Search Results (192)

Achieving thickness uniformity is a critical challenge in superplastic forming (SPF) of hemispherical shells, as standard constant-thickness blanks suffer from excessive thinning at the pole. While the literature suggests using variable thickness blanks to mitigate this issue, existing solutions often rely on complex, non-linear profiles that are expensive and difficult to manufacture. This work proposes a cost-effective, truncated conical blank design (linearly variable thickness) to optimize material distribution. The approach combines Finite Element Method (FEM) analysis and experimental validation on AZ31 magnesium alloy. The study demonstrates that the optimized truncated conical profile (α = 0.2) yields superior structural quality, drastically reducing the thinning factor to 9%. This represents a significant improvement compared to the ~14% thinning observed with conical profile (α = 0) blanks and outperforms constant-thickness blanks (30%). These results demonstrate that a simplified, easily machinable blank geometry can effectively address the thinning problem, providing a practical solution for industrial SPF applications. Full article

This paper presents the design, manufacturing, instrumentation and validation by tests (ground and icing wind tunnel) of a full-scale Hybrid Laminar Flow Control (HLFC) leading-edge demonstrator based on Airbus A330 outer wing plan-form. The Ground-Based Demonstrator (GBD) was developed to reproduce a full-scale, realistic wing section integrating into the leading-edge three key systems: micro-perforated skin for the hybrid laminar flow control suction system (HLFC), the hot-air Wing Ice Protection System (WIPS) and a folding “bull nose” Krueger high-lift device. The demonstrator combines a superplastic-formed and diffusion-bonded (SPF/DB) perforated titanium skin mounted on aluminum ribs jointed with a carbon-fiber-reinforced polymer (CFRP) wing box. Titanium internal ducts were designed to ensure uniform hot-air distribution and structural compatibility with composite components. Manufacturing employed advanced aeronautical processes and precision assembly under INCAS coordination. Ground tests were performed using a dedicated hot-air and vacuum rig delivering up to 200 °C and 1.6 bar, thermocouples and pressure sensors. The results confirmed uniform heating (±2 °C deviation) and stable operation of the WIPS without structural distortion. Relevant tests were performed in the CIRA Icing Wind Tunnel facility, verifying the anti-ice protection system and Krueger device. The successful design, fabrication, testing and validation of this multifunctional leading edge—featuring integrated HLFC, WIPS and Krueger systems—demonstrates the readiness of the concept for subsequent aerodynamic testing. Full article

This research focuses on the investigation of microstructure, deformation, and superplastic behavior in wide range of strain rates of novel crossover Al-Zn-Mg-Cu alloy with Y/Er. The precipitation and superplastic behavior of the Al-Zn-Mg-Cu-Zr-Cr-Ti with Er/Y and Fe/Si impurities alloys have been studied. The microstructure of the alloys with nano-sized precipitates and micron-sized particles allows obtaining a micrograin stable microstructure. The spherical D0₂₃-Al₃(Er,Zr) precipitates with a diameter of about 20 nm and rod-like crystalline and qusicrystalline E (Al₁₈Mg₃Cr₂) precipitates with a thickness of about 20 nm and length of about 150–200 nm were identified by transmission electron microscopy. The superplastic deformation behaviors were investigated under different temperatures of 460–520 °C and different strain rates of 3 × 10⁻⁴ to 3 × 10⁻³ s⁻¹. The microstructure observation shows that uniform and equiaxed grains can be obtained by dynamic recrystallization before superplastic deformation. The alloy with Y exhibits inferior superplastic properties, while the alloy with Er has an elongation of more than 350% at a rate of 1 × 10⁻³ s⁻¹ and a temperature of 510 °C. Full article

Biodegradable magnesium (Mg) alloys are promising materials for temporary orthopaedic implants, combining favourable mechanical properties and superplastic behaviour with in vivo resorption. This enables (i) prolonged implant duration, (ii) fabrication of complex-shaped prostheses via superplastic forming (SPF), (iii) elimination of removal surgery, and (iv) reduced risk of long-term complications. However, rapid corrosion under physiological conditions remains a major limitation, highlighting the need for surface treatments that slow degradation while preserving implant integrity. This study investigates the effects of hydrothermal surface treatment on MgAZ31-SPF alloys, focusing on immunomodulatory responses, antibacterial potential, and degradation behaviour. Hydrothermally treated MgAZ31-SPF (MgAZ31-SPF-HT) extracts released lower Mg²⁺ concentrations (29.2 mg/dL) compared to untreated MgAZ31-SPF (47.5 mg/dL) while maintaining slightly alkaline pH (7–8.7), indicating improved control of early degradation. In vitro assays with human peripheral blood mononuclear cells (hPBMCs) and normal human dermal cells (NHDCs) showed that MgAZ31-SPF-HT extracts maintained higher cell viability over 24–72 h. Gene expression analysis revealed significant downregulation of pro-inflammatory markers CTSE and TNF-α, while protein quantification via ELISA and BioPlex confirmed reduced secretion of TNF-α, TGF-β1, TGF-β2, IL-6, and IL-8, suggesting mitigation of early immune activation. Antibacterial assays demonstrated limited Staphylococcus aureus colonisation on both MgAZ31-SPF and MgAZ31-SPF-HT scaffolds, with CFU counts (~10⁵–10⁶) well below the threshold for mature biofilm formation (~10⁸), and SEM analysis confirmed sparse bacterial distribution without dense EPS-rich layers. Overall, hydrothermal treatment improves Mg alloy biocompatibility by controlling Mg²⁺ release, modulating early immune responses, and limiting bacterial adhesion, highlighting its potential to enhance clinical performance of Mg-based implants. Full article

