Search Results (86)

To investigate the effects of trace phosphorus (P) addition on the solidification behavior, microstructure, and local mechanical response of β-Sn alloys, Sn–P alloys containing 0.02, 0.05, and 0.08 wt.% P were prepared. Phase constitution, solidification characteristics, and nanomechanical properties were characterized by X-ray diffraction, thermogravimetry–differential scanning calorimetry, and nanoindentation, respectively. Electron backscatter diffraction was additionally conducted on representative pure Sn and Sn–P0.08 samples to qualitatively compare the endpoint microstructures. All alloys were primarily composed of β-Sn, while localized P-rich secondary regions in Sn–P0.08 were indexed as Sn₄P₃. Trace P promoted heterogeneous nucleation and markedly modified solidification, increasing the solidification peak temperature by approximately 20–22 °C and reducing the undercooling from 39.83 °C to 17.50–20.33 °C. Relative to pure Sn, Sn–P0.08 exhibited more grain regions and grain boundaries, together with pronounced dendritic and locally refined features, indicating modified β-Sn nucleation and growth. Young’s modulus and hardness of Sn–P0.08 reached 29.86 GPa and 0.232 GPa, respectively. Inverse nanoindentation analysis revealed increased representative stress, strain-hardening exponent, and strength coefficient. Fracture-energy analysis showed superior crack-growth energy dissipation for Sn–P0.02, whereas Sn–P0.08 exhibited greater resistance to plastic deformation. Full article

Simultaneous multi-ion detection is important for interpreting leaching, corrosion, hydration, and solidification processes in cement-based materials, because these processes are controlled by coupled ion migration, binding, and precipitation–dissolution reactions. Conventional methods such as pore-solution extraction, ion chromatography, inductively coupled plasma optical emission spectroscopy, and single-ion potentiometric measurements provide useful chemical information, but they generally rely on discrete sampling or isolated ion channels and therefore have limited ability to capture time-aligned multi-ion evolution. In this study, an IoT-based in situ multi-ion detection system was developed by integrating ion-selective electrodes for Cl⁻, Ca²⁺, F⁻, and H⁺ with an ADS1115 analog-to-digital converter, an ESP32 microcontroller, and a voltage amplification module. The system achieved minimum resolvable concentrations of 10⁻⁵ M for Cl⁻ and F⁻ and 10⁻⁴ M for Ca²⁺, while maintaining pH measurement over the range of 2–12. Ten consecutive measurements at 0.01 M showed relative standard deviations below 0.12%, indicating good short-term repeatability under laboratory calibration conditions. Interference and temperature tests showed that Br⁻ and NO₃⁻ affected the chloride channel at high concentrations, Ca²⁺ reduced free F⁻ activity through Ca–F precipitation equilibrium, and the temperature drift of Cl⁻ and F⁻ electrodes changed direction with concentration, whereas the Ca²⁺ response decreased monotonically with increasing temperature. When applied to phosphogypsum–cement hardened pastes, the system captured rapid Ca²⁺ release, low-level F⁻ fluctuation controlled by Ca–F interaction, non-monotonic Cl⁻ release, and alkaline pH evolution on the same time axis. Compared with existing single-ion or offline methods, the proposed system provides synchronized in situ evidence for interpreting coupled ion leaching in cement-based solid-waste systems. Full article

High-speed laser cladding shows significant potential for application in the field of high-performance surface hardening due to its low heat input and high cladding efficiency. However, the pool solidification time is significantly reduced at high scanning speeds, resulting in a narrower process window and making it more difficult to ensure coating formation stability and control performance. Therefore, this study employed high-speed laser cladding technology to prepare FeCrNiB alloy coatings, and systematically conducted research on process parameter optimization and friction properties. Firstly, the response surface method (RSM) was used to establish quantitative relationship models between laser power, scanning speed, and powder feed rate and the dilution ratio, forming coefficient, and microhardness. Then, the hybrid differential evolution and NSGA-II algorithm (DE-NSGA-II) was employed for multi-objective optimization. Finally, a systematic analysis was conducted on the friction and wear properties of the coatings produced under the optimal process parameters. The results indicate that the interaction between laser power and scanning speed has a significant impact on the dilution behavior of the coating, while the coupling between scanning speed and powder feed rate governs the formation characteristics and microhardness evolution of the coating. The experiment verified that the prediction error for the optimal parameters is controlled within 5%, demonstrating good engineering applicability. Further analysis indicates that grain refinement and the formation of strengthening phases in the optimal coating are the key mechanisms behind the significant improvement in hardness and wear resistance, and the coating primarily exhibits a mild abrasive wear mechanism. This work realizes the multi-objective optimization of the high-speed laser cladding process via RSM and DE-NSGA-II algorithm, which provides a novel and efficient method for parameter optimization and engineering application of high-speed laser cladding. Full article

