Search Results (91)

High-strength low-alloy (HSLA) steel is widely used in automotive industry for reduction of consumption and emissions. The microstructure and mechanical properties of two automotive HSLA steels with different strength grades were systematically investigated in present study. Microstructural characterization was conducted using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD), while mechanical properties were evaluated with Vickers hardness tester and tensile tests. Both steels exhibited a ferrite matrix with spheroidized carbides/pearlites. However, Sample A displayed equiaxed ferrite grains with localized pearlite colonies, while Sample B featured pronounced elongated ferrite grains with a band structure. Tensile testing revealed that Sample B had higher ultimate tensile stress and yield stress compared to Sample A. Texture analysis indicated that both steels were dominated by α-fiber and γ-fiber textures, with minor θ-fiber texture, resulting in minimal mechanical anisotropy between the rolling direction (RD) and transverse direction (TD). The quantitative assessment of strengthening mechanisms, based on microstructural parameters and experimental data, revealed that grain boundary strengthening dominates, with dislocation strengthening also contributing significantly. This work provides the first comprehensive quantification of individual strengthening contributions in automotive HSLA steels, offering critical guidance for developing further higher-strength automotive steels. Full article

Grey cast iron brake discs with lamellar graphite (GJL) offer excellent strength and thermal conductivity but are prone to wear and dust emissions. To mitigate these issues, a multilayer coating was applied via Laser Metal Deposition (LMD), comprising a 316L stainless steel base layer and a WC-reinforced top layer. This study examines the microstructural evolution of the coatings under simulated thermomechanical and corrosive conditions using a brake shock corrosion test. Microstructural characterization was performed via Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD), focusing on grain size, orientation, and texture before and after testing. EBSD analysis revealed significant grain coarsening, with sizes increasing from below 20 µm to 30–60 µm, and a shift toward <101> texture. Hardness measurements showed a reduction in the WC-reinforced layer from 478 HV to 432 HV and in the 316L base layer from 232 HV to 223 HV, confirming the influence of thermomechanical stress. SEM analysis revealed a transition from horizontal cracks—caused by residual stress during LMD—to vertical microcracks propagating from the substrate, activated by braking-induced loads. These findings provide insights into the microstructural response of LMD coatings under realistic service conditions and underscore the importance of grain boundary control in designing durable brake disc systems. Full article

Achieving keyhole-free joints is critical in Friction Stir Spot Welding (FSSW). This study presents a new approach to eliminate this volumetric defect in AA6082-T6 FSSW sheet joints using a continuous multi-layer Friction Stir Deposition (CMFSD) technique, employing a newly designed AA6082-T6 consumable tool. FSSW was performed at various rotational speeds (350, 550, 750 and 950 rpm) with a 5 s dwell time. Comprehensive macro- and micro-scale evaluations, along with mechanical properties (hardness and tensile-shear load) of the produced joints, were conducted. Additionally, microstructures were examined using Optical Microscopy (OM), while fracture surfaces were analyzed via Scanning Electron Microscopy (SEM). Optimal FSSW conditions were identified at 550 rpm, yielding a stir zone (SZ) hardness of 94.6 ± 1.4 HV and a maximum tensile-shear load of 4.73 ± 0.27 kN. The keyhole was successfully refilled using AA6082-T6 rod material via CMFSD, resulting in a defect-free joint of the same base alloy. Electron Backscattered Diffraction (EBSD) technique was also used to examine the microstructural features. A comparative analysis revealed significant enhancements: the refilled FSSW joints exhibited a 46.5% increase in maximum tensile-shear load and a 66.66% improvement in elongation to failure compared to the highest-FSSW joint performance with the keyhole defect. Full article

This study investigates the effect of Al_x and Ti_x content (x = 0.1, 0.2, 0.3, 0.4, 0.5, and 0.6) on the microstructural evolution and mechanical properties of Co-free high-entropy Al_xTi_xCrFe₂Ni alloys in both as-cast and homogenized conditions. The research focused on the characterization of structural features, melting behavior, and mechanical performance. Microstructural characterization was carried out using optical microscopy, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), X-ray diffraction (XRD), and differential thermal analysis (DTA). Mechanical properties were evaluated through Vickers hardness testing and uniaxial compression tests. Increasing the Al and Ti content induced a transformation from a single-phase FCC structure to a dual-phase BCC structure, with the primary BCC phase strengthened by spherical precipitates rich in Al, Ti, and Ni. Homogenization annealing at 1100 °C led to an overall improvement in the mechanical properties. The Al_0.3Ti_0.3CrFe₂Ni alloy exhibited the most balanced combination of strength and ductility after annealing, achieving a compressive yield strength of 1510 MPa, a compressive strength of 3316 MPa, and a compressive plastic strain of 45%. Full article

