Search Results (412)

To improve the low sensitivity of electromagnetic acoustic testing (EMAT) to micro-debonding defects in metal–rubber bonded structures, this study proposes a detection framework combining a magnetic-field-enhanced focusing EMAT with entropy-weighted multi-feature fusion imaging. First, a Halbach-type focusing magnet was designed and evaluated through finite element simulations, showing a substantial enhancement of the effective bias magnetic field in the working region. Then, three complementary echo features, namely amplitude (AMP), time-domain integral (TDI), and power spectral density (PSD), were extracted from the acquired resonance signals and integrated using an adaptive entropy-weighted fusion strategy. Comparative and ablation analyses were further conducted to distinguish the respective contributions of probe enhancement and feature fusion, and to compare entropy-weighted fusion with single-feature imaging and equal-weight fusion. The results indicate that the focused probe mainly improves the defect-response strength at the hardware level, whereas feature fusion mainly improves image contrast, background suppression, and segmentation consistency at the image level. Among the compared methods and under the present experimental conditions, entropy-weighted fusion provides the best overall imaging performance. Under the present experimental conditions, the proposed framework enables reliable detection of 5 mm debonding defects in aluminum-alloy–rubber bonded specimens and 10 mm debonding defects in titanium-alloy–rubber bonded specimens. These results suggest that the combined use of magnetic-field focusing and adaptive multi-feature fusion is a promising approach for the detection and quantitative characterization of micro-debonding defects in metal–rubber bonded structures. Full article

Seafloor hydrothermal systems at mid-ocean ridges are focal points for heat and matter exchange between the seawater and lithosphere. While seafloor seismographs (OBS) and pressure recorders (BPR) are standard for regional monitoring, achieving high-precision, vertical sub-surface data in complex hydrothermal terrains remains a significant technical objective. This study presents a novel in situ penetration probe designed for multi-parameter monitoring of marine hydrothermal vent areas. A key innovation of this work is its operational versatility and engineering efficiency: the probe is specifically designed for post-drilling deployment in boreholes, effectively utilizing existing coring sites to achieve direct coupling with the deep-seated crust, or for targeted placement via Remotely Operated Vehicles (ROVs). The device integrates a titanium-alloy conical tip and cylindrical chamber, housing tri-axial accelerometers and dual temperature-pressure sensors. Numerical simulations using the SST k-ω turbulence model and finite element analysis optimized the cone aperture and assessed fluid–structure stability under deep-sea conditions. Laboratory vibration tests and shallow-water sea trials validated the probe’s basic dynamic response, electromechanical integrity, and capability to acquire coupled environmental parameters. This compact, modular design provides a scalable and cost-effective framework for precise three-dimensional observation of sub-surface hydrothermal processes and deep-sea resource exploration. Full article

In the 21st century, the desire for improved fuel efficiency of engines, lower fuel prices, and the need to reduce greenhouse gas emissions such as ${\mathrm{C}\mathrm{O}}_2$ and ${\mathrm{N}\mathrm{O}}_{\mathrm{x}}$ are leading the aviation industry to seek hybrid-electric jet engines for commercial aircraft. These aircraft will have greater maintenance challenges due to additional components requiring more reliable materials for the engine’s parts, such as turbine blades. Turbine blades must be composed of materials that have enhanced fatigue performance. Resistance to dynamic loads and high strength will be needed to ensure modern gas turbine blades are as reliable as possible. This review paper examines hybrid-electric engine turbine blades and subsequently introduces additive manufacturing (AM) and multi-principal element alloys (MPEAs) with a focus on laser powder bed fusion (LPBF), high-entropy alloys (HEAs), and medium-entropy alloys (MEAs). The tensile properties of LPBF HEAs range from 5 to 47% elongation and a UTS of 572–1640 MPa, while LPBF MEAs range from 8 to 73.9% and a UTS of 573–1382 MPa. This study focused on dynamic and fatigue properties while acknowledging gaps in high-temperature testing. The combination of mechanical properties with the ability to control internal geometry makes these AM alloys an attractive option for the next generation of gas turbine blades. Full article