Magnesium phosphate cement (MPC) is a type of rapid-hardening inorganic cementitious material, which has important application value in rapid road repair, solidification of hazardous and radioactive waste, and other fields. However, it suffers from excessively fast setting and hardening and a short working time retention, which severely restrict its engineering application. Therefore, the development of high-efficiency set retarders is of great significance for optimizing MPC performance, enhancing its construction workability, and expanding its application scope. In this study, the effect of sodium polyacrylate (PAAS) on the setting and hardening of magnesium potassium phosphate cement (MKPC) was investigated by testing the setting time and fluidity at a low water-to-solid ratio (W/S = 0.18). Through pH and electrical conductivity measurements, combined with XRD, TG/DTG, and FTIR characterizations, we elucidated the retarding mechanism of PAAS on MKPC using a high water-to-solid ratio (W/S = 10). The results indicate that the setting time of MKPC is positively correlated with the PAAS dosage, whereas the fluidity and compressive strength exhibited a negative correlation with the PAAS dosage. Additionally, PAAS reduces the total heat release and the heat release rate of MKPC. The addition of PAAS increased the pH of the suspension, thereby reducing the solubility of MgO, but did not inhibit the dissolution of KH₂PO₄. The carboxylate groups in PAAS chemically reacted with Mg²⁺ on the surface of MgO to form magnesium carboxylate complexes (Mg-PAA), which remained as precipitates in the MKPC suspension system, thus reducing the amount of available Mg²⁺ participating in the hydration reaction. Furthermore, PAAS had no effect on the final precipitate composition at the end of hydration, which was composed of MgKPO₄·6H₂O and Mg₃(PO₄)₂·22H₂O in all cases. Full article

Modern materials science is focused on the development of steels with a range of performance characteristics, including high strength, wear resistance, corrosion resistance, and long-term performance in various conditions. Special attention is paid to the control of the microstructure of steels at the crystallization stage, which allows for the improvement of metal properties without significantly increasing the cost of the manufacturing process. One of the promising methods of microstructural engineering is the modification of steels with dispersed particles of refractory compounds, such as titanium carbide (TiC), zirconium carbide (ZrC), and tungsten carbide (WC). However, the processes of dissolution, dissociation, and interaction of such ceramic particles with the metal melt, as well as their influence on the formation of the microstructure and properties under the conditions of non-equilibrium crystallization, which is typical for centrifugal casting, are not sufficiently studied for austenitic stainless steels. In this work, the influence of dispersed carbide particles of TiC, ZrC, and WC, which are introduced into the melt of austenitic stainless steel (Cr ≈ 18%, Ni ≈ 10%) during centrifugal casting, on the redistribution of alloying elements, the formation of the microstructure, and the mechanical properties of the material is investigated. Special attention is paid to the kinetic nature of the dissolution and interaction of the carbides with the melt, as well as the directional distribution of elements across the cross-section of the billets. The study includes the analysis of the distribution of Ti, W, and Zr across the cross-section of the centrifugally cast billets, the study of the microstructure and phase composition of the inclusions using SEM/EDS, and mechanical testing. It is found that the implementation of dispersion hardening leads to an increase in the tensile strength by up to ~22% compared to the initial alloy (from 496 to 612 MPa), while the impact strength decreases by 5–25% (from 110 to 82 J/cm²) depending on the type and quantity of the introduced particles. The analysis of microhardness shows the presence of a gradient of local properties across the cross-section of the centrifugally cast billets, with microhardness values ranging from ~110 to 195 HV0.5. For the modified samples, the relative difference between the inner and outer zones is ~5–20%, reflecting the combined effect of non-equilibrium solidification, redistribution of alloying elements, formation and spatial distribution of secondary phases, and local structural heterogeneity. These results confirm the possibility of controlling the distribution of properties within a single billet. Full article

