Journal Description
Metals
Metals
is an international, peer-reviewed, open access journal published monthly online by MDPI. The Portuguese Society of Materials (SPM), and the Spanish Materials Society (SOCIEMAT) are affiliated with Metals and their members receive a discount on the article processing charges.
- Open Access— free for readers, with article processing charges (APC) paid by authors or their institutions.
- High Visibility: indexed within Scopus, SCIE (Web of Science), Inspec, CAPlus / SciFinder, and other databases.
- Journal Rank: JCR - Q2 (Metallurgy & Metallurgical Engineering) / CiteScore - Q1 (Metals and Alloys)
- Rapid Publication: manuscripts are peer-reviewed and a first decision is provided to authors approximately 15 days after submission; acceptance to publication is undertaken in 2.7 days (median values for papers published in this journal in the second half of 2023).
- Recognition of Reviewers: reviewers who provide timely, thorough peer-review reports receive vouchers entitling them to a discount on the APC of their next publication in any MDPI journal, in appreciation of the work done.
- Companion journals for Metals include: Compounds and Alloys.
Impact Factor:
2.9 (2022);
5-Year Impact Factor:
2.9 (2022)
Latest Articles
Comparison of Fluid Flow and Tracer Dispersion in Four-Strand Tundish under Fewer Strand Casting and Sudden Blockage of Strand Conditions
Metals 2024, 14(5), 571; https://doi.org/10.3390/met14050571 (registering DOI) - 12 May 2024
Abstract
The study focuses on the four-strand tundish as the research object, aiming at the phenomenon of fewer strand casting (stable blockage) and sudden blockage of the tundish in industrial production. Numerical simulation methods are employed to compare the velocity vectors, flow fields, residence
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The study focuses on the four-strand tundish as the research object, aiming at the phenomenon of fewer strand casting (stable blockage) and sudden blockage of the tundish in industrial production. Numerical simulation methods are employed to compare the velocity vectors, flow fields, residence time distribution (RTD) curves, and outflow percentage curves under stable blockage and sudden blockage of the tundishes with a double-weir structure, U-shaped weir structure, and U-shaped weir structure with holes in the front. The results indicate that, after sudden blockage of the tundish strands, the flow field transitions from an unstable four-strand flow field to a stable three-strand flow field. Both the double-weir tundish and the U-shaped weir tundish reach a stable state after 200 s, while the U-shaped weir tundish with holes in the front reaches stability after 150 s. Additionally, compared to other structures, the tundish strands of the U-shaped weir with holes in the front are less affected by blockage, showing better consistency among strands and better adaptability under non-standard casting conditions.
Full article
(This article belongs to the Special Issue Modeling and Simulation of Multiphase Transport Phenomena in Process Metallurgy)
Open AccessArticle
Study of the Dynamic Recrystallization Behavior of Mg-Gd-Y-Zn-Zr Alloy Based on Experiments and Cellular Automaton Simulation
by
Mei Cheng, Xingchen Wu and Zhimin Zhang
Metals 2024, 14(5), 570; https://doi.org/10.3390/met14050570 (registering DOI) - 12 May 2024
Abstract
The exploration of the relationship between process parameters and grain evolution during the thermal deformation of rare-earth magnesium alloys using simulation software has significant implications for enhancing research and development efficiency and advancing the large-scale engineering application of high-performance rare-earth magnesium alloys. Through
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The exploration of the relationship between process parameters and grain evolution during the thermal deformation of rare-earth magnesium alloys using simulation software has significant implications for enhancing research and development efficiency and advancing the large-scale engineering application of high-performance rare-earth magnesium alloys. Through single-pass hot compression experiments, this study obtained high-temperature flow stress curves for rare-earth magnesium alloys, analyzing the variation patterns of these curves and the softening mechanism of the materials. Drawing on physical metallurgical theories, such as the evolution of dislocation density during dynamic recrystallization, recrystallization nucleation, and grain growth, the authors of this paper establish a cellular automaton model to simulate the dynamic recrystallization process by tracking the sole internal variable—the evolution of dislocation density within cells. This model was developed through the secondary development of the DEFORM-3D finite element software. The results indicate that the model established in this study accurately simulates the evolution process of grain growth during heat treatment and the dynamic recrystallization microstructure during the thermal deformation of rare-earth magnesium alloys. The simulated results align well with relevant theories and metallographic experimental results, enabling the simulation of the dynamic recrystallization microstructure and grain size prediction during the deformation process of rare-earth magnesium alloys.
