Search Results (402)

The paper presents the results of investigations of flow velocity field distribution downstream of the nanofibrous filter in a minichannel determined by the particle image velocimetry (PIV) method. The nonwoven nanofibrous filter was produced by electrospinning technology from a PVDF polymer dissolved in DMAC and acetone mixture. The nanofibers were deposited onto a mesh scaffold made of stainless steel wires 0.2 mm in diameter and with a 2 mm pitch. The gas velocity in the channel with the inserted nanofibrous filter was below 1.2 m/s. The flow field distribution in the channel was investigated by the Dantec FlowMap System. It was shown that the turbulence can be generated downstream of the filter, even for low Reynolds numbers smaller than 1300. This turbulence was attributed to the inhomogeneity of the fibrous filter structure. Another cause of this phenomenon could be the large area of the boundary layer at the channel walls compared to the channel cross section. Full article

To address the corrosion of 304 stainless steel in marine environments, TiO₂/NiCo₂S₄ composite photoanodes were fabricated via anodic oxidation and hydrothermal methods. X-ray diffraction, scanning electron microscope, energy-dispersive x-ray spectroscopy, and x-ray photoelectron spectroscopy analyses indicated the growth of hexagonal NiCo₂S₄ particles on anatase TiO₂ nanotube arrays, forming a type-II heterojunction. Spectroscopy of ultraviolet-visible diffuse reflectance absorption showed that NiCo₂S₄ extended TiO₂’s light absorption into the visible region. Electrochemical tests revealed that under visible light, the composite photoanode decreased the corrosion potential of 304ss to −0.7 V vs. SCE and reduced charge transfer resistance by 20% compared to pure TiO₂. The enhanced performance stemmed from efficient electron-hole separation and transport enabled by the type-II heterojunction. Cyclic voltammetry tests indicated the composite’s electrochemical active surface area increased 1.8-fold, demonstrating superior catalytic activity. In conclusion, the TiO₂/NiCo₂S₄ composite photoanode offers an effective approach for marine corrosion protection of 304ss. Full article

The Scalable and Expeditious Additive Manufacturing (SEAM) process is an advanced additive manufacturing (AM) technique that relies on the optimization of metal powder suspensions to achieve high-quality 3D-printed components. This study explores the critical role of dispersants in enhancing the performance of stainless steel (SS) 420 metal powder suspensions for the SEAM process by improving powder loading, recyclability, flowability, and consequent final part density. The addition of dispersant allows for increased powder contents while preserving stable rheological properties, thereby enabling higher powder loading without compromising the rheological characteristics required in the SEAM process. Previously, our team implemented a two-step printing strategy to address the segregation issues during printing. Nonetheless, the semi-cured layer was not recyclable after printing, resulting in a significant amount of waste in the SEAM process. This, in turn, leads to a considerable increase in material costs. On the other hand, the addition of a dispersant has been shown to enhance suspension stability, enabling multiple cycles of reuse. This novel approach has been demonstrated to reduce material waste and lower production costs. The enhanced flowability guarantees uniform suspension spreading, resulting in defect-free layer deposition and superior process control. Moreover, the dispersant’s ability to impede particle agglomeration and promote powder loading contributes to the attainment of a 99.33% relative density in the final sintered SS420 parts, thereby markedly enhancing their mechanical integrity. These findings demonstrate the pivotal role of dispersants in refining the SEAM process, enabling the production of high-density, cost-effective metal components with superior material utilization and process efficiency. Full article

The erosion resistance of materials against solid particles is a very important property, especially in the transportation of powders or in aeronautics (dust inside jet engines). There is a strong need to introduce new materials that have higher solid particle erosion resistance than state-of-the-art materials. Thus, in the present work, the solid erosion particles of high entropy alloys (HEAs) based on the Al0.7CoCrFeNi matrix were studied compared to the state-of-the-art stainless steel AISI 304. Furthermore, the effect of the addition of Ti to HEAs on hardness and erosion resistance was investigated. Current research included the development of the chemical composition of a new kind of HEA designed on the basis of thermodynamical calculations performed in CALPHAD, its manufacturing, full characterization involving microstructural and phase analyses, hardness measurements, solid particle erosion tests, and finally, the elucidation of erosion mechanisms. It was found that HEAs showed higher hardness as well as erosion resistance than AISI 304. Moreover, it was found that the increase in Ti content in an HEA resulted in an increase in the hardness and resistance to the erosion of the studied HEA. As the main reason for this phenomenon, the stabilization of the β-BCC phase, suppression of the α-FCC phase, and the appearance of the Ni₃Ti phase in the studied HEA were claimed. Full article