This study investigates the solution and artificial aging processes of TiB₂/7050 composites. Using microscopic and mechanical tests, we systematically evaluate the material’s microstructural evolution and mechanical performance, aiming to optimize heat treatment parameters. The study shows that a solution temperature of 475 °C for 1 h is optimal for fully dissolving the second-phase particles. Regarding artificial aging, peak hardness of 246 HV is achieved at 140 °C for 16 h. Analysis of the phases and microstructure in O and T6-states shows that strengthening occurs through grain boundary hardening and precipitation hardening. The effect of TiB₂ particles on the above process was also explored. During solidification, TiB₂ particles were pushed by the advancing solid–liquid interface and primarily distributed along grain boundaries. This distribution subsequently slowed the solid solution process by reducing the contact area between the η(MgZn₂) phase and the α(Al) matrix. During aging, they enhance grain boundary precipitates (GBPs) in particle-rich regions and inhibit the formation of precipitate-free zones (PFZs), with a concentration of the η’ phase forming around the particles. Beyond a certain distance from the particles, there is a decrease in η’ phase concentration. This study is expected to contribute to advanced lightweight materials research and development, opening up new opportunities for their application in various industries. Full article

Current research on rapid-setting geopolymers primarily focuses on accelerating the “dissolution-gelation” reaction process (including dissolution, polycondensation, and hardening) to achieve the faster solidification of the material. In this work, the low-temperature crystallization phenomenon of sodium silicate solution is innovatively introduced into the geopolymer system, and a rapid-setting strategy is proposed by exploiting the synergistic effects of a low preparation temperature and a low activator modulus (the SiO₂/Na₂O molar ratio) to intentionally induce the rapid crystallization of the alkali activator solution (sodium silicate solution), thereby enabling rapid setting of the geopolymer. Experimental results show that, at a preparation temperature of 0–10 °C and an activator modulus of 1.0, the final setting time of the metakaolin-based geopolymer is shortened to 20 min, corresponding to a reduction of up to 91.63%. Unlike the typical “dissolution stage–gelation stage–hardening stage” route of conventional geopolymers, the rapid-setting geopolymer in this study follows a distinct reaction sequence of “hardening stage–dissolution stage–gelation stage”. Meanwhile, to further enhance performance and expand pathways for solid waste valorization, vanadium-extraction shale tailings (VST) were employed to partially replace metakaolin. The results indicate that, with a tailings replacement of 30%, an alkali-to-solid ratio of 0.4, and an alkali-to-water ratio of 0.7, the rapid-setting geopolymer achieves a compressive strength of 38.32 MPa. These findings confirm the broad applicability and practical potential of the proposed approach for emergency repair in cold regions and solid waste utilization. Full article

Post-grouting is an active reinforcement technique that can significantly enhance the bearing performance of bored piles. This study conducted field tests on three in situ test piles using tip grouting, side grouting, and combined tip-side grouting. Based on the analysis of static load test data, the improvement effects of different grouting methods on the vertical bearing behavior of the piles were quantified. In situ tests were then performed to elucidate the reinforcement mechanisms of various post-grouting techniques on the pile foundations. Based on the validated finite element model, the study explored the influence of key grouting parameters on the bearing performance of grouted piles. Analysis of the test data shows that all grouting methods improved the vertical bearing capacity of bored piles. The positive effect of tip grouting was more pronounced than that of side grouting. Furthermore, in the clay layer of the soft soil region, side grouting primarily manifested as splitting grouting, while tip grouting formed a hardened grout bulb at the pile tip through cementation and solidification, thereby significantly enhancing the mobilization of the pile tip bearing capacity. Finite element model analysis shows that, in terms of enhancing the bearing capacity of the pile, expanding the grout diffusion range is more effective than increasing the grout material strength. Full article

Portland cement (PC) is widely regarded as a cost-effective and reliable binding material for the stabilization and solidification of municipal solid waste incineration fly ash (MSWI FA). However, the soluble salts and heavy metals present in MSWI FA retard PC hydration, thereby limiting the amount of fly ash that can be incorporated. The present study investigates the feasibility of normalizing the hydration of PC-based mixtures containing MSWI FA by applying a fly ash pre-granulation step with 25% PC, followed by coating the resulting granules with a geopolymer layer to reduce the release of harmful ions during the early stages of hydration. Isothermal calorimetry, TG/DTA, XRD, SEM, and mechanical testing were used to investigate the hydration characteristics of composites containing such granules and to assess their properties at 7, 28, and 90 days. It was found that a 20% substitution of PC with the studied FA disrupted PC hydration within the first 48 h. In contrast, both types of granules exhibited the main exothermic peak within the first 10–12 h, with hydration heat release (about 300 J/g) comparable to that of sand-containing references. Uncoated granules exhibited more active behavior with hydration kinetics similar to pure cement paste, whereas the effect of geopolymer-coated granules was close to sand. TG/DTA revealed reduced calcite content in mixtures containing granules, whereas uncoated granules promoted greater portlandite formation than the sand-based system. Hardening the samples under wet conditions resulted in the development of a dense cement matrix, firm integration of the granules, redistribution of chlorine and sulfur ions, and mechanical properties that reached at least 93% of those of the sand-containing reference, despite a lower density of ~4.5%. Full article