Fracture toughness anisotropy is a key concern in IN718 components produced by Laser Powder Bed Fusion (LPBF), due to their strong crystallographic texture and characteristic lamellar microstructure. In this study, the effect of grain orientation on fracture toughness was evaluated by testing two LPBF IN718 builds with the same laser scanning strategy (R0), but with two different orientations: vertical (R0-0) and 45° inclined (R0-45) relative to the build direction. The mechanical response was assessed through compact tension (CT) tests following ASTM E399 and ASTM E1820 standards. Results show that the R0-45 specimens exhibited a fracture toughness nearly 2.5 times higher than R0-0 specimens. Detailed microstructural analysis, supported by EBSD and SEM, reveals that the higher toughness in the R0-45 orientation is linked to a combination of smaller effective grain size along the crack path, higher levels of geometrically necessary dislocations (GND), and increased kernel average misorientation (KAM), which collectively enhance plastic accommodation and crack-tip shielding. These findings support and reinforce the established understanding of the relationship between microstructure and anisotropic fracture behavior in LPBF IN718, facilitating its practical application in the design and orientation of additively manufactured components. Full article

This study systematically evaluates the influence of copper (Cu) addition in gas-shielded solid wires on the microstructure and cryogenic toughness of X80 pipeline steel welds. Welds were fabricated using solid wires with varying Cu contents (0.13–0.34 wt.%) under identical gas metal arc welding (GMAW) parameters. The mechanical capacities were assessed via tensile testing, Charpy V-notch impact tests at −20 °C and Vickers hardness measurements. Microstructural evolution was characterized through optical microscopy (OM), scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). Key findings reveal that increasing the Cu content from 0.13 wt.% to 0.34 wt.% reduces the volume percentage of acicular ferrite (AF) in the weld metal by approximately 20%, accompanied by a significant decline in cryogenic toughness, with the average impact energy decreasing from 221.08 J to 151.59 J. Mechanistic analysis demonstrates that the trace increase in the Cu element. The phase transition temperature and inclusions is not significant but can refine the prior austenite grain size of the weld, so that the total surface area of the grain boundary increases, and the surface area of the inclusions within the grain is relatively small, resulting in the nucleation of acicular ferrite within the grain being weak. This microstructural transition lowers the critical crack size and diminishes the density for high-angle grain boundaries (HAGBs > 45°), which weakens crack deflection capability. Consequently, the crack propagation angle decreases from 54.73° to 45°, substantially reducing the energy required for stable crack growth and deteriorating low-temperature toughness. Full article

AISI 347H stainless steel is widely used in high-temperature environments due to its excellent creep strength and oxidation resistance; however, its corrosion performance remains highly sensitive to thermal oxidation, and the effects of thermal history on its passive film stability are not yet fully understood. This study addresses this knowledge gap by systematically investigating the influence of solution treatment on the corrosion and oxidation resistance of AISI 347H stainless steel. The specimens were subjected to solution heat treatment at 1050 °C, followed by air cooling, and then evaluated through electrochemical testing, high-temperature oxidation experiments at 550 °C, and multiscale surface characterization techniques. The solution treatment refined the austenitic microstructure by dissolving coarse Nb-rich precipitates, as confirmed by SEM and EBSD, and improved passive film integrity. The stabilizing effect of Nb also played a critical role in suppressing sensitization, thereby enhancing resistance to intergranular attack. Electrochemical measurements and EIS analysis revealed a lower corrosion current density and higher charge transfer resistance in the treated samples, indicating enhanced passivation behavior. ToF-SIMS depth profiling and oxide thickness analysis confirmed a slower parabolic oxide growth rate and reduced oxidation rate constant in the solution-treated condition. At 550 °C, oxidation was suppressed by the formation of compact, Cr-rich scales with dual-distributed Nb oxides, effectively limiting diffusion pathways and stabilizing the protective layer. These findings demonstrate that solution treatment is an effective strategy to improve the long-term corrosion and oxidation performance of AISI 347H stainless steel in harsh service environments. Full article

