Search Results (151)

In this paper, the supersaturated solid solution of Al-Cu3-Si-Mg alloy prepared by molten metal die forging (MMDF) was used as the research object. The formation and evolution of precipitates during aging treatment were investigated through experiments at different temperatures and times, and the precipitation mechanisms and sequences of various precipitates were analyzed. The main precipitated phases formed in the supersaturated solid solution of the Al-Cu3-Si-Mg alloy after aging treatment are θ(Al₂Cu), θ′(Al_3.6Cu₂), γ′(Al_0.63Mg_0.37), and η′(Cu, Si). Based on XRD and TEM analysis under different aging treatment conditions, the precipitation sequence is determined as follows: SSS → GP₀ → GP₀ + γ′ → GP₀ + (γ′ + γ) + θ″ + η′ → (γ′ + γ) + (θ″ + θ′) + (η′ + η) → (γ′ + γ) + (θ + θ′) + (η′ + η) → (γ′ + γ) + (θ + θ′) + η → γ + θ + η. After aging treatment at 165–185 °C for 4 h, chain-like θ(Al₂Cu) precipitates are discontinuously distributed at the α-Al grain boundaries, and disc-shaped θ′(Al_3.6Cu₂) and θ″(Al₂Cu) phases mainly precipitate within the grains. When the temperature exceeds 185 °C, the chain-like θ(Al₂Cu) precipitates at the grain boundaries gradually become continuous, and the fraction increase from 1.5% to 15.2%. The amount of the θ(Al₂Cu) phase in the grains increases from 2 to 6, and the size of θ′(Al_3.6Cu₂) decreases obviously. After aging treatment at 185 °C for 5–6 h, the chain-like θ(Al₂Cu) precipitates become more continuous, and the fraction continues to increase from 32.1% to 52.6%. The effect of chain-like precipitates at grain boundaries on the mechanical properties of the matrix is opposite to the strengthening contribution of dispersed intragranular precipitates. When the aging condition exceeds 185 °C × 5 h, the excessive formation of chain-like grain boundary precipitates causes both the strength and hardness of the alloy to show a decreasing trend. Full article

The effect of treatment time on arc-enhanced glow discharge plasma-assisted nitriding (AEGD-PAN) of AISI M2 high-speed steel was investigated for non-heat-treated and heat-treated substrates. Nitriding treatments were carried out at 350 °C for 1.5 and 3.5 h, producing diffusion layers with thicknesses ranging from approximately 38 to 75 µm without formation of a continuous brittle compound layer. X-ray diffraction combined with Rietveld refinement revealed the progressive formation of γ′-Fe₄N and ε-Fe₂₃N nitrides together with lattice expansion of the α-Fe matrix, indicating nitrogen supersaturation and precipitation strengthening within the diffusion zone. Heat-treated specimens exhibited higher surface hardness, reaching ~1350 HV_0.1, while non-heat-treated substrates developed pronounced hardness gradients associated with diffusion-controlled layer growth. Scratch testing showed improved resistance to contact-induced damage with increasing nitriding time, particularly for the 3.5 h treatment, where lateral cracking was significantly reduced and load-bearing capacity increased. Multi-pass scratch wear tests revealed a reduction in the Archard wear coefficient by up to four orders of magnitude compared with untreated M2 steel. These results demonstrate that AEGD-PAN at moderate temperature enables efficient diffusion layer formation and significant improvement in the tribological performance of high-alloy tool steels. Full article

