Search Results (308)

The effective removal of oxygen (O), nitrogen (N), sulfur (S), and oxide inclusions from superalloy reverts is crucial for enhancing service life and achieving cost efficiency. However, refining DZ125 superalloy presents particular challenges, as conventional processes prove ineffective against hafnium (Hf) oxides. This study introduces an innovative purification method combining droplet electron-beam melting (EBM) with centrifugal directional solidification. Through this advanced EBM technique, we successfully produced ultrapure DZ125 superalloy with nitrogen content reduced below 5 ppm and total O + N + S content below 10 ppm. Most significantly, the process nearly eliminated Hf oxides from the reverts, meeting the stringent purity standards for DZ125 superalloy. We conducted a comprehensive analysis of inclusion morphology and composition in three distinct regions: the top slag layer, final solidification zone, and interior section of the ingot processed at varying EBM power levels. Our findings reveal that MC-type carbides at the slag–crucible interface were formed. There are HfO₂, TaC, and Al₂O₃ in the final solidification zone, with notable encapsulation of HfO₂ particulates within Al₂O₃ particles; and few HfO₂ and Al₂O₃ inclusions exist in the ingot interior. It is also found that increasing EBM power from 36 kW to 46 kW significantly improved impurity removal efficiency, as evidenced by substantial reductions in both inclusion quantity and size. This enhanced purification stems from two primary mechanisms: (1) flotation of inclusions during EBM melting, facilitated by Marangoni convection, droplet stirring effects, and centrifugal forces generated by ingot rotation; and (2) decomposition of stable oxides enabled by the high-energy density characteristic of EBM and high-vacuum processing environment. This combined approach demonstrates superior capability in overcoming the limitations of traditional refining methods, particularly for challenging Hf oxide removal, while establishing an effective pathway for superalloy revert recycling. Full article

Diffusiophoresis of a liquid metal droplet (LMD) in a cylindrical pore is investigated theoretically in this study. A patched pseudo-spectral method based on Chebyshev polynomials combined with a geometric mapping technique is adopted to solve the resulting governing electrokinetic equations in irregular geometries. Several interesting phenomena are found which provide useful guidelines in practical applications involving liquid metal droplets (LMDs) such as drug delivery. In particular, the severe boundary confinement effect brings about unique features of droplet motion, leading to mobility reversal and a “stagnation phenomenon” where droplets cease to move regardless of their surface charge densities in a narrow cylindrical pore. An overwhelming exterior vortex flow nearly enclosing the entire droplet is found to be responsible for this. This finds various practical applications in droplet microfluidics and drug delivery. For instance, a cylindrical pore or blood vessel may be clogged by a droplet much smaller than its radius. In addition, the “solidification phenomenon”, where all droplets move with identical speed regardless of their viscosities like rigid particles with no interior recirculating vortex flows, is also discovered. The electrokinetic mechanism behind it and its potential applications are discussed. Overall, the geometric configuration considered here is a classic one, with many other possible applications yet to be found by experimental researchers and engineers in the field of colloid industry and operations. Full article

Laser cladding rapid solidification technique is an effective strategy for manufacturing ultra-high-strength martensitic stainless steels (UHS-MSS). Due to super-saturation solution strengthening of interstitial atoms (IAs), martensitic stainless steels containing IAs exhibit excellent ultra-high strength and toughness and have high tolerance for oxygen impurities. Hence, studying the specific speciation and structural characteristics of IAs is of great significance for guiding laser cladding of ultra-high-strength steels. Herein, we use density functional theory (DFT) computations to analyze the stable occupancies of IAs and their interactions in body-centered cubic iron (BCC Fe). The findings show that single IAs prefer to occupy octahedral sites over tetrahedral sites. Therefore, octahedral sites are selected as the optimal sites for the following double IAs study. For homo IAs, C-C and N-N configurations exhibit greater stability at long-range distances, whereas O-O demonstrate optimal stability at intermediate distances. Crucially, hetero IAs configurations are more stable compared to single IAs and homo IAs, exhibiting a synergistic effect. Especially, the C-O combination shows the highest stability and strongest bonding character. Meanwhile, the dissociation behavior of O indicates that C-O and N-O have higher dissociation temperatures than single O, further verifying the synergistic effect of hetero IAs. This provides a theoretical basis for understanding the interstitial solution strengthening of laser cladding UHS-MSS. Full article