The extensive use of copper in thermal and electrical systems calls for constant performance enhancement by means of innovative material treatments. The effects on the microstructural, mechanical, and electrical characteristics of copper in deep cryogenic treatment (DCT) and deep cryogenic treatment followed by heat treatment (DCT + HT) are investigated in this work. Copper samples were treated for various soaking durations ranging from 6 to 24 h. Mechanical properties such as tensile strength, hardness, and wear rate were analyzed. In the DCT-treated samples, tensile strength increased, reaching a peak of 343 MPa at 18 h, alongside increased hardness (128 HV) and a refined grain size of 9.58 µm, primarily due to elevated dislocation density and microstrain. At 18 h of soaking, DCT + HT resulted in improved structural stability, high hardness (149 HV), a fine grain size (7.42 µm), and the lowest wear rate (7.73 × 10⁻¹⁰ mm³/Nm), consistent with Hall–Petch strengthening. Electrical measurements revealed improved electron mobility (52.08 cm²/V·s) for samples soaked for 24 h in DCT + HT, attributed to increased crystallite size (39.9 nm), reduced lattice strain, and higher (111) texture intensity. SEM–EBSD analysis showed a substantial increase in low-angle grain boundaries (LAGBs) in DCT + HT-treated samples, correlating with enhanced electrical conductivity. Overall, an 18 h soaking duration was found to be optimal for both treatments. However, the strengthening mechanism in DCT + HT is influenced by grain boundary stabilization and thermal recovery and is different to DCT, which is strain-induced enhancement. Full article

Zn-Ag alloys are deemed extremely promising materials for manufacturing biodegradable medical implants. Nonetheless, their practical applications are still constrained by inferior mechanical properties. To tackle this issue, Zn-0.5Ag alloy was alloyed with Mg (0.2 wt.%) and processed by combined equal-channel angular pressing (ECAP) and rolling, with different rolling reductions (40%, 60%, and 75%). ECAP-processed Zn-0.5Ag-0.2Mg alloy exhibited superior mechanical properties to its as-cast counterpart. Subsequent rolling of 40% further enhances the mechanical performance of ECAP-processed Zn-0.5Ag-0.2Mg alloy, with yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) reaching 255 MPa, 309 MPa, and 52%, respectively, surpassing the application requirements. As the rolling reduction increased to 60% and further to 75%, YS and UTS declined, whereas EL rose continuously. The underlying mechanisms for the variation in strength and ductility were elucidated based on microstructure evolution analysis through optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) characterizations. Full article

The laser-based powder bed fusion of metal (PBF-LB/M) process of 316L stainless steel (SS) was systematically investigated under varying scanning spacings to assess its microstructural and mechanical properties. Optimized laser parameters were employed, and the resulting microstructure and mechanical performance were thoroughly characterized through surface and cross-sectional scanning electron microscopy (SEM), electron backscatter diffraction (EBSD) analysis, fracture surface examination, and tensile testing. The results indicated that a scanning spacing of 0.11 mm produced the most favorable mechanical properties, characterized by a dense microstructure and refined grain morphology. These findings provide critical insights for the optimization of PBF-LB/M process parameters, contributing to the advancement of additive manufacturing techniques for 316L SS. Full article

Characterising and quantifying complex multiphase steels is a challenging and time-consuming process, which is often open to subjectivity when based on image analysis of optical metallographic or SEM images. The properties of multiphase steels are highly sensitive to their individual phase properties and fractions, necessitating the development of robust characterisation tools. This paper presents a method for classifying nanoindentation maps into proportional fractions of up to five distinct microstructural regions in dual-phase and complex-phase steels. The phases/regions considered are ferrite, ferrite containing mobile dislocations, bainite, tempered martensite, and untempered martensite. A range of microstructures with varying fractions of phases were evaluated using both SEM/EBSD and nanoindentation. A machine learning (ML) approach applied to EBSD data showed good consistency in characterising a two-phase system. However, as the microstructural system complexity increased, variations were observed between different analysts and the sensitivity to the ML training data increased when four phases were present (reaching up to ~11% difference in the ferrite phase fraction determined). The proposed nanoindentation mapping technique does not show operator sensitivity and enables the quantification of additional microstructural features, such as identifying and quantifying ferrite regions with a high density of mobile dislocations and the degree of martensite tempering. Full article