This study addresses the challenge of through-hole defects in ZM6 cast magnesium alloy components by proposing an innovative repair strategy using ultrasonic-assisted Tungsten Inert Gas (U-TIG) welding. The microstructure and mechanical properties of the repaired joint were systematically characterized through optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), and room-temperature tensile testing. The results indicate that, assisted by the ultrasonic energy field, the repair zone successfully reconstitutes a typical and optimized triple-phase microstructure: (1) the matrix: α-Mg solid solution (dark gray), supersaturated with Nd and Zr; (2) the strengthening phase: a eutectic Mg₁₂Nd phase (light gray), rich in Nd, distributed along grain boundaries acting as the primary strengthening component; (3) the grain refiner: dispersed Zr-rich particles (bright white spots), which effectively pin grain boundaries. Crucially, the application of ultrasound significantly refined the α-Mg grains and transformed the continuous network of the Mg₁₂Nd phase into a more fragmented and uniform dispersion. This refined microstructure synergistically integrates the strengthening mechanisms of solid solution, precipitation hardening, and grain refinement. Consequently, the repaired joint exhibits excellent mechanical properties, achieving over 90% of the base metal’s tensile strength and elongation at room temperature. This work not only validates the feasibility of U-TIG welding for repairing ZM6 alloys but also provides a solid theoretical foundation and a promising technical pathway for the in-service repair and remanufacturing of high-performance magnesium alloy components. Full article

Laser powder bed fusion (LPBF) was adopted to manufacture AlSi10Mg, and two post-processing schedules, T4 (510 °C/2 h + water quench) and T6 (T4 + 180 °C/6 h), were applied to elucidate how Si precipitation size controls ductility. The as-built alloy consisted of an α-Al matrix with a grid-like eutectic Si network and achieved UTS > 480 MPa but exhibited build-direction-dependent tensile anisotropy. Heat treatment promoted Si precipitation from the supersaturated α-Al matrix and transformed the eutectic network via fragmentation, spheroidization, and Ostwald ripening, leading to pronounced softening and improved elongation. After T4, the yield strength and UTS decreased by >50%, while elongation increased from 10.9% to 22.27%; T6 provided a slight strength recovery accompanied by a marginal ductility reduction. Mechanistically, a high number density of fine Si precipitates enhances dislocation storage and delays damage accumulation, whereas coarse, non-shearable Si particles intensify local strain gradients, facilitate void nucleation at the matrix/particle interface, and accelerate fracture. Overall, tailoring Si precipitation/coarsening offers an effective route to improve ductility and mitigate anisotropy in LPBF AlSi10Mg. Full article

The microstructure and properties of a cobalt-free, cost-effective Al_0.4CrFe₂Ni₂ medium-entropy alloy (MEA) after multi-stage thermomechanical processing, including annealing, rolling over a wide temperature range from hot to cryogenic conditions, and subsequent precipitation strengthening, were investigated in the present study. The initially cast microstructure was effectively homogenized through hot rolling with an 80% thickness reduction followed by homogenization annealing, resulting in the formation of a single-phase supersaturated solid solution and enhanced stability of plastic deformation. Strengthening of the MEA was achieved by rolling under both ambient and cryogenic conditions, with the deformation process predominantly governed by shear band formation. However, rolling under cryogenic conditions led to a more pronounced localization of plastic deformation, promoting the formation of deformation nanotwins and resulting in significantly higher strengthening compared to ambient rolling, with the alloy reaching a yield strength of 1040 MPa and an ultimate tensile strength of 1235 MPa. Precipitation hardening was governed by the formation of B2-type (ordered body-centered cubic, BCC) precipitates, which preferentially nucleated along deformation bands, thereby effectively strengthening the alloy to a yield strength of 1420 MPa and an ultimate tensile strength of 1465 MPa. Our results demonstrate that the investigated MEA offers a wide range of tunable mechanical properties, which can be effectively tailored through appropriate combinations of thermomechanical processing routes. Full article