Levitation techniques reduce the available heterogeneous nucleation sites and provide stable access to deeply undercooled melts. However, some samples have repeatably demonstrated that, in the presence of strong stirring, solidification may be induced at moderate, sub-critical undercoolings. Dynamic nucleation is a mechanism by which solidification may be induced through flow effects within a sub-critically undercooled melt. In this mechanism, collapsing cavities within the melt produce very high-pressure shocks, which shift the local melting temperature. In these regions of locally shifted melt temperatures, thermodynamic conditions enable nuclei to grow and trigger solidification of the full sample. By deepening the local undercooling, dynamic nucleation enables solidification to occur in conditions where classical nucleation does not. Dynamic nucleation has been observed in several zirconium and zirconium-based samples in the Electromagnetic Levitator onboard the International Space Station (ISS-EML). The experiments presented here address conditions in which a zirconium sample alloyed with 2.5 atomic percent niobium spontaneously solidifies during electromagnetic levitation experiments with strong melt stirring. In these experimental conditions, classical nucleation predicts the sample to remain liquid. This solidification behavior is consistent with the solidification behavior observed in prior experiments on pure zirconium. Full article

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing and manufacturing a MacPherson steering knuckle using topology optimization (TO), additive manufacturing, and rapid investment casting (RIC). Static structural simulations confirmed the mechanical integrity of the optimized design, with stress and strain values remaining within the elastic limits of the SG A536 iron alloy. The TO process achieved a 30% reduction in mass, resulting in lower material use and production costs. Additive manufacturing of optimized geometry reduced resin consumption by 27% and printing time by 9%. RIC simulations validated efficient mold filling and solidification, with porosity confined to removable riser regions. Life cycle assessment (LCA) demonstrated a 27% reduction in manufacturing environmental impact and a 31% decrease throughout the component life cycle, largely due to vehicle lightweighting. The findings highlight the potential of integrated TO and advanced manufacturing techniques to produce structurally efficient and environmentally sustainable automotive components. This workflow offers promising implications for broader industrial applications that aim to balance mechanical performance with ecological responsibility. Full article

Nickel is used in aerospace, military, energy, and chemical sectors. Commercially pure (CP) Ni, and its alloys, including solid-solution strengthened (SSS), precipitation strengthened (PS), and specialty alloys (SA), are widely utilized, typically at elevated temperatures, in corrosive settings and in cryogenic milieu. Ni or Ni-based alloys frequently require welding realized, inter alia, via methods using electric arc and beam power. Tungsten inert gas (TIG) and Electron-beam welding (EBW) have been utilized most often. Friction stir welding (FSW) is the most promising solid-state welding technique for connecting Ni and its alloys. The primary weldability issues related to Ni and its alloys are porosity, as well as hot and warm cracking. CP Ni exhibits superior weldability. It is vulnerable to porosity and cracking during the solidification of the weld metal. Typically, SSS alloys demonstrate superior weldability when compared to PS Ni alloys; however, both types may experience weld metal solidification cracking, liquation cracking in the partially melted and heat-affected zones, as well as ductility-dip cracking (DDC). Furthermore, PS alloys are prone to strain-age cracking (SAC). The weldability of specialty Ni alloys is limited, and brazing might provide a solution. Employing appropriate filler metal, welding settings, and minimal restraint can reduce or avert cracking. Full article

Using the enzyme-induced carbonate precipitation (EICP) technique to solidify rubber and clay mixtures as lightweight backfill is a feasible way to reduce waste tire impacts and boost rubber recycling in geotech engineering. In this study, a comprehensive laboratory investigation, including triaxial compression, oedometer, permeability, and nuclear magnetic resonance (NMR) tests, was conducted on EICP-reinforced rubber particle solidified clay (hereafter referred to as EICP-RC solidified clay) to evaluate the effects of rubber particle content and size on the mechanical behavior of the improved soil under various solidification conditions and to elucidate the solidification mechanism. The results show that although rubber particles inhibit EICP, they significantly enhance the mechanical properties of the samples. The addition of 5% rubber particles (rubber A) increased cohesion by 11% and the internal friction angle by 18% compared to EICP-treated clay without rubber. Additionally, incorporating smaller-sized tire particles facilitated pore filling, resulting in lower compression and swelling indices and reduced permeability coefficients, making these materials suitable for use behind retaining walls and in embankment construction. Full article

