Search Results (1,465)

A total of 0.3%C-Cr-Mo-V steel, a high-strength alloy steel widely used in rocket motor housings, suspension systems in high-performance vehicles, etc., is noted due to its high strength-to-weight ratio. However, its high carbon equivalent (CE > 1%) makes it challenging to weld, as it is prone to brittle martensitic formation, which increases the risk of cracking and embrittlement. The present paper focuses on enhancing the microstructure and mechanical properties of 0.3% C-Cr-Mo-V steel by gas tungsten arc welded (GTAW) joints, utilizing post-weld heat treatment and cooling strategies (PWHTCS). A systematic experimental approach was employed to ensure a defect-free weld through dye penetrant testing (DPT) and X-ray radiography techniques. Subsequently, test specimens were extracted from the welded sections and subjected to PWHT protocols, including hardening, tempering, and rapid quenching using air and oil cooling (AC and OC, respectively) mediums. Results show that OC has enhanced tensile strength and hardness while simultaneously maintaining and improving ductility, ensuring a well-balanced combination of strength and toughness. Fractography analysis revealed ductile fracture in AC samples, whereas OC weldments exhibited a mixed ductile–brittle fracture mode. Thus, the findings demonstrate the critical role of PWHTCS, with OC, as an effective method for achieving enhanced mechanical performance and microstructural stability in high-integrity applications. Full article

Bimetallic-clad pipes demonstrate exceptional advantages in transporting corrosive oil and gas through the combination of the load-carrying capacity of the base material and the anti-corrosive function of the thin layer of corrosion-resistant alloy. This study investigates the mechanical properties of 24-inch X65 + Alloy625 metallurgically clad pipes through experimental tests and finite element analysis. Uniaxial tensile testing with digital image correlation reveals uniform deformation between the base and clad layers until interfacial failure initiates at an average strain threshold of 34.17%. Microstructural characterization shows continuous metallurgical bonding, with the X65 layer exhibiting polygonal ferrite and bainitic phases, contrasting with the austenitic equiaxed grain structure of Alloy625. In terms of numerical modeling, finite element analyses that consider both initial geometric imperfections and manufacturing-induced residual stresses are performed to evaluate the bending response of the clad pipe. The effect of initial ovality and residual stresses on its bending capacity is also studied. Full article

NiTi and NiMnGa stand out as prime thermal and magnetic shape memory alloys (SMAs), possessing a superior shape memory effect (SME) and superelasticity (SE). These alloys have crucial current and potential future applications across industries. Additive manufacturing (AM) offers a transformative approach to fabricating these materials into complex geometries; however, the quest to create integral additively manufactured structures with reliable thermal or magnetic shape memory properties remains a recent and fast-emerging research frontier. This article provides a comprehensive review on (i) the intricate principles giving rise to the thermal SME and SE in NiTi, and the magnetic SME in NiMnGa alloys, emphasising their specific relevance in the realm of AM, and (ii) the latest developments, recent findings, and ongoing challenges in the AM of NiTi- and NiMnGa-based SMAs, including their functional lattice structures. Based on this review, for the first time, novel, empirically derived AM process design maps tailored to maximise SME and SE in laser powder bed fusion- and directed-energy deposition-processed NiTi structures are proposed. Similarly, promising avenues to resolve the key challenges regarding the AM of NiMnGa magnetic SMAs are suggested. This article concludes by outlining the most promising future research directions shaping the trajectory of AM of these SMAs. Full article

High-entropy alloys (HEAs) are a novel class of metallic materials composed of five or more principal elements in near-equimolar ratios. This unconventional composition leads to high configurational entropy, which promotes the formation of solid solution phases with enhanced mechanical properties, thermal stability, and corrosion resistance. Phase stability plays a critical role in determining their structural integrity and performance. This study provides a focused review of HEA phase transitions, emphasizing the role of lattice gas models in predicting phase behavior. By integrating statistical mechanics with thermodynamic principles, lattice gas models enable accurate modeling of atomic interactions, phase segregation, and order-disorder transformations. The combination of computational simulations (e.g., Monte Carlo, molecular dynamics) with experimental validation (e.g., XRD, TEM, APT) improves predictive accuracy. Furthermore, advances in data-driven methodologies facilitate high-throughput exploration of HEA compositions, accelerating the discovery of alloys with optimized phase stability and superior mechanical performance. Beyond structural applications, HEAs demonstrate potential in functional domains, such as catalysis, hydrogen storage, and energy technologies. This review brings together theoretical modeling—particularly lattice gas approaches—and experimental validation to form a unified understanding of phase behavior in high-entropy alloys. By highlighting the mechanisms behind phase transitions and their implications for material performance, this work aims to support the design and optimization of HEAs for real-world applications in aerospace, energy systems, and structural materials engineering. Full article

