Search Results (5,949)

This study investigates the production of chromium–manganese ligature by a metallothermic process using complex silicon–aluminum reducing agents. Low-grade chromium and iron–manganese ores from the Kempirsai and Kerege-Tas deposits in Kazakhstan were used as raw materials, while the reducing agents included alumosilicomanganese alloy (AlSiMn) and ferrosilicoaluminum (FeSiAl). Thermodynamic calculations were performed with HSC Chemistry 10 at 1400–1800 °C and reducing agent dosages of 10–100 kg per 100 kg of ore charge. Crucible smelting experiments were then carried out in a Tamman furnace, followed by large-scale laboratory trials in a 100 kVA refining electric furnace to verify reproducibility, with a total of 14 runs. The chemical composition of the ligatures varied depending on the reductant: with AlSiMn the alloy contained Fe—23.14%, Cr—53.74%, Mn—20.03%, and Si—3.06%; with FeSiAl, it contained Fe—42.01%, Cr—25.74%, Mn—27.15%, and Si—5.05%; and with FeSiCr dust, it contained Fe—34.45%, Cr—21.45%, Mn—39.82%, and Si—4.24%. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the presence of α-(Fe,Cr,Mn), FeSi, and Cr₅Si₃ phases. The results demonstrate the efficiency of complex silicon–aluminum reducing agents and the ability to regulate the composition of chromium–manganese ligatures by the selected reductant. Full article

To improve the dry-machining performance of a traditional-coated cemented carbide tool when cutting the laser-clad Cr-Ni-based steel, TiN/DLC multilayer coatings were fabricated using physical vapor deposition (PVD). The coated tools were tested for their surface and cross-sectional morphology, roughness, and microhardness. Dry-cutting experiments were conducted to compare the performance of a TiN monolayer-coated tool and a TiN/DLC multilayer-coated tool. The results indicated that the TiN/DLC multilayer coatings significantly improved the machining performance, lowered the cutting force and cutting temperature, decreased the average friction coefficient at the rake face, and reduced surface roughness compared to the TiN-coated tool. This improvement is mainly attributed to the low shear strength of the DLC layer, which effectively reduces surface friction and wear of the tool. The main failure modes were abrasive wear and adhesive wear. The results suggest that the composite coating offers a promising approach to improving traditional-coated tool life and enhancing machining efficiency in the dry cutting of laser-clad alloy components. Full article

Titanium and its alloys are the most widely used metallic materials for bone contact implants. However, despite advances in implant technology, these alloys are still susceptible to post-operative clinical complications such as inflammation, which is often joined by infections and biofilm formation. A number of coatings were studied to overcome the drawbacks of these complications, but the controlled release of bioactive molecules over the first few days and the adhesion of the coating to the substrate remain recognized challenges. Carbon dots and the antibacterial potential of chiral carbon dots (CCDs) were recently reported, and their chirality was identified as a major contribution to the bactericidal effect. This study aimed to achieve a stimuli-responsive medium-term controlled release for up to one month. Two types of chiral carbon dots (CCDs) with distinct functional groups were incorporated into a stable and adherent biodegradable polymer coating, i.e., poly(lactic-co-glycolic acid) (PLGA). To enhance the coating adhesion, the titanium alloy surfaces were pre-treated and activated. The wettability, morphology, and surface composition of the coatings were characterized by contact angle, profilometry, SEM, and XPS, respectively. Coating degradation, adhesion, and CCDs release were studied at physiological pH (7.4) and at an acidic pH characteristic of an inflammatory site (pH 3.0) for up to one month. Their biological performances and blood compatibility were assessed as well. Degradation studies conducted over 28 days revealed a slow mass loss of approximately 10%, with maximum release rates for CCDs-OH and CCDs-NH₂ of 67% and 45% at pH 7.4, respectively. At pH 3.0 an inverse trend was observed with 49% and 59% maximum release after 28 days. Furthermore, the coatings did not exhibit any cytotoxic and hemolytic effects. These findings demonstrate the potential of this approach to providing titanium implants with pH-sensitive controlled release of bioactive CCDs lasting up to one month, which could address key challenges in implant-associated complications. Full article