Vacuum arc remelting (VAR) is essential for producing premium titanium alloys, where an externally applied alternating magnetic field enables circumferential stirring to control ingot homogeneity. However, current magnetic field parameter design relies on empirical trial-and-error approaches, lacking systematic theoretical guidance. To address this issue, this study establishes a comprehensive multi-physics framework through a two-dimensional axisymmetric swirl model integrating electromagnetic, fluid dynamics, thermal, and solute transport phenomena. Our findings demonstrate that both the magnetic field strength and period exhibit optimal operating ranges, which directly influence ingot homogeneity. As magnetic field strength increases progressively, ingot uniformity shows a distinctive non-monotonic response—initially improving before subsequently deteriorating. Correspondingly, with increasing stirring period, macrosegregation undergoes a distinct three-stage evolution: initial mitigation, subsequent aggravation, and final alleviation. These phenomena originate from the small-scale circulatory flow generated by the external magnetic field on the surface of the VAR molten pool. The interactions among the flow, the solute diffusion layer, and the mushy zone collectively alter elemental diffusion behavior, ultimately determining the homogeneity of the ingot. This study provides a theoretical foundation for precise control of ingot homogeneity in titanium alloy VAR processes and demonstrates significant potential for engineering applications. Full article

High-strength stainless steels are essential materials for critical load-bearing aerospace components, and solution treatment serves as a core process governing their strength–toughness balance. However, in novel multi-element alloy systems, the complex dissolution behavior of precipitates and its underlying mechanisms affecting matrix phase transformations require further investigation. This study systematically explores the thermodynamic evolution and microstructural response of a novel Fe-Ni-Cr-Mo-Al-Ti ultra-high-strength stainless steel during solution treatment. The research highlights how solution temperature drives Laves phase dissolution, controls prior austenite grain growth, redistributes local chemical elements, and dictates retained austenite stability. By establishing the relationship between microstructural features and macroscopic properties, this study aims to provide crucial theoretical guidance for optimizing heat treatment protocols to achieve superior comprehensive mechanical properties in advanced high-strength stainless steels. Full article

The microstructure, phase composition, and high-temperature oxidation behavior of Al_0.5CoCr_0.5NiPt_0.1 and AlCoCr_0.5NiPt_0.1 multi-principal element alloys (MPEAs) at 1100 °C in air were investigated. Depending on the content of aluminum, the microstructure of as-cast samples contains FCC and BCC solid solutions. Similarly, the ratio of two solid solutions varies depending on the aluminum content in the alloy. When the content of aluminum is x = 0.5, the microstructure is dominated by the FCC solid solution, while a BCC solid solution is dominated when the concentration of aluminum is increased to x = 1.0. Moreover, in both MPEAs, platinum exists as a part of solid solutions rather than a separate phase. High-temperature oxidation was carried out in a Plavka.Pro PM-1 SmartKiln muffle furnace under isothermal conditions at 1100 °C for 100 h exposure in air, and weighing was performed every 10 h. The maximum specific weight gain for the Al_0.5CoCr_0.5NiPt_0.1 alloy was 0.965 mg/cm², and 0.675 mg/cm² for the AlCoCr_0.5NiPt_0.1 alloy. Based on the high-temperature oxidation experiment results, it was established that AlCoCr_0.5NiPt_0.1 MPEA exhibits greater resistance towards high-temperature dry air corrosion with the formation of an exclusive Al₂O₃ scale on the surface with 3–5 μm thickness; the parabolic oxidation rate constant for this alloy is k_p = 20.2 × 10^–13 (g²/cm⁴s). Introduction of platinum into the composition of the Fe-free AlCoCr_0.5Ni alloy reduces the value of the parabolic oxidation rate constant by half. Full article

