Search Results (304)

Ni–Mo alloy claddings were fabricated on low-carbon steel substrates using powder metallurgy combined with hot isostatic pressing (PM-HIP). The interfacial microstructure, elemental interdiffusion, phase composition and microhardness distribution of the bimetallic composite were investigated systematically. The results show that sound metallurgical bonding without pores, cracks and element dilution is achieved under the HIP process of 1100 °C, 120 MPa and 4 h holding time. Interdiffusion of Fe, Ni and Mo atoms forms a 20–50 μm thick interfacial transition layer, and Mo exhibits a relatively low diffusion capacity due to its large atomic radius. Two intermetallic phases, Ni₄Mo and NiMo, are formed in the cladding layer because of the inhomogeneous distribution of Mo. A prominent microhardness gradient is observed throughout the composite, and the interfacial layer presents the highest hardness of 905 HV resulting from multiple strengthening mechanisms. As an effective alternative to traditional welding and cladding technologies, the PM-HIP process exhibits great potential for manufacturing complex bimetallic components with prospective service prospects in severe corrosive environments. Full article

Transition joints between lightweight aluminum alloys and high-strength steel are widely employed in the transportation industry, and especially in shipbuilding, as intermediate inserts between structural components made of dissimilar metals. While traditional fusion welding presents considerable difficulties in joining such metals, explosive welding is particularly suitable for producing thick plates with large contact surfaces between aluminum and steel. The process setup and the various parameters involved have been described in several articles, as also documented by some recent overviews. However, there has been no review of the most recent papers specifically dealing with the metallurgical characteristics of these interfaces, as well as with their mechanical properties. Thus, the present article aims to fill this gap by outlining a review on the state of the art to correlate the process parameter setting, interface characteristics, and weldability of aluminum/steel transition joints, and then focusing on the most relevant studies concerning the mechanical behavior under static and fatigue conditions of trimetallic joints (Al alloy/commercially pure Al/structural steel) for shipbuilding applications. The effects of welding-induced thermal fields during structural joint insertion are also taken into account, and the most recent proposals for strategies to improve mechanical performance are examined. Full article

Industrial steel property prediction is often constrained by limited labelled data, reducing the effectiveness of conventional machine learning models. This study investigated whether metallurgy-informed feature engineering enhances predictive performance under small-data conditions. A representative set of 300 samples from an industrial low-carbon hot-rolled steel strip dataset (C: 0.02–0.06 wt%; Mn: 0.17–0.38 wt%) was used to derive five physically meaningful descriptors: carbon equivalent (CE), nitrogen-to-aluminum ratio (N/Al), microalloying efficiency index (MEI), thermal processing parameter (TPP), and solid solution strengthening index (SSSI). These descriptors were combined with the original 17 compositional and processing variables to create a 22-feature dataset. Random Forest (RF) and Extreme Gradient Boosting (XGBoost) models were evaluated on an independent 60-sample test set using 5-fold cross-validation. Feature engineering improved the prediction accuracy, with the greatest gain observed for elongation. For XGBoost, the mean percentage error decreased from 3.23% to 3.05%, whereas the test-set R² increased from 0.4935 to 0.5444, representing a 10.3% improvement in the explained variance. For the yield strength, the Random Forest method increased the R² from 0.4744 to 0.4861. Permutation importance and partial dependence analyses identified MEI and TPP as the six most influential predictors across all targets, confirming that the engineered descriptors provide complementary metallurgical information. Learning curve analysis showed slightly higher cross-validation R² values at intermediate training sizes (n = 125–175), indicating modestly improved sample efficiency. These findings establish domain-informed feature engineering as an interpretable and practical strategy for improving machine learning in data-limited steel manufacturing processes. Full article

