advantageous for smoother surfaces and improved crystallinity, while SS enhances stiffness, wear resistance, and thermal endurance, providing design guidelines for PA12 composites in aerospace, automotive, and engineering applications. Full article

This study demonstrates a high-value pathway for fabricating porous ceramics by utilizing gold tailings (GT) as the principal raw material, with silicon carbide (SiC) as a high-temperature foaming agent. The microstructure, mechanical strength, and thermal conductivity were tailored by adjusting GT content, sintering temperature, raw material particle size, and foaming agent dosage. The optimized ceramics exhibit a total porosity of 60.1–83.7%, a compressive strength of 3.25–7.18 MPa, and a thermal conductivity of 0.15–0.32 W·m⁻¹·K⁻¹. These properties not only meet, but in fact exceed the key requirements specified in the Chinese National Standard GB/T 16533-1996 for porous thermal insulation ceramics. Notably, the materials achieve an optimal balance between high porosity and adequate mechanical strength. The findings confirm that gold tailings can be effectively valorized to produce standardized, porous ceramics suitable for industrial thermal insulation applications. Full article

This study systematically investigates the influence of 3D printing parameters on the surface morphology and coating performance of polylactic acid (PLA) substrates finished with traditional Chinese lacquer. PLA specimens were fabricated using fused deposition modeling (FDM) with varying print speeds, layer heights, and infill densities, followed by natural lacquer coating and controlled curing. Surface roughness, gloss, adhesion, and wear resistance were evaluated through standardized tests, while microstructural analysis using SEM revealed the interfacial morphology and film uniformity. Results indicate that layer height is the most dominant factor, exerting significant effects on all surface and coating properties. Increasing layer height led to higher surface roughness, which in turn reduced gloss due to enhanced diffuse scattering but improved adhesion and wear resistance through stronger mechanical interlocking. Print speed showed a secondary influence on adhesion, attributed to its effect on interlayer bonding and surface porosity, while infill density exhibited minimal influence except on wear resistance. The application of Chinese lacquer significantly reduced surface irregularities owing to its excellent self-leveling and gap-filling capabilities, producing smooth, durable, and well-adhered coatings. Overall, the study demonstrates that integrating traditional lacquer with modern FDM technology provides a sustainable and high-performance finishing solution for 3D-printed PLA, bridging cultural craftsmanship with advanced additive manufacturing for potential applications in decorative, protective, and eco-friendly products. Full article

Al-Zn-Mg-Cu alloys are widely used as heat-treatable ultra-high-strength materials in aerospace structural applications. While conventional single-stage aging enables high strength, advanced performance demands call for precise microstructural control via multi-stage aging. In this study, we employ a combination of scanning transmission electron microscopy (STEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to investigate the microstructural evolution and its correlation with mechanical properties of AA7150 aluminum alloy subjected to two-step aging treatments, following a 6 h pre-aging at 120 °C. Through atomic-scale STEM imaging along the [110]_Al zone axis, we systematically characterize the precipitation behavior of GPII zones, η′ phases, and equilibrium η phases both within the grains and at grain boundaries under varying secondary aging (SA) conditions. Our results reveal that increasing the SA temperature from 140 °C to 180 °C leads to coarsening and reduced number density of intragranular precipitates, while promoting the continuous and coarse precipitation of η phases along grain boundaries, accompanied by a widening of the precipitation-free zone (PFZ). Notably, SA at 160 °C induces the formation of fine, uniformly dispersed nanoscale η′ precipitates in the alloy, as confirmed by XRD phase analysis. Aging at this temperature markedly enhances the mechanical properties, achieving an ultimate tensile strength (UTS) of 613 MPa and a yield strength (YS) of 598 MPa, while presenting an exceptionally broad peak-aging plateau. Owing to this feature, a moderate extension of the SA duration does not reduce strength and can further improve ductility, increasing the elongation (EL) to 14.26%. These results demonstrate a novel two-step heat-treatment strategy that simultaneously achieves ultra-high strength and excellent ductility, highlighting the critical role of advanced electron microscopy in elucidating phase-transformation pathways that inform microstructure-guided alloy design and processing. Full article

