Search Results (688)

In this study, the effects of friction stir welding (FSW) parameters on the mechanical properties and formability of pre-hardened (PH) 2219 aluminum alloy welds were systematically investigated through tensile testing and Erichsen tests. Energy dispersive spectrometry (EDS), electron back scatter diffraction (EBSD), and a transmission electron microscope (TEM) were employed to characterize the microstructure of the PH alloy weld joints, revealing the strength–ductility synergy mechanism of the PH welded sheets. Experimental results indicated that with respect to mechanical properties, when the welding rotational speed was fixed at 1000 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the ultimate tensile strength (UTS) by 6.3% and decreased the EL by 21.4%. When the forward speed was fixed at 50 mm/min, increasing the rotational speed from 500 rpm to 1500 rpm resulted in only a 0.4% variation in UTS and maintained a stable EL, demonstrating that forward speed is the dominant parameter affecting mechanical properties. In terms of formability, at a lower forward speed (50 mm/min), the Erichsen value exhibited a single-peak trend with increasing rotational speeds. At higher forward speeds (100 or 150 mm/min), the Erichsen value was insensitive to changes in rotational speed. When the rotational speed was fixed at 1500 rpm, increasing the forward speed from 50 mm/min to 150 mm/min reduced the Erichsen value by 21.3%. Microstructural strengthening mechanism: In the weld zone, the cooperative precipitation of the θ″ and θ′ phases effectively hindered dislocation motion. Simultaneously, the high geometric compatibility factor promoted the activation of multiple slip systems, and dislocation rearrangement subsequently led to the formation of sub-grain boundaries, thereby achieving strength–ductility cooperation. These findings provide theoretical support for the performance-driven welding process design of high-strength aluminum alloy components in aerospace applications. Full article

Aluminum alloys, particularly those in the Al-Cu and Al-Mg-Si series, are extensively employed in aerospace, automotive, and structural applications owing to their favorable strength-to-weight ratio. However, optimizing their mechanical and surface properties to meet advanced performance requirements remains a critical challenge. Over the past three decades, extensive research has explored thermochemical treatments, precipitation hardening, and thermomechanical processing, yet most studies have examined these methods in isolation. This review systematically analyzes the influence of each treatment route on microstructural evolution, precipitation behavior, and mechanical performance, with emphasis on grain refinement, precipitation kinetics, surface hardening, and fatigue resistance. Particular attention is given to severe plastic deformation, advanced surface modification techniques, and aging behavior under different conditions. The review also highlights gaps in the current literature, including limited integration of hybrid treatment cycles, insufficient understanding of coupled diffusion-precipitation mechanisms, a lack of high-temperature performance data, and minimal industrial-scale validation. Future research directions are proposed to develop optimized hybrid processing strategies, predictive computational models, and scalable treatment cycles. This consolidated review provides a comprehensive foundation for advancing aluminum alloy design, aiming to achieve tailored surface-to-core property gradients suitable for next-generation aerospace and automotive applications. Full article

This study presents research on optimizing the parameters of the passivation process for precipitation-hardening stainless steels (PHSS) to improve the corrosion resistance of AM350 and CUSTOM 450 alloys, which are extensively utilized in the aerospace and aviation sectors, since, as this is a complex process, it requires the implementation of a robust methodological approach that allows for multi-response optimization. Experiments were designed using the Taguchi method, which offered a strong framework for examining the impact of material, type of passivation solution, concentration, temperature, and passivation process time on the corrosion resistance of both PHSS alloys. To confirm the ideal PHSS passivation process parameters and measure the significance of each component, gray relational analysis (GRA) and analysis of variance (ANOVA) were also employed. The combined use of the Taguchi/GRA represents a robust and efficient methodological approach to the multi-response optimization of complex processes, overcoming the limitations inherent in the individual application of each technique. It was determined that the optimized parameters were a PHSS AM 350, a solution composed of a combination of citric acid and oxalic acid, acid concentration of 25% v/v, temperature of 50 °C, and time of 120 min. This combination of parameters resulted in significant improvements of up to 55% in corrosion resistance in the H₂SO₄ and NaCl evaluation solutions, demonstrating the effectiveness of the optimized conditions. This work emphasizes the efficacy of integrating Taguchi, GRA, and ANOVA techniques to significantly reduce the corrosion rate of PHSS undergoing the passivation process using alternatives to nitric acid. The integration of the Taguchi methodology with GRA enables the normalization and combination of responses with different scales and performance criteria into a single gray relational index, facilitating the overall evaluation of the system. Full article