Full article
(This article belongs to the Special Issue Modeling, Simulation and Experimental Studies in Metal Forming)
Open AccessArticle
Improving the Corrosion Resistance of Micro-Arc Oxidization Film on AZ91D Mg Alloy through Silanization
by
Junchi Liu, Hang Yin, Zhengyi Xu, Yawei Shao and Yanqiu Wang
Metals 2024, 14(5), 569; https://doi.org/10.3390/met14050569 (registering DOI) - 12 May 2024
Abstract
The presence of inherent micro-pores and micro-cracks in the micro-arc oxidation (MAO) film of Mg alloys is a key factor contributing to substrate corrosion. A composite film layer with high corrosion resistance was achieved through silanizing the micro-arc oxidation film. The corrosion performance
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The presence of inherent micro-pores and micro-cracks in the micro-arc oxidation (MAO) film of Mg alloys is a key factor contributing to substrate corrosion. A composite film layer with high corrosion resistance was achieved through silanizing the micro-arc oxidation film. The corrosion performance of the MAO films treated with various silane coupling agents was assessed through morphological characterization and electrochemical tests. SEM graphs depicted that the silane film can effectively seal the defects existing in micro-arc oxidation film, and electrochemical tests indicated the significant corrosion resistance improvement of MAO film after silanization treatment.
Full article
(This article belongs to the Special Issue Preparation and Processing Technology of Advanced Magnesium Alloys)
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Open AccessArticle
Magnetic Hardening of Heavily Helium-Ion-Irradiated Iron–Chromium Alloys
by
Yasuhiro Kamada, Daiki Umeyama, Takeshi Murakami, Kazuyuki Shimizu and Hideo Watanabe
Metals 2024, 14(5), 568; https://doi.org/10.3390/met14050568 (registering DOI) - 12 May 2024
Abstract
This study reports on the magnetic hardening phenomenon of heavily helium ion-irradiated iron–chromium alloys. The alloys are important structural materials in next-generation nuclear reactors. In some cases, problems may arise when the magnetic properties of the materials change due to neutron irradiation. Therefore,
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This study reports on the magnetic hardening phenomenon of heavily helium ion-irradiated iron–chromium alloys. The alloys are important structural materials in next-generation nuclear reactors. In some cases, problems may arise when the magnetic properties of the materials change due to neutron irradiation. Therefore, it is necessary to understand the effects of irradiation on magnetism. Helium irradiation was conducted as a simulated irradiation, and the effect of cavity formation on magnetic properties was thoroughly investigated. High-quality single-crystal Fe-x%Cr (x = 0, 10, 20) films, with a thickness of 180–200 nm, were fabricated through ultra-high vacuum evaporation. Subsequently, irradiation of 19 dpa with 30 keV He+ ions was conducted at room temperature. X-ray diffraction measurements and electron microscopy observations confirmed significant lattice expansion and the formation of high-density cavities after irradiation. The magnetization curve of pure iron remained unchanged, while magnetic hardening was noticed in iron–chromium alloys. This phenomenon is believed to be due to the combined effect of cavity formation and changes in the atomic arrangement of chromium.
Full article
(This article belongs to the Special Issue Irradiation Response and Microstructure Characterization of Metallic Materials)
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Open AccessArticle
Modelling and Prediction of Process Parameters with Low Energy Consumption in Wire Arc Additive Manufacturing Based on Machine Learning
by
Haitao Zhang, Xingwang Bai, Honghui Dong and Haiou Zhang
Metals 2024, 14(5), 567; https://doi.org/10.3390/met14050567 (registering DOI) - 11 May 2024
Abstract
Wire arc additive manufacturing (WAAM) has attracted increasing interest in industry and academia due to its capability to produce large and complex metallic components at a high deposition rate. One of the basic tasks in WAAM is to determine appropriate process parameters, which
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Wire arc additive manufacturing (WAAM) has attracted increasing interest in industry and academia due to its capability to produce large and complex metallic components at a high deposition rate. One of the basic tasks in WAAM is to determine appropriate process parameters, which will directly affect the morphology and quality of the weld bead. However, the selection of process parameters relies heavily on empirical data from trial-and-error experiments, which results in significant time and cost expenditures. This paper employed different machine learning models, including SVR, BPNN, and XGBoost, to predict process parameters for WAAM. Furthermore, the SVR model was optimized by the Genetic Algorithm (GA) and Particle Swarm Optimization (PSO) algorithms. A 3D laser scanner was employed to obtain the weld bead’s point cloud, and the weld bead size was extracted using the point cloud processing algorithm as the training data. The K-fold cross-validation strategy was applied to train and validate machine learning models. The comparison results showed that PSO–SVR predicted process parameters with the highest precision, with the RMSE, R2, and MAE being 1.1670, 0.9879, and 0.8310, respectively. Based on the process parameters produced by PSO–SVR, an optimal process parameter combination was chosen by taking into comprehensive consideration the impacts of power consumption and efficiency. The effectiveness of the process parameter optimization method was proved through three groups of validation experiments, with the energy consumption of the first two groups decreasing by 10.68% and 11.47%, respectively.
Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing and Their Applications (2nd Edition))
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Open AccessArticle
Non-Contact Evaluation of Deformation Characteristics on Automotive Steel Sheets
by
Ľubomír Ambriško and Ladislav Pešek
Metals 2024, 14(5), 566; https://doi.org/10.3390/met14050566 (registering DOI) - 11 May 2024
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The work is focused on experimental research of deformation characteristics on three grades of hot-dip galvanized steels for the automotive industry. Deformation maps were obtained using the DIC (Digital Image Correlation) method. The map documents the development of longitudinal and transverse deformations under
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The work is focused on experimental research of deformation characteristics on three grades of hot-dip galvanized steels for the automotive industry. Deformation maps were obtained using the DIC (Digital Image Correlation) method. The map documents the development of longitudinal and transverse deformations under tensile stress. In addition to uniaxial tension, the investigated specimens were subjected to eccentric tension. The stable crack growth (SCG) was evaluated using a non-contact measurement technique on CT (compact tension) specimens. The deformation of steels, which affects the resistance to stable crack growth (confirmed by the Design of Experiments—DOE method), was manifested in the first stages of eccentric loading of specimens. The notch root radius varies considerably due to the blunting of the starting fatigue crack. The resistance to stable crack growth, which represents a safety reserve during a vehicle crash, was obtained.
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Open AccessArticle
Microwave Treatment of Copper–Nickel Sulfide Ore for Promotion of Grinding and Flotation
by
Xiaolei Fang, Zhiwei Peng, Tianle Yin, Mingjun Rao and Guanghui Li
Metals 2024, 14(5), 565; https://doi.org/10.3390/met14050565 (registering DOI) - 11 May 2024
Abstract
The effect of microwave treatment on the grinding and flotation performance of a typical copper–nickel sulfide ore was evaluated, based on the determination of its microwave absorption capability, grinding and flotation indexes such as crack percentage, mineral liberation degree, particle size distribution, relative
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The effect of microwave treatment on the grinding and flotation performance of a typical copper–nickel sulfide ore was evaluated, based on the determination of its microwave absorption capability, grinding and flotation indexes such as crack percentage, mineral liberation degree, particle size distribution, relative work index (RWI), metal enrichment ratio, and recovery. There were obvious differences between the microwave absorption capabilities of the main minerals in the ore, as demonstrated by their different microwave penetration depths. They also induced temperature differences between sulfide minerals and gangue minerals which could reach 418 °C after microwave treatment for 20 s. It was shown that microwave treatment could effectively improve the grindability of the ore, as proven by the increase in fine particles smaller than 0.074 mm and a decrease in RWI after grinding due to the higher crack percentage and mineral liberation degree. Moreover, microwave treatment affected the ore floatability because of the generation of cuprite, retgersite, and rozenite with poor floatability when the treatment time was extended. By microwave treatment for a proper time, 20 s, an optimal balance between the grindability and flotation performance could be achieved. Compared with the untreated ore, the RWI of the ore decreased by 11.5%. After flotation, the Cu and Ni enrichment ratios of the flotation concentrate increased by 0.3 and 0.2, respectively. Meanwhile, their corresponding recoveries increased by 4.2% and 3.1%. This study provides new insights for the treatment of copper–nickel sulfide ore to enhance the grinding and flotation process.
Full article
(This article belongs to the Special Issue Toward Achieving a Carbon-Neutral Society: Beneficiation and Extractive Metallurgy for Producing Critical Metals from Ores/Wastes)
Open AccessArticle
Niobium’s Effect on the Properties of a Quasi-High-Entropy Alloy of the CoCrFeMnNi System
by
Svetlana Kvon, Aristotel Issagulov, Vitaliy Kulikov and Saniya Arinova
Metals 2024, 14(5), 564; https://doi.org/10.3390/met14050564 (registering DOI) - 10 May 2024
Abstract
This paper deals with the possibility of smelting quasi-high-entropy alloys (QHEAs) with the partial use of ferroalloys in the charge instead of pure metals. The Cantor alloy (CoCrFeMnNi) was used as the base alloy and the comparison sample, into which niobium was introduced
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This paper deals with the possibility of smelting quasi-high-entropy alloys (QHEAs) with the partial use of ferroalloys in the charge instead of pure metals. The Cantor alloy (CoCrFeMnNi) was used as the base alloy and the comparison sample, into which niobium was introduced in the amount of 14 to 18% by weight. The structure, hardness, strength, and tribological properties of prototypes were studied. The results obtained showed, on the one hand, the possibility of using ferroalloys as charge components in the smelting of QHEAs and, on the other hand, the positive effect of niobium in the amount of 14–17% on the strength and wear resistance of the alloy. Increasing the niobium content above 18% leads to its uneven distribution in the structure, consequently decreasing the strength and wear resistance of the alloy. The structure of the studied alloys is represented by a solid solution of FCC, which includes all metals, and the niobium content varies widely. In addition, the structure is represented by the phases of implementation: niobium carbide NbC 0.76–1.0, manganese carbide Mn7C3, and a CrNi intermetallic compound with a cubic lattice.