This study investigates the synergistic effects of Cr–Zr and Mn–Zr additions on the microstructural evolution and mechanical properties of Al–6 wt.%Cu alloys. Alloys were designed with solute concentrations positioned below, near, and above their maximum solubility limits, and were evaluated under as-cast, T4, and T6 heat treatment conditions. Mechanical testing revealed distinct behavioral trends depending on the heat treatment: the T4 heat treatment condition generally exhibited superior hardness and yield strength, whereas the T6 heat treatment condition resulted in a slight reduction in hardness but facilitated a significant recovery in tensile strength and structural stability, particularly in alloys designed near the solubility limit. To elucidate the crystallographic origins of these mechanical variations, X-ray diffraction analysis was conducted to monitor changes in lattice parameters, dislocation density, and micro-strain. The results showed that T4 heat treatment induced lattice contraction and a decrease in dislocation density, suggesting that the high strength under T4 heat treatment conditions arises from lattice distortion caused by supersaturated solute atoms. Conversely, T6 aging led to lattice relaxation approaching that of pure aluminum, yet simultaneously triggered a re-accumulation of dislocation density and micro-strain due to the coherency strain fields surrounding precipitates, which effectively impede dislocation motion. Therefore, rather than proposing a single, definitive optimization condition, this study aims to secure foundational data regarding the correlation between these microstructural descriptors and mechanical behavior, providing a guideline for balancing the strengthening contributions in transition metal-modified Al–Cu alloys. Full article

This work investigates the effect of titanium content and the duration of mechanical alloying on the structural and phase state of powder mixtures in the Ni–Al–Ti system. The initial mixtures of Ni₆₈Al₂₅Ti₇, Ni₇₂Al₂₂Ti₆, Ni₇₀Al₂₁Ti₉, and Ni₇₅Al₂₅ were subjected to high-energy milling in a planetary ball mill for 1–6 h. It was found that the addition of titanium accelerates the dissolution of components and promotes the formation of a supersaturated fcc Ni(Al,Ti) solid solution. The most pronounced effects were observed for the Ni₇₀Al₂₁Ti₉ composition, where after 6 h of alloying, the minimum crystallite size (11.3 nm) and maximum lattice strain (1.52%) were achieved. It is shown that titanium reduces the tendency for cold welding and promotes more uniform particle refinement. The optimal conditions for synthesizing a nanocrystalline solid solution with a homogeneous structure are a titanium content of 9 at.% and a mechanical alloying duration of 6 h. The resulting powders are promising for subsequent sintering and application in structural and heat-resistant intermetallic alloys and coatings. Full article

To address the technical challenge of balancing formability and strength in automotive aluminum alloys, this study examined an Al-4.35Mg-3.6Zn-0.2Cu alloy subjected to a combined heat-treatment schedule consisting of a two-step solution treatment (470 °C for 24 h followed by 460 °C for 30 min) and a subsequent two-step aging process (T4P: 80 °C for 12 h, followed by BH: 180 °C for 30 min). Microstructural evolution was characterized using transmission electron microscopy, and uniaxial tensile tests were performed in accordance with the GB/T 228.1-2021 standard at a strain rate of 0.2 mm/min. In the T4P condition, the matrix contained both GPI zones (~0.9 nm) and GPII zones (~1.2 nm), with no detectable T-phase precipitation. The presence of GPII zones enhanced ductility by promoting dynamic recovery after dislocation shearing, resulting in a yield strength (YS) of 178 MPa, an ultimate tensile strength (UTS) of 310 MPa, and an elongation (El) of 9%. After BH treatment, the GPII zones transformed into semi-coherent T′-Mg₃₂(AlZnCu)₄₉ precipitates (~2.4 nm), which strengthened the alloy through their semi-coherent interfaces. The retained GPII zones mitigated the loss of ductility, and the final mechanical properties reached a YS of 275 MPa, a UTS of 340 MPa, and an El of 8.5%, corresponding to a BH response of 97 MPa. Strengthening-mechanism calculations indicated that GP zones contributed approximately 120 MPa to the yield strength in the T4P state, whereas T′ precipitates contributed about 169.64 MPa after BH treatment. The calculated values agreed well with the experimental results, with a deviation of less than 3%. This study clarifies the precipitation sequence in the alloy—supersaturated solid solution → GPI zones → GPII zones → T′ phase—and establishes the relationship between microstructure and strength–ductility behavior. The findings provide theoretical guidance for the design and optimization of high-strength, high-formability aluminum alloys for automotive outer-panel applications. Full article

