Search Results (94)

Manufacturing high-performance turbomachinery blades remains one of the most demanding challenges in aerospace and energy engineering, requiring tight control over microstructure, geometry, and cooling architectures. Despite rapid progress in casting, machining, and additive manufacturing, the field lacks a structured classification that links process capabilities with blade functional requirements and future design trends. This review addresses that gap by introducing a new classification scheme for turbomachinery blade manufacturing technologies, organized into three complementary domains: (i) foundational fabrication routes (casting, forging, precision machining); (ii) advanced and hybrid processes (powder-bed fusion, directed-energy deposition, additive–subtractive systems, laser repair); and (iii) digital and intelligent manufacturing enablers (in situ monitoring, AI-driven process control, digital twins, and automated inspection). Within each class, the review maps process parameters to resulting structural performance, defect modes, cost drivers, and certification challenges. Special emphasis is placed on the manufacturing implications of emerging blade architectures, such as intricate internal cooling channels, gradient materials, and bio-inspired aerodynamic profiles. By consolidating disparate techniques into a structured taxonomy, this paper clarifies current limitations, identifies cross-technology synergies, and outlines priority research directions for achieving next-generation turbomachinery blade manufacturing. Full article

Achieving high density in complex powder metallurgy components like spur gears is often hindered by friction-induced density gradients and ejection defects. This study investigates a novel elastic die system designed to mitigate these issues through controlled radial deformation. Spur gears were compacted using Ancorsteel 2000 powder under pressures of 400–700 MPa, utilizing a tapered elastic sleeve to apply radial compression. Green and sintered densities were measured, while porosity distribution was quantified via image analysis. Additionally, a 3D finite element simulation using FORGE software was conducted to model the thermo-mechanical behavior and stress distribution during the process. Experimental trials demonstrated that the elastic relaxation of the sleeve enabled free ejection of the compacts without requiring an extraction force. Image analysis confirmed a homogenous porosity distribution across the gear teeth, and higher die pre-stressing strokes were found to correlate with increased sintered density. Finite element modeling accurately predicted critical stress concentrations of 700 MPa at the die–sleeve interface and validated the strain distribution. The results confirm that elastic die technology effectively eliminates ejection friction and improves density uniformity in complex gears, offering a viable solution for reducing tool wear and manufacturing defects in high-precision powder metallurgy. Full article

Additive manufacturing (AM) of Ti-6Al-4V alloy is widely used in aerospace and medical fields due to its excellent strength and corrosion resistance. However, the microstructural heterogeneity induced by the AM process often results in fatigue properties inferior to those of their forged counterparts. Synchrotron Radiation Computed Tomography (SR-CT) was employed to conduct an in situ three-dimensional investigation of fatigue damage evolution in Ti-6Al-4V alloy fabricated via laser powder bed fusion (LPBF). Experimental results revealed phenomena of crack bridging and deflection, accompanied by the consistent presence of local high-density zones (LHDZs) throughout the fatigue damage progression. Combined with quantitative analysis of crack propagation rates, the influence of LHDZs on fatigue damage evolution was analyzed, and the relationship between AM processes, LHDZs, and fatigue damage was discussed. The results indicate that the basket-weave α-phase microstructure in Ti-6Al-4V prepared by LPBF exhibits a high correlation with the distribution of LHDZs, and the orientation of LHDZs aligns with the crack propagation direction. By adjusting process parameters such as cooling rate and temperature gradient, the formation of LHDZs can be modified, thereby influencing the fatigue properties of the material. This provides theoretical support for achieving process optimization of the fatigue properties of Ti-6Al-4V alloy prepared via LPBF. Full article