Natural supplemental cementitious materials (SCMs) with pozzolanic qualities, such as rice husk ash (RHA) and sugarcane bagasse ash (SCBA), are a promising alternative to the currently used SCMs that are becoming increasingly unavailable. This work presents a comprehensive comparative examination of their impact on mortar properties when OPC was partially replaced by RHA and SCBA. The percentage substitution of OPC with ashes was 0, 5, 10, and 15%. The air content, consistency, compressive strength, flexural strength, and shrinkage of the mortar were investigated primarily. Microstructural characteristics were analysed using porosimetry, MIP, and SEM photography. According to the study, up to 10% replacement of OPC with RHA or 15% with SCBA has the potential to be used as a partial cement substitute while maintaining good mechanical qualities. Mortars with up to 15% SCBA exhibited no significant change in compressive strength after 28 days or a decrease with <11%, while for 10% RHA, there was no difference in compressive strength or increase. Use of 5% RHA decreased shrinkage by 35%, while addition of 5% SCBA by 30%. Obtained results demonstrated the usefulness of SCMs in masonry mortars. Full article

Developing sustainable ceramic formulations that integrate industrial by-products addresses the high energy and raw material demands of refractory manufacturing while advancing circular economy goals. This study investigates the recycling of chamotte waste from rejected fired electrical porcelain as a partial substitute (5 and 10 wt.%) for flint clay in aluminosilicate refractory castables. Samples were fired at 110, 815, 1050, and 1400 °C and evaluated for bulk density, apparent porosity, cold crushing strength, and flexural strength. Microstructural and mineralogical changes were analyzed by SEM and XRD. Incorporating 10 wt.% chamotte waste fostered an in situ mullite-reinforced microstructure, enhancing mechanical strength (58 MPa—CCS, 18.8 MPa—MOR) and lowering porosity (24.4%), demonstrating chamotte’s dual role as recycled raw material and reinforcement phase for densification and durability. These properties matched or surpassed those of the conventional formulation, with strength improvements of up to 44%. The findings demonstrate that high-temperature industrial waste can be effectively valorized in advanced refractories, reducing reliance on virgin raw materials, diverting waste from landfills, and promoting industrial symbiosis within the ceramics and metallurgical sectors. Full article

Magnesium (Mg) alloys are prized as the lightest structural materials but often suffer from a strength–ductility trade-off that is particularly challenging for applications demanding high thermal conductivity. Aiming to resolve this issue, rolled ternary Mg-0.9Mn-1.9Ce (wt.%) alloy sheets were designed and fabricated, and the influence of rolling strain on optimizing the property balance was systematically investigated. The cast alloy was homogenized and rolled to two accumulated strains to obtain S10 (90%) and S20 (95%), followed by microstructure characterization and mechanical/thermal evaluation. Compared with S10, S20 developed finer, more equiaxed grains and a weaker basal texture via enhanced dynamic recrystallization; concurrent fragmentation and uniform dispersion of second-phase particles further contributed to strengthening. Consequently, S20 achieved 14.2% and 13.7% increases in yield and tensile strengths, respectively, with a slight improvement in elongation, while retaining high thermal conductivity (134.4 W·m⁻¹·K⁻¹ vs. 138.1 W·m⁻¹·K⁻¹ for S10). The minimal conductivity penalty is attributed to the low solute level in the α-Mg matrix, which limits electron scattering. These results provide experimental and mechanistic guidance for developing rolling Mg alloys that combine high mechanical performance with excellent thermal efficiency. Full article

This review presents a comprehensive overview of metallic abradable coatings and the advanced testing methodologies used to evaluate their performance in gas turbine engines. Abradable materials are engineered to act as sacrificial coatings, enabling minimal blade tip wear while maintaining tight clearances between rotating blades and stationary components. Such functionality is critical in aerospace applications, where engines operate at high rotational speeds and across wide temperature ranges. The review examines the principal factors governing the design and selection of metallic-based abradable coatings, including material composition, thermal stability, and microstructural tailoring through the addition of phase modifiers, porosity formers, and solid lubricants. The performance of various metallic matrix materials is also discussed concerning their operational temperature ranges and wear characteristics. Particular attention is given to abradability evaluation methods, emphasizing the need to replicate engine-representative conditions to capture blade–coating interactions, frictional behavior, and wear mechanisms. This review consolidates advances in material compositions, microstructural engineering, and experimental testing, integrating perspectives from materials science, tribology, and methodology to guide the development of next-generation turbine coatings. It specifically addresses the lack of a unified review linking material design, thermal spray processes, and performance evaluation by summarizing key compositions, microstructures, and testing methods. Full article