This review systematically synthesizes the research progress on θ-series precipitates. It traces the historical evolution of θ-series precipitate research, from the accidental discovery of age hardening in Duralumin to the atomic-scale insights enabled by advanced electron microscopy and computational methods. The precipitation sequence (supersaturated solid solution → GP zones → θ″ → θ′ → θ), transformation mechanisms, and interfacial characteristics of θ′/Al are comprehensively analyzed, with special attention to ongoing controversies such as the structure of GP zones and the pathways of θ″ → θ′ transition. Furthermore, the review discusses how alloying elements regulate θ′ stability through interfacial segregation, vacancy interactions, and co-precipitation effects. Critical unresolved challenges are highlighted, including the kinetic limitations of θ′ coarsening and the need for mechanistic studies on multi-element microalloying. This synthesis aims to provide a foundation for future research toward designing high-performance age-hardenable aluminum alloys. Full article

This study investigates the control of the phase-structural state in Ni–45Ti–xCu (x = 5, 7 at.%) shape memory alloys fabricated via a shortened powder metallurgy route: mechanical activation → spark plasma sintering (SPS) → heat treatment. Compact samples were produced from mechanically alloyed powders (650–750 rpm, up to 5 h) and sintered at 900 °C. The structure and microstructure were characterized using X-ray diffraction (to identify B2/B19′/Ni₄Ti₃ phases and assess ordering) and SEM–BSE/EDS (to analyze morphology, porosity, and Ni-rich precipitates). Two post-processing treatments were applied: single-stage annealing (500 °C, 2 h) and a three-stage treatment (900 °C/30 min → water quenching → 300 °C/20 min). Mechanical alloying transformed the initial elemental powder mixture (fcc-Ni, hcp-Ti, fcc-Cu) into a supersaturated fcc-(Ni, Cu, Ti) solid solution with emerging NiTi phases, with a minimum particle size achieved after ~300 min at 750 rpm. SPS compaction yielded a high-density matrix consisting predominantly of the B2 phase. Single-stage annealing preserved B19′ martensite and Ni₄Ti₃ precipitates, particularly in the 5 at.% Cu alloy. In contrast, the three-stage treatment dissolved the Ni₄Ti₃ precipitates, suppressed the formation of B19′ and R phases, and stabilized a highly ordered B2 matrix. Increasing the Cu content from 5 to 7 at.% significantly enhanced the B2 phase fraction, reduced secondary nickel-rich phases, and improved structural homogeneity, evidenced by a continuous neck network and closed porosity. The optimized condition—7 at.% Cu combined with the three-stage annealing—produced a microstructure with >95% B2 phase, <1% Ni₄Ti₃, and ~98% relative density. This forms the prerequisite microstructural state for a narrow transformation hysteresis and high functional cyclic stability. 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

This study focuses on S32654 super austenitic stainless steel (SASS) and systematically characterizes the morphology of the sigma (σ) phase and the segregation behavior of alloying elements in its as-cast microstructure. High-temperature confocal scanning laser microscopy (HT-CSLM) was employed to investigate the effect of the rare earth element yttrium (Y) on the solidification microstructure and σ phase precipitation behavior of SASS. The results show that the microstructure of SASS consists of austenite dendrites and interdendritic eutectoid structures. The eutectoid structures mainly comprise the σ phase and the γ₂ phase, exhibiting lamellar or honeycomb-like morphologies. Regarding elemental distribution, molybdenum displays a “concave” distribution pattern within the dendrites, with lower concentrations at the center and higher concentrations at the sides; when Mo locally exceeds beyond a certain threshold, it easily induces the formation of eutectoid structures. Mo is the most significant segregating element, with a segregation ratio as high as 1.69. The formation mechanism of the σ phase is attributed to the solid-state phase transformation of austenite (γ → γ₂ + σ). In the late stages of solidification, the concentration of chromium and Mo in the residual liquid phase increases, and due to insufficient diffusion, there are significant compositional differences between the interdendritic regions and the matrix. The enriched Cr and Mo cause the interdendritic austenite to become supersaturated, leading to solid-state phase transformation during subsequent cooling, thereby promoting σ phase precipitation. The overall phase transformation process can be summarized as L → L + γ → γ → γ + γ₂ + σ. Y microalloying has a significant influence on the solidification process. The addition of Y increases the nucleation temperature of austenite, raises nucleation density, and refines the solidification microstructure. However, Y addition also leads to an increased amount of eutectoid structures. This is primarily because Y broadens the solidification temperature range of the alloy and prolongs grain growth perio, which aggravates the microsegregation of elements such as Cr and Mo. Moreover, Y raises the initial precipitation temperature of the σ phase and enhances atomic diffusion during solidification, further promoting σ phase precipitation during the subsequent eutectoid transformation. Full article