Cold forging backward extrusion is mainly employed in the manufacturing of axisymmetric cup-like components used extensively in automotive and aerospace assemblies due to the process-induced strength that has a pivotal role in such applications. Although cold forging backward extrusion yields mechanically robust components, it demands high forces, subjecting tooling to immense stress, thereby restricting process capacity. The process encounters hindrances in gaining widespread industrial acceptance due to frequent failures of die elements, necessitating proper die design and control of major influencing factors for process viability and cost-effectiveness. The punches in backward extrusion are often susceptible to failures when processing steel billets. The punch service life is significantly affected by geometrical attributes, the type of steel undergoing deformation, and tool manufacturing aspects. Hence, the present study evaluates punch performance in cold forging backward extrusion using optimized geometrical attributes, manufactured through a design of an experimental approach comprising an L9 orthogonal array. The manufacturing factors considered are punch material, hardness, and advanced surface coating. Punches were designed for two industrial components using powder metallurgy (PM) steels—S600, S290, and S590, heat treated to 60–66 HRC, and coated via physical vapor deposition with TiN, AlTiN, and TiAlCN. Punch performance was analyzed against existing industry practices, and the strategy demonstrated improved productivity. Punch performance was determined based on the number of forgings produced before wear- and fatigue-induced failures. Significant improvements in punch performance were witnessed in both high-speed steel (HSS) and PM punches with optimized geometries. Fractographic investigations were carried out on fractured punches and analyzed, focusing on the coating’s effect on the thermal aspects of the punches. The proposed study will assist the cold-forging industry in determining appropriate variables to minimize forming responses, thereby enhancing tool life. The research also benefits industries by enhancing process robustness and improving process efficiency with respect to cost and time. Full article

This study reports the fabrication and characterization of copper–silicon carbide (Cu–SiC) metal matrix composites produced using powder metallurgy (PM) combined with thermo-compression processing (TCP), a dual route that remains limited in Cu–SiC research. Micro-sized SiC particles (1–25 wt.%) were incorporated into Cu, compacted, sintered, and subsequently subjected to sequential forging and annealing. Unlike conventional PM-only processing, TCP significantly reduced porosity, promoted more uniform reinforcement dispersion, and relieved residual stresses, creating a strong synergy between densification and microstructural refinement. SEM, EDS, XRD, and Raman analyses confirmed phase stability, homogeneous reinforcement distribution, and the absence of deleterious interfacial phases. The integrated PM + TCP route achieved an ultimate tensile strength of ~209 MPa, hardness of ~65 HRB, and toughness of ~35 MJ/m³ at approximately 3 wt.% SiC. The superior performance at this composition resulted not from the lowest porosity but from the combined effects of uniform particle dispersion, improved particle–matrix bonding, and deformation-driven refinement. These findings establish TCP as an effective post-sintering strategy that overcomes intrinsic porosity and interfacial limitations in Cu–SiC composites. Overall, powder metallurgy combined with the thermo-compression processing is identified as a promising processing pathway for developing high-strength, thermally stable Cu–SiC materials for structural and thermal management applications. Full article

This study presents the first application of Machine Learning (ML) models to optimise Powder Bed Fusion using Laser Beam (PBF-LB) process parameters for H13 steel fabricated on a 350 °C preheated building platform. A total of 189 cylindrical specimens were produced for training and testing machine learning (ML) models using variable process parameters: laser power (250–350 W), scanning speed (1050–1300 mm/s), and hatch spacing (65–90 $\mathsf{\mu }$m). Eight ML models were investigated: 1. Support Vector Regression (SVR), 2. Kernel Ridge Regression (KRR), 3. Stochastic Gradient Descent Regressor, 4. Random Forest Regressor (RFR), 5. Extreme Gradient Boosting (XGBoost), 6. Extreme Gradient Boosting with limited depth (XGBoost LD), 7. Extra Trees Regressor (ETR) and 8. Light Gradient Boosting Machine (LightGBM). All models were trained using the Fast Library for Automated Machine Learning & Tuning (FLAML) framework to predict the relative density of the fabricated samples. Among these, the XGBoost model achieved the highest predictive accuracy, with a coefficient of determination $R^2=0.977$, mean absolute percentage error MAPE = 0.002, and mean absolute error MAE = 0.017. Experimental validation was conducted on 27 newly fabricated samples using ML predicted process parameters. Relative densities exceeding 99.6% of the theoretical value (7.76 g/cm³) for all models except XGBoost LD and KRR. The lowest MAE = 0.004 and the smallest difference between the ML-predicted and PBF-LB validated density were obtained for samples made with LightGBM-predicted parameters. Those samples exhibited a hardness of 604 ± 13 HV0.5, which increased to approximately 630 HV0.5 after tempering at 550 °C. The LightGBM optimised parameters were further applied to fabricate a part of a forging die incorporating internal through-cooling channels, demonstrating the efficacy of machine learning-guided optimisation in achieving dense, defect-free H13 components suitable for industrial applications. Full article