Honeycomb graphene aerogels offer a combination of graphene wall qualities, such as mechanical strength and binding, and the unique, engineered architecture of honeycombs. The honeycomb structure opens new opportunities for property modification, such as reinforcement with metal nanoparticles, which can increase strength and electrochemical performance. This study uses molecular dynamics simulations to examine the reinforcement of graphene honeycomb aerogels containing 2.7% and 5.8% randomly distributed Ni or Al nanoparticles. Metal nanoparticles considerably increase the resistance to compression: stress increase occurred for aerogels with Al nanoparticles at a density of 1.3 g/cm³, while for aerogels and filled with Ni, stress increase occurred at 2.0 g/cm³. The strengthening mechanism is volume repulsion when Al NPs repel the graphene cell walls, while Ni nanoparticles easily spread along the cell walls and provide less compression resistance, analogous to pure graphene aerogels. The tensile properties remained unaffected by the presence of either nanoparticle type since the same deformation mechanism (cell collapse) occurred for all aerogels. The maximal ultimate tensile strength achieved was 160 GPa. Temperatures ranging from 300 to 3000 K slightly affected the strength of all aerogels. Full article

The processing of bulk amorphous alloys is typically realized through superplastic deformation in the supercooled liquid region, and current research efforts predominantly focus on enhancing formability by optimizing processing parameters such as temperature and duration. However, excessive temperatures or prolonged exposure times can induce crystallization, which severely compromises the mechanical and functional properties of the alloy. This study presents the design of an ultrasonic vibration (UV)-assisted metal hot-forming apparatus that integrates an ultrasonic vibration field into the superplastic flow deformation of amorphous alloys. High-temperature compression experiments were conducted on Zr₅₅Cu₃₀Al₁₀Ni₅ amorphous alloy, and finite element simulations were performed to model the experimental process. Results show that ultrasonic vibration reduces the flow stress of the amorphous alloy, thereby enhancing its superplastic deformation capability. Simulation analysis reveals that surface effects arise from periodic interface separation between the pressure plate and the specimen caused by ultrasonic vibration, leading to a cyclic disappearance of friction forces, which manifest macroscopically as a reduction in effective friction. On the other hand, vibration introduces additional strain rates. Since the undercooled liquid of amorphous alloys exhibits non-Newtonian fluid behavior characterized by shear-thinning, ultrasonic vibration assistance can effectively reduce the apparent viscosity, thereby improving their filling capacity. Full article

We present analytical investigations of evolution of localized disturbances during their propagation in an infinite monoatomic nonlinear one-dimensional lattice, specifically the $\alpha$-Fermi-Pasta-Ulam (FPU) chain. We focus on two key disturbance characteristics: the position of the energy center and the energy radius. Restricting our analysis to long-wave low-amplitude disturbances, we investigate the dynamics in the $\alpha$-FPU chain and its two continuous versions described by the Boussinesq and Korteweg–de Vries (KdV) equations. Utilizing the energy dynamics approach and leveraging the known property of the KdV equation that any localized disturbance eventually decomposes into a set of non-interacting solitons and a dispersive oscillatory tail, we establish a similarity between the behavior of the disturbance in the linear chain and the nonlinear chain under consideration. Namely, at large time scales, the disturbance energy center propagates and the energy radius increases linearly in time, meaning dispersion also occurs at a constant velocity, analogous to the linear case. It was also found that, prior to its decomposition into non-interacting components, a disturbance in the KdV equation generally evolves as if subjected to an effective force from the medium. Furthermore, for two reduced versions of the KdV equation—one lacking the dispersive term and the other lacking the nonlinear term—the energy center of any disturbance moves with constant velocity. These results generalize the behavior observed in harmonic chains to weakly nonlinear systems and provide a unified framework for understanding energy transport. Full article