With the launch of the Artemis program and the International Lunar Research Station project, the construction of lunar bases has emerged as a global research focus. In situ manufacturing technologies for robust lunar regolith-based building materials are critical to ensuring building safety under the Moon’s extreme environmental conditions. This paper reviews the relevant advancements in two areas: solidification technologies for lunar regolith-based construction materials and simulation techniques of extreme lunar environments. This review reveals that, although significant advancements have been made in solidification technologies, the development of lunar environment simulation technologies, particularly for 1/6 g gravity, has lagged, thereby hindering the assessment of the in situ applicability of these solidification methods. To address these limitations, this paper introduces a newly developed comprehensive lunar extreme environment simulation system based on superconducting magnetic suspension technology and its potential applications in lunar regolith-based construction material solidification. This review highlights the current progress and challenges in solidification techniques for lunar regolith-based building materials, aiming to enhance researchers’ attention to the extreme environmental conditions on the lunar surface. Full article

Additive manufacturing techniques, such as laser-based powder bed fusion of metals (PBF-LB/M), have now gained high industrial and academic interest. Despite its design flexibility and the ability to fabricate intricate components, LPBF has not yet reached its full potential, partly due to the challenges associated with microstructure control. The precise manipulation of the microstructure in LPBF is a formidable yet highly rewarding endeavor, offering the capability to engineer components at a local level. This work introduces an innovative parallelized Cellular Automaton (CA) framework for modeling the evolution of the microstructure during the LPBF process. LPBF involves remelting and subsequent nucleation followed by crystal growth during solidification, which complicates and burdens microstructure simulations. In this research, a novel approach to nucleation seeding and crystal growth is implemented, focusing exclusively on the final stages of melting and solidification, enhancing the computational efficiency by 30%. This approach streamlines the simulation process, making it more efficient and effective. The developed model was employed to simulate the microstructure of an austenitic advanced high-strength steel (AHSS). The model was validated by comparing the simulation results qualitatively and quantitatively with the experimental data obtained under the same process parameters. The predicted microstructure closely aligned with the experimental findings. Simulations were also conducted at varying resolutions of CA cells, enabling a comprehensive study of their impact on microstructure evolution. Furthermore, the computational efficiency was critically evaluated. Full article

We investigated the morphological patterns, crystalline structures and their thermal stability in solidified Au–Ge nanoparticles ranging in size from 10 to 500 nm. Liquid Au–Ge alloy nanoparticles with hypoeutectic composition were rapidly cooled from a temperature of 500 °C in a TEM and characterized using advanced TEM techniques. We demonstrated that Au–Ge nanoparticles 10–80 nm in size predominantly solidified into a Janus-like morphology with nearly pure single-crystalline hcp Au and diamond cubic Ge domains. These particles remained stable up to the eutectic temperature, indicating that Ge doping and particle size play key roles in stabilizing the hcp Au phase. In turn, larger nanoparticles exhibited a metastable core–shell morphology with polycrystalline Ge shell and hcp Au-Ge alloy core under solidification. It was shown that the mentioned morphology and crystalline structure evolved into the equilibrium Janus morphology with fcc Au and diamond Ge domains at temperatures above ≈160 °C. Full article

High-chromium cast irons (HCCIs) have emerged as preferred materials for critical wear-resistant components operating under extreme conditions, owing to their excellent wear resistance, low cost, and good castability. They are widely used in metallurgy, energy, and mechanical engineering industries. The evolution of solidification microstructure directly governs the final properties of HCCIs, making the in-depth investigation of their solidification behavior of great significance. This paper provides a comprehensive review of recent experimental and simulation-based advances in understanding the solidification microstructure evolution of HCCIs. The effects of alloy composition, cooling rate, and inoculation treatments on microstructure development and phase distribution during solidification are critically analyzed. Furthermore, the application of simulation techniques—including thermodynamic modeling, phase-field method, cellular automata, and finite element analysis—is discussed in detail, highlighting their roles in revealing the mechanisms of microstructural evolution. Finally, the current challenges and potential future research directions in the study of the solidification behavior of high-chromium cast irons are outlined. Full article

Loess, predominantly distributed in arid and semi-arid regions of central and western China, exhibits low shear strength and structural instability, rendering it prone to geological hazards such as landslides and collapses, which pose significant threats to local infrastructure and safety. This study evaluated the urease activity of soybean and sword bean at different temperatures to screen the optimal enzyme source for enzyme-induced carbonate precipitation (EICP). Methods including single EICP, EICP combined with nano-SiO₂, and EICP combined with both nano-SiO₂ and soil stabilizer (SS) were adopted to enhance the surface strength of loess. The results showed that the EICP technique significantly improved the surface strength of loess, especially with the addition of nano-SiO₂ and soil stabilizer. This study confirmed that using sword bean urease treated at −20 °C for 24 h in combination with 1.5% nano-SiO₂ was both cost-effective and efficient in reinforcement. The incorporation of 5% soil stabilizer further enhanced the surface strength, and the accuracy was further verified by combining the results of SEM and XRD. Future research will focus on optimizing the material ratio to maximize the improvement of surface strength, providing an economical and feasible solution for rapid loess solidification, and evaluating the long-term durability under cyclic wet and dry conditions. Full article