Metallurgical slags produced in the zinc–lead, copper, iron and steel metallurgical industries are characterized by a variety of technical parameters and varying chemical and mineral compositions, which depend on the type of raw material and the technological process selected and its workflow. These slags are characterized by a high content of valuable elements, including Cu, Pb, Zn, and Fe, which form complex multiphase conglomerates. In the chemical composition of Zn-Pb smelting slags, the contents of the dominant elements, i.e., Fe, Zn, and Pb, range from a few to several dozen %. These elements occur mainly in the form of polyphase oxides and silicates. The chemical composition of Cu smelting slag contains up to a few % Cu and up to several dozen % Fe, with these elements mainly forming silicates and sulphides. Iron and steel metallurgy slag contains up to several dozen % Fe, which occurs mainly in the form of silicates, oxides, and spinels. Due to their phase composition, metallurgical slags stored in landfills can have a negative impact on the environment. The phase composition of slags is one of the main factors determining their behavior in a weathering environment, i.e., their ability to release metals when exposed to atmospheric factors such as precipitation or temperature. On the other hand, such high concentrations of elements in metallurgical slags mean that they become anthropogenic deposits, and the phase composition of the slags determines how the deposited slags are processed. The aim of this article is to present the mineralogical and chemical characteristics of Zn, Pb, Cu and steel metallurgical slags deposited in landfills, along with an assessment of these materials as a source of secondary raw materials. Full article

Under China’s “carbon peaking before 2030 and carbon neutrality before 2060” targets, the low-carbon transformation of the ironmaking stage—which contributes approximately 70% of the CO₂ emitted per ton of steel in the dominant blast furnace–basic oxygen furnace (BF–BOF) route—is decisive for decarbonizing the steel industry. In contrast to earlier reviews that describe individual technologies in isolation, this review provides a structured, cross-technology synthesis: the main routes are classified into short-/medium-term low-carbon blast furnace technologies (hydrogen-rich carbon-recycling oxygen blast furnace, hydrogen-rich injection, biomass char injection and ultimate energy-efficiency measures) and medium-/long-term non-blast furnace technologies (hydrogen-based shaft furnace direct reduction, smelting reduction, rotary hearth furnace, fluidized-bed reduction and electric smelting reduction) and are then compared on a common set of quantitative indicators—CO₂ mitigation, specific energy and hydrogen demand, technology readiness level (TRL) and relative cost. On this basis, emerging hydrogen-based flash ironmaking, developed from the interdisciplinary integration of “iron and steel–non-ferrous metallurgy–hydrogen metallurgy–plasma”, is critically assessed, with a clear separation between laboratory/pilot feasibility and industrial readiness. We conclude that low-carbon blast furnace technologies, owing to low retrofit cost and high maturity, will dominate near-term mitigation, whereas hydrogen-based shaft furnaces and, in the longer term, hydrogen-based flash ironmaking define the pathway toward near-zero-carbon ironmaking—conditional on the availability of green hydrogen and low-carbon electricity and on overcoming key engineering barriers. Full article

Self-lubricating iron-based composites produced by powder metallurgy are promising materials for reducing friction and improving component durability under dry-sliding conditions. In this study, three composites reinforced with graphite and/or graphene oxide (Fe10%Gr, Fe10%GO, and Fe5%Gr5%GO) were fabricated to evaluate the influence of solid lubricants on densification, hardness, and tribological behavior. Powders were uniaxially compacted at 500 MPa and low-temperature-sintered at 880 °C under an argon atmosphere. The tribological performance was assessed by pin-on-disk tests against an AISI 52100 steel ball. Pure Fe exhibited the highest hardness (approximately 97 HV) and a final porosity of 17.5%, whereas the lubricant-containing composites showed porosities ranging from 17.3% to 22.8% and lower hardness values of 45–60 HV. Despite the reduction in hardness, all lubricant-containing compositions decreased the coefficient of friction relative to pure Fe (~0.33). Fe10%Gr and Fe5%Gr5%GO exhibited the lowest friction coefficients, reaching ~0.08 and ~0.05, respectively, while Fe10%GO showed the highest wear rate (~1.1 × 10⁻² mm³/Nm). Among the compositions studied, Fe5%Gr5%GO showed the best friction–wear balance among the self-lubricating formulations, combining low friction and moderate wear due to a surface synergy where graphite promotes continuous low-shear lubrication while GO promotes the formation of a more compact and resilient protective tribolayer. Full article