This study focuses on optimizing the machinability of Al-Fe-Cu (8000 series) alloys by developing new compositions with varying Fe and Cu contents and evaluating their mechanical, microstructural, and energy performance. For this purpose, 6061 Al alloy was melted in an induction furnace and cast into molds, and samples containing 2.5% and 5% Fe were produced. Microstructural features were analyzed using Python-based image processing, while Specific Energy Consumption (SEC) theory was applied to assess machining efficiency. An alloy with 2.5% Fe and 2.64% Cu showed superior mechanical properties and the lowest energy consumption. Increasing cutting speed and depth of cut notably decreased SEC. Machine learning (ML) analysis confirmed strong predictive capability, with R² values above 0.80 for all models. Decision Tree (DT) achieved the highest accuracy for SEC prediction (R² = 0.98634, MAE = 0.02209, MSE = 0.00104), whereas XGBoost (XGB) performed best for SCEC (R² = 0.96533, MAE = 0.25578, MSE = 0.10178). Response Surface Methodology (RSM) optimization further validated the significant influence of machining parameters on SEC and specific cutting energy consumption (SCEC). Overall, the integration of machine learning (ML), response surface methodology (RSM), and energy equations provides a comprehensive approach to improve the machinability and energy efficiency of 8000 series alloys, offering practical insights for industrial applications. Full article

Titanium and its alloys are widely used in biomedical implants due to their favorable mechanical properties and corrosion resistance; however, their natural surface lacks sufficient bioactivity and antibacterial performance. Micro-arc oxidation is a promising approach to producing bioactive coatings, and the incorporation of nanoparticles such as TiO₂ may further improve their functionality. This study aimed to determine the optimal TiO₂ nanoparticle concentration in the micro-arc oxidation electrolyte that ensures coating stability and biological safety. Calcium–phosphate coatings were fabricated on commercially pure titanium using micro-arc oxidation with two TiO₂ concentrations: 0.5 wt.% (MAO 1) and 1 wt.% (MAO 2). Surface morphology, porosity, and phase composition were analyzed by scanning electron microscopy, energy-dispersive spectroscopy, and X-ray diffraction. Corrosion resistance was evaluated via potentiodynamic polarization in NaCl and Ringer’s solutions, while biocompatibility was assessed in vitro using HOS human osteosarcoma cells and MTT assays. Increasing the TiO₂ content to 1% decreased coating porosity (13.7% vs. 26.3% for MAO 1), enhanced corrosion protection, and reduced the friction coefficient compared to bare titanium. However, MAO 2 exhibited high cytotoxicity (81% cell death) and partial structural degradation in the biological medium. MAO 1 maintained integrity and showed no toxic effects (3% cell death). These results suggest that 0.5% TiO₂ is the optimal concentration, providing a balance between corrosion resistance, mechanical stability, and biocompatibility, supporting the development of safer implant coatings. Full article

Quasicrystals are ordered phases without periodicity. They are often found in aluminium and other alloys. They can appear in different sizes. Therefore, several metallographic and characterisation techniques are required to fully determine their shape, size, crystallography, and chemical composition. This review paper gives special attention to identifying quasicrystals in aluminium alloys using classical metallographic techniques, such as etching, deep etching, and particle extraction, which allow the investigation of larger areas by light and scanning electron microscope, giving additional information by combining with complementary high-resolution techniques. Full article

This study investigates the fabrication and performance of a novel composite material by infiltrating SnSb11Cu6 babbitt alloy into an open-cell AlSn6Cu-SiC matrix. The composites, produced via a multi-stage liquid-state processing route, were comprehensively characterized for their microstructural, mechanical, and tribological properties. The inclusion of 5 wt.% silicon carbide reinforcement resulted in a significant improvement in tribological performance under dry-sliding conditions. Specifically, the reinforced composite exhibited a 24.8% reduction in wear and a 10.8% reduction in the coefficient of friction compared to its unreinforced counterpart. Crucially, this enhancement in wear resistance was achieved while the bulk compressive mechanical properties and ductile deformation behavior remained virtually identical to the unreinforced material. Microstructural analysis confirmed that the high-hardness SiC particles act as primary load-bearing agents, shielding the softer metallic matrix from severe wear. These findings demonstrate the successful development of a high-performance composite with enhanced tribological durability without a mechanical trade-off, making it a promising candidate for advanced bearing applications. Full article