This study explores the damage behavior of typical titanium alloy aircraft panel structures under high-speed fragment impacts via ballistic experiments and FEM-SPH simulations. Using a ballistic gun and two-stage light gas gun, tests were conducted with spherical, rhombic, and rod-shaped fragments at 1100–2100 m/s to analyze damage morphology. The FEM-SPH method effectively modeled dynamic impacts, capturing primary penetration and debris cloud-induced secondary damage. Residual strength under tension was evaluated via multiple restart analysis, linking impact dynamics to post-damage mechanics. Experimental results revealed fragment-dependent damage modes: spherical fragments caused circular shear holes with conical/jet-like debris clouds; rhombic fragments induced irregular tearing and triangular perforations due to unstable flight; rod-shaped fragments produced elongated breaches with extensive plastic deformation in stringers. Numerical simulations accurately reproduced debris cloud diffusion and secondary effects like spallation. Residual strength analysis showed tensile capacity was governed by breach geometry and location: rhombic breaches (34.6 kN) had lower strength than circular/square ones (38.1–38.3 kN) due to tip stress concentration, while stringer-located damage increased ultimate load by 8–12% via structural redundancy. In conclusion, high-speed fragment impacts dominate shear/tensile tearing, with morphology dependent on fragment characteristics and impact conditions. Debris cloud-induced secondary damage must be considered in structural assessments. The FEM-SPH method is effective for complex damage simulation, while breach geometry and damage location are critical for residual strength. Stringer involvement enhances load-bearing capacity, highlighting component-level design importance for aircraft survivability. The study results and methodologies presented herein can serve as references for aircraft structural damage analysis, residual strength evaluation of battle-damaged structures, and survivability design. Full article

This study presents an innovative numerical investigation into the synergistic effects of pre-tensile loading and multi-fragment hypervelocity impacts on thin-walled 7075-T6 aluminum alloy structures, addressing a critical gap in aircraft survivability design under realistic combat conditions. Utilizing an advanced finite element framework with stress dynamic relaxation preloading, the established model was rigorously validated against experimental gas-gun impact data, achieving less than 11% deviation in residual velocity. Distinct from prior single-impact studies, our work pioneers a systematic multi-parameter analysis encompassing multiple pre-stress levels, circumferential/linear fragment distributions, velocity gradients, and geometries. The findings of this parametric study establish a linkage between dynamic penetration mechanics and operational airframe stresses, offering guidelines for damage-tolerant design optimization in aircraft structures. Full article

The galvanostatic electrodeposition of cobalt–nickel alloy coatings performed out on a 304 stainless steel substrate. The electrolyte baths contained metals salts, along with boric acid and sodium benzene sulfonate (SBS) as an organic additive in the deposition process. Structural and topographic analyses were performed using SEM-EDS and AFM techniques, respectively. The findings confirm the formation of nanostructured coatings. The images depicting various stages of coating formation indicated the inhibitory role of the organic additive. The presence of SBS enabled the formation of a coating composed of grains with diverse geometries and significantly reduced surface roughness. Hydrogen evolution was conducted in an alkaline environment (1 M NaOH). Overpotentials for the different structures were recorded at 10 mA/cm², yielding 196 mV and 225 mV for the coatings deposited with and without SBS, respectively. Additionally, experiments were performed in a laboratory-designed electrolyzer, which allowed for the measurement of gas volumes (H₂ and O₂) generated under constant voltage and current conditions. The results demonstrated that the obtained coatings perform more effectively as hydrogen evolution cathodes than currently used materials, particularly under higher current densities. Electrolysis was conducted for 8 h, revealing improved stability of the coating deposited in the presence of SBS. Full article