Oil condition monitoring can ensure the safe operation of mechanical equipment. Metal debris is full of friction information, and the identification of debris material helps to locate wear of parts. A method based on impedance analysis is proposed to identify debris material in this article. The differences in permeability and conductivity result in the nonlinear variation trend of inductance–resistance amplitude with debris volume. By establishing a database of amplitude–size curves, debris information (material and size) can be obtained through impedance analysis. Based on experimental and simulation results, iron, stainless steel, aluminum, copper, and brass particles are effectively distinguished. This method is not affected by oil’s light transmittance, other impurities, and debris surface dirt and can be used to distinguish metals with similar colors. This work provides a novel solution for debris material identification, which is expected to promote the development of fault diagnosis. Full article

The application of additive manufacturing technology in the field of nuclear power is becoming increasingly promising. The low-cycle fatigue behavior of Z2CN19-10 controlled-nitrogen-content stainless steel (SS) was investigated by fatigue equipment, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM), including additive manufactured (AM) and forged materials. The results showed that the microstructure of the AM material exhibited anisotropy for the X, Y, and Z directions. The tensile and impact properties of the X, Y, and Z directions in AM material were similar. The fatigue life (N_f) of X- and Y-direction specimens was better than that of Z-direction specimens. The tensile, impact, and fatigue properties of all AM materials were lower than those of the forged specimens. The Z direction specimens of AM material showed the best plastic strain by the highest transition fatigue life (N_T) during the fatigue strain amplitude at 0.3% to 0.6%. The forged specimens showed the best fatigue properties under the plastic strain amplitude control mode. Fatigue fracture surfaces of AM and forged materials exhibited multi- and single-fatigue crack initiation sites, respectively. This could be attributed to the presence of incompletely melted particles and manufacturing defects inside the AM specimens. The dislocation morphology of AM and forged fatigue specimens was observed to study the low-cycle fatigue behaviors in depth. Full article

In this study, we investigated the electrochemical corrosion behavior and mechanisms of FeCrNi/WC alloys with varying contents of CTC-S (spherical WC) and CTC-A (angular WC) in a 3.5 wt.% NaCl solution, addressing the corrosion resistance requirements for stainless steel composites in marine environments. The electrochemical test results demonstrate that the corrosion resistance of the alloy initially increases with the CTC-A content, followed by a decrease, which is associated with the formation, stability, and rupture of the passivated film. Nyquist and Bode diagrams for electrochemical impedance spectroscopy confirm that the charge transfer resistance of the passivated film is the primary determinant of the composite’s corrosion performance. A modest increase in CTC-A contributes to the formation of a more heterogeneous second phase, providing a physical barrier and enhancing solid solution strengthening, and thus delaying the cracking and corrosion processes of the passivation film. However, excessive CTC-A content leads to significant dissolution of the alloy’s reinforcement phase and promotes decarburization, resulting in the formation of corrosion pits, craters, and cracks that compromise the passivation film and expose fresh alloy surfaces to further corrosion. When the CTC-A content is 10% and the CTC-S content is 30%, this combination results in minimal degradation in the corrosion performance (0.213 μA·cm²) while balancing the hardness and toughness of the alloy. Additionally, electrochemical evaluations reveal that incorporating angular CTC-A particles at 10 vol% effectively delays the breakdown of the passivation film by mitigating the interfacial galvanic coupling through enhancing the mechanical interlocking at the WC/FeCrNi interface. The CTC-A/CTC-S hybrid system exhibits a remarkable 62% reduction in the pitting propagation rate compared to composites reinforced solely with spherical WC, which is attributed to the preferential dissolution of angular WC protrusions that sacrificially suppress crack initiation at the phase boundaries. Full article

Based on laser cladding technology, six composite coatings with different amounts of Inconel 718 and 0~5% CeO₂ were successfully prepared on the 316L stainless steel substrate. The effect of different amounts of CeO₂ particles was investigated and discussed, such as microstructure, phases, elemental distribution, microhardness, wear resistance and corrosion resistance. The results show that the phases are composed of γ~(Fe, Ni), Ni₃Nb, (Nb_0.03Ti_0.97)Ni₃, and MC_X(M = Cr, Nb and Mo). When the amount of CeO₂ particles is higher than 1%, some Ce₂O₃ compounds can be detected in coatings. The average microhardness values of N0~N5 are 604.6, 754.5, 771.6, 741.4, 694.5 and 677.3 HV_0.2, respectively. There is a trend that the microhardness increases firstly and then decreases, because an appropriate amount of CeO₂ can improve the solid solution strength. The average wear rate values of N0~N5 are 2.97 × 10⁻⁵, 1.22 × 10⁻⁵, 0.94 × 10⁻⁵, 1.53 × 10⁻⁵, 1.81 × 10⁻⁵ and 2.26 × 10⁻⁵ mm³∙N⁻¹∙min⁻¹, respectively. The N2 coating has the smallest corrosion current density of 2.05 × 10⁻⁴ A·cm⁻², which is about 56% of the N0 coating. When the amount of CeO₂ particles is 2%, the coating has the best wear resistance and corrosion resistance due to fine grains and Cr, Nb and Mo compounds. Full article