Cohesive soil in the reservoir area is vulnerable to natural disasters because of its poor erosion resistance and low strength. Therefore, it needs to be reinforced. Microbially induced calcium carbonate precipitation (MICP) is a sustaibable soil reinforcement technique with low energy consumption and no pollution. Different combinations of Bacillus subtilis bacterial solution (BS) concentrations and cementing solution (CS) concentrations were set to perform MICP solidification treatment. The characterization of cohesive soil before MICP was carried out by means of Scanning Electron Microscopy (SEM), Fourier-Transform Infrared Spectroscopy (FTIR), and Laser Particle Size Analyzer (LPSA). The results showed that the unreinforced soil showed an amorphous state with low strength and the particle size distribution was dominated by powder particles. However, with the addition of BS concentrations and CS concentrations, SEM results showed that spherical and rhombohedral minerals filled the pores of the cohesive soil, which increased the content of precipitations and enhanced the cementitious characteristics. When the concentrations of CS or BS were fixed, CaCO₃ content, deviatoric stress, shear strength, cohesive force, and internal friction angle all showed a trend of first increasing and then decreasing with the increase in CS or BS concentration. The optimal combination of CS and BS concentration was 1.5 mol/L and OD₆₀₀ = 1.8. Thermochemical analyses showed an improved thermal stability of the reinforcing cohesive soil, with the lowest mass loss (32%) and the highest pyrolysis temperature (812 °C) of the samples at the optimal combination of BS and CS concentration. This study is expected to improve the understanding of the MICP reinforcement process and contribute to the optimal design of future biologically mediated soil amendments, promoting bioremediation. Full article

Hypereutectic Al-Si alloys containing primary Si exhibit unique material properties that make them suitable for various industrial applications. Understanding the characteristics of primary Si is crucial for predicting the effect of solidification conditions on the microstructure of these alloys. This paper presents a comprehensive characterisation study of primary Si in hypereutectic alloys. This study provides a detailed analysis of the size, distribution, and morphology of primary Si, providing valuable insights into the alloy structure, mechanical properties, and even the performance of the production process. The effect of forced melt flow by a rotating magnetic field (RMF) and solid/liquid front velocity on the size and morphology of primary Si in a hypereutectic Al-18 wt.% Si alloy was investigated. The purpose of using the RMF technique during the solidification process of Al-Si alloys is to enhance the alloy’s microstructure by inducing electromagnetic stirring. The hypereutectic samples were solidified at five different front velocities (0.02, 0.04, 0.08, 0.2, and 0.4 mm/s), under an average temperature gradient (G) of 8 K/mm, in a crystalliser equipped with an RMF inductor. Each sample was divided into two parts: the first solidified without stirring, while the second underwent electromagnetic stirring using RMF at an induction (B) of 7.2 mT. The results revealed that increasing the front velocity during solidification refined the primary Si in stirred and non-stirred parts. In non-stirred parts, it decreased dendritic forms and increased star-like Si, while polyhedral shapes remained nearly constant. Stirred parts showed stable Si morphology across velocities. Higher velocities also promoted equiaxed over elongated Si forms in both parts. Full article

Eutectic high-entropy alloys (EHEAs) exhibit excellent casting properties and comprehensive mechanical performance, making them suitable for fabricating spatial engineering components using additive manufacturing techniques. However, the rapid solidification process also leads to increased internal stress and reduced structural stability in the components. Therefore, this study focuses on the AlFeCoCrNi_2.1 EHEA as the research subject, utilizing laser additive manufacturing to fabricate components and systematically investigating the influence of heat treatment processes on the microstructure and mechanical properties of the components. The research demonstrates that low-temperature heat treatment (700 °C and below) acts as a stress relief-annealing process for the components. The yield strength decreased from 1003.2 MPa to 742.1 MPa. At 900 °C heat treatment, the constraining effect between recrystallized grains and surrounding grains outweighs the dislocation release effect caused by recrystallization, resulting in an increase in dislocation density. The yield strength remained approximately stable at around 730 MPa. High-temperature heat treatment (1100 °C) alters the orientation of phase structures and fragments the two-phase structure through recrystallization, leading to generally stable mechanical properties of the components. The yield strength of the cast components further decreased to 582.6 MPa, while that of the LMD-fabricated parts retained stability at approximately 730 MPa. Full article