The precipitation characteristics and grain-boundary structure of Al–Cu–Mg alloys strongly affect their corrosion behavior, whereas the roles of Si and Ag microalloying in low Cu/Mg ratio systems are not yet fully understood. In this work, the effects of Si and Ag additions on age-hardening response, precipitation characteristics, and corrosion performance were systematically investigated by combining transmission electron microscopy with electrochemical and corrosion measurements. Si addition significantly accelerated the age-hardening kinetics, enabling the alloy to reach a hardness of 147 HV after only 6 h of aging, whereas the base alloy required 24 h to reach a similar level. This accelerated response was accompanied by refined S-phase precipitation and a markedly narrowed precipitation-free zone along grain boundaries. Further Ag addition introduced coherent Ω precipitates and a more complex multi-phase precipitation structure, which increased microstructural heterogeneity. As a result, the Al–Cu–Mg–Si alloy exhibited the lowest corrosion current density and the shallowest corrosion depth, whereas the Al–Cu–Mg–Si–Ag alloy showed deteriorated corrosion resistance. These results indicate that Si microalloying alone can simultaneously accelerate aging and improve corrosion resistance, while further Ag addition enhances precipitation complexity and strengthening potential but increases susceptibility to localized corrosion. Full article

Friction stir welding (FSW) of dissimilar aluminium alloys often results in non-uniform microstructure and hardness distributions due to asymmetric temperature fields and material flow. The objective of this study is to establish a quantitative relationship between thermal history, microstructural evolution, and hardness distribution in dissimilar AA5052-H32/AA6061-T6 FSW joints by combining experimental characterisation with validated thermal modelling. AA5052-H32 and AA6061-T6 plates were welded under five different parameter sets. A thermal finite element model was developed in COMSOL Multiphysics to simulate temperature evolution during welding and was validated using embedded thermocouple measurements, with predicted peak temperatures ranging from 455 °C to 641 °C. Optical microscopy, scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to characterise grain structure and dynamic recrystallisation (DRX) behaviour, while Vickers microhardness mapping was used to evaluate the local mechanical response. The results show that DRX occurred in the nugget zone (NZ), leading to significant grain refinement, with a minimum grain diameter of 6.07 µm, representing an approximately eightfold reduction compared with the base material AA5052-H32. In contrast, the thermo-mechanically affected zone (TMAZ) experienced limited recrystallisation due to insufficient plastic deformation and temperature. The lowest hardness was observed in the TMAZ on the AA5052-H32 side, with the hardness reduction of 22% primarily caused by work hardening loss. Hardness was also reduced by 34% on the AA6061-T6 side due to decreased precipitation strengthening caused by high temperatures. This combined experimental–numerical study provides a systematic thermal–microstructure–hardness framework for understanding and predicting local property variations in dissimilar FSW joints. Full article

The trade-off between strength and ductility remains a pivotal challenge in the development of multi-principal element alloys (MPEAs) for structural applications. Here, we report a dual-scale ordering strategy to achieve triple strengthening in a Ni-26.6Co-18.4Cr-5.4Nb-4.1Mo-2.3Al-0.3Ti-0.05Y (wt.%) MPEA through the synergistic interplay of L1₂ nanoprecipitates and local chemical order (LCO). The alloy was processed via cold rolling followed by aging at 750 °C for 8 h, resulting in a high density of coherent L1₂ precipitates (average size 47 ± 1 nm, volume fraction ~27%) with an ultra-low lattice misfit of 0.5%. Additionally, sub-nanoscale LCO domains with an average diameter of 0.62 nm were identified within the face-centered cubic matrix. This hierarchical microstructure yields an exceptional combination of mechanical properties at room temperature: yield strength of 1480 ± 6 MPa, ultimate tensile strength of 1678 ± 10 MPa, and a total elongation of 13.9 ± 0.2%. Quantitative strengthening analysis reveals that precipitation strengthening (697 MPa) is the dominant contributor, followed by dislocation strengthening (397 MPa). Transmission electron microscopy characterization of deformed samples reveals that the low stacking fault energy, promoted by LCO, facilitates the dissociation of perfect dislocations and the formation of extensive stacking faults. The intersection of stacking faults on different {111} planes generates a large number of Lomer–Cottrell locks, which significantly enhance work hardening and delay plastic instability. The findings demonstrate that engineering dual-scale ordered structures offers a promising pathway for developing MPEAs with a superior strength-ductility combination. Full article