Eutectic high-entropy alloys (EHEAs) combine the casting advantages of eutectic alloys with the comprehensive properties of high-entropy alloys, making them a research hotspot in the field of metallic materials. Among them, the AlCoCrFeNi_2.1 EHEA has attracted significant attention due to its excellent strength–toughness balance characteristics. In this study, alloy samples of AlCoCrFeNi_2.1Si_x (x = 0, 0.1, 0.2, 0.3) were prepared to investigate the regulatory effects of trace Si on its phase composition, microstructure, and mechanical properties. The results show that the base alloy AlCoCrFeNi_2.1 is composed of an FCC and BCC phase composition. With the increase in the Si content to x = 0.3, the CrSi₂ phase gradually precipitates in the alloy, and its microscopic morphology transforms from the regular lamellar to the dendrite and network structure. The introduction of Si significantly enhances the room-temperature microhardness, wear resistance, and yield strength of the alloy through the mechanisms of solid solution strengthening and second phase strengthening. However, an excessive addition leads to a decrease in ductility and toughness. This study reveals the role of Si in phase control and the strengthening and toughening mechanism of eutectic high-entropy alloys, providing experimental evidence and a theoretical reference for the design of high-performance silicon-modified high-entropy alloys. Full article

Additive manufacturing via selective laser sintering (SLS) enables the rapid production of geometrically complex polyamide 12 (PA12) components. However, conventional pointwise analysis techniques often overlook the full depth of continuous experimental datasets, thus limiting the interpretation of structure–function relationships that are essential to high-performance design. This study employs functional data analysis (FDA) to elucidate the microstructural, chemical, thermal, and mechanical behaviours of SLS-fabricated PA12, focusing on the effects of build orientation (horizontal, transverse, vertical) and wall thickness (2.0–3.0 mm). The samples were produced via a commercial SLS platform and characterised via X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), and tensile testing. The FDA was applied to raw, normalised, and first derivative datasets via Python’s Scikit-FDA package, increasing the sensitivity to latent material variations. The findings demonstrate that the build orientation has a marked influence on the crystallinity and mechanical performance: horizontal builds yield narrower gamma-phase XRD peaks, greater structural order, and enhanced tensile properties, whereas vertical builds exhibit broader peak dispersion and greater thermal sensitivity. The wall thickness effects were minor, with only isolated flux-related anomalies. The FTIR spectra confirmed the consistent chemical stability across all the conditions. The FDA successfully identified subtle transitions and anisotropies that eluded traditional methods, underscoring its methodological strength for advanced polymer characterisation. These insights offer practical guidance for refining SLS process parameters and improving predictive design strategies in polymer-based additive manufacturing. Full article

To overcome the limitations imposed by the anisotropy and heterogeneity of natural loess, this study establishes a novel quantitative macro–micro correlation framework for investigating the deformation mechanisms of artificial structural loess (ASL). ASL samples were prepared by mixing remolded loess with cement (0–4%) and NaCl (0–16%), followed by static compaction (95% degree) and 28-day curing (20 ± 2 °C, >90% RH) to replicate the structural properties of natural loess under controlled conditions. An integrated experimental methodology was employed, incorporating consolidation/collapsibility tests, particle size analysis, X-ray diffraction (XRD), and mercury intrusion porosimetry (MIP). A three-dimensional nonlinear model was proposed. The findings show that intergranular cementation, particle size distribution, and pore architecture are the main factors influencing loess’s compressibility and collapsibility. A critical transition from medium to low compressibility was observed at cement content ≥1% and moisture content ≤16%. A strong correlation (Pearson |r| > 0.96) was identified between the mesopore volume ratio and the collapsibility coefficient. The innovation of this study lies in the establishment of a three-dimensional nonlinear model that quantitatively correlates key microstructural parameters (fractal dimension value (D), clay mineral ratio (C), and large and medium porosity (n)) with macroscopic deformation indicators (porosity ratio (e) and collapsibility coefficient (δ_s)). The measured data and the model’s output agree quite well, with a determination coefficient (R²) of 0.893 for porosity and 0.746 for collapsibility, verifying the reliability of the model. This study provides a novel quantitative tool for loess deformation prediction, offering significant value for engineering settlement assessment in controlled cementation and moisture conditions, though its application to natural loess requires further validation. Full article