Full article
Open AccessArticle
Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry
by
Hongming Na, Jingchao Sun, Yuxing Yuan, Ziyang Qiu, Lei Zhang and Tao Du
Metals 2024, 14(5), 563; https://doi.org/10.3390/met14050563 (registering DOI) - 10 May 2024
Abstract
Exploring theoretical energy consumption introduces a fresh perspective for energy-saving research within the iron and steel industry, with a primary focus on the energy expended during material transformation. Building upon the theory of theoretical energy consumption, this study meticulously investigates the theoretical energy
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Exploring theoretical energy consumption introduces a fresh perspective for energy-saving research within the iron and steel industry, with a primary focus on the energy expended during material transformation. Building upon the theory of theoretical energy consumption, this study meticulously investigates the theoretical energy consumption associated with each stage of the iron and steel making process, including coking, sintering, pelletizing, ironmaking, steelmaking, and hot rolling. The findings reveal that, under specific conditions, the theoretical energy consumption for each process is as follows: coking (2.59 GJ), sintering (1.36 GJ), pelletizing (1.02 GJ), ironmaking (8.81 GJ), steelmaking (−0.16 GJ), and hot rolling (0.76 GJ). Additionally, this study delves into the analysis of influencing factors on theoretical energy consumption. Using the coking process as an illustrative example, it is observed that the theoretical energy consumption in coking decreases with a reduction in both moisture and volatile content in coal. Under the specified conditions, the minimum theoretical energy consumption for each process is as follows: coking (2.51 GJ), sintering (0.98 GJ), pelletizing (0.67 GJ), ironmaking (8.38 GJ), steelmaking (−0.58 GJ), and hot rolling (0.07 GJ), respectively. This comprehensive analysis serves as a valuable resource for advancing sustainable practices in the iron and steel industry.
Full article
Open AccessArticle
Phase Formation and Magnetic Properties of (Y1−xSmx)Co5 Melt-Spun Ribbons
by
Xiang Liu, Siyue Yang, Xingping Zheng, Feilong Dai, Qingrong Yao and Jiang Wang
Metals 2024, 14(5), 562; https://doi.org/10.3390/met14050562 - 10 May 2024
Abstract
Using X-ray diffraction (XRD) and a vibrating sample magnetometer (VSM), the effects of Sm substitution, wheel speed, and annealing temperature on the phase formation and magnetic properties of (Y1−xSmx)Co5 (x = 0.2, 0.3, 0.4, 0.5) melt-spun ribbons were
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Using X-ray diffraction (XRD) and a vibrating sample magnetometer (VSM), the effects of Sm substitution, wheel speed, and annealing temperature on the phase formation and magnetic properties of (Y1−xSmx)Co5 (x = 0.2, 0.3, 0.4, 0.5) melt-spun ribbons were investigated. The results indicate the following: (1) With the increase in Sm substitution, it was found that (Y1−xSmx)Co5 ribbons are entirely composed of the (Y-Sm)Co5 phase with a CaCu5-type structure. Additionally, the coercivity gradually increases, while the remanence and saturation magnetization gradually decrease. (2) As the wheel speed increases, the (Y1−xSmx)Co5 ribbons exhibit an increasing proportion of (Y-Sm)Co5 phase until reaching a speed of 40 m/s, where they are entirely composed of the (Y-Sm)Co5 phase. Magnetic measurements show that the coercivity (Hcj) and remanence (Br) of (Y0.5Sm0.5)Co5 ribbons increase gradually with increasing wheel speed, while saturation magnetization decreases. The variation in magnetic properties is mainly attributed to the formation of nucleation centers for reversed magnetic domain (2:7 and 2:17 phases); (3) (Y0.5Sm0.5)Co5 ribbons are composed of the (Y-Sm)Co5 phase and a small amount of the Sm2Co7 phase after annealing at 550 °C, 600 °C, and 650 °C. Temperature elevation promotes crystallization of the amorphous phase, resulting in a gradual decrease in coercivity, while the remanence and saturation magnetization exhibit an overall increasing trend. Through continuous optimization of the process, favorable magnetic properties were achieved under the conditions of a 0.5 Sm substitution level, a wheel speed of 40 m/s, and an annealing temperature of 550 °C, with a coercivity of 7.98 kOe, remanence of 444 kA/m, and saturation magnetization of 508 kA/m.