In recent years, the rapid growth in demand for liquefied natural gas (LNG) has brought significant challenges and opportunities to LNG storage and transportation technologies. As critical equipment for LNG loading operations, marine and land-based LNG loading and unloading arms play a vital role in improving LNG storage and transportation efficiency and ensuring safety performance. By extensively collecting relevant domestic and international literature, technical standards, and engineering cases, systematically reviewing and analyzing existing achievements, and engaging with technical personnel from related enterprises, the current development status of marine and land-based LNG loading and unloading arms is introduced from multiple perspectives, including overall structure, sealing technology, safety protection devices, and intelligent and automated development. This paper highlights trajectory planning and image processing involved in the automatic docking technology. Marine loading/unloading arms need to operate in high-humidity, high-corrosion, and even extreme weather conditions. In the future, they should further enhance stability in marine high-corrosion environments and improve anti-overturning capability under extreme conditions by simplifying mechanical structures, developing new balancing systems, and using low-temperature-resistant alloy materials. Land-based loading and unloading arms focus on multi-vehicle parallel operations, improving operational efficiency through simplified mechanical structures, integrated intelligent positioning systems, and adaptive control algorithms. Full article

SAE 5160 steel, classified as high-strength, low-alloy steel, is widely used in the automotive sector due to its excellent mechanical strength and ductility. However, its inherently low corrosion resistance limits its broader application. This study explores the application of the cathodic cage plasma deposition (CCPD) technique to enhance the corrosion resistance of SAE 5160 steel. The treatment was performed using a Hastelloy cathodic cage under two atmospheric conditions: hydrogen-rich (75%H₂/25%N₂) and nitrogen-rich (25%H₂/75%N₂). Comprehensive analyses revealed significant improvements in surface properties and corrosion resistance. The hydrogen-rich condition (H25N) facilitated the formation of Cr_0.4Ni_0.6 and CrN phases, associated with a nanocrystalline structure (37.6 nm) and a thicker coating (45.5 μm), resulting in polarization resistance over 290 times greater than that of untreated steel. Conversely, nitrogen-rich treatment (H75N) promoted the formation of Fe₃N and Fe₄N phases, achieving a dense but thinner layer (19.6 μm) with polarization resistance approximately 20 times higher than that of untreated steel. These findings underscore the effectiveness of CCPD as a versatile and scalable surface engineering technique capable of tailoring the properties of SAE 5160 steel for use in highly corrosive environments. This study highlights the critical role of optimizing gas compositions and treatment parameters, offering a foundation for advancing plasma-assisted technologies and alloying strategies. The results provide a valuable framework for developing next-generation corrosion-resistant materials, promoting the longevity and reliability of high-strength steels in demanding industrial applications. Full article

The Er-Zr-Sc-modified Al-Mg alloys produced by additive manufacturing (AM) exhibit good formability and excellent mechanical properties, and present great potential for applications in the fields of aerospace and automotive fields. In this work, the preparation process of Al-4.5Mg-0.7Er-0.5Zr-0.3Sc high-strength aluminum alloy powder for additive manufacturing by vacuum induction melting gas atomization (VIGA) was investigated. With the goal of obtaining excellent sphericity and higher powder yield in the particle size range of 15~53 μm, a new type atomizer with optimized convergence angle and tube extension length was designed based on finite element numerical simulation and experimental research, and the optimal atomization processing parameters were determined. The results revealed that when the convergence angle was 32° and the extension length was 5 mm, the large negative pressure and suction force at the tube outlet could facilitate the smooth flow of the melt and a refined powder particle size; when the melt temperature was 800 °C and the atomization pressure was 3.25 Mpa, the melt had low viscosity and the atomization gas could fully interact with the melt. Meanwhile, the melt droplets had suitable cooling conditions, avoiding the generation of irregular powders and improving the powder sphericity. Under the above optimal processing parameters, the prepared powders were spherical or nearly spherical with fine particle size and a high yield of about 39.45%. Full article

Ni-based superalloys with enhanced environmental resistance at high temperatures are crucial for advanced gas turbine engines. The new polycrystalline nickel-based superalloy has excellent mechanical properties, but as a low-Cr, high-alloying superalloy, its environmental resistance has never been investigated. The hot corrosion behavior of the nickel-based superalloy under molten salt conditions and its effect on its tensile properties were investigated in this paper. The results showed the following: The diffusion of the Cr, Al, and Ni elements governs the majority of the corrosion process, resulting in the production of an environmentally damaged organization with internal sulfidation and surface oxidation. The Wagner model predicts the inability to form a dense Al oxide scale on the surface because the crucial generation condition of external Al oxides is not met. In addition, the growth stress in the damage scales is the main cause of cracking and spalling in the isothermal corrosion process. Due to the increased local stress concentration brought on by this environmental degradation, the sulfide scale acts as a fracture source, guiding the matrix cracking and influencing the tensile properties of the alloy. Full article

