Search Results (1,101)

To enhance surface hardness, laser surface remelting (LSR) was performed to treat the surface of a novel nuclear-grade Zr-1.0Sn-1.0Nb-0.3Fe zirconium alloy. A combination of advanced characterization techniques was used to systematically analyze the microstructural features of the samples before and after the LSR treatment, and their correlation with hardness variations was studied. Results show that the LSR-treated surface consists of two distinct microstructural regions: (i) the remelted zone (RZ), characterized by fine lath structures and precipitates distributed along the lath boundaries; and (ii) the heat-affected zone, comprising blocky α phase, α laths, and precipitates. The surface of the LSR-treated samples exhibits a random texture, which is attributed to the selection suppression of α variants during the laser-induced rapid transformation. The average hardness of the RZ reaches 285.7 ± 8.3 HV, ~40% higher than the substrate. This hardness enhancement is ascribed to LSR-induced grain refinement. Full article

The aim of this study was to determine the influence of heat treatment parameters on the microstructure and mechanical properties of the AlMn1Cu (EN AW-3003) aluminium alloy with a one-sided cladding layer of AlSi7.5 alloy (EN AW-4343). The investigation was conducted within an annealing temperature range of 200 °C to 500 °C, analysing changes in hardness, mechanical strength, formability, and planar anisotropy. The results clearly indicate that within the temperature range of 300–340 °C, an intensive process of static recrystallisation occurs, leading to the restoration of a fine-grained and homogeneous microstructure. This is accompanied by a sharp reduction in hardness and yield strength, along with a significant increase in ductility and deep drawing capability. A notable reduction in the anisotropy of plastic properties was also observed, confirming effective homogenisation of the material’s microstructure. The findings unambiguously demonstrate that heat treatment within the range of 300–500 °C enables the formation of an isotropic microstructure with low hardness and high formability, rendering the material particularly suitable for shaping thin-walled components, including heat exchangers. Full article

This work employed laser powder bed fusion (LPBF) technology to prepare pure tungsten (W) metal components and investigated their internal defects, microstructural characteristics and mechanical properties within the horizontal and vertical planes to evaluate their anisotropic behavior. The steep temperature gradient and extremely rapid cooling rate during the LPBF process caused the as-deposited W grains to grow in a columnar crystal structure along the vertical height direction, with cracks propagating along the high-angle grain boundaries (HAGBs). Although the near-equiaxed W grains within the horizontal plane were finer than the epitaxial grains within the vertical plane, the increased number of cracks within the horizontal plane weakened the fine-grained strengthening effect, resulting in lower hardness and wear resistance within the horizontal plane than within the vertical plane. The wear behavior transformed from a comprehensive wear mechanism involving delamination wear and abrasive wear within the vertical plane to an abrasive wear mechanism with slight adhesive wear within the horizontal plane. The reported results demonstrate that the anisotropic behavior of hardness and wear resistance within the different deposition planes was mainly attributed to the differences in microstructure and crack distribution between the horizontal and vertical planes of LPBF-fabricated W parts. Full article

Welded structures, such as offshore platforms, require robust toughness in their heat-affected zones (HAZ) to withstand low-temperature environments. The coarse-grained HAZ (CGHAZ) adjacent to the fusion boundary often exhibits reduced toughness due to grain coarsening, particularly under high heat input welding conditions aimed at enhancing productivity. To address this, high-nitrogen steels containing TiN particles were developed to suppress austenite grain growth by leveraging the thermal stability of TiN precipitates. Three high-nitrogen steels with varying carbon contents (0.09%, 0.11%, and 0.15%) were fabricated and subjected to crack tip opening displacement (CTOD) testing at −20 °C and −40 °C to evaluate low-temperature HAZ toughness. Results indicate that high-nitrogen TiN steels exhibit superior CTOD values (1.38–2.73 mm) compared to conventional 490-MPa class steels, with no significant reduction in toughness despite increased carbon content. This is attributed to the presence of stable TiN particles, which restrict austenite grain growth during welding thermal cycles, and the formation of fine ferrite–pearlite microstructures in the HAZ. These findings highlight the efficacy of high-nitrogen TiN steels in enhancing low-temperature fracture resistance for welded structures. Full article