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(This article belongs to the Section Metallic Functional Materials)
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Open AccessArticle
Investigation into the Hot-Forming Limit for 22MnB5 Hot-Forming Steel under a Stamping Process
by
Wenwu He, Bin Yang, Xuezhong Zhang, Min Li, Shuli Sun, Bao Wang and Qingxian Ma
Metals 2024, 14(5), 561; https://doi.org/10.3390/met14050561 - 10 May 2024
Abstract
Hot-forming technology for 22MnB5 hot-forming steel (22MnB5 HF steel) plates has been widely used in the automobile manufacturing industry in recent years. Physical simulation and numerical modeling were carried out in order to determine the forming limit of a 22MnB5 steel plate for
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Hot-forming technology for 22MnB5 hot-forming steel (22MnB5 HF steel) plates has been widely used in the automobile manufacturing industry in recent years. Physical simulation and numerical modeling were carried out in order to determine the forming limit of a 22MnB5 steel plate for the stamping process. The deformation experiments were performed in a temperature range of 600~900 °C and a strain rate range of 0.1~10 s−1. In the uniaxial tensile tests, it was found that at the forming temperature of 600 °C, the condition of dynamic recrystallization was not fully reached, and thus the corresponding tensile strength was much larger than that at other deformation temperatures. In the numerical simulation of bulging experiments, it was found that 22MnB5 steel had good formability when the initial deformation temperature was high and the forming speed was low by using the instability criterion, combining the maximum punch force and strain path transition. The forming limit diagram of 22MnB5 steel at a temperature of 700 °C and tool speed of 25 mm/s was obtained by means of simulation and a hot stamping experiment. The establishment of the forming limit of the 22MnB5 steel plate can provide theoretical and technical guidance for the hot-forming process.
Full article
(This article belongs to the Special Issue Simulation and Optimization Methods in Machining and Structure/Material Design)
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Open AccessArticle
Long-Range Influence of Cr on the Stacking Fault Energy of Cr-Containing Concentrated Solid-Solution Alloys
by
Hao Xiao, Qingyuan Liu, Shijun Zhao, Songqin Xia, Yugang Wang and Chenxu Wang
Metals 2024, 14(5), 560; https://doi.org/10.3390/met14050560 - 10 May 2024
Abstract
Single-phase concentrated solid-solution alloys (CSAs) have exhibited excellent mechanical and radiation tolerance properties, making them potential candidate materials for nuclear applications. These excellent properties are closely related to dislocation movements, which depend on the stacking fault energies (SFEs). In CSAs, SFEs show large
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Single-phase concentrated solid-solution alloys (CSAs) have exhibited excellent mechanical and radiation tolerance properties, making them potential candidate materials for nuclear applications. These excellent properties are closely related to dislocation movements, which depend on the stacking fault energies (SFEs). In CSAs, SFEs show large fluctuations due to variations in the local atomic environments in the vicinity of the stacking faults. In this work, first-principle calculations were performed to investigate the origin of the fluctuations in the SFEs of the widely studied CSA, NiCoCr, which show a very wide distribution from about −200 mJ/m2 to 60 mJ/m2. Compared to the common understanding that only atoms in close proximity to the stacking fault influence the SFEs in pure metals and dilute alloys, charge redistribution can be observed in several nearby planes of the stacking fault in NiCoCr, indicating that atoms several atomic layers away from stacking fault also contribute to the SFEs. Our analysis shows that Cr plays a major role in the large fluctuation in the SFEs of NiCoCr based on both electronic and magnetic responses. The flexible electronic structure of Cr facilitates easier charge transfer with Cr in several nearby atomic planes near the stacking fault, leading to significant changes in the d-electron number, orbital occupation number, and magnetic moments of Cr.