Despite significant interest in their functional properties, the mechanical behavior of high-entropy oxides (HEOs) is not well studied, particularly at elevated temperatures. Bulk (Co,Cu,Mg,Ni,Zn)O (transition metal (TM)-HEO) samples were deformed under compression at applied stresses and temperatures ranging from 5 to 31 MPa and 600 to 850 °C, respectively. All of the deformation conditions result in creep stress exponents of n < 3, indicating that TM-HEO exhibits superplastic deformation. A transition from structural to solution-precipitation-based superplasticity is observed during deformation above 650 °C. Additionally, TM-HEO exhibits shear-thickening behavior when deformed at stresses above 9 MPa. The formation and behavior of a Cu-rich tenorite secondary phase during deformation is identified as a key factor underpinning the deformation mechanisms. The microstructure and phase state of TM-HEO before deformation also influenced the behavior, with finer grain sizes and increasing concentrations of Cu-rich tenorite, resulting in the increased prevalence of solution-precipitation deformation. While complex, the results of this study indicate that TM-HEO deforms through known superplastic deformation mechanisms. Superplasticity is a highly efficient manufacturing method and could prove to be a valuable strategy for forming HEO ceramics into complex geometries. Full article

Biodegradable zinc-based alloys have recently emerged as promising candidates for temporary biomedical implants due to their favorable biocompatibility, appropriate degradation rate, and relatively simple processing. In this study, the Zn-0.1Mg alloy was investigated after being processed by means of a two-step equal-channel angular pressing (ECAP) route, consisting of the first pass at 150 °C followed by a second pass at room temperature. The mechanical properties were evaluated using uniaxial tensile tests at different strain rates, while the microstructure and phase composition were analyzed using synchrotron hard X-ray diffraction and transmission electron microscopy (TEM). The processed alloy exhibited a remarkable enhancement in both strength and ductility compared to the annealed state. At the lowest applied strain rate, a fracture elongation of up to 240% was achieved at room temperature, representing a unique manifestation of superplasticity under ambient conditions. Diffraction analysis confirmed the stability of the supersaturated Zn matrix with minor Mg₂Zn₁₁ intermetallic phase. TEM observations revealed an ultrafine-grained microstructure and activation of non-basal slip systems, which enabled efficient plastic flow. These findings demonstrate that controlled severe plastic deformation provides an effective pathway for tailoring Zn-Mg alloys, opening opportunities for their use in the next generation of bioresorbable low-to-moderate load orthopedic fixation devices, e.g., plates, screws, suture anchors and craniofacial miniplates. Full article

Understanding and controlling thermal rectification is pivotal for designing phononic devices that guide heat flow in a preferential direction. This study investigates one-dimensional atomic chains with binary mass asymmetry and nonlinear interatomic potentials, focusing on how energy propagates under thermal and wave excitation. Two potential models—the β-FPU and Morse potentials—were employed to examine the role of nonlinearity and bond softness in energy transport. Simulations reveal strong directional energy transport governed by the interplay of mass distribution, nonlinearity, and excitation type. In FPU chains, pronounced rectification occurs: under “cold-heavy” conditions, energy in the left segment increases from ~1% to over 63%, while reverse (“hot-heavy”) cases show less than 4% net transfer. For wave-driven excitation, the rectification coefficient reaches ~0.58 at 100:1. In contrast, Morse-based systems exhibit weaker rectification (∆E < 1%) and structural instabilities at high asymmetry due to bond breaking. A comprehensive summary and heatmap visualization highlight how system parameters govern rectification efficiency. These findings provide mechanistic insights into nonreciprocal energy transport in nonlinear lattices and offer design principles for nanoscale thermal management strategies based on controlled asymmetry and potential engineering. Full article

This study investigates the microstructure and mechanical properties of copper (Cu) and graphene/Cu (Gr/Cu) composites produced via high-pressure torsion (HPT) under 5 GPa at room temperature. Microstructural analysis revealed significant grain refinement, with average grain sizes of 0.39 μm for pure Cu and 0.35 μm for Gr/Cu composite. The Gr/Cu composite exhibited slightly higher microstrains and effective stacking fault energy (SFE). Tensile tests showed ultimate tensile strengths of 689 MPa (pure Cu) and 674 MPa (Gr/Cu), with the latter demonstrating improved ductility (~10% elongation). Ab initio calculations confirmed a 27% increase in SFE for Gr/Cu, aligning with experimental results. These findings highlight the potential of Gr/Cu composites for applications requiring high strength and efficient heat dissipation. Full article