Lightweight high-entropy alloys are primarily designed to overcome the strength-to-density ratio limitations of conventional counterparts and often consist of elements with drastically different melting temperature and vapor pressure. Their chemistry, therefore, imposes challenges on alloy synthesis, particularly through liquid metal engineering routes, since elements with high vapor pressure (e.g., Mg, Zn, Li) vaporize before the higher-melting-point ingredients (e.g., Cu, V, Ni) are fully molten, resulting in volatile element loss. To overcome this challenge, a novel pressure-assisted induction melting (PAIM) process was developed and the proprietary furnace for its implementation was designed and built. The system allows precision melting of up to 10 cm³ of an alloy at temperatures up to 1700 °C while addressing the partial pressure requirements during the melting progress. The chamber is prepared using rough vacuum and re-filled with inert gas such as argon with the operating pressure range from about 10⁻⁴ MPa up to maximum of 1.6 MPa (233 psi). The alloy chemical composition can be modified in situ by feeding solid additives at specific melting stages through the isolated airlock without disrupting the pressure conditions within the chamber. The viability of the concept was verified by synthesis of two lightweight non-equimolar high-entropy alloys: Mg-rich Mg₅₀(MnAlZnCu)₅₀ and Al-rich Al₃₅Mg₃₀Si₁₃Zn₁₀Y₇Ca₅. The experiments showed that sequential multi-step melting procedures, designed based on inputs from FactSage computational analysis, when combined with PAIM synthesis, allowed manufacturing fully dense and chemically homogenous complex alloy compositions with optimal volumes for materials discovery research. Full article

To address the issues of high cutting temperatures and severe tool wear during titanium alloy machining, this study proposes a hybrid surface modification strategy combining micro-textures and multicomponent titanium nitride (TiN)-based coatings on cemented carbide tools. Using YG8 cemented carbide as the substrate, micro-dimple textures were fabricated by fiber laser, and three coatings with different architectures (TiAlSiN, TiSiN/TiAlN, and TiSiN/TiAlSiN/TiAlN) were deposited via multi-arc ion plating technology. Based on a two-factor (texture diameter and texture spacing) and three-level orthogonal experiment, the evolution behaviors of surface morphology, phase composition, and mechanical properties of the textured multicomponent TiN-based coatings were systematically characterized and comparatively analyzed. The results reveal that: compared to the monolithic-structured TiAlSiN coating, the TiSiN/TiAlSiN/TiAlN and TiSiN/TiAlN composite coatings with multilayered composite structures can effectively relieve the residual stress inside the film–substrate system, and significantly suppress the phenomena of coating cracking and localized spallation caused by irregular protrusions of the recast layer at the micro-texture edges. X-ray diffraction (XRD) and crystallite size analyses indicate that the amorphous Si₃N₄ phase promoted by the Si element in the composite coatings effectively impedes the growth of TiN columnar crystals, achieving significant grain refinement. Mechanical property tests confirm that the existence of multicomponent composite interfaces effectively hinders dislocation movement. Among them, the textured TiSiN/TiAlSiN/TiAlN composite coating exhibits the optimal comprehensive performance; its microhardness, nanohardness, and H/E ratio (characterizing the resistance to plastic deformation) are increased by 17.94%, 8%, and approximately 45%, respectively, compared to those of the textured TiAlSiN coating. This study deeply elucidates the synergistic strengthening and toughening mechanisms between micro-texture parameters and the internal structures of the coatings, providing important theoretical guidance and experimental data support for the surface design of long-lifespan tools oriented towards the high-efficiency machining of titanium alloys. 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

The trade-off between strength and ductility remains a pivotal challenge in the development of multi-principal element alloys (MPEAs) for structural applications. Here, we report a dual-scale ordering strategy to achieve triple strengthening in a Ni-26.6Co-18.4Cr-5.4Nb-4.1Mo-2.3Al-0.3Ti-0.05Y (wt.%) MPEA through the synergistic interplay of L1₂ nanoprecipitates and local chemical order (LCO). The alloy was processed via cold rolling followed by aging at 750 °C for 8 h, resulting in a high density of coherent L1₂ precipitates (average size 47 ± 1 nm, volume fraction ~27%) with an ultra-low lattice misfit of 0.5%. Additionally, sub-nanoscale LCO domains with an average diameter of 0.62 nm were identified within the face-centered cubic matrix. This hierarchical microstructure yields an exceptional combination of mechanical properties at room temperature: yield strength of 1480 ± 6 MPa, ultimate tensile strength of 1678 ± 10 MPa, and a total elongation of 13.9 ± 0.2%. Quantitative strengthening analysis reveals that precipitation strengthening (697 MPa) is the dominant contributor, followed by dislocation strengthening (397 MPa). Transmission electron microscopy characterization of deformed samples reveals that the low stacking fault energy, promoted by LCO, facilitates the dissociation of perfect dislocations and the formation of extensive stacking faults. The intersection of stacking faults on different {111} planes generates a large number of Lomer–Cottrell locks, which significantly enhance work hardening and delay plastic instability. The findings demonstrate that engineering dual-scale ordered structures offers a promising pathway for developing MPEAs with a superior strength-ductility combination. Full article