Full article
(This article belongs to the Special Issue Study of Microstructure and Irradiation Damages in Metals and Alloys—2nd Edition)
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Open AccessReview
Some Recent Advances in Germanium Recovery from Various Resources
by
Francisco Jose Alguacil and Jose Ignacio Robla
Metals 2024, 14(5), 559; https://doi.org/10.3390/met14050559 - 9 May 2024
Abstract
Though nowadays germanium does not reach the range of popularity of other metals, i.e., rare earth elements, its utility in target industries makes it a strategic metal. Though germanium can be found in a series of raw materials, the principal source for its
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Though nowadays germanium does not reach the range of popularity of other metals, i.e., rare earth elements, its utility in target industries makes it a strategic metal. Though germanium can be found in a series of raw materials, the principal source for its recovery is from secondary wastes of the zinc industry; also, the recyclability of germanium-bearing waste materials is becoming of interest. In this recovery and due to the size of the target materials, because the diffusion and reaction are to be considered, hydrometallurgy performs a key role in achieving this goal. The present work reviews the most recent applications (2023 and 2024 years) of hydrometallurgical operations on the recovery of germanium from different solid and liquid sources.
Full article
(This article belongs to the Special Issue Advances in Sustainable Hydrometallurgy)
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High-Throughput Multi-Principal Element Alloy Exploration Using a Novel Composition Gradient Sintering Technique
by
Brady L. Bresnahan and David L. Poerschke
Metals 2024, 14(5), 558; https://doi.org/10.3390/met14050558 - 9 May 2024
Abstract
This work demonstrates the capabilities and advantages of a novel sintering technique to fabricate bulk composition gradient materials. Pressure distribution calculations were used to compare several tooling geometries for use with current-activated, pressure-assisted densification or spark plasma sintering to densify a gradient along
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This work demonstrates the capabilities and advantages of a novel sintering technique to fabricate bulk composition gradient materials. Pressure distribution calculations were used to compare several tooling geometries for use with current-activated, pressure-assisted densification or spark plasma sintering to densify a gradient along the long dimension of the specimen. The selected rectangular tooling design retains a low aspect ratio to ensure a uniform pressure distribution during consolidation by using a side loading configuration to form the gradient along the longest dimension. Composition gradients of NixCu1−x, MoxNb1−x, and MoNbTaWHfx (x from 0 to 1) were fabricated with the tooling. The microstructure, composition, and crystal structure were characterized along the gradient in the as-sintered condition and after annealing to partially homogenize the layers. The successful fabrication of a composition gradient in a difficult-to-process material like the refractory multi-principal element alloy system MoNbTaWHfx shows the utility of this approach for high-throughput screening of large material composition spaces.
Full article
(This article belongs to the Special Issue Advances in Field-Assisted Processing of Metallic Materials: Experiments and Simulations)
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Open AccessArticle
Influence of Various Processing Routes in Additive Manufacturing on Microstructure and Monotonic Properties of Pure Iron—A Review-like Study
by
Christof J. J. Torrent, Seyed Vahid Sajadifar, Gregory Gerstein, Julia Richter and Thomas Niendorf
Metals 2024, 14(5), 557; https://doi.org/10.3390/met14050557 - 8 May 2024
Abstract
Additive manufacturing processes have attracted broad attention in the last decades since the related freedom of design allows the manufacturing of parts with unique microstructures and unprecedented complexity in shape. Focusing on the properties of additively manufactured parts, major efforts are made to
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Additive manufacturing processes have attracted broad attention in the last decades since the related freedom of design allows the manufacturing of parts with unique microstructures and unprecedented complexity in shape. Focusing on the properties of additively manufactured parts, major efforts are made to elaborate process-microstructure relationships. For instance, the inevitable thermal cycling within the process plays a significant role in microstructural evolution. Various driving forces contribute to the final grain size, boundary character, residual stress state, etc. In the present study, the properties of commercially pure iron processed on three different routes, i.e., hot rolling as a reference, electron powder bed fusion, and laser powder bed fusion, using different raw materials as well as process conditions, are compared. The manufacturing of the specimens led to five distinct microstructures, which differ significantly in terms of microstructural features and mechanical responses. Using optical and electron microscopy as well as transmission electron microscopy, the built specimens were explored in various states of a tensile test in order to reveal the microstructural evolution in the course of quasistatic loading. The grain size is found to be most influential in enhancing the material’s strength. Furthermore, substructures, i.e., low-angle grain boundaries, within the grains play an important role in terms of the homogeneity of strain distribution. On the contrary, high-angle grain boundaries are found to be regions of strain localization. In summary, a holistic macro-meso-micro-nano investigation is performed to evaluate the behavior of these specific microstructures.