A Mg-Gd-Y alloy prepared by surface mechanical attrition treatment (SMAT) was annealed at 450 °C combined with peak aging. The deformation and fracture mechanisms were investigated using in situ tensile tests. Through quantitative calculations of the geometrically necessary dislocation (GND) densities, it was found that the fine-grained (FG) layer in the gradient structure carried greater plastic strain than the coarse-grained (CG) layer during tension. The calculation results of the geometric compatibility parameter (m’) and microstructure characterization during in situ tests showed that crack initiation and propagation were prone to occur between adjacent coarse grains. However, the hetero-deformation-induced (HDI) strengthening and strain hardening induced by the strain gradient between the FG and CG layers effectively improved the strength–ductility synergy of the gradient-structured (GS) alloy. In addition, the synergistic effect of intrinsic and extrinsic toughening mechanisms in the GS alloy played a significant role in delaying premature failure. Full article

Laser powder bed fusion (L-PBF) is a unique technology that enables manufacturing geometrically complex metal alloys, including Ti-6Al-4V parts. The microstructure of Ti-6Al-4V is determined by its localized thermal history, which is affected by not only the L-PBF process but also the geometry of the part. Understanding the microstructure at specific locations in complex geometries is of great importance in predicting the mechanical performance of Ti-6Al-4V parts. This work investigates the effects of geometric features on the local microstructure. Three geometries, namely, holes, overhangs, and penholders, were designed and used for this study. Three different laser powers, namely 150 W, 250 W, and 350 W, were set to print those geometries. The use of a lower laser power results in improved print quality. While the martensite phase dominates the bulk of the L-PBF Ti-6Al-4V parts, a fine α+β lamellar structure can form at down-skin regions of printed horizontal holes and overhangs. Moreover, the direction of the columnar prime β grain can shift due to directional heat dissipation. The local microstructural evolution after heat treatment is investigated as well. Full article

A (NiCoCr)_99.25C_0.75 medium entropy alloy (MEA) was developed via laser powder bed fusion (LPBF) using pre-alloyed powder feedstock containing 0.75 at%C, followed by a precipitation heat treatment. The as-built alloy exhibited high density (>99.9%), columnar grains, fine substructures, and strong <111> texture. Heat treatment at 700 °C for 1 h promoted the precipitation of Cr-rich carbides (Cr₂₃C₆) along grain and substructure boundaries, which stabilized the microstructure through Zener pinning and the consumption of carbon from the matrix. The heat-treated alloy achieved excellent cryogenic tensile properties at 77 K, with a yield strength of 1230 MPa and an ultimate tensile strength of 1.6 GPa. Compared to previously reported LPBF-built NiCoCr-based MEAs, this alloy exhibited superior strength at both room and cryogenic temperatures, indicating its potential for structural applications in extreme environments. Deformation mechanisms at cryogenic temperature revealed abundant deformation twinning, stacking faults, and strong dislocation–precipitate interactions. These features contributed to dislocation locking, resulting in a work hardening rate higher than that observed at room temperature. This study demonstrates that carbon addition and heat treatment can effectively tune the stacking fault energy and stabilize substructures, leading to enhanced cryogenic mechanical performance of LPBF-built NiCoCr MEAs. Full article

This study systematically investigates 50 μm-diameter 631 stainless steel fine wires subjected to both sequential and simultaneous electrothermomechanical loading to simulate probe spring conditions in microelectronic test environments. Under cyclic current loading (~10⁴ A/cm²), the 50 μm 631SS wire maintained electrical integrity up to 0.30 A for 15,000 cycles. Above 0.35 A, rapid oxide growth and abnormal grain coarsening resulted in surface embrittlement and mechanical degradation. Current-assisted tensile testing revealed a transition from recovery-dominated behavior at ≤0.20 A to significant thermal softening and ductility loss at ≥0.25 A, corresponding to a threshold temperature of approximately 200 °C. These results establish the endurance limit of 631 stainless steel wire under coupled thermal–mechanical–electrical stress and clarify the roles of Joule heating, oxidation, and microstructural evolution in electrical fatigue resistance. A degradation map is proposed to inform design margins and operational constraints for fatigue-tolerant, electrically stable interconnects in high-reliability probe spring applications. Full article