This study presents a systematic literature review on the environmental impact of industrial applications of Rare Earth Elements (REEs), particularly those classified as Critical Raw Materials (CRMs), such as Neodymium alloys. These materials are key components of permanent magnets (PMs) used in electrical machines, including automotive applications, wind turbine generators, and various consumer electronics. A structured methodology began with a comprehensive search across multiple scientific databases utilizing primary and secondary keywords. Studies were selected through a multi-step process, including screening by title, abstract, and full-text review, ensuring the inclusion of relevant and high-quality research. This approach allowed for a rigorous and reproducible assessment of the literature. The review was conducted to address two central issues: the main environmental impacts of using rare earths in permanent magnets for electric motors, and the role of recycling and reuse strategies in reducing them. The review summarizes current knowledge on the life cycle environmental impacts of REEs, from extraction to end-of-life management, highlighting opportunities and challenges in recycling and reuse. While recycling can partially reduce environmental impact, significant gaps remain in efficiency and large-scale feasibility. The literature also emphasizes the substantial impacts of REEs in permanent magnets, including resource depletion, energy use, and emissions. Overall, the study highlights the need to integrate environmental considerations into the design and management of REE-containing systems and identifies research gaps to support more sustainable and efficient materials management. Full article

A Cu-containing FeCrMnNiAl multi-principal element alloy was processed by laser-based and electron beam-based powder bed fusion (PBF-LB/M and PBF-EB/M) to investigate processing–microstructure–property relationships. In focus were alloy variants with a relatively high Cu content. Two PBF-LB/M scan strategies, employing a Gaussian beam with and without a re-scan with a laser featuring a flat-top profile, were compared to PBF-EB/M processing, followed by heat-treatments between 300 °C and 1000 °C. The phase constitution, elemental partitioning and grain boundary characteristics were analyzed by X-ray diffraction, electron backscatter diffraction and energy-dispersive X-ray spectroscopy. Mechanical behavior was assessed by hardness and tensile testing. Both manufacturing routes promoted the evolution of stable multi-phase microstructures composed of face-centered-cubic (FCC)- and body-centered-cubic (BCC)-type phases across all heat-treatment conditions. PBF-LB/M processing resulted in finer, dendritic microstructures and suppressed formation of a Cu-rich FCC phase due to higher cooling rates, whereas PBF-EB/M promoted the evolution of Cu-rich FCC segregates and equiaxed grain morphologies. Heat-treatment above 700 °C led to recrystallization, accompanied by an increase of the FCC phase fraction, grain coarsening, and recovery. At lower heat-treatment temperatures, the changes in microstructure are different. Here, it is assumed that small, non-clustered Cu-rich precipitates formed at the grain and sub-grain boundaries, although this assumption is only based on the assessment of the mechanical properties. The size of these precipitates is below the resolution limit of the techniques applied for analysis in the present work. Additional structures seen within the Cu-rich areas of PBF-EB/M-manufactured samples treated at lower temperatures also seem to have an influence on the hardness and yield strength. All of the conditions investigated exhibited pronounced brittleness, limiting reliable tensile property evaluation and indicating the need for further optimization of processing strategies and microstructural control for high-Cu-fraction-containing multi-principal element alloys. Full article