Severe lost circulation frequently occurs in deep and ultra-deep wells under high-temperature/high-pressure (HPHT) conditions and in fracture-cavity composite loss channels. Conventional lost-circulation materials (LCMs) often fail because of premature loss of mobility, insufficient residence in loss paths, and irreversible failure after solidification. Cement-based sealing systems, owing to their ability to plug large leakage channels and their cost-effectiveness, have become the mainstream solution. To improve their performance under extreme downhole conditions, recent studies have focused on base-cement design, reinforcement phases, and property regulation strategies-including the use of granular/fibrous/nanoscale additives for bridging reinforcement, rheology and thickening control to enhance injectability and residence, and chemical/functional modifiers to improve compactness and durability of the hardened matrix. Significant progress has been achieved in terms of HPHT resistance, densification design, regulation of rheological properties and thickening behavior, and self-healing/responsive sealing functions. However, most existing studies still focus on improving individual properties and lack a cross-scale, holistic design and unified mechanistic perspective for fracture-cavity coupled flow and long-term sealing stability. Distinct from previous reviews that mainly catalogue material types or discuss single-performance optimization, this review is framed by fracture-cavity composite loss channels and long-term sealing requirements under HPHT conditions, systematically synthesizes the material design strategies, reinforcement mechanisms and applicability boundaries of cement-based plugging systems, builds cross-scale linkages among these aspects, and proposes future research directions toward sustainable plugging design. Full article

In manufacturing processes, both material processing methods and the resulting microstructure play a fundamental role in determining material behavior during component fabrication and subsequent service conditions. Materials produced by additive manufacturing exhibit a unique microstructure due to the rapid heating and solidification cycles inherent to the process, distinguishing them from conventionally cast counterparts and leading to differences in mechanical and functional properties. This article presents problems related to the longitudinal turning of Ti6Al4V titanium alloy elements produced by the casting and powder laser sintering (DMLS) methods. The authors made an attempt to establish a procedure for determining the optimal parameters of finishing cutting while minimizing the specific cutting force, taking into account the criterion of machined surface quality. In the course of the experiments, the influence of the cutting data on the cutting force values, surface roughness parameters, and chip shape was examined. The material hardening state during machining and the variability of the specific cutting force as a function of the cross-sectional shape of the cutting layer were also tested. The authors presented a practical application of the proposed optimization algorithm. It was found that by changing the shape of the cross-section of the cutting layer, it was possible to carry out the turning process with significantly reduced specific cutting force (from 2300 N/mm² to 1950 N/mm²) without deteriorating the surface roughness. Full article

This study systematically investigated the effects of solution temperature (460–560 °C) on the microstructure, mechanical properties, and corrosion behavior of AlSi37Cu0.7Mg0.9Ni0.2 alloy rods prepared by rapid solidification and hot-extrusion. The results demonstrated that the solution temperature critically governed the alloy’s recrystallization behavior, precipitation kinetics, and phase distribution. With the increase in solution temperature, the alloy exhibited progressive grain coarsening (from 4.51 μm at 460 °C to 13.25 μm at 560 °C) and enhanced precipitation hardening, leading to a 108.8% increase in hardness (198.4 HV at 560 °C) but a concurrent reduction in ductility (from 2.5% to 1.0%). Electrical conductivity initially improved by 3.4% at 460 °C (27.44% IACS) compared with the extruded state, but deteriorated at higher temperatures due to increased electron scattering. Anodic oxidation tests revealed a non-monotonic corrosion trend, with maximum weight loss (57.50 mg·g⁻¹) occurring at 480 °C due to microstructural inhomogeneity, while higher temperatures (560 °C) partially restored corrosion resistance. Electrochemical analysis corroborated these findings, showing the 480-treated sample exhibited the lowest corrosion potential (−1.0159 V). Microstructural characterization confirmed that optimal mechanical properties were achieved through a combination of fine β″-Mg₂Si (<20 nm), θ′-Al₂Cu precipitates, and thermally stable Al₃Ni phase. These results established a comprehensive process-structure-property relationship, which provided critical guidance for tailoring the alloy’s performance in structural–functional applications. Full article