This study systematically investigates the homogenization-induced Laves phase dissolution kinetics and recrystallization mechanisms in laser powder bed fusion (L-PBF) processed IN718 superalloy. The as-built material exhibits a characteristic fine dendritic microstructure with interdendritic Laves phase segregation and high dislocation density, featuring directional sub-grain boundaries aligned with the build direction. Laves phase dissolution demonstrates dual-stage kinetics: initial rapid dissolution (0–15 min) governed by bulk atomic diffusion, followed by interface reaction-controlled deceleration (15–60 min) after 1 h at 1150 °C. Complete dissolution of the Laves phase is achieved after 3.7 h at 1150 °C. Recrystallization initiates preferentially at serrated grain boundaries through boundary bulging mechanisms, driven by localized orientation gradients and stored energy differentials. Grain growth kinetics obey a fourth-power time dependence, confirming Ostwald ripening-controlled boundary migration via grain boundary diffusion. Such a study is expected to be helpful in understanding the microstructural development of L-PBF-built IN718 under heat treatments. Full article

Understanding the limitations of cold-formed aluminum alloys in practice applications is essential, particularly due to the risk of substructural changes and a reduction in strength when exposed to elevated temperatures. In this study, the thermal stability of the ultra-fine-grained (UFG) structure formed by equal channel angular pressing (ECAP) at room temperature and the mechanical properties of the AlSi7MgCu0.5 alloy were investigated. Prior to ECAP, the plasticity of the as-cast alloy was enhanced by a heat treatment consisting of solution annealing, quenching, and artificial aging to achieve an overaged state. Four repetitive passes via ECAP route A resulted in the homogenization of eutectic Si particles within the α-solid solution, the formation of ultra-fine grains and/or subgrains with high dislocation density, and a significant improvement in alloy strength due to strain hardening. The main objective of this work was to assess the microstructural and mechanical stability of the alloy after post-ECAP annealing in the temperature range of 373–573 K. The UFG microstructure was found to be thermally stable up to 523 K, above which notable grain and/or subgrain coarsening occurred as a result of discontinuous recrystallization of the solid solution. Mechanical properties remained stable up to 423 K; above this temperature, a considerable decrease in strength and a simultaneous increase in ductility were observed. Synchrotron radiation X-ray diffraction (XRD) was employed to analyze the phase composition and crystallographic characteristics, while transmission electron microscopy (TEM) was used to investigate substructural evolution. Mechanical properties were evaluated through tensile testing, impact toughness testing, and hardness measurements. Full article

The development of technology has driven a rising need for high-accuracy and high-efficiency manufacturing of low-volume products. Incremental forming technology, characterized by die-free flexibility and low production costs, can effectively replace stamping processes for manufacturing customized small-batch products. However, high-performance aluminum alloys generally exhibit poor room-temperature plasticity but excellent high-temperature plasticity, necessitating the integration of thermal-assisted methods for manufacturing such products. However, the temperature of the forming region will excessively rise without temperature control, which will affect the forming performance of the material in hot incremental sheet forming of AA2024-T4 aluminum alloy. This study focuses on AA2024-T4 aluminum alloy and proposes a uniform temperature control method for the electric hot tube-assisted incremental sheet forming process, incorporating an adaptive fuzzy PID algorithm. The temperature difference of the forming region is lower than 6% under the various temperatures. On this basis, the forming limit angle and the microstructure state of the material are analyzed, and the grain feature of the material exhibits significantly refined grains and the uniform fine grain distribution under 180 °C with the temperature control of the adaptive fuzzy PID algorithm. Full article

Ultra-fine-grained bainitic (UFGB) steels offer excellent mechanical properties, which can be further improved by applying diamond-like carbon (DLC) coatings. However, poor adhesion between the coating and substrate remains a key limitation. Since the steel’s microstructure degrades at high temperatures, enhancing adhesion without heating the substrate is essential. This study investigates surface hardening combined with simultaneous nitrogen and hydrogen doping during the Radio Frequency Chemical Vapor Deposition (RFCVD) process to improve coating performance. Varying gas compositions were tested to assess their effects on coating properties. Nitrogen incorporation decreased hardness from 12 GPa to 9 GPa but improved adhesion, while hydrogen limited damage after coating failure. Optimizing the gas mixture led to enhanced adhesion and wear resistance. Raman and X-ray photoelectron spectroscopy (XPS) analyses confirmed that the optimized coatings had the highest sp³ bond content and elevated nitrogen levels. While both hardness and adhesion contributed to wear resistance, no direct link to coating thickness was found. Overall, co-doping with nitrogen and hydrogen is an effective approach to improve adhesion and wear resistance without requiring high processing temperatures or complex equipment. Full article