Friction stir additive manufacturing (FSAM) is a promising solid-state technique for fabricating high-strength aluminum alloys, such as Al-7075, which are difficult to process using conventional melting-based additive manufacturing (AM) methods. This study investigates the mechanical properties and tool wear behavior of seven-layered Al-7075 multi-layered composites reinforced with silicon carbide (SiC) and titanium carbide (TiC) fabricated via FSAM. Microstructural analysis confirmed defect-free multi-layered composites with a homogeneous distribution of SiC and TiC reinforcements in the nugget zone (NZ), although particle agglomeration was observed at the bottom of the pin-driven zone (PDZ). The TiC-reinforced composite exhibited finer grains than the SiC-reinforced composite in both as-welded and post-weld heat-treated (PWHT) conditions, achieving a minimum grain size of 1.25 µm, corresponding to a 95% reduction compared to the base metal. The TiC-reinforced multi-layered composite demonstrated superior mechanical properties, attaining a microhardness of 93.7 HV and a UTS of 263.02 MPa in the as-welded condition, compared to 88.6 HV and 236.34 MPa for the SiC-reinforced composite. After PWHT, the TiC-reinforced composite further improved to 159.12 HV and 313.46 MPa UTS, along with a higher elongation of 11.14% compared to 7.5% for the SiC-reinforced composite. Tool wear analysis revealed that SiC reinforcement led to greater tool degradation, resulting in a 1.17% weight loss. These findings highlight the advantages of TiC reinforcement in FSAM, offering enhanced mechanical performance with reduced tool wear in multi-layered Al-7075 composites. Full article

This study evaluates coke for iron ore sintering manufactured from Ekibastuz coal fines (fraction 0–3 mm), spent anode material (SAM) from aluminum electrolysis, and coal tar pitch. Laboratory coking was performed at 1000 °C (60 min hold), followed by sintering trials using coke containing 10 wt% and 20 wt% SAM. Microstructural (SEM/EDS) and spectral data indicate an optimal SAM range of 10–20 wt%: higher additions (≥30 wt%) lead to structural degradation of coke, accompanied by reduced mechanical integrity. The produced coke shows C = 85%, S = 0.9–1.1%, ash ≈ 19%, volatiles = 1.5–2.5%, and moisture (Wr) ≤ 1%, which is acceptable for sintering use. In sintering tests, the yield of usable sinter reached 72.4% (10 wt% SAM) and 73.5% (20 wt% SAM); impact strength was 83% and 78%, respectively. XRF of sinter showed Fe_total > 51%, CaO ≈ 5.5–6.8%, SiO₂ ≈ 6.6–7.2%, and S = 0.40–0.45%, meeting technological requirements for blast-furnace practice. Overall, using spent anode material within 10–20 wt% increases fixed-carbon content, enables valorization of aluminum industry waste, and delivers coke for agglomeration performance without compromising key chemical or mechanical indices. Full article

This study investigates the adhesion of polypropylene (PP), steel and basalt fibres to geopolymer matrices of varying composition. Geopolymers formed via alkali activation of fly ash (FA) and ground granulated blast-furnace slag (GGBFS) offer significant environmental advantages over Portland cement by reducing CO₂ emissions and energy consumption. The addition of water treatment sludge (WTS) was also investigated as a partial or complete replacement for FA. Pull-out tests showed that replacing FA with WTS significantly reduces the mechanical properties of the matrix and at the same time the adhesion to the fibres tested. The addition of 20% WTS reduced the compressive strength by more than 50% and full replacement to less than 5% of the reference value. Steel fibres showed the highest adhesion (9.3 MPa), while PP fibres had the lowest, with adhesion values three times lower than steel. Increased GGBFS content improved fibre adhesion, while the addition of WTS weakened it. Calculated critical fibre lengths ranged from 50 to 70 mm in WTS-free matrices but increased significantly in WTS-containing matrices due to reduced matrix strength. The compatibility of the fibres with the geopolymer matrix was also confirmed via SEM microstructural observations, where a homogeneous transition zone was observed in the case of steel fibres, while numerous discontinuities at the interface were observed in the case of other fibres, the surface of which is made of organic polymers. These results highlight the potential of fibre-reinforced geopolymer composites for sustainable construction. Full article