A systematic study was conducted on the influence of Cr on the property evolution and precipitation behavior of Cu-Ni-Si alloys. Results indicate that Cu-Ni-Si alloys containing 0.33 at% Cr exhibit superior mechanical properties after three-stage cryogenic rolling and aging, achieving a tensile strength of up to 862 MPa. The addition of Cr induces competitive precipitation behavior between Cr and Ni for Si. It promotes the precipitation of Cr₃Si phases at various scales while suppressing the formation of Ni₃Si phases. Concurrently, it enhances the precipitation of fine nanoscale precipitation-hardening phases Ni₂Si, optimizing the alloy’s precipitation hardening effect. Furthermore, the addition of Cr suppresses dislocation annihilation. The formation of finer precipitates pins the dislocations introduced during cryogenic rolling and impedes their motion, thereby enhancing the alloy’s strength and hardness. The alternating and staggered distribution of soft and hard microzones in the Cr-containing alloy results in more uniform overall properties of the sample. However, the reduced proportion of soft microzones slightly decreases the alloy’s electrical conductivity. Full article

Magnesium phosphate cement (MPC) is a type of rapid-hardening inorganic cementitious material, which has important application value in rapid road repair, solidification of hazardous and radioactive waste, and other fields. However, it suffers from excessively fast setting and hardening and a short working time retention, which severely restrict its engineering application. Therefore, the development of high-efficiency set retarders is of great significance for optimizing MPC performance, enhancing its construction workability, and expanding its application scope. In this study, the effect of sodium polyacrylate (PAAS) on the setting and hardening of magnesium potassium phosphate cement (MKPC) was investigated by testing the setting time and fluidity at a low water-to-solid ratio (W/S = 0.18). Through pH and electrical conductivity measurements, combined with XRD, TG/DTG, and FTIR characterizations, we elucidated the retarding mechanism of PAAS on MKPC using a high water-to-solid ratio (W/S = 10). The results indicate that the setting time of MKPC is positively correlated with the PAAS dosage, whereas the fluidity and compressive strength exhibited a negative correlation with the PAAS dosage. Additionally, PAAS reduces the total heat release and the heat release rate of MKPC. The addition of PAAS increased the pH of the suspension, thereby reducing the solubility of MgO, but did not inhibit the dissolution of KH₂PO₄. The carboxylate groups in PAAS chemically reacted with Mg²⁺ on the surface of MgO to form magnesium carboxylate complexes (Mg-PAA), which remained as precipitates in the MKPC suspension system, thus reducing the amount of available Mg²⁺ participating in the hydration reaction. Furthermore, PAAS had no effect on the final precipitate composition at the end of hydration, which was composed of MgKPO₄·6H₂O and Mg₃(PO₄)₂·22H₂O in all cases. Full article

The influence of pre-deformation on the microstructure and mechanical properties of a Mg-rich high-Cu Al-Mg-Si-Cu alloy was systematically investigated by hardness measurement, tensile test, and atomic resolution high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM). With the increase in pre-deformation strain (0–10%), the hardness and strength of the alloy after PB hardening increased progressively, accompanied by a continuous reduction in tensile elongation. Notably, increasing pre-deformation strain from 2% to 10% did not bring a significant enhancement in bake hardening response, despite the gradual improvement in the strain hardening capability of the alloy. An optimal pre-deformation strain of 5% is identified, which enabled the alloy to achieve a superior and industrially feasible combination of strength and ductility, balancing practical forming demand (T4 temper) and service performance (PB state). Pre-deformation can significantly affect the morphology and atomic structure of precipitates for the alloy. Dislocations introduced by pre-deformation acted as heterogeneous nucleation sites, inducing the formation of elongated and string-like precipitates along dislocation lines. A distinct Cu segregation behavior was observed in the pre-deformed alloy with the majority of Cu atoms segregated at the precipitate/α-Al interface, which was in sharp contrast to their dominant distribution within the precipitate interior in the non-pre-deformed alloy. These findings provide new insights into deformation-assisted precipitation regulation in Mg-rich high-Cu Al-Mg-Si-Cu alloys and offer practical guidance for optimizing the strength–ductility synergy of such alloys for automotive lightweight manufacturing applications. Full article