316L stainless steel slender tubes with smooth inner surfaces play an important role in fields such as aerospace and medical testing. In order to solve the challenge of difficult machining of their inner surfaces, this paper introduces a novel rotary magnetorheological finishing (RMRF) method specifically designed for processing the inner surfaces of slender tubes. This method does not require frequent replacement of the polishing medium during the processing, which helps to simplify the processing technology. By combining the rotational motion of a magnetic field with the linear reciprocating movement of the workpiece, uniform material removal on the inner surfaces of 316L stainless steel tubes was achieved. Initially, a finite element model coupling the magnetic and flow fields was developed to investigate the flow behavior of the MPF under a rotating magnetic field, to examine the theoretical feasibility of the proposed polishing principle. Subsequently, experimental validation was performed using a custom-designed polishing apparatus. Through processing experiments, with surface quality designated as the index, the influences of key parameters such as the volume content and sizes of carbonyl iron particles and abrasive particles in the MPF were comprehensively evaluated, and the composition and ratio of the MPF were optimized. Based on the optimized formulation, the optimal processing time was established, reducing the inner surface roughness from an initial Sa of approximately 320 nm to 28 nm, and effectively eliminating the original defects. Full article

This study investigates the applicability and advantages of using additive manufacturing to moderate heat generation in dry milling. Grinding medium balls of different sizes were designed and fabricated using computer-aided design (CAD) and a stereolithographic 3D printer. Milling processes with particle size distribution and warmup measurements were employed with the printed medium balls. The results were compared with the measurements executed with conventional stainless-steel balls. Differential scanning calorimetry (DSC) was employed to evaluate the effect of the warmup of the system during the milling process. A two-variable, three-level experimental design was used for the measurements. We selected two grinding parameters considered critical: speed and time. The effect of these two independent variables on heating was examined. The results show that if printed balls are applied with the same total mass as that of metal balls, the particle size reduction is increased. The greater the number of balls used, the greater the particle size reduction. In this process, where additively manufactured milling bodies were used, the temperature of the system increased by less than when stainless-steel balls were used. The use of 3D-printed medium balls demonstrated beneficial warmup behavior. Full article

This study investigates the degradation characteristics of turbocharger nozzle rings in marine diesel engines by conducting numerical analysis and solid particle erosion (SPE) tests to examine their structural stability and morphological surface damage trends. The fatigue analysis was conducted under a load condition corresponding to 100% output of the main engine, using ANSYS software. The SPE test was conducted in accordance with ASTM G76-05 standards, and the weight loss and erosion rate were calculated. Surface damage was closely examined through 3D analysis and scanning electron microscopy (SEM). The flow analysis revealed that the loads were highly concentrated at the nozzle ring inlet and the leading edge of the blades, with a maximum pressure coefficient of 0.07678 MPa. The load decreased toward the trailing edge of the nozzle ring, and the surface pressure coefficients of the flange, inner hoop, and outer hoop—where the nozzle ring blades are fixed—were found to be nearly identical. The fatigue life of the nozzle ring under 100% engine load was calculated as 1.377e⁺⁷ cycles, with a fatigue damage value of 1.32e⁺³². Notably, the fatigue life in the regions near the inner and outer hoops of the nozzle ring approached zero. The results of the SPE test using spherical SiO₂ particles confirmed that the surface damage of the nozzle ring material, 316L stainless steel, followed a typical ductile material damage mechanism. In addition, the surface damage characteristics were significantly influenced by SPE test parameters such as the shape of solid particles, nozzle diameter, and impact angle. Full article

Laser cutting processes entail the cutting of metal sheets by the emission of a laser source that melts the material along defined paths, potentially generating incidental metal nanoparticles (IMNPs). These particles have been associated with genotoxicity, oxidative stress, and pro-inflammatory responses. However, quantitative data on IMNP emissions remain limited. This study assessed IMNP emissions from CO₂ and fiber laser cutting through two monitoring days at a high-precision metalworking facility in Italy. The first day dealt with environmental monitoring, while the second included both personal and environmental monitoring. Personal sampling consistently indicated elevated particle number concentrations and lung-deposited surface area, with average values reaching up to five times the background level (161,960 n/cm³) and peak concentrations as high as 2,781,962 particles/cm³. Environmental concentrations increased significantly only during CO₂ stainless steel cutting (95,670 n/cm³). Depending on the process, 73–89% of the emitted particles were <300 nm, with substantial enrichment in the nanoparticle fraction. Emission profiles varied by laser source, metal, and sheet thickness, with the highest concentrations recorded during CO₂-laser cutting of stainless steel. These findings provide preliminary evidence of occupational exposure to IMNPs during laser cutting and highlight the need for systematic exposure assessments to quantify the potential occupational health risk. Full article