A significant contradiction exists between the demand for standardized processes and the need for precise process parameter design in the rapid design of superplastic forming (SPF). To address this, an SPF process parameter design method integrating a knowledge graph and artificial intelligence is proposed. Firstly, based on process data analysis, the entity labels, relationship categories, and attributes are determined. On this basis, the knowledge graph for the SPF process is constructed, comprising the pattern layer and the data layer, which provides structured knowledge support for process generation. Secondly, the process parameter prediction model based on small samples and an improved back propagation (BP) neural network is constructed, with model convergence ensured through an adaptive maximum iteration strategy. Experimental results show that the improved BP model significantly outperforms support vector regression (SVR), random forest (RF), extreme gradient boosting (XGBoost), and standard BP models in prediction accuracy. Compared to the standard BP model, the improved model reduces the mean squared error (MSE), mean absolute error (MAE), and root mean squared error (RMSE) by 82.1% (to 0.0005), 46% (to 0.0188), and 57.1% (to 0.0229), respectively. Finally, the effectiveness, feasibility, and superiority of the method in the SPF process parameter design are verified by taking typical hemispherical parts as an example. Full article

The crystal structure, texture, martensitic transformation, and magnetic properties of magnetic shape-memory Heusler alloys of Ni_51−xMn_33.4In_15.6V_x (x = 0; 0.1; 0.3; 0.5; 1) were investigated. Experimental studies of the magnetic properties and meta-magnetostructural transition (martensitic transition—MT) confirm the main sensitivity of the martensitic transition temperature to vanadium doping and to an applied magnetic field. This makes this family of shape-memory alloys promising for use in numerous applications, such as magnetocaloric cooling and MEMS technology. Diffuse electron scattering was analyzed, and the structures of the austenite and martensite were determined, including the use of TEM in situ experiments during heating and cooling for an alloy with a 0.3 at.% concentration of V. In the austenitic state, the alloys are characterized by a high-temperature-ordered phase of the L2₁ type. The images show nanodomain structures in the form of tweed contrast and contrast from antiphase domains and antiphase boundaries. The alloy microstructure in the temperature range from the martensitic finish to 113 K consists of a six-layer modulated martensite, with 10 M and 14 M modulation observed in local zones. The morphology of the double structure of the modulated martensite structure inherits the morphology of the nanodomain structure in the parent phase. This suggests that it is possible to control the structure of the high-temperature austenite phase and the temperature of the martensitic transition by alloying and/or rapidly quenching from the high-temperature phase. In addition, attention is paid to maintaining fine interface structures. High-resolution transmission electron microscopy showed good coherence along the austenite–martensite boundary. Full article

Superplastic materials are characterised by extreme lightness and remarkable ductility. Instead of a punch, a gas is used to push the sheet into the die cavity, and it is precisely regulated to control the material’s strain rate. Forming a superplastic material while maintaining a high strain rate sensitivity index requires the forming gas to follow a precise pressure–time loading curve. This can be excellently predicted with the aid of the finite element method (FEM). Therefore, for the superplastic material to exhibit its best formability throughout the entire process, it is necessary to control the strain rate step by step to keep the maximum strain rate within the material’s optimal superplastic range. In this work, the results of a superplastic-forming process used to create a hemispherical shell are presented. This was carried out using both a circular blank of uniform thickness and a blank with a conical cross-section. The analysis was performed using finite element modelling. Specifically, the results obtained using 3D analysis were compared with those obtained using axisymmetric analysis for conditions of axial symmetry. Using the conical cross-section blank helped achieve a more uniform thickness distribution in the produced hemispherical shell. The success of the numerical activity was validated through results from appropriate experimental work conducted on the magnesium alloy AZ31. The results show that, by employing a blank characterised by a conical section profile, the thickness distribution appears more uniform than that of a constant-thickness blank. Full article

Optimizing superplastic forming (SPF) process parameters is vital for improving production efficiency and addressing the growing complexity of product requirements in high-end manufacturing fields. Current optimization of SPF process parameters focuses on meeting product requirements, often overlooking constraints related to quality indicators, process, and equipment limitations. This paper proposes an optimization approach that integrates SPF manufacturing process information using model-based systems engineering and simulation validation techniques to establish a continuous mapping between product requirements, process parameters, and equipment control parameters. First, SPF is modeled using the systems modeling language to describe the relationships between processes and equipment. Then, the process parameters are extracted via object flow analysis and categorized according to shape and performance control. The key process parameters and impact indicators for meeting customized product requirements are identified using the analytic hierarchy process. Finally, orthogonal experimental design and process simulation are employed to optimize the parameters, with the results mapped onto the physical model to guide the equipment control parameter design. A case study demonstrates its feasibility and effectiveness in meeting customized products. Full article