This study primarily investigated the microstructural and mechanical properties of Cu-Ni-Be alloys subjected to thermomechanical treatments at 30% and 75% deformation levels. Precipitates in Cu-Ni-Be alloys are dominated by Ni-Be phases. The misfit between the Ni-Be phase/Cu interface is 0.12%. Experimental observations have revealed the existence of three classical orientation relationships between precipitates and the matrix: (110)p//(100)α; [110]p//[001]α, (110)p//(010)α; [110]p//[001]α, and (110)p//(100)α; [001]p//[001]α (p: precipitates, α: α-Cu supersaturated solid solution). Additionally, a fourth orientation relationship, (110)p//(1-1-1)α; [110]gp//[1-1-1]α (gp: Guinier–Preston), induced by deformation, has also been identified. The width of the second phase was found to be two to three atomic layers. Under 75% deformation, a substantial amount of the γ′ phase emerged at grain boundaries. Notably, at neither 30% nor 75% deformation levels were prominent cellular structures observed. Full article

High-entropy alloys (HEAs) with ultrafine grained and high strength can be prepared by mechanical alloying (MA) followed by sintering. Therefore, MA, as a unique solid powder processing method, has many effects on the microstructures and mechanical properties of the sintered bulk HEAs. This work focused on the alloying behavior, morphology, and phase evolution of Fe_xCrNiAl (x = 1.0, 0.5, 0.25) HEAs by MA. The X-ray diffraction results show that the powders achieved a supersaturated solid solution body-centered-cubic (BCC) phase after MA; the crystalline size reached the nanoscale and was refined to ~80 nm. The morphology and composition of the alloyed powders were studied by scanning electron microscopy with energy dispersive spectroscopy. The results indicate that the powder was decreased to 1.59 μm for Fe_1.0 powder with excellent homogeneity in composition. There exists a phase transformation during high-temperature annealing, as the non-equilibrium BCC supersaturated solid solution phase transformed into the equilibrium phase of BCC and ordered BCC (B2) phases. Full article

The structure and phase composition of a eutectic silumin surface layer modified by compression plasma flow impact were investigated in this work. Plasma flows were generated by a magnetoplasma compressor of a compact geometry in a nitrogen atmosphere. The energy density absorbed by the surface layer was varied in the range of 10–35 J/cm². X-ray diffraction analysis, scanning electron microscopy, transmission electron microscopy and X-ray microanalysis were used as investigation techniques. It was found that the plasma impact led to the formation of a molten layer with a thickness of up to 50 μm. The layer thickness increased with the growth of the absorbed energy density. Dissolution of the intermetallic compounds and primary silicon crystals occurred as a result. The modified surface layer contained grains of a supersaturated solid silicon solution in aluminum. Grains with sizes of 100–500 nm were separated by interlayers of hypereutectic silumin containing nanocrystalline silicon precipitates. The doping elements of the alloy were concentrated mainly in these interlayers. The plasma impact resulted in a 1.5-fold microhardness increase. Full article