Nickel superalloy Inconel 718 (IN718) is widely employed in harsh environments with prolonged cyclic stresses in the aerospace and energy sectors, due to its corrosion/oxidation resistance and mechanical strength obtained by precipitation hardening. This work investigates the mechanical behavior in fatigue of IN718 manufactured by Additive Manufacturing (AM), specifically by Laser Powder Bed Fusion (PBF-LB), and compares its results with the material produced by forging and rolling. Samples from both processes were subjected to heat treatments of solution and double aging to increase their mechanical strength. Then, tensile, microhardness, microstructural characterization, and uniaxial fatigue tests were performed (with loading ratio R = −1). The results showed that, although the IN718 produced by AM had higher microhardness and a higher tensile strength limit than the forged and rolled material, its fatigue performance was lower. The S–N curve (stress vs. number of cycles) for the material obtained by PBF-LB demonstrated shorter fatigue life, especially under low and medium stresses. The analysis of the fracture surfaces revealed differences in the regions where the crack initiated and propagated. The shorter fatigue life of the material obtained by PBF-LB was attributed to typical process defects and microstructural differences, such as the shape of the grains, which act as points of crack nucleation. Full article

Based on hot-compression simulations combined with SEM and TEM analyses, the high-temperature deformation behavior and mechanisms of a new nickel-based powder superalloy FGH101 were investigated over 1020–1110 °C and strain rates of 0.001–0.05 s⁻¹. From the experimental data, the variations in the strain-rate sensitivity index m, the apparent activation energy for hot deformation Q, and the grain-size exponent p were determined as functions of strain rate and temperature. Hot deformation processing maps and mechanism maps incorporating dislocation density were established. The processing maps clearly revealed the evolution of formable regions at different temperatures and strains, while the mechanism maps successfully predicted the dislocation evolution and its operative hot deformation mechanisms by introducing the grain size evolution corrected by Burgers-vector compensation and the rheological flow stress behavior compensated by the modulus. The results indicated an optimal processing window of 1060–1100 °C at 0.001–0.003 s⁻¹. Within the tested regime, as the strain rate decreased, the operative mechanism for grain-boundary sliding transitioned from pipe-diffusion control to lattice-diffusion control. These findings provide a solid theoretical basis for the design and optimization of the isothermal forging process of the new FGH101 alloy. Full article

The distinct solidification behavior of additively manufactured (AM) Inconel 718 (IN718) produces a unique microstructure and precipitation response compared with its conventionally forged counterpart, leading to fundamentally different responses to heat treatment and intermediate-temperature deformation behaviors. In this work, the intermediate-temperature (450–750 °C) deformation mechanisms of laser powder bed fusion (LPBF)-fabricated and forged IN718 alloys were systematically compared under various heat-treatment conditions. Overall, under solution treatment state, the LPBF alloy exhibited fine columnar grains, a high dislocation density, and retained δ phases along the grain boundaries, whereas the forged alloy showed coarse equiaxed γ grains without the δ phase. Under solution + aging (STA) treatment, the δ phase in the LPBF alloy effectively pinned grain boundaries and enhanced flow stress, while in the forged alloy, strengthening was dominated by the uniform precipitation of γ″ and γ′ phases. Owing to Nb consumption by δ-phase formation, the STA-treated LPBF alloy contained fewer γ″/γ′ precipitates and exhibited slightly lower strength than the STA-treated forged alloy. This study demonstrates that the inherent δ phase retention and Nb segregation in LPBF-built IN718 critically influence its precipitation behavior and deformation resistance, distinguishing it from conventionally processed alloys and providing valuable insights for microstructure design in AM-built high-temperature superalloys. Full article