This study investigates the effects of B₄C content (2.5, 5, 7.5, and 10 wt.%) on the microstructure and wear resistance of laser cladding 316 stainless steel coatings on a 2Cr12MoV steel substrate. The coating was prepared by laser cladding technology. The phase composition, microstructure evolution, microhardness, and tribological properties of the coating were analyzed. The results show that the decomposition of B₄C particles is complete, and the phase composition of the coating includes Austenite, Fe₂₃ (B₃C₃), Cr₂₃ (B_1.5C_4.5), and a Fe-Ni solid solution. The increase in B₄C content significantly increased the microhardness of the material from 206 HV_0.2 (substrate) to 829 HV_0.2 (10 wt.% B₄C) by 4.02 times. Wear resistance also improved, with the 10 wt.% coating exhibiting the lowest wear rate (10 × 10⁻⁸ mm³/N·m) due to fine-grained and dispersion strengthening mechanisms. However, excessive B₄C (10 wt.%) induced cracks from increased brittleness, resulting in higher friction coefficients. The wear mechanism consists of fatigue wear, adhesive wear, and oxidative wear, and the degree of wear decreases with the increase in B₄C content. This work demonstrates that the addition of B₄C effectively improves the hardness and wear resistance of 316 stainless steel coatings, providing practical insights into surface engineering in high wear applications. Full article

Tungsten Inert Gas (TIG) welding is a widespread welding process used in the industry for high-quality joints. However, this welding process suffers from lower productivity. Activated Tungsten Inert Gas (ATIG) is a variant of the TIG that aims to increase the depth penetration capability of conventional TIG welding. This is achieved by applying a thin coating of activating flux material onto the workpiece surface before welding. This work investigates the effect of the thermophysical properties of individual metallic oxide fluxes on 316L stainless steel weld morphology. Four levels of current intensity (120, 150, 180, 200 A) are considered. The weld speed up to 15 cm/min and arc length of 2 mm are maintained constant. Thirteen oxides were tested under various levels of current intensity in addition to multiple thermophysical properties combinations, and the depth penetration (D) and the aspect ratio (R) were recorded. This process has provided 52 combinations (13 oxides * 4 currents). Based on the numerical observations, linear and nonlinear models for describing the effect of the thermophysical parameters on the weld characteristics were tuned using a particle swarm optimization algorithm. While the linear model provided good prediction accuracy, the nonlinear exponential model outperformed the linear one for the depth yielding a mean absolute percentage error of 17%, a coefficient of determination of 0.8266, and a root mean square error of 0.9665 mm. The inverse optimization process, where the depth penetration ranged from 1.5 mm to 12 mm, thus covering a large spectrum of industries, the automotive, power plants, and construction industries, was solved to determine the envelopes’ lower and upper limits of optimal oxide thermophysical properties. The results that allowed the design of the fluxes to be used in advance were promising since they provided the oxide designer with the numerical ranges of the oxide components to achieve the targeted depths. Future directions of this work can be built around investigating additional nonlinear models, including saturation and dead-zone, to efficiently estimate the effect of the thermophysical properties on the welding process of other materials. Full article

This study aims to investigate the wear and corrosion–wear behavior of 17-4PH stainless steel specimens, both fabricated via Selective Laser Melting (SLM) and conventional bulk material, after undergoing Solution Treatment (S.T.) in a seawater medium. Microstructural observations indicated that solution treatment contributed to a more uniform distribution of martensitic structures on the sample surface. Moreover, the solution-treated specimens exhibited improved microstructural uniformity and structural stability. SLM specimens exhibit the elimination of fine particles and scanning track traces. Based on the results of dynamic polarization tests, SLM specimens demonstrate superior corrosion resistance. However, in corrosion–wear conditions, the bulk material outperforms the SLM specimens, primarily due to the presence of pores in the latter, which are detrimental under such environments. XPS analysis of the passive film structure indicates that the passive layer is mainly composed of FeO, Cr₂O₃, and NiO, with the inner layer predominantly consisting of chromium oxide. The Cr₂O₃ layer, formed by the reaction between chromium and oxygen, significantly enhances the corrosion resistance of the material due to its extremely low chemical reactivity and high stability. Full article