“Replacing carbon with hydrogen” represents one potential pathway for green development in the steel industry, with hydrogen metallurgy playing a crucial role in advancing the sector’s green transformation. This paper systematically reviews existing fundamental theoretical achievements in this field, clarifies the current research status and core advancements, while also analyzing existing scientific challenges and theoretical bottlenecks. It reviews the kinetic mechanisms and control methods for hydrogen reduction of iron oxides, focusing on the influence of key factors such as temperature and hydrogen partial pressure on the reduction process. The applicability of the unreacted nucleus model and other models in describing gas–solid reaction processes is analyzed. The hydrogen reduction reaction follows a multi-step mechanism of “gas-phase diffusion-adsorption-interfacial reaction-product layer diffusion-desorption,” with its rate governed by both diffusion control and chemical reaction control. At the kinetic level, rationally controlling temperature and increasing hydrogen partial pressure are effective approaches to enhance reaction efficiency. Future efforts should strengthen fundamental theoretical research, advance the integration of multiple technological pathways, and promote large-scale application. This review provides theoretical support for subsequent fundamental research on hydrogen metallurgy and offers reasonable recommendations for the development of hydrogen metallurgy technology in China’s steel industry. More importantly, this review critically compares representative kinetic interpretations and model assumptions reported in the literature, and proposes an interface-oriented analytical framework that links process variables, interfacial elementary steps, structural evolution, kinetic transition, and regulation strategy. Full article

The objective of this study is to develop a methodological approach to the integral assessment of the investment attractiveness of metallurgical enterprises to improve the efficiency of investment activities and the implementation of projects and ensure sustainable development. The metallurgy industry faces the challenge of balancing efficiency goals and sustainable objectives (ESG) and risks. Our approach takes into account the relationship between investment potential, realized opportunities, and the level of risk. Based on a systematic analysis of theoretical approaches, an integral investment attractiveness index is proposed that aggregates investment potential (consisting of seven sub-potentials), an assessment of the results of project implementation, and an aggregated risk index. Assessing investment attractiveness is important for ensuring the sustainable implementation of effective projects and determining their priority. A panel dataset was constructed using data from two metallurgy companies. The relationship between investment attractiveness and classical indicators (ROIC, EVA, MVA, Tobin’s Q, and P/BV) is examined through panel regression with fixed effects, cross-correlation analysis of the temporal structure of relationships, a CUSUM test for model stability, and decomposition of investment attractiveness changes. Decomposition of investment attractiveness changes makes it possible to quantify the contribution of potential, opportunities, and risk to the dynamics of investment attractiveness across various periods, including crisis and post-crisis ones describing the specifics of the metallurgic industry. The presented methodology is relevant for increasing the efficiency of project implementation within the framework of an integral company policy and contributes to the acceleration of industrial implementation of sustainable projects in the metallurgy sector. Full article

Significant amounts of smelting slag are generated during the production of steel, refined copper, and refined magnesium. These slags contain abundant valuable metallic elements, such as Fe, Cu, Zn, Co, and Mg, that have not been fully utilized in the past. This study proposes a method for modifying copper slag by mixing it with steel slag and magnesium slag, followed by roasting with additions of Fe₂O₃ and MgO. The samples were roasted at 1400 °C for 30 min, cooled to 1000 °C at 1.5 °C/min, and then water-quenched to room temperature. Phase transformations during modification were analyzed using FactSage 8.0, DSC–TG, and XRD. The effects of factors such as the content of Fe₂O₃ and MgO on the modification efficiency were investigated. The results indicate that, under the condition of maintaining a steel slag: copper slag: magnesium slag ratio of 37:37:26 and adjusting the basicity (CaO/SiO₂ ratio) with CaO to 2.0, the addition of Fe₂O₃ and MgO promotes the formation of spinel. However, excessively high contents of Fe₂O₃ and MgO lead to refinement of the spinel grains and reduce the iron grade of the concentrate. Within the investigated composition range, the samples with total Fe₂O₃ and MgO contents of 27.66 wt% and 7.56 wt%, respectively, showed the best magnetic separation performance among the tested compositions. Through magnetic separation, the concentrate has good economic and industrial application value in industries such as steelmaking and powder metallurgy, while the tailings can be utilized as raw materials for manufacturing ceramics, glass–ceramics, cement, and concrete. Full article

