Search Results (192)

Aluminum matrix composites provide an ideal solution for lightweight brake disks, but conventional casting processes are prone to crack initiation due to inhomogeneous reinforcement dispersion, gas porosity, and inadequate toughness. To break the conventional trade-off between high wear resistance and low toughness of brake disks, this study fabricated a bimetallic structure of SiC_p/Al–Fe–V–Si aluminum matrix composite and cast ZL101 alloy using friction stir lap welding (FSLW). Then, the microstructural evolution, mechanical properties, and tribological behavior of the FSLW joints were studied by XRD, SEM, TEM, tensile testing, and tribological tests. The results showed that the FSLW process homogenized the distribution of SiC particle reinforcements in the SiC_p/Al–Fe–V–Si composites. The Al₁₂(Fe,V)₃Si heat-resistant phase was not decomposed or coarsened, and the mechanical properties were maintained. The FSLW process refined the grains of the ZL101 aluminum alloy through recrystallization and fragmented eutectic silicon, improving elongation to 22%. A metallurgical bond formed at the joint interface. Tensile fracture occurred within the ZL101 matrix, demonstrating that the interfacial bond strength exceeded the alloy’s load-bearing capacity. In addition, the composites exhibited significantly enhanced wear resistance after FSLW, with their wear rate reduced by approximately 40% compared to the as-received materials, which was attributed to the homogenized SiC particle distribution and the activation of an oxidative wear mechanism. Full article

This study investigates the fabrication and residual stress behavior of a 0.5 wt.% graphene-reinforced AA2195 aluminum matrix composite, developed for advanced aerospace structural applications. The composite was synthesized via squeeze casting, followed by a multi-pass hot rolling process and subsequent T8 heat treatment. The evolution of residual stress was systematically examined after each rolling pass and during thermal treatments. The successful incorporation of graphene into the matrix was confirmed through Energy-Dispersive Spectroscopy (EDS) analysis. Residual stress measurements after each pass revealed a progressive increase in compressive stress, reaching a maximum of −68 MPa after the fourth hot rolling pass. Prior to the fifth pass, a solution treatment at 530 °C was performed to dissolve coarse precipitates and relieve internal stresses. Cold rolling during the fifth pass reduced the compressive residual stress to −40 MPa, and subsequent artificial aging at 180 °C for 48 h further decreased it to −23 MPa due to recovery and stress relaxation mechanisms. Compared to the unreinforced AA2195 alloy in the T8 condition, which exhibited a tensile residual stress of +29 MPa, the graphene-reinforced composite in the same condition retained a compressive residual stress of −23 MPa. This represents a net improvement of 52 MPa, highlighting the composite’s superior capability to retain compressive residual stress. The presence of graphene significantly influenced the stress distribution by introducing thermal expansion mismatch and acting as a barrier to dislocation motion. Overall, the composite demonstrated enhanced residual stress characteristics, making it a promising candidate for lightweight, fatigue-resistant aerospace components. Full article

The production of AISI 304 stainless steel (a corrosion-resistant alloy prone to solidification defects from high alloy content) particularly benefits from twin-roll strip casting—a short-process green technology enabling sub-rapid solidification (the maximum cooling rate exceeds 1000 °C/s) control for high-performance steels. However, the internal phenomena within its molten pool remain exceptionally challenging to monitor. This study developed a multiscale numerical model to simulate coupled fluid flow, heat transfer, and solidification in AISI 304 stainless steel twin-roll strip casting. A quarter-symmetry 3D model captured macroscopic transport phenomena, while a slice model resolved mesoscopic solidification structure. Laboratory experiments had verified that the deviation between the predicted temperature field and the measured average value (1384.3 °C) was less than 5%, and the error between the solidification structure simulation and the electron backscatter diffraction (EBSD) data was within 5%. The flow field and flow trajectory showed obvious recirculation zones: the center area was mainly composed of large recirculation zones, and many small recirculation zones appeared at the edges. Parameter studies showed that, compared with the high superheat (110 °C), the low superheat (30 °C) increased the total solid fraction by 63% (from 8.3% to 13.6%) and increased the distance between the kiss point and the bottom of the molten pool by 154% (from 6.2 to 15.8 mm). The location of the kiss point is a key industrial indicator for assessing solidification integrity and the risk of strip fracture. In terms of mesoscopic solidification structure, low superheat promoted the formation of coarse columnar crystals (equiaxed crystals accounted for 8.9%), while high superheat promoted the formation of equiaxed nucleation (26.5%). The model can be used to assist in the setting of process parameters and process optimization for twin-roll strip casting. Full article