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(This article belongs to the Section Additive Manufacturing)
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Open AccessArticle
An ANN Hardness Prediction Tool Based on a Finite Element Implementation of a Thermal–Metallurgical Model for Mild Steel Produced by WAAM
by
Jun Cheng, Yong Ling and Wim De Waele
Metals 2024, 14(5), 556; https://doi.org/10.3390/met14050556 - 8 May 2024
Abstract
WAAM has emerged as a promising technique for manufacturing medium- and large-scale metal parts due to its high material deposition efficiency and automation level. However, its high heat accumulation and complex thermal evolution strongly affect the resulting microstructures and mechanical properties. The heterogeneous
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WAAM has emerged as a promising technique for manufacturing medium- and large-scale metal parts due to its high material deposition efficiency and automation level. However, its high heat accumulation and complex thermal evolution strongly affect the resulting microstructures and mechanical properties. The heterogeneous and unpredictable nature of these properties hinder the widespread application of WAAM in the steel construction industry. In this study, an artificial neural network (ANN) hardness model is developed, based on a thermal–metallurgical model for mild steel. The objective is to establish non-linear relationships between the input process parameters and the desired output, i.e., hardness. The thermal–metallurgical model utilizes a well-distributed heat source model, a death-and-birth algorithm, and a metallurgical model to simulate the temperature field and to calculate the microstructure phase fraction. The temperature prediction errors at four thermocouple positions are mostly below 20%. Because of the limited experimental data, twenty-five simulation experiments are performed using the L25 orthogonal array based on the Taguchi method. The analysis of variance (ANOVA) reveals that the travel speed has the greatest impact on hardness. With the dataset from the thermal–metallurgical model, an ANN model to predict hardness is developed. A comparison to experimental data shows excellent performance and accuracy, with the Mean Absolute Percentage Error (MAPE) of ANN predictions within 10% of the targeted hardness.
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(This article belongs to the Section Additive Manufacturing)
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Open AccessArticle
Finite Element Analysis and Experimental Verification of Thermal Fatigue of W-PFM with Stacked Structure
by
Chao Qi, Yanfei Qi, Hanfeng Song, Xiao Wang, Shanqu Xiao and Bo Wang
Metals 2024, 14(5), 555; https://doi.org/10.3390/met14050555 - 8 May 2024
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As the prime candidate for plasma-facing materials (PFM), the response of tungsten (W) to thermal shock loads is an important research topic for future fusion devices. Under heat loads, the surface of tungsten plasma-facing materials (W-PFM) can experience thermal damage, including brittle cracking
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As the prime candidate for plasma-facing materials (PFM), the response of tungsten (W) to thermal shock loads is an important research topic for future fusion devices. Under heat loads, the surface of tungsten plasma-facing materials (W-PFM) can experience thermal damage, including brittle cracking and fatigue cracks. Therefore, exploring solutions for thermal damage of W-PFM remains one of the current research focuses. We propose a novel approach to mitigate thermal radiation damage in PFM, namely, the stacked structure W-PFM. The surface thermal stress distribution of the stacked structure W-PFM under heat loads was simulated and analyzed by the finite element method. As the foil thickness decreases, both the peak thermal stresses in the normal direction (ND) and rolling direction (RD) decrease. When the thickness decreases to a certain value, the peak thermal stress in the RD decreases to about 1384 MPa and no longer decreases; while the peak thermal stress in the ND approaches 0 MPa and can be neglected. In the range of approximately 5–100 mm, the accumulated equivalent plastic strain decreases sharply as the thickness decreases; in other thickness ranges, it decreases slowly. Thermal fatigue experiments were conducted on the stacked structure W composed of W foils with different thicknesses and bulk W using an electron beam facility. The samples were applied with a power density of 30 MW/m2 for 10,000 and 20,000 pulses. The cracks on the surface of the stacked structure W extended along the ND direction, while on the surface of bulk W, besides the main crack in the ND direction, a crack network also formed. The experimental results were consistent with finite element simulations. When the pulse number was 10,000, as the thickness of the W foil decreased, the number and width of the cracks on the surface of the stacked structure W decreased. Only four small cracks were present on the surface of stacked structure W (0.05 mm). When the pulse number increased to 20,000, the plastic deformation and number of cracks on the surface of all samples increased. However, the stacked structure W (0.05 mm) only added one small crack and had the smallest surface roughness (Ra = 1.536 μm). Quantitative analysis of the fatigue cracks showed that the stacked structure W-PFM (0.05 mm) exhibited superior thermal fatigue performance.