Facing the severe environmental challenge of massive red mud (RM) stockpiles, iron extraction research is accelerating from traditional pyrometallurgy and other conventional processes toward green low-carbon, multi-source synergistic, and total-component high-value utilization approaches—a transition that continues to evolve. This review systematically examines three frontiers: green reduction technologies, synergistic valorization via waste-treating-waste, and integrated cascading strategies for total-component high-value utilization. Evaluation focuses on the principles, advantages, and challenges of biomass reduction, hydrogen metallurgy, selective flocculation, advanced heating techniques, co-processing with other solid wastes, and multi-metal cascading extraction. Evidence suggests that future RM iron extraction technology lies in establishing cross-industry circular economy networks, transforming RM from a singular waste into a resource hub linking aluminum, steel, and construction industries to maximize environmental and economic benefits. Full article

Micro-structured SAE H13 tool steel inserts for polymer injection molding require accurate replication of sub-millimeter features while retaining adequate densification and heat-treatment response. This study compared two powder-based routes on the same hemispherical insert containing pyramidal features of approximately 0.145 mm base width: hot embossing (HE) of water-atomized SAE H13 powder (supplier d50 = 5.7 µm, irregular morphology) compounded with a commercial M1 binder, and material extrusion (MEX) of a commercial gas-atomized SAE H13 filament processed on a Markforged Metal X. Rheological screening selected a 57:43 vol% powder-to-binder ratio for the in-house HE feedstock, and DSC/TGA measurements defined two-step debinding windows. The best HE conditions were 220 °C, 8 MPa, and 45 min for the in-house mixture, and 210 °C, 8 MPa, and 30 min for the granulated commercial filament; the latter showed a 0.15% linear deviation from the silicone replica diameter among the best-rated samples. Under the tested commercial MEX configuration, the pyramidal features were not resolved because the 0.40 mm deposition line width exceeded the target feature base width, causing the slicer to omit the sub-line-width geometry. The defect populations differed qualitatively: HE specimens showed porosity and local cracking associated with powder morphology and pressureless sintering, whereas MEX specimens showed build-direction-aligned inter-raster voids associated with the toolpath. Microhardness and tensile data are therefore interpreted as process-history-specific results rather than as a direct route ranking, because sintering conditions were not uniform across all specimens. The study defines an experimentally bound process-selection limit for SAE H13 micro-tooling: HE remains preferable for sub-nozzle surface features, whereas MEX remains attractive for macro-scale geometric freedom, if resolution, densification, and post-sintering consolidation are addressed. Full article

Copper and its alloys are widely used in electrical, automotive, aerospace, and energy applications because of their excellent thermal and electrical conductivity. However, the low hardness and poor wear resistance of pure Cu limit its use under tribologically demanding sliding conditions. In this study, Cu matrix composites reinforced with 1 wt.% boron carbide (B₄C), boron (B), chromium (Cr), cobalt (Co), alumina (Al₂O₃), and graphite (Gr) were fabricated by powder metallurgy and comparatively evaluated under identical processing and testing conditions. Phase constitution and microstructural characteristics were analyzed by XRD, SEM, and EDS, while mechanical and tribological behavior was assessed by Vickers hardness and dry sliding wear tests. All reinforcements improved the hardness of the Cu matrix compared with unreinforced Cu. The hardness increase followed the order Cu–B₄C (68.91%) > Cu–B (66.43%) > Cu–Gr (63.97%) > Cu–Al₂O₃ (61.79%) > Cu–Cr (42.69%) > Cu–Co (36.04%). Dry sliding wear tests, performed under a 10 N normal load, 0.05 m s⁻¹ sliding speed, and 1000 m sliding distance against a 316L stainless-steel ball, showed that all reinforced composites exhibited lower mass loss and more stable sliding behavior than pure Cu. Among all samples, Cu–B₄C displayed the best wear performance, with a 154.8% improvement in wear resistance relative to pure Cu. SEM analysis of the worn surfaces revealed that reinforcement addition reduced severe plastic deformation, groove formation, and delamination, leading to a more stable wear regime. Graphite- and boron-containing composites benefited from interfacial lubrication and contact stabilization, whereas B₄C and Al₂O₃ improved wear resistance through rigid-particle strengthening and enhanced load-bearing capacity. By comparing ceramic, metalloid, metallic, oxide, and solid-lubricating reinforcements at the same low addition level and under identical processing and testing conditions, this study provides a reinforcement-selection framework for Cu-based composites requiring improved hardness and dry-sliding durability. Full article