In this study, lanthanum (La), a rare earth element, was added at concentrations of 0.25 wt.%, 0.5 wt.%, and 0.75 wt.% to an Al–10%Si–2%Cu-based alloy prepared by die casting. The effects of solution and aging heat treatment conditions on the mechanical properties and corrosion resistance were investigated. Microstructural changes, hardness, and corrosion behavior were analyzed as functions of La content and heat treatment parameters. The optimal hardness was achieved at a solution treatment temperature of 500 °C or higher and an aging time of 2 h. In particular, the addition of 0.5 wt.% La led to significant refinement of the α-Al grains, enhancing hardness through the Hall–Petch strengthening mechanism. Furthermore, the combined effects of aging treatment and La addition promoted the formation of a fine, uniform microstructure and stable dispersion of precipitates, resulting in improved mechanical performance. Electrochemical polarization tests revealed that the alloy containing 0.5 wt.% La exhibited the best corrosion resistance. This enhancement was attributed to the formation of the LaCu₂Al₄Si intermetallic compound, which has a lower electrochemical potential than the Al₂Cu phase, thereby reducing corrosion susceptibility within the microstructure. Full article

This research presents the results of different periods of T6 heat treatment (homogenization and artificial aging) for A356 aluminum alloy used in the fabrication of motorcycles. The samples were cast using gravity die casting, and industrial furnaces for T6 were used in the experiment. Two heat treatment conditions were used, with a total time of 7 h and 12 h, and the results were compared with the alloy without heat treatment. The effects of the reduction of treatment time on mechanical behavior were evaluated in terms of hardness, Charpy and tensile tests, as well as morphological analysis of fractures and microstructural behavior via optical microscopy, SEM-EDS, measurement of eutectic Si evolution, and XRD. Excellent mechanical properties were achieved with a treatment period of 7 h, which achieved a yield strength of 226.58 (±3.76) MPa, tensile strength limit of 264.78 (±4.27) MPa and elongation of 3.41 (±0.47) %. This is competitive with other cast alloys subjected to T6 heat treatment in longer treatment cycles. The peak of hardness and highest impact resistance was recorded for the sample treated for 12 h; however, in the impact test, there was no significant difference between the two experiments. Full article

This paper studies how heat treatments influence the corrosion of an AlCoCrFeNi_2.1 eutectic high-entropy alloy (EHEA) in a 3.5 wt% NaCl solution, by comparing the corrosion behaviors of as-cast, 600 °C heat-treated, and 1000 °C heat-treated samples using microstructure characterization, electrochemical measurements, and surface characterization. The electrochemical results show that the pitting potential rises and the passive current density and passive film resistance are almost changeless with an increasing heat treatment temperature. The enhancement in the pitting corrosion resistance results from the increased amount of the Cr-rich FCC phase and decreased amount of the B2 phase rich in the Al element, which are induced by the heat treatment. On one hand, this microstructure evolution can make the passive film have more Cr₂O₃ and less Al₂O₃, thereby enhancing its protective properties, as confirmed by the X-ray photoelectron spectroscopy analysis. On the other hand, the decreased amount of the Al-rich B2 phase can make the pitting corrosion less prone to initiate since the B2 phase can act as the pit initiation site, which is supported by the observation of corrosion morphologies, due to its higher electrochemical activity. In a summary, the heat treatment is beneficial for improving the pitting corrosion resistance of the AlCoCrFeNi_2.1 EHEA. Full article

Recent progress in metal matrix composites (MMCs) has led to significant research efforts aimed at refining reinforcement methods and processing techniques and enhancing material properties. Incorporating reinforcements has notably improved both mechanical strength and tribological performance while addressing issues such as porosity and particle agglomeration. This study investigates the impact of copper reinforcement (1–4 wt.%) on the tribological characteristics of A356 alloy under both as-cast and heat-treated conditions. The process of heat treatment involved age hardening, where the composites were solution heat treated (SHT) at 535 °C for 2 h, followed by rapid quenching and aging at 100 °C and 200 °C. The results demonstrate that increasing the copper content enhances the composite’s mechanical properties. Specifically, heat treatment promoted the redistribution of the Al₂Cu intermetallic phase during peak aging, leading to improved hardness and wear resistance. Wear testing demonstrated that heat-treated composites exhibited significantly better wear resistance than their as-cast counterparts, with improvements of 50–60% under lower loads and 80–90% under higher loads. Among the tested samples, A356 alloy reinforced with 4 wt.% copper showed the lowest wear rate across all the applied loads, along with a reduced coefficient of friction and enhanced load-bearing capacity, minimizing material deformation. Additionally, aging at 100 °C resulted in the greatest hardness and the lowest wear rate in comparison to untreated A356 alloy. These findings underscore the viability of copper-reinforced A356 composites for applications demanding enhanced mechanical characteristics and wear resistance. Full article