Multi-material structures based on titanium alloys represent a promising approach for the fabrication of functionally graded orthopedic implants capable of combining high mechanical strength with reduced stiffness to minimize the stress-shielding effect. In the present work, multi-material Ti15Ta/Ti6Al4V specimens were fabricated by laser powder bed fusion (L-PBF) for the first time, and the processing parameters of the transition zone were systematically optimized. Three regimes were investigated: baseline (93 J/mm³), double scanning (186 J/mm³), and reduced speed (116 J/mm³). The microstructure and elemental distribution were examined by SEM and EDS; mechanical properties were evaluated through tensile testing and microhardness measurements; biocompatibility was assessed using osteoblasts and gingival fibroblasts. The double scanning regime provided the highest density of the transition zone (99.49%). Tensile failure of the specimens occurred in the Ti15Ta region, confirming the quality of the metallurgical bond. The ultimate tensile strength ranged from 534 to 543 MPa with an elongation at break of 15.7–16.4%. Heat treatment at 875 °C led to the formation of an equilibrium lamellar microstructure and smoothing of the interface. Cell viability on both alloys exceeded 88% as confirmed by flow cytometry and remained above the 70% non-cytotoxicity threshold defined by ISO 10993-5. The obtained results demonstrate the technological feasibility of fabricating multi-material Ti15Ta/Ti6Al4V structures and achieving high-quality metallurgical bonding, which constitutes a necessary first step toward the development of functionally graded orthopedic implants. Full article

This review develops a materials-to-clinic framework for patient-specific, functionally graded (FG) NiTi shape memory alloy (SMA) rods as a complementary paradigm for scoliosis correction that targets durable alignment with motion preservation. The article synthesizes the thermomechanical basis of NiTi (thermoelastic martensitic transformation, near constant superelastic plateau, and hysteretic damping) while leveraging additive manufacturing (AM) capabilities to spatially program transformation temperatures (e.g., A_f), effective stiffness, and geometric inertia along the rod. Consolidated process–structure–property linkages are provided for the PBF-LB, DED, and BJAM routes, together with contamination and composition-control strategies (mitigation of Ni volatilization; management of O/C uptake; gradient heat treatments) and segment-level quality assurance (DSC mapping, micro-CT, EBSD/indentation, and bench bending/torsion in physiologic media). Building on clinical curve classification, the methodology formalizes a grading mask and target moment vector that drive multi-objective optimization of the segmental A_f, relative density/architecture, and cross-section, followed by route-specific build plans and acceptance tolerances. A phenomenological constitutive description provides the forward map from local design variables to temperature-dependent moment–curvature loops for finite element verification and uncertainty control. Surgical handling and activation policies are codified (cold shaping in martensite and controlled intra-/postoperative warming within tissue-safe bounds), and a translational roadmap is outlined, encompassing prospective calibration of classification-to-design mappings, AM process maps with in situ monitoring, digital twin planning, and long-horizon fatigue/corrosion protocols. The proposed graded structures provide an adaptive transformation temperature gradient and tunable mechanical response, representing an important design direction toward 3D-printed, patient-specific SMA rods for durable, adjustable, and efficient scoliosis correction. Full article

Vanadium (V), molybdenum (Mo), iron (Fe), and aluminum (Al) are crucial alloying elements in certain high-performance titanium alloys. Traditionally, these elements are added to titanium alloys in the form of binary master alloys such as V-Al, Mo-Al, and Ti-Fe. The preparation and use of multiple master alloys complicates titanium alloy production and increases cost. It is therefore desirable to introduce a single multi-component master alloy containing several alloying elements into the titanium alloy smelting process. This study proposes an aluminothermic co-reduction process for V₂O₅ and MoO₃ to form a V-Al-Mo-Fe alloy with Al and Fe. Thermodynamic analysis indicates that the reduction of MoO₃ by aluminum takes precedence over that of Fe₂O₃ and V₂O₅. Utilizing metallic iron as the iron source can effectively control the heat release of the system and reduce aluminum consumption. The formation of an Al-Fe alloy prior to the aluminothermic reactions decreases the reducibility of Al. Experiments confirmed that a specific Al/O ratio in the starting materials is necessary to complete the aluminothermic reduction of V₂O₅ and MoO₃. The results show that the recovery rates of V, Mo, and Fe are strongly influenced by the Al/O ratio. When the Al/O ratio exceeds 1.6, recovery rates over 99% can be achieved for all alloying elements, with complete reduction of vanadium oxide and clear slag–alloy separation. This research provides a fundamental basis for preparing V-Al-Mo-Fe multi-component master alloys, demonstrating significant potential for applying the aluminothermic process to the preparation of other alloys. Full article