This study investigates the possibility of producing a complex W–Mo–Cr-containing alloy via metallothermic reduction of oxide concentrates in the presence of direct reduced iron (DRI) in an induction furnace under atmospheric conditions. A complex FeAlSiCa alloy was used as a reductant due to its high exothermicity and combined reducing potential. Thermodynamic analysis showed that the reduction of WO₃ and MoO₃ is more favorable compared to Cr₂O₃, which is reflected in the temperature profiles of the process. Experimental results confirmed that the addition of FeAlSiCa leads to intensive exothermic reactions and promotes melt formation. The estimated apparent recovery of W and Mo reached up to ~99%, while Cr estimated apparent recovery remained lower (up to ~70%) due to its higher thermodynamic stability and kinetic limitations. Microstructural analysis revealed a heterogeneous structure consisting of an Fe-based matrix and W–Mo-rich phases, including characteristic “fishbone” morphologies. An increase in reductant amount led to higher Si content in the alloy, indicating the need for composition optimization. The results demonstrate the feasibility of direct complex alloying as an alternative to conventional ferroalloy-based methods and highlight the potential for developing resource-efficient and low-carbon metallurgical technologies. Full article

The unique powder-pack boriding technique using an open retort with boriding medium was applied for the first time in order to produce boride layers on K190 ledeburitic chromium steel manufactured using powder metallurgy. The processes were carried out using the commercial Durborid^®G powder mixture at 1173 K, 1223 K, and 1273 K for 3 h, 6 h, and 9 h. As a result of the boriding of the high-carbon and high-chromium substrate, three zones were revealed in the produced surface layers: the outer FeB zone, the inner Fe₂B zone, and the transition zone, with increased carbon content. The total thickness of the boride layers (FeB + Fe₂B) ranged from 14.13 µm at the lowest temperature and shortest time to 65.49 µm at the highest temperature and longest duration. Increasing the temperature and extending the boriding time resulted in a deeper FeB zone as well as a thicker total layer (FeB + Fe₂B). The growth kinetics of the produced layers on the surface of K190 steel were analyzed for the first time using the mean diffusion coefficient model. The thicknesses of the FeB zone and the total layer (FeB + Fe₂B) were determined. The activation energies of boron for the FeB and Fe₂B phases calculated in this work are comparable with other results for the powder-pack boriding of high-carbon tool steels. As a consequence of the high chromium content in K190 steel, chromium borides were observed in the boride zones, which increased the hardness of the surface layer. The highest temperature used resulted in the formation of vanadium borides. The presence of the transition zone with an increased carbon concentration and a high percentage of carbides resulted from the movement of carbon atoms toward the core by the advancing boron diffusion front. The parameters of boriding (temperature and time) as well as the presence of alloying elements in the substrate material influenced the microhardness of the boride layers. Full article

Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable technique for producing large metallic components; however, coarse columnar microstructures, strong crystallographic texture, and significant residual stresses limit its widespread adoption. Hybrid WAAM processes that integrate deformation-based techniques have been developed to address these limitations. This review provides an analysis of deformation-assisted WAAM, covering interlayer rolling, friction stir processing (FSP), machine hammer peening, laser shock peening, and ultrasonic-vibration-assisted techniques. These hybrid techniques introduce additional thermomechanical parameters (strain, strain rate, and applied stress) that significantly influence microstructure evolution. The governing physical metallurgy mechanisms are discussed in detail, including dislocation accumulation, recovery, static and dynamic recrystallization, and severe plastic deformation. Studies from 2022 to 2025 are critically reviewed, highlighting the effectiveness of hybrid WAAM in promoting columnar-to-equiaxed grain transformation, reducing anisotropy, mitigating defects, and improving mechanical properties across aluminum, titanium, steels, and nickel-based alloys. The integration of auxiliary processes such as in situ machining and heat treatment is also discussed. This review establishes a process–structure–property framework for hybrid WAAM and provides guidance for the development of advanced additive manufacturing systems for the production of near-net-shape components, with reported yield-strength gains of 20–40%, elongation gains of 10–30%, and fatigue-life improvements of up to 60% relative to as-built WAAM. Full article