The significance of the matrix morphology of vermicular cast iron for the alloy’s thermal shock resistance was determined. The study included vermicular cast iron subjected to heat treatment in order to obtain an ausferritic matrix. Heat treatment involved austenitization at 960 °C for 90 min, followed by two different austempering variants at 290 °C and 390 °C, each for 90 min. Austempering at 390 °C resulted in a higher content of retained austenite compared to austempering at 290 °C. A test stand was used to determine thermal shock resistance, enabling repeated heating and cooling of the samples. The samples were heated inductively and subsequently cooled in water at a constant temperature of approximately 30 °C. The total length of cracks formed on the wedge-shaped surfaces of the tested samples was adopted as a characteristic value inversely proportional to the material’s thermal shock resistance. The samples heated to 500 °C were subjected to 2000 heating–cooling test cycles. It was found that in as-cast iron, structural changes were minor, whereas in the heat-treated material, changes in the structure were more noticeable. Under the influence of thermal shocks, ausferrite transforms into ferrite with carbides. Among the analyzed materials, the most resistant cast iron was the one austempered at 290 °C. Oxide precipitates were observed near cracks and graphite regions. Full article

The development of high-strength cast irons with multiphase metal matrix structures is one of the new areas of modern materials science and mechanical engineering. This is so because of the high dissipative properties of such materials, which, in turn, ensure an improvement in their functional characteristics. It is known that one of the effective methods for obtaining alloys with a heterogeneous structure is a multi-stage heat treatment. Therefore, this study aimed to enhance the corrosion and friction properties of high-strength cast irons by combining different processing methods to create a bainite-martensitic matrix. High-strength cast irons with high ductility micro-alloyed with boron were chosen as the object for research. The experiments studied the effect of various types of multi-stage heat treatment on the structural features, tribological properties, hardness and corrosion resistance. The cast irons were quenched in water or liquid nitrogen after a controlled duration of isothermal exposure at different temperatures. It was established that cooling of isothermally hardened samples in liquid nitrogen makes it possible to effectively engineer the morphology and amount of the formed martensitic phase. It was observed that the high-strength cast irons with 10–15% lower bainite, residual austenite and martensite have the best frictional characteristics. This innovative method allowed the quenching of cast iron directly into liquid nitrogen without violent cracking. Full article

The HP40Nb alloy, commonly used in the petrochemical industry as a heat-resistant material, undergoes significant microstructural changes at high temperatures. This study examined samples from the HP40Nb radiant tube used in a reformer furnace, exposed to 950, 1050, and 1150 °C for 2 and 8 h. Metallographic analysis, including optical microscopy, SEM, EDS, and XRPD, revealed that the as-cast alloy has an austenitic dendritic matrix with primary eutectic-like carbides (M₂₃C₆ and MC types). Prolonged exposure to high temperatures transformed the primary carbides into coarse M₂₃C₆ forms, losing their lamellar shape. The number of secondary carbides decreased with increasing temperature, and at 1150 °C for 480 min, secondary Cr₂₃C₆ carbides nearly decomposed, and Nb carbides dissolved into the austenitic matrix. Full article

The existing Al-Ce heat-resistant alloys are not extensively utilized in high-temperature applications due to their poor room-temperature mechanical properties. In this study, the Al-10Ce-3Mg-5Zn alloy was enhanced using hot extrusion and heat treatment. The as-extruded alloy exhibited bimodal intermetallic compounds and grain structures. Additionally, high-density microcracks and twins were observed in the micron-sized intermetallic compounds. Compared with the as-cast state, the as-extruded alloy demonstrated a higher ultimate tensile strength (UTS) of 317 MPa and better elongation of 11.0%. Numerous nano-sized T phases precipitated in the α-Al matrix after the heat treatment, contributing to a further rise in UTS (365 MPa). The high strength of the alloy is primarily due to its strong strain hardening capacity, fine grain strengthening, and precipitation strengthening effect. The change in elongation mainly results from the expansion of pre-existing microcracks, twin deformation, and microstructural refinement. The heat-treated alloys exhibited superior strength retention ratios at elevated temperatures (64% at 200 °C) compared to conventional heat-resistant aluminum alloys. The results of this paper indicate that hot extrusion and heat treatment are effective for developing heat-resistant Al-Ce alloys with high room-temperature strength, offering a simple process suitable for industrial production. Full article