The influence of minute-scale preaging (MSP) at 200 °C on the microstructures and formability of 2195-T34 Al-Li alloy in the creep-aging (CA) process was systematically investigated. The elongation of the alloy before CA first increased and then decreased with MSP time (2 to 15 min), reaching a maximum of 17.86% at 5 min; the yield ratio exhibited the opposite trend, attaining a minimum of 65.55% at 5 min. When the true strain was greater than 1.4%, the strain hardening rate of the samples after MSP treatment for less than 8 min was similar to and higher than that of the samples preaged for 15 min. Compared with the non-preaged specimens, the ultimate creep deformation of samples preaged for less than 8 min was improved, reaching a maximum improvement of 29.5% at 5 min. Simultaneously, the peak aging was retarded without reducing the final peak strength (T6 level), thereby broadening the formability window. HAADF-STEM observations revealed that MSP for 5 min markedly reduces the density of G.P. zones, which delays T₁ precipitation and reduces the resistance to dislocation motion. When the preaging time was less than 8 min, the number of movable dislocations increased. However, exceeding 8 min led to obvious precipitation of the T₁ phase, reducing the plasticity of AA2195-T34 sheets. Full article

This study addresses the challenge of through-hole defects in ZM6 cast magnesium alloy components by proposing an innovative repair strategy using ultrasonic-assisted Tungsten Inert Gas (U-TIG) welding. The microstructure and mechanical properties of the repaired joint were systematically characterized through optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), and room-temperature tensile testing. The results indicate that, assisted by the ultrasonic energy field, the repair zone successfully reconstitutes a typical and optimized triple-phase microstructure: (1) the matrix: α-Mg solid solution (dark gray), supersaturated with Nd and Zr; (2) the strengthening phase: a eutectic Mg₁₂Nd phase (light gray), rich in Nd, distributed along grain boundaries acting as the primary strengthening component; (3) the grain refiner: dispersed Zr-rich particles (bright white spots), which effectively pin grain boundaries. Crucially, the application of ultrasound significantly refined the α-Mg grains and transformed the continuous network of the Mg₁₂Nd phase into a more fragmented and uniform dispersion. This refined microstructure synergistically integrates the strengthening mechanisms of solid solution, precipitation hardening, and grain refinement. Consequently, the repaired joint exhibits excellent mechanical properties, achieving over 90% of the base metal’s tensile strength and elongation at room temperature. This work not only validates the feasibility of U-TIG welding for repairing ZM6 alloys but also provides a solid theoretical foundation and a promising technical pathway for the in-service repair and remanufacturing of high-performance magnesium alloy components. Full article

This study investigates the solution and artificial aging processes of TiB₂/7050 composites. Using microscopic and mechanical tests, we systematically evaluate the material’s microstructural evolution and mechanical performance, aiming to optimize heat treatment parameters. The study shows that a solution temperature of 475 °C for 1 h is optimal for fully dissolving the second-phase particles. Regarding artificial aging, peak hardness of 246 HV is achieved at 140 °C for 16 h. Analysis of the phases and microstructure in O and T6-states shows that strengthening occurs through grain boundary hardening and precipitation hardening. The effect of TiB₂ particles on the above process was also explored. During solidification, TiB₂ particles were pushed by the advancing solid–liquid interface and primarily distributed along grain boundaries. This distribution subsequently slowed the solid solution process by reducing the contact area between the η(MgZn₂) phase and the α(Al) matrix. During aging, they enhance grain boundary precipitates (GBPs) in particle-rich regions and inhibit the formation of precipitate-free zones (PFZs), with a concentration of the η’ phase forming around the particles. Beyond a certain distance from the particles, there is a decrease in η’ phase concentration. This study is expected to contribute to advanced lightweight materials research and development, opening up new opportunities for their application in various industries. Full article