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Open AccessArticle
Development of Neural Networks to Study Flow Behavior of Medium Carbon Microalloyed Steel during Hot Forming
by
Anas Al Omar, Pau Català, Jose Ignacio Alcelay and Esteban Peña
Metals 2024, 14(5), 554; https://doi.org/10.3390/met14050554 - 8 May 2024
Abstract
In the present article, the application of an artificial neural network (ANN) model whose function is the development of plastic instability maps of a medium carbon microalloyed steel during the hot forming process is studied. Secondly, we proceed to create another ANN capable
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In the present article, the application of an artificial neural network (ANN) model whose function is the development of plastic instability maps of a medium carbon microalloyed steel during the hot forming process is studied. Secondly, we proceed to create another ANN capable of providing the recrystallized grain size in the steady state resulting from forming deformation. We start from the experimental data of a medium carbon microalloyed steel obtained by hot compression tests with strain rates that vary between 10−4 s−1 and 3 s−1 and in a range of temperatures between 900 °C and 1150 °C. These experimental data are used to train the proposed ANN and obtain flow curves. Finally, the processing maps are developed by applying the dynamic materials model (DMM), according to which the safe hot forming domains and the plastic instability domains of the studied material are delineated. The comparison between the ANN and the experimental maps is carried out. It is ascertained that the optimal regions of forging in the ANN maps coincide with those obtained in the experimental maps. In addition, a study of the influence of the microstructure on the behavior of the studied steel during hot forming is carried out.
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(This article belongs to the Section Metal Casting, Forming and Heat Treatment)
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Open AccessReview
Overview: Machine Learning for Segmentation and Classification of Complex Steel Microstructures
by
Martin Müller, Marie Stiefel, Björn-Ivo Bachmann, Dominik Britz and Frank Mücklich
Metals 2024, 14(5), 553; https://doi.org/10.3390/met14050553 - 7 May 2024
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The foundation of materials science and engineering is the establishment of process–microstructure–property links, which in turn form the basis for materials and process development and optimization. At the heart of this is the characterization and quantification of the material’s microstructure. To date, microstructure
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The foundation of materials science and engineering is the establishment of process–microstructure–property links, which in turn form the basis for materials and process development and optimization. At the heart of this is the characterization and quantification of the material’s microstructure. To date, microstructure quantification has traditionally involved a human deciding what to measure and included labor-intensive manual evaluation. Recent advancements in artificial intelligence (AI) and machine learning (ML) offer exciting new approaches to microstructural quantification, especially classification and semantic segmentation. This promises many benefits, most notably objective, reproducible, and automated analysis, but also quantification of complex microstructures that has not been possible with prior approaches. This review provides an overview of ML applications for microstructure analysis, using complex steel microstructures as examples. Special emphasis is placed on the quantity, quality, and variance of training data, as well as where the ground truth needed for ML comes from, which is usually not sufficiently discussed in the literature. In this context, correlative microscopy plays a key role, as it enables a comprehensive and scale-bridging characterization of complex microstructures, which is necessary to provide an objective and well-founded ground truth and ultimately to implement ML-based approaches.
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Open AccessArticle
Investigation of the Influence of Alloy Atomic Doping on the Properties of Cu-Sn Alloys Based on First Principles
by
Zongfan Wei, Jiaying Chen, Jingteng Xue, Nan Qu, Yong Liu, Ling Sun, Yuchen Xiao, Baoan Wu, Jingchuan Zhu and Huiyi Tang
Metals 2024, 14(5), 552; https://doi.org/10.3390/met14050552 - 7 May 2024
Abstract
In order to design Cu-Sn alloys with excellent overall performance, the structural stability, mechanical properties, and electronic structure of X-doped Cu-Sn alloys were systematically calculated using first-principles calculations. The calculation results of the cohesive energy indicate that the Cu-Sn-X structures formed by X
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In order to design Cu-Sn alloys with excellent overall performance, the structural stability, mechanical properties, and electronic structure of X-doped Cu-Sn alloys were systematically calculated using first-principles calculations. The calculation results of the cohesive energy indicate that the Cu-Sn-X structures formed by X atoms (X = Ag, Ca, Cd, Mg, Ni, Zr) doping into Cu-Sn can stably exist. The Cu-Sn-Ni structure is the most stable, with a cohesive energy value of −3.84 eV. Doping of X atoms leads to a decrease in the bulk modulus, Possion’s ratio and B/G ratio. However, doping Ag and Ni atoms can improve the shear modulus, Young’s modulus, and strain energy of the dislocation. The doping of Ni has the highest enhancement on shear modulus, Young’s modulus, and strain energy of the dislocation, with respective values as follows: 63.085 GPa, 163.593 GPa, and 1.689 W/J· . The analysis of electronic structure results shows that the covalent bond between Cu and X is the reason for the performance differences in Cu-Sn-X structures.
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(This article belongs to the Section Computation and Simulation on Metals)
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