Forging plays a crucial role in various industries, including aerospace, automotive, oil and gas, and defense. We investigated the effect of post-processing forging on microstructural and mechanical properties of 316L stainless steel forging preforms fabricated by laser powder bed fusion. The as-built samples were subjected to hot forging in order to refine the microstructure and enhance mechanical performance. Detailed characterization was performed using Electron Backscatter Diffraction, Scanning Electron Microscopy, Energy Dispersive Spectroscopy, Tensile testing, and Hardness Testing. Substantial grain refinement (up to 97%) was observed, in addition to a reduction in porosity. The forging process effectively transformed the columnar grain morphology into equiaxed grains, increased yield and ultimate tensile strengths of 560 MPa and 740 MPa, representing 27% and 32% improvements, respectively, with a corresponding decrease in elongation to 32% from 47%. The horizontally built samples achieved the highest yield strength of 605 MPa but slightly lower UTS 710 MPa, representing 32% and 5% increment and decrease in ductility to 28% from 37.5%. These trends reflect the combined effects of work hardening and grain refinement, which enhance strength at the expense of ductility. Full article

This study presents an experimental investigation of steels used in special knife applications, focusing on the interrelationship between chemical composition, microstructure, heat treatment, and mechanical properties. Four representative materials were analysed: VG10 (stainless steel with nickel-laminated edges and a VG10 core), RWL₃₄^TM (powder-metallurgical steel), laminated steel K110+N695 (with a nickel interlayer), and forge-welded steel K600+K720. The steels were characterised using OES, optical microscopy and SEM, supported by EDS for local chemical analysis. Microhardness testing was applied to individual structural regions to correlate carbide morphology, layer interfaces, and heat-treatment response with hardness values. The results reveal pronounced differences in structural homogeneity and defect occurrence. Powder-metallurgical RWL₃₄^TM exhibited the most uniform microstructure with finely dispersed Cr carbides, achieving high hardness and absence of structural defects. In contrast, laminated and forge-welded steels contained large primary carbides, carbide precipitation at grain boundaries, porous cavities, and insufficient cohesion in interlayers or weld zones, which may compromise toughness. VG10 and K110+N695 showed carbide coarsening caused by inadequate heat treatment, whereas K600+K720 revealed weld-related defects and heterogeneous phase structures. Overall, the study demonstrates the critical role of heat treatment and processing route in determining blade quality and performance. The findings provide guidance for optimising steel selection and processing technologies in advanced cutlery engineering. Full article

Fe-Cr-Nb-C wear-resistant alloy coatings were successfully fabricated on high-carbon forged steel via coaxial powder feeding laser cladding. The evolution of microstructure and wear resistance with varying Nb content was systematically investigated. The results indicate that appropriate NbC addition markedly modifies the distribution of grain and boundary carbides. As Nb content increases from 2.5 wt% to 3.5 wt%, nanoscale rod-like NbC precipitates form uniformly along boundaries, effectively suppressing the formation of brittle Cr₂₃C₆ precipitation. Semi-coherent NbC/matrix interfaces and NbC-induced grain refinement reduce adhesive/abrasive wear, thereby improving hardness and wear resistance. At 4.5 wt% Nb, discrete micron-sized NbC particles form within the grains, yielding optimal performance. However, excessive Nb (≥5.5 wt%) causes NbC agglomeration, inducing stress concentrations and large spallation pits that deteriorate wear resistance. This work highlights NbC morphology as a key factor for tailoring coating properties. Full article