The formation of hard/brittle layers (HBLs) forming in proximity to the transition-layer interface during the welding process of stainless steel clad plates constitutes a pivotal element in determining the limitations on joint homogeneity and toughness. In order to elucidate their formation mechanisms and develop viable suppression routes, S31603/Q420qENH clad plates were utilised to fabricate five butt joints. This was achieved by varying the carbon content of the welding consumables and the heat input in the transition layer. A programme was conducted that combined microstructural and microhardness characterisation, mechanical testing, and numerical welding simulations. The findings indicate that base-layer consumables with comparatively elevated carbon content (w(C) ≥ 0.06%) expeditiously engender a constricted, localised hardened band in close proximity to the transition-layer interface. This is characterised by the predominance of martensite and Cr-rich compounds of the M_xCr_y type, which function as the principal genesis of bending cracks. Conversely, the utilisation of low-carbon welding consumables has been shown to markedly reduce interfacial carbon activity and C-Cr segregation, thereby suppressing the precipitation of M_xCr_y phases and effectively decreasing the overall thickness of the HBLs. Further numerical analysis shows that moderately increasing the transition-layer heat input lowers the T_8/5 cooling rate and shifts the cooling path away from the martensite region. This transforms the interfacial microstructure from a localised hardened band into a more uniform, graded structure. These findings provide an engineerable process-control strategy for enhancing both microstructural uniformity and toughness in stainless steel clad joints. Full article

This study systematically investigates the influence of annealing time on the microstructure and mechanical properties of a (CoCrNi)_93.5Al₃Ti₃C_0.5 medium-entropy alloy. Following hot-rolling, the alloy was subjected to annealing treatments at 900 °C for 10 min (HA900-10) and 60 min (HA900-60). Microstructural characterization revealed that both alloys contained three types of precipitates: intergranular M₂₃C₆ and MC-type carbides, as well as γ′ phase. The HA900-10 specimen exhibited a low degree of recrystallization, whereas prolonged annealing promoted partial recrystallization, leading to the formation of a slightly heterogeneous structure (HA900-60). Additionally, the extended annealing facilitated the intragranular precipitation of nanoscale γ′ phase. Room-temperature tensile tests demonstrated that the HA900-10 and HA900-60 specimens achieved yield strengths of 1276 MPa and 1202 MPa, with total elongations reaching 26% and 28%, respectively. Quantitative strengthening analysis indicated that the strength of HA900-10 primarily originated from dislocation and grain boundary strengthening. For HA900-60, an additional significant contribution arose from the dislocation shearing mechanism induced by the intragranular γ′ precipitates. Analysis of the deformation mechanisms revealed that planar slip, assisted by the formation of stacking faults, dominated the room-temperature deformation, thereby ensuring sustained work-hardening capacity. This research provides a theoretical foundation for tailoring the microstructure and properties of multi-phase medium-entropy alloys through annealing process control. Full article

This work investigates the effect of pre-nitriding treatment before vacuum carburizing on the carburizing efficiency of 20CrMnTi steel. The results show that pre-nitrocarburizing significantly enhances the vacuum carburizing efficiency of 20CrMnTi steel, refines the microstructure of the carburized layer’s martensite, and promotes the precipitation of carbides. At the same carburized layer depth, the hardness and carbon content of the pre-nitrocarburized samples are significantly higher than those of the samples without pre-nitriding. Specifically, the effective hardening depth and surface hardness increase by approximately 0.15 mm and 75 HV, respectively. These improvements are attributed to the formation of loose and porous nanoscale nitride particles on the surface during the pre-nitrocarburizing process, which significantly increases the surface roughness and porosity. This surface morphology facilitates the adsorption and inward diffusion of carbon atoms during the carburizing process. This study provides some inspiration for pretreatment techniques to improve the efficiency of vacuum carburizing. Full article