The nominal compositions of Fe₆₅Co_10−xNi_10−xCr₁₅Si_2x (x = 1, 2, and 3 at.%) medium-entropy alloys (MEAs) were designed and fabricated by vacuum arc melting. Their microstructure, hardness, and mechanical properties were systematically characterized. Corrosion behavior was evaluated in 3.5 wt.% NaCl solution by potentiodynamic polarization and electrochemical impedance spectroscopy. The investigated MEAs exhibit a dual-phase microstructure composed of face-centered cubic (FCC) and body-centered-cubic (BCC) phases. With increasing Si content, yield strength and ultimate tensile strength increase, while uniform elongation decreases. Hardness also increases with increasing Si content. For the x = 3 MEA, the yield strength, ultimate tensile strength, and hardness of are ~518 MPa, ~1053 MPa, and 262 ± 4.8 HV, respectively. The observed strengthening can be primarily attributed to solid solution strengthening effect by Si. Polarization curves indicate that the x = 3 MEA exhibits the best corrosion resistance with the lowest corrosion current density ((0.401 ± 0.19) × 10⁻⁶ A × cm⁻²) and corrosion rate ((4.65 ± 0.19) × 10^–2 μm × year⁻¹)). Equivalent electric circuit analysis suggests the formation of a stable passive oxide film on the MEAs. This conclusion is supported by the capacitive behavior, high impedance values (> 10⁴ Ω cm²) at low frequencies, and phase angles within a narrow window of 80.05°~80.64° in the medium-frequency region. The passive-film thickness was calculated and the corrosion morphology was analyzed by SEM. These results provide a reference for developing high-strength, corrosion-resistant, medium-entropy alloys. Full article

Recent literature reports have shown that individual HEAs, especially those of the AlCoCrFeNi composition system alloyed with appropriately selected elements, exhibit excellent mechanical properties and corrosion resistance, making them promising candidates for replacing conventional materials such as austenitic steels in corrosive environments. Therefore, in the present study, the high-entropy alloy AlCoCrFeNiMo_0.25 was examined and compared with AISI 304L steel and the reference alloy AlCoCrFeNi. The HEA was produced by arc melting in vacuum. The effect of molybdenum addition (5% at.) on the structure, mechanical properties, and corrosion resistance was evaluated. Potentiodynamic polarization and electrochemical impedance spectroscopy tests were carried out in a 3.5% NaCl solution in a three-electrode electrochemical system. The addition of molybdenum to AlCoCrFeNiMo_x alloy additionally caused, along with the BCC phase, the formation of σ phase and FCC phase (less than 1%), as well as changes in the microstructure, leading to the fragmentation of grains and the formation of a mosaic structure. On the basis of nanoindentation tests, it was established that the addition of Mo increases hardness and elastic modulus and improves nanoindentation coefficients H/E and H³/E², as well as an increase in the elastic recovery index while decreasing plasticity index (vs. the reference equiatomic HEA). This indicates the improvement of anti-wear properties with impact loading resistance. In turn, electrochemical tests have shown that the addition of Mo improves corrosion resistance. Corrosion pitting develops in Al- and Ni-rich areas of HEA alloys, as a result of galvanic microcorrosion related to Cr chemical segregation. In general, the addition of 5% Mo results in a fine-grained mosaic structure, which primarily translates into favorable nanoindentation and corrosion properties of the AlCoCrFeNiMo_0.25 alloy. Full article

This work investigated the effect of cerium (Ce) addition on the wear behavior of commercially pure titanium (CP-Ti) by varying the Ce content to 0.8, 1.4, and 2.0 wt.%. Alloys were fabricated using plasma arc melting, and wear resistance was evaluated under loads of 1 N and 5 N dry sliding condition. Microstructural characterization confirmed the formation of CeO₂ precipitates, whose size and distribution varied with the Ce content. The Ti-0.8Ce alloy exhibited the highest hardness (203 HV), showing a 35% increase compared to CP-Ti, and the lowest wear rate reduced by approximately 47% and 22% under 1 N and 5 N loads, respectively. In contrast, Ti-1.4Ce and Ti-2.0Ce formed coarse CeO₂ precipitates, which acted as third-body abrasives. Although these alloys showed lower average friction coefficients than CP-Ti (up to 22% reduction), the enhanced abrasive interaction promoted material removal and increased wear rates. Notably, Ti-2.0Ce exhibited the most severe degradation in wear resistance, with wear rates increases of 21% and 27% under 1 N and 5 N loads, respectively. These findings demonstrate that while CeO₂ precipitates reduce friction by suppressing direct metal–metal contact, their abrasive nature adversely affects wear resistance when the particle size and volume fraction are excessive. Therefore, 0.8 wt.% Ce was identified as the optimal composition for improving the wear resistance, achieving the best combination of high hardness, low wear rate without excessive third-body abrasion. Full article