Modern energetic materials (EMs) have many different civil applications. One of their most promising applications in civil engineering is explosive hardening, which facilitates the fast and cost-effective improvement of mechanical properties in the treated material. In this work, we present the results of our investigation on the explosive hardening of S235JR Steel with PBX formulations containing silicone binders and 1,3,5-trinitro-1,3,5-triazinane (RDX). In terms of safety, the impact (5–15 J) and friction (240–360 N) sensitivity of the tested plastic-bonded explosives (PBXs) was verified, simultaneously with DSC tests, energy of activation calculations, and critical diameter measurement. The developed material, prepared with techniques similar to the anticipated working conditions, is characterized by a high detonation velocity (up to 7300 m/s), low sensitivity for mechanical factors (10 J, 288 N), and a small critical diameter (3.3 mm). The developed PBX based on a silicone binder demonstrated grain fragmentation, recrystallization, and an increase in the surface hardness of S235JR steel, which was confirmed with SEM, EBSD, microstructure analysis, and microhardness studies. Full article

The integral welded panel represents a highly promising aircraft structural component, owing to its lightweight design and reduced connector requirements. However, the complexity of its welded structure results in the formation of cross-welded joints. This study systematically investigated the mechanical properties of the cross-welded joints through tensile tests across different welded regions, which were complemented by fracture morphology examination via scanning electron microscopy (SEM). The residual stress distribution was characterized using X-ray diffraction, while electron backscatter diffraction (EBSD) analysis was used to elucidate the relationship between residual stress and microstructure. Key findings revealed that the cross-welded zone exhibited lower yield strength and ductility than the single-welded zone, and the advancing heat-affected zone demonstrated superior tensile properties relative to the retreating side. Residual stress analysis showed that the cross-welded joint lacked the “double peak” profile characteristic and displayed lower maximum residual stress than the single-welded joint. EBSD analysis indicated significant grain elongation in the cross-welded zone due to mechanical forces during the welding process, resulting in higher dislocation density and deformation, corresponding with elevated residual stress levels. Full article

Color metallographic samples of H59 brass alloy have been prepared by aqua regia etching. In this paper, combined with XRD (X-ray diffraction), traditional metallographic analysis, FE-SEM (field emission scanning electron microscopy), and EBSD (electron backscattering diffraction), the effect of the color metallographic method on the microstructure characterization of the H59 brass alloy was analyzed. The experimental results showed that α phases and β phases could be distinguished clearly, and the phase morphology, distribution, and content could be expressed accurately with an average error value of 5.25% for the α phase and 4.71% for the β phase. The average error rate of the phase content characterization was 4.98% (less than 5%) with the color metallographic method. In addition, it was also found in the study that the brightness and darkness of the β phase would be related to the grain orientation, and the bright grains would correspond to the low-index surface, and the dark grains to the high-index surface. As a low-cost, fast, and efficient characterization technique, the experimental results show that color metallography (CM) could replace electron backscattering diffraction (EBSD) for the analysis of the phase composition, phase distribution, phase content, and grain orientation of brass alloys, which would provide an experimental basis for optimizing alloy properties and expanding applications. Full article

In this study, we investigated the two-phase hardening behavior and microstructural evolution of S32750 duplex stainless steel during the tensile deformation process. The analysis was conducted using in situ electron backscatter diffraction (EBSD), scanning electron microscopy (SEM), and microhardness testing. It was observed that strain transfer occurred between the two phases in the position away from the fracture. The ferrite phase exhibited softening, while the austenite phase underwent hardening. In the region less than 1 mm from the fracture site, both phases experienced a rapid hardening, with the maximum hardness difference between the two phases near the fracture reaching approximately 45 HV. In situ EBSD results indicate that the kernel average misorientation (KAM) value for the ferrite phase consistently exceeds that of the austenite phase during the initial stages of deformation. Conversely, in the final stages of deformation, the KAM value for austenite surpasses that of ferrite. In the initial stage of deformation, the type of grain boundaries in both phases remains largely unaltered. However, in the later stages of deformation, there is a marked increase in the number of small-angle grain boundaries within ferrite, which become approximately three times that of the large-angle grain boundaries. As deformation progresses, the maximum orientation distribution density of the ferrite phase is reduced by approximately 50%, with the preferred orientation shifting from the {100} plane to the {111} plane. In contrast, the orientation distribution of the austenite remains relatively uniform, with no significant change in the maximum orientation distribution density observed. This indicates that after substantial deformation, the rotation of ferrite grains significantly increases the deformation resistance, whereas the austenite phase continues to harden. This differential behavior leads to the continuous accumulation of strain at the phase boundaries, ultimately causing cracks to form at these boundaries and resulting in the sample’s fracture. Full article