This work investigates on how Fe incorporation influences the surface, microstructural, and optical properties of solution precursor plasma-sprayed TiO₂ coatings. The Fe-TiO₂ coatings were prepared using titanium isopropoxide and iron acetylacetonate as precursors, with ethanol as the solvent. X-ray diffraction analysis revealed the existence of both anatase and rutile TiO₂ phases, with a predominant rutile phase, also confirmed by Raman spectroscopy. There was an increase in the anatase crystals upon the addition of Fe ions. A longer spray distance further enhanced the anatase content and reduced the average TiO₂ crystallite sizes present in the Fe-added coatings. SEM cross-sectional images displayed finely grained, densely packed deposits in the Fe-added coatings. UV-Vis spectroscopy showed visible-light absorption by the Fe-TiO₂ coatings, with reduced band gap energies ranging from 2.846 ± 0.002 eV to 2.936 ± 0.003 eV. Photoluminescence analysis showed reduced emission intensity at 356 nm (3.48 eV) for the Fe-TiO₂ coatings. These findings confirm solution precursor plasma spray to be an effective method for developing Fe-TiO₂ coatings with potential application as visible-light-active photocatalysts. Full article

The existing studies mainly focus on the coarse-grained heat-affected zone and the inter-critically reheated coarse-grained heat-affected zone, while the studies on other sub-zones are relatively low. Meanwhile, the studies on the Cr element in steel mainly focus on the influence of the Cr element on strength and hardness; however, its mechanism is not very clear. Therefore, three kinds of X80 experimental steels with different Cr contents (0 wt.%, 0.13 wt.%, and 0.40 wt.%) were designed in this paper. The thermal simulation experiments on the supercritically coarse-grained heat-affected zone (SCCGHAZ) were carried out using a Gleeble-3500 thermal simulator. The effects of Cr on the microstructure and toughness of SCCGHAZ were systematically investigated through Charpy impact tests and microstructural characterization techniques. The results indicate that the microstructures of the three Cr-containing X80 experimental steels in SCCGHAZ are predominantly composed of fine granular bainite. However, impact tests at −10 °C show that the SCCGHAZs of 0 wt.% and 0.13 wt.% Cr steel exhibit higher impact energy, while that of the 0.40 wt.% Cr steel demonstrates significantly reduced energy impact (<100 J). Microstructural characterization reveals that the impact toughness of the SCCGHAZ in X80 steel is correlated with microstructural features, including effective grain size, grain boundary angles, and the volume fraction and shape of martensite–austenite (M-A) constituents. Among these factors, the volume fraction of M-A constituents substantially influences toughness. It was found that island-shaped M-A constituents inhibit crack propagation, whereas blocky M-A constituents impair toughness. Full article

The microstructure and mechanical properties of welded joints of API 5L X-52 steel plates cladded with AISI 316L-Si austenitic stainless steel were evaluated. The gas metal arc welding process with pulsed arc (GMAW-P) and controlled arc oscillation were used to join the bimetallic plates. After the root welding pass, buttering with an ERNiCrMo-3 filler wire was performed and multi-pass welding followed using an ER70S-6 electrode. The results obtained by optical and scanning electron microscopy indicated that the shielding atmosphere, welding parameters, and electric arc oscillation enabled good arc stability and proper molten metal transfer from the filler wire to the sidewalls of the joint during welding. Vickers microhardness (HV) and tensile tests were performed for correlating microstructural and mechanical properties. The mixture of ERNiCrMo-3 and ER70S-6 filler materials presented fine interlocked grains with a honeycomb network shape of the Ni–Fe mixture with Ni-rich grain boundaries and a cellular-dendritic and equiaxed solidification. Variation of microhardness at the weld metal (WM) in the middle zone of the bimetallic welded joints (BWJ) is associated with the manipulation of the welding parameters, promoting precipitation of carbides in the austenitic matrix and formation of martensite during solidification of the weld pool and cooling of the WM. The BWJ exhibited a mechanical strength of 380 and 520 MPa for the yield stress and ultimate tensile strength, respectively. These values are close to those of the as-received API 5L X-52 steel. Full article