Advancements in material science have allowed us to exploit the potential of new era for aircraft production. High-performance composites and alloys have allowed us to improve the performance and durability of aircraft, but they have become more and more precious with time. These materials can provide significant advantages in use but are costly, energy-intensive to produce, and their recovery and reuse has become a critical step to be addressed. Accordingly, a new approach in which end-of-life aircrafts represent unconventional mines rather than a disposal challenge is becoming increasingly relevant, providing access to high-value strategic raw materials and aligning with circular economy principles including European Green Deal and the United Nations Sustainable Development Goals. The complexity of dismantling and processing hybrid structures composed of metal alloys, ceramics, and advanced composites requires multiple approaches able to integrate chemical, mechanical, and thermal recovery routes. Accordingly, this review critically discusses the state of the art of the routes of end-of-life aircraft treatments, evaluating the connections between technology and regulation, and positions material recycling and reuse as central pillars for advancing sustainability in aerospace. Furthermore, this review provides a comprehensive reference for addressing the technical, economic, and policy challenges of waste management in aviation, contributing to broader goals of resource circularity and environmental preservation set forth by international sustainability agendas. Full article

The present paper compares the microstructure and mechanical properties of Inconel 625 alloy samples produced by using wire-arc additive manufacturing (WAAM) and wire electron beam additive manufacturing (WEBAM). The obtained wall-shaped samples did not contain any macroscopic defects in the form of cracks, delaminations and geometry distortions. The WAAM-built “wall” exhibits finer dendritic structures (WAAM—10–16 μm; WEBAM—20–25 μm). Also, the WAAM-built one is characterized by the more homogeneous-sized distribution of microstructure components. In both cases, the material is represented by the γ-phase, with large precipitates of MC-type carbides in the interdendritic spaces. Additionally, the sample obtained using the WAAM contained aluminum oxide. It was found that the intrinsic periodic heat treatment is not sufficient for the formation of the γ″-phase, and it is necessary to perform a subsequent long-term aging. However, the overall mechanical properties of both samples show similar levels of yield stress and ultimate tensile strength, and demonstrate the same degree of anisotropy. Full article

Tribological tests were conducted on eutectic white cast iron subjected to directional solidification (resulting in a directionally oriented microstructure) and, for comparison, on white cast iron with an equiaxed (non-directional) structure. The tests were performed under dry sliding conditions on a pin-on-block rig using Cu, AlSi12CuNiMg alloy, AlSi12CuNiMg + SiC composite, and steel grade 1.3505. The friction coefficient and wear rates of these materials were systematically compared. Quantitative and qualitative evaluations of the wear tracks formed on the test specimens were carried out using profilometry. The results demonstrate that the directionally solidified white cast iron exhibits improved friction coefficient stability and reduced wear in the specific tribological pairs. The oriented directional structure demonstrated more favourable interactions when paired with AlSi12CuNiMg + SiC composite and 1.3505 steel. These tribological combinations exhibited reduced roughness values across selected cross-sectional analyses, resulting in correspondingly lower Sa parameter measurements. This finding suggests a promising new application for inserts made of directionally structured white cast iron in structural components requiring enhanced wear resistance at elevated temperatures. Full article

This study investigates the structural and magnetic properties of ultra-high coercivity (Fe₈₀B₁₄Nb₆)_0.88Dy_0.12 alloys, doped with 0.5–5 at.% of selected metallic additions: magnetic (Ni, Co) and non-magnetic (Pt, Cu) elements. Material characterization involved both structural and magnetic measurements. Alloys containing dopant concentrations up to 2 at.% exhibited similar phase compositions, with the Dy₂Fe₁₄B compound being dominant. Magnetic hysteresis loops revealed a superposition of two components: magnetically soft and hard phases. A significant change in magnetic properties was observed within the 0.5 to 1 at.% dopant concentration range. Notably, the addition of 0.5 at.% Ni increased the apparent anisotropy field from 5.2 T to 7.5 T. Furthermore, 0.5 at.% Pt led to an increase in the coercive field from 4.6 T to 5.5 T. These additions influenced crystallization, resulting in the formation of a more regular microstructure without submicrometric dendrite branches, when compared to the base alloy. Full article