In this paper, high-strength W-1%La₂O₃ alloy wire was obtained by solid-state doping using tungsten powder and lanthanum oxide, large deformation rotary forging and wire drawing, which solved the disadvantages of traditional tungsten alloy wire processing such as the uneven distribution of rare earth oxides. The effects of rotary forging and annealing on the microstructure and properties of tungsten alloy were studied, which provided some basis for preparing high-strength tungsten alloy wire. The results indicate that tungsten alloy undergoes recovery at relative high temperatures (1480–1380 °C) during the rotary forging process. After large deformation, subgrains and uneven microstructures appear, so annealing is required before tungsten alloys wire drawing processing. With increasing annealing temperature, the recrystallization degree gradually increases and the hardness of tungsten alloy gradually decreases. When the deformation is less than 81.2%, tungsten alloy wire exhibits brittle fracture. When the deformation increases to 88.4% (ø0.8 mm), the fracture surface of the wire exhibits a plastic–brittle mixed fracture mechanism. Full article

Enhanced Geothermal Systems (EGS) require thermochemically stable proppant materials capable of sustaining fracture conductivity under harsh subsurface conditions. This study systematically investigates the response of commercial proppants to coupled thermo-hydro-chemical (THC) effects, focusing on chemical stability and microstructural evolution. Four proppant types were evaluated: an ultra-low-density ceramic (ULD), a resin-coated sand (RCS), and two quartz-based silica sands. Experiments were conducted under simulated EGS conditions at 130 °C with daily thermal cycling over a 25-day period, using diluted site-specific Utah FORGE geothermal fluids. Static batch reactions were followed by comprehensive multi-modal characterization, including scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), X-ray diffraction (XRD), and micro-computed tomography (micro-CT). Proppants were tested in both granular and powdered forms to evaluate surface area effects and potential long-term reactivity. Results indicate that ULD proppants experienced notable resin degradation and secondary mineral precipitation within internal pore networks, evidenced by a 30.4% reduction in intragranular porosity (from CT analysis) and diminished amorphous peaks in the XRD spectra. RCS proppants exhibited a significant loss of surface carbon content from 72.98% to 53.05%, consistent with resin breakdown observed via SEM imaging. While the quartz-based sand proppants remained morphologically intact at the macro-scale, SEM-EDS revealed localized surface alteration and mineral precipitation. The brown sand proppant, in particular, showed the most extensive surface precipitation, with a 15.2% increase in newly detected mineral phases. These findings advance understanding of proppant–fluid interactions under low-temperature EGS conditions and underscore the importance of selecting proppants based on thermo-chemical compatibility. The results also highlight the need for continued development of chemically resilient proppant formulations tailored for long-term geothermal applications. Full article

The solid solution cooling heat treatment of powder, high-temperature alloys is a crucial part of the process for ensuring the strength of materials during the forging processing. The influence of the γ′ phase and other microstructures in high-temperature alloy forgings on their macroscopic mechanical properties has been confirmed in numerous studies. Among them, the performance of the γ′ phase during the solid solution cooling process varies significantly depending on the cooling rate. This study uses the FGH99 nickel-based high-temperature alloy as the research material. It examines the precipitation and microstructure evolution law of the material under different cooling rates and its impact on the macroscopic mechanical properties of the material. Additionally, a prediction model of the organizational properties based on the cooling rate is constructed. The research findings indicate that there is a distinct positive correlation between the yield strength of the material and the cooling rate. As the cooling rate increases, the yield strength rises from 910.8 MPa to 1025.4 MPa, showing an increase of 12.6%. Moreover, an increase in the cooling rate has an evident promoting effect on the refinement of the precipitation phase. When the cooling rate is elevated from 50 °C/min to 250 °C/min, the average size of the γ′ phase decreases from 106 nm to 82.1 nm, and its morphology transforms from an irregular state to a spherical shape. For the microstructure of the material, such as the size of the precipitated phase and dislocation density, the maximum prediction error of the heat treatment organization performance prediction model established in this study is 2.97%. Moreover, the prediction error of the yield strength is 1.76%. Full article