This study systematically investigated the effects of tailored heat treatments on the microstructural evolution, mechanical properties, and erosion–corrosion resistance of Cu-10Ni-3Al-1.8Fe-0.8Mn alloy. Four heat treatment conditions—as-cast (AC-1); homogenized (H-2); and deformation–aged at 500 °C (D-3) and 750 °C (D-4)—were applied to elucidate the interplay between microstructure and performance. The D-3 specimen, subjected to deformation followed by aging at 500 °C for 0.5 h, demonstrated superior properties: a Vickers hardness of 118 HV5 (83.3% higher than H-2) and an erosion–corrosion rate of 0.0075 mm/a (84.1% reduction compared to H-2). These enhancements were attributed to the uniform dispersion of nanoscale Ni₃Al precipitates within the matrix, which optimized precipitation strengthening and reduced micro-galvanic corrosion. The D-3 specimen also formed a dense, crack-free Cu₂O corrosion product film with a flat matrix interface, confirmed by SEM cross-sectional analysis and electrochemical impedance spectroscopy (EIS), exhibiting the highest charge transfer resistance and film impedance. Full article

Al-Si alloy, known for its excellent corrosion resistance and high strength, is utilized across various industries, such as electric vehicles, requiring light metal parts for efficiency. Heat treatment is an effective process for enhancing the performance of Al-Si alloys by controlling the microstructure and precipitation. Optimized heat treatment improves the mechanical properties of Al-Si alloy, including strength, hardness, and corrosion resistance. In this study, the effect of heat treatment on the microstructure, corrosion resistance, and hardness of A356 casting alloy, which has recently been used in electric vehicles, was analyzed. The as-cast A356 alloy was used as a control sample, with a solid solution treatment, followed by aging treatment. The results showed that the hardness and corrosion resistance of A356 alloy can be changed by controlling the formation and distribution of Mg₂Si precipitates within the microstructure through the solution heat treatment and following aging. Additionally, the distribution and strengthening mechanism of Mg₂Si precipitates were examined using XRD. With increasing aging time, more Mg₂Si precipitates were formed, increasing hardness. However, the precipitation of Mg₂Si reduces the corrosion resistance of A356 alloy. Thus, it was revealed that the heat treatment of A356 alloy for enhancing mechanical properties by precipitating Mg₂Si causes a side effect of corrosion resistance. Full article

High chromium cast iron (HCCI) is widely used in the manufacturing of equipment parts in the fields of mining, cement, electric power, metallurgy, the chemical industry, and paper-making because of its excellent wear and corrosion resistance. Although the microstructure and properties of HCCI can be modified by controlling the casting and heat treatment process, alloying is still the most basic and important method to improve the properties of HCCI. There are about 14 common alloying elements in HCCI, among which nickel, copper, and manganese are typical austenite stabilizing elements, which can increase austenite content and matrix electrode potential. The addition of elements such as silicon, nitrogen, boron, and rare earth (RE) is often small, but it has a significant effect on tailoring the microstructure, thereby improving wear resistance and impact toughness. It was thought that after years of development, the research on the role of the above elements in HCCI was relatively complete, but in the past 5 to 10 years, there has been a lot of new research progress. Moreover, the current development situation of HCCI is still relatively extensive, and there are still many problems regarding the alloying of HCCI to be further studied and solved. In this paper, the research results of austenitic stabilizing elements and modifying elements in HCCI are reviewed. The existing forms, distribution law of these elements in HCCI, and their effects on the microstructure, hardness, wear resistance, and corrosion resistance of HCCI are summarized. Combined with the current research situation, the future research and development direction of HCCI alloying is prospected. Full article

The effect of Yb on the microstructure and tensile properties at room temperature and high temperature (350 °C) of as-cast and T6 heat-treated Al-6Cu-0.4Mn alloys was investigated. The results show that Yb can refine the α-Al primary grain and α-Al + Al₂Cu eutectic structure. The eutectic structure of the alloy containing 0.3 wt.%Yb has the best refining effect. After the T6 heat treatment, most of the network α-Al + Al₂Cu eutectic structure disappeared, and many dispersed (200–400 nm) θ′-Al₂Cu phases were precipitated in the matrix. With the addition of Yb, the amount of θ′-Al₂Cu phases increases, and the average size decreases from 260 nm in the base alloy to 176 nm in the Yb-containing alloy, which indicates that Yb can promote the precipitation and refinement of the θ′-Al₂Cu phase; after adding Yb, the high-temperature ultimate tensile strengths (UTS) of the as-cast and heat-treated alloy significantly increase. Both reached their highest when the Yb additions were 0.3 wt.%, reaching 95.5 MPa and 142.3 MPa, respectively, 13.66% and 17.71% higher than the base alloy. The thermal exposure test at 350 °C shows that Yb can improve the θ′-Al₂Cu phase’s coarsening resistance. Analysis shows that the improvement of mechanical properties at room temperature is due to solid solution strengthening and grain refinement of Yb. The reason for improving mechanical properties at high temperatures is that adding Yb promotes the precipitation, refinement, and thermal stability of the θ′-Al₂Cu phase. Full article