Erosion wear is a major cause of surface degradation in metallic materials exposed to harsh marine environments. In this study, the erosion wear resistance of the 18Ni300 maraging steel repaired by underwater direct metal deposition (UDMD) is investigated. Results show that UDMD is successfully applied to repair the 18Ni300 samples in underwater environment. Full groove filling and sound metallurgical bonding without cracks are achieved, demonstrating its potential for underwater structural repair. Microstructural analyses reveal good forming quality with fine cellular structures and dense lath martensite in the deposited layer, attributed to rapid solidification under water cooling. Compared to in-air DMD, the UDMD sample exhibits higher surface microhardness due to increased dislocation density and microstructural refinement. Erosion wear behavior is evaluated at 30° and 90° impingement angles, showing that wear mechanisms shift from micro-cutting and plowing at 30° to indentation, crack propagation, and spallation at 90°. The UDMD samples demonstrate superior erosion wear resistance with lower mass loss, particularly at 30°, benefiting from surface work hardening and microstructural advantages. Progressive surface hardening occurs during erosion due to severe plastic deformation, reducing wear rates over time. The combination of refined microstructure, high dislocation density, and enhanced work hardening capability makes UDMD-repaired steel highly resistant to erosive degradation. These findings confirm that UDMD is a promising technique for repairing marine steel structures, offering enhanced durability and long-term performance in harsh offshore environments. Full article

Directed Energy Deposition-Laser Beam (DED-LB) is an ideal Additive Manufacturing (AM) process to obtain very complex geometries, which can be important for several applications in industries such as aerospace and biomedical engineering. The present study aims to determine optimized DED-LB parameters for printing 17-7 PH stainless steel, a semi-austenitic precipitation-hardening alloy renowned for its exceptional combination of high yield strength, toughness, and corrosion resistance. The experimental work used different combinations of laser power, scanning speed, and powder feed rate to investigate the effects on the morphology, surface roughness, and microstructure of the deposited material. The results indicated that a powder feed rate of 4.7 g/min yielded uniform beads, reduced surface roughness, and increased substrate dilution, enhancing the metallurgical bond between the bead and substrate. Conversely, higher feed rates, such as a rate of 9.2 g/min, resulted in increased surface irregularities due to an excessive amount of partially melted powder particles. Microstructural analysis, supported by thermodynamic calculations, confirmed a ferritic–austenitic solidification mode. The austenite and ferrite fractions varied significantly, depending mainly on the substrate dilution due to the decrease in aluminum content. The combination of 400 W laser power and a 2000 mm/min scanning speed resulted in the optimal set of parameters, with an approximately 30% dilution and 80% austenite. Full article

Stainless steel wires exhibit excellent mechanical properties and are widely used in engineering applications. This study fabricates 15 μm stainless steel wires for potential integration into wire bonding technology for electronic packaging. The research explores the microstructural characteristics, electrical conduction mechanisms, and ball formation behavior of ultra-fine stainless-steel wires to assess their feasibility for wire bonding applications. Results indicate that both 15 μm and 30 μm stainless steel wires exhibit elongated grains with outstanding tensile strength and hardness. Compared to the 30 μm wires, the 15 μm wires undergo more pronounced work hardening, leading to higher tensile strength and resistance. This study investigates the differences between vacuum and electrified annealing processes to address the work hardening and ductility issues in stainless steel wires. Results confirm that the hardness of the original wire significantly decreases after vacuum annealing at 780 °C for 15 min. Furthermore, using the derived equation, $T={\displaystyle \frac{IV}{2.3085\times {10}^{-3}}}+25$, the annealing temperature of 780 °C is converted into an equivalent current, and electrify annealing is conducted under a condition of 0.08 A for 15 min. The annealed wires exhibit a softening effect and enhance ductility. Furthermore, due to stored deformation energy and recrystallization effects, the electrical fatigue life of 15 μm stainless steel wires is approximately 300 cycles. After electrifying annealing, the base microstructure becomes more homogeneous due to thermal effects, reducing fatigue life to around 150 cycles. However, due to the softening effect, the annealed wires make the EFO process easier and minimize solidification segregation in the free air ball (FAB) microstructure, demonstrating their potential for electronic packaging applications. Full article