Additive Manufacturing (AM) processes, particularly PBF-LB/M, are considered advantageous due to their flexibility, which allows process engineers to design and fabricate intricate structures both in the prototyping and component manufacturing phases. It is well known that the behavior of the process directly impacts the quality of the materials and thereby induces inhomogeneities on the powder bed on the building platform. Several parameters can be tuned to keep the process under control, getting rid of process uncertainty and distinguishing aspects of a specific machine model. Such behavior requires an extended analysis of the powder bed inhomogeneities and the definition of limits in the printing process. In this work, carried out on Alloy 718 specimens printed using an EOS M290 machine, the inhomogeneities of the melt pool stability, density, and material properties were investigated based on three main factors: the amount of area melted or fused, the gas flow speed setpoint, and the location on the building platform. The test results for Track Stability, melt-pool shape, and porosity analysis show that criticality occurs when more than 50% of the building platform is exposed. This can be partly fixed by raising the differential pressure value. Full article

The aerospace industry is actively seeking sustainable solutions within the aviation sector to mitigate greenhouse gas (GHG) emissions driven by increasing population demands. This study presents the first environmental life cycle assessment (LCA) of economy-class seating frames, comparing conventional alloy steel with lightweight alternative materials, including magnesium alloy, aluminum alloy, and titanium. Seat frames account for an aircraft’s total weight, making them a critical component for innovation toward more sustainable solutions. Using SolidWorks V3.1, economy-class seat frames were designed and evaluated through a cradle-to-grave assessment of a functional unit (FU) representing the interior of a single aircraft. The analysis was conducted using SimaPro V8.4.0 with the Ecoinvent V3.10 database. The total GHG emissions associated with seat frames composed of alloy steel, titanium, aluminum alloy, and magnesium alloy were 208 kt CO₂ equivalent (eq.), 120 kt CO₂ eq, 71.1 kt CO₂ eq, and 44.9 kt CO₂ eq per FU, respectively. This study identifies alloy steel and titanium to be the most sustainable seat frame materials relative to other considered materials for commercial aircrafts. Full article

Zr₄₈Cu_47.5Al₄Co_0.5 bulk amorphous alloy composites were prepared by selective laser melting (SLM) technology under different processing conditions and their non-isothermal crystallization behaviors were systematically investigated. The results show that the crystallization phases are Cu₁₀Zr₇ and CuZr₂ for both gas-atomized powder and SLMed samples. The dependence of volume fraction of Cu₁₀Zr₇ and CuZr₂ on laser energy density can be fitted by an exponential function. The crystalline sizes of Cu₁₀Zr₇ and CuZr₂ linearly increase with increasing energy density. The thermal stability is larger for the gas-atomized powders than for the SLMed bulk samples. It is interestingly found that there is an exponential relationship between the crystallization enthalpy ΔH_x and the amorphous content. In addition, the glass transition is more difficult for the gas-atomized powders than for the SLMed bulk samples. The crystallization procedure is more difficult for the SLMed bulk samples than for the gas-atomized powders. The local activation energy E_α decreases with increasing α for the gas-atomized powder and the SLMed bulk samples. In addition, the E_α is larger for the SLMed bulk samples than for the gas-atomized powder at the corresponding crystallization fraction α. The dependence of the local Avrami exponent n(α) on the α is similar for both the gas-atomized powders and the SLMed bulk samples at studied heating rates. The crystallization mechanism is also discussed. Full article

Considering the issues of significant ammonia volatilization loss and toxic gas emission associated with the conventional ammonia leaching method used in the resource utilization of cobalt-rich alloy slag, a novel approach involving selective complexation leaching of cobalt in an alkaline histidine solution has been proposed. Under conditions of 35 °C temperature, a molar ratio of histidine to cobalt of 1.5, pH of 8, a leaching period of 12 h, and a stirring speed of 300 rpm, the cobalt leaching rate from cobalt-rich alloy slag exceeds 95%. In contrast, the leaching rates for impurity metals such as iron, lead, and copper remain below 3%, demonstrating outstanding leaching selectivity. Leaching kinetics calculations indicate that the rate-controlling step is chemical reaction control, with an apparent activation energy of 64.32 kJ/mol. Through the use of FTIR and XPS characterization techniques, it has been confirmed that histidine molecules form a stable complex with cobalt ions via the dual coordination of the carboxyl (COO⁻) and amino (-NH₂) groups. This distinctive bifunctional synergistic coordination mechanism markedly enhances leaching selectivity and reaction efficiency. Full article