Search Results (9)

The investment casting process, also known as lost-wax casting, is widely used for producing ferrous and non-ferrous metal parts due to its excellent surface finish and dimensional accuracy. In recent years, the use of Co-Cr-Mo alloy has increased due to its high corrosion resistance, good biocompatibility, and relatively high wear resistance. Laser melting of materials has been demonstrated to refine the surface grain structure, reduce surface roughness, and improve both wear and corrosion resistance. The ability to fine-tune parameters such as laser power density and scanning speed facilitates the optimization of the treated layers’ thickness and homogeneity, thereby addressing many of the shortcomings inherent in conventional methods. This study investigates the microstructural, mechanical wear and bioactive behavior of investment-cast Co-Cr-Mo parts subjected to a Nd:YAG laser surface treatment. The effects of different processing parameters were analyzed quantitatively and comprehensively. The specimens were characterized using metallographic techniques, bioactivity evaluation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), wear testing (Pin-on-Disk), and hardness testing. Our results demonstrate that Nd:YAG laser melting significantly enhances the surface properties and maintains the dimensional accuracy of complex Co-Cr-Mo biomedical components, through microstructural refinement, increased hardness, improved wear resistance, and preserved biocompatibility. The specific combination of investment casting with precisely controlled laser surface modification represents a significant advancement for improving the longevity and performance of biomedical implants. Full article

Coating welding with cobalt alloys on pipelines is crucial for the offshore industry due to its exceptional resistance to corrosion and wear. In this paper, two welding conditions with different currents were proposed to observe the behavior of the dissimilar joint. The microstructure, mechanical properties, and dilution of a dissimilar material consisting of AISI 4130 steel substrate coated with Stellite 6 alloy were analyzed. Firstly, samples were metallographically prepared for the evaluation of the weld bead and the coating phases using SEM, EDS, and XRD analyses. Then, microstructural characterization was performed qualitatively using confocal microscopy and quantitatively to determine the phase fraction volumes in the dendritic and interdendritic regions, as well as the resulting dilution. Results revealed that varying welding conditions did not significantly affect the hardness of the coatings, which remained within the alloy standard of 36-45 HRC, with microhardness varying by 3%–5% from one condition to another and phase fraction volume showing a variation of 5.6% between welding conditions. On the other hand, experimental results indicated a clear effect of welding current variation on dilution values, with 4.6% for condition 1 and 16.7% for condition 2, allowing for direct proportional relationships to be established, i.e., higher deposition current results in greater dilution. Full article

As a detection tool to identify metal or alloy, metallographic quantitative analysis has received increasing attention for its ability to evaluate quality control and reveal mechanical properties. The detection procedure is mainly operated manually to locate and characterize the constitution in metallographic images. The automatic detection is still a challenge even with the emergence of several excellent models. Benefiting from the development of deep learning, with regard to two different metallurgical structural steel image datasets, we propose two attention-aware deep neural networks, Modified Attention U-Net (MAUNet) and Self-adaptive Attention-aware Soft Anchor-Point Detector (SASAPD), to identify structures and evaluate their performance. Specifically, in the case of analyzing single-phase metallographic image, MAUNet investigates the difference between low-frequency and high-frequency and prevents duplication of low-resolution information in skip connection used in an U-Net like structure, and incorporates spatial-channel attention module with the decoder to enhance interpretability of features. In the case of analyzing multi-phase metallographic image, SASAPD explores and ranks the importance of anchor points, forming soft-weighted samples in subsequent loss design, and self-adaptively evaluates the contributions of attention-aware pyramid features to assist in detecting elements in different sizes. Extensive experiments on the above two datasets demonstrate the superiority and effectiveness of our two deep neural networks compared to state-of-the-art models on different metrics. Full article

Experimental series of alloys for (Sm,Zr)(Co,Cu,Fe)_Z permanent magnets are presented in the concentration ranges that provide wide variations of (4f)/(4d)/(3d) ratios of comprising elements. Optical metallographic analysis, observation of the surface domain structure upon magnetization reversal (Kerr effect), electron microprobe analysis, and measuring the major hysteresis loops of samples at different stages of heat treatment are used to study processes related to the development of the highly coercive state of these samples. It was found that the volume fractions of two main structural components A and B, which comprise 90% of the total sample volume, rigorously control the coercivity at all stages of thermal aging. At the same time, structural components A and B themselves in samples being in the high-coercivity state differ qualitatively and quantitatively in the chemical composition, domain structure and its development in external magnetic fields and, therefore, are characterized by different morphologies of the phases comprising the structural components. Two stages of phase transformations in the sample structure are observed. During isothermal annealing, the cellular structure develops within the B component, whereas, during stepwise (slow) cooling or quenching from the isothermal aging temperature to 400 °C, a phase structure evolves within both the cell boundaries in B and the structural component A. The degree of completion of the phase transformations within micro- and nano-volumes of the components determines the ultimate hysteretic characteristics of the material. Full article

Friction stir welding (FSW) has become an up-and-coming joining method with a wide range of industrial applications. Besides the unique weld seam properties, recent investigations have focused on the process-related tool wear of shoulder and probe, which can have detrimental economic and technological effects. This paper presents a systematic quantitative characterization of FSW tool wear using stripe light projection as a novel method to detect weight and form deviations of shoulder and probe. The investigations were carried out with a robotic welding setup in which AA-6060 T66 sheets, with a thickness of 8 mm, were joined by weld seams up to a total length of 80 m. During the experimental tests, geometrical deviations of the tool induced by wear were detected for varying weld seam lengths and different measuring points on the probe and shoulder. It was shown that wear depended on welding length which in turn caused significant deviations and weight losses on shoulder and probe. Furthermore, it was demonstrated that the wear on shoulder and probe can be considered separately. It was found that there is a progressive wear rate on the shoulder and a degressive wear rate on the probe depending on the weld seam length. To demonstrate the negative impact of tool wear on shoulder and probe after 80 m weld seam length, visual and metallographic inspections and tensile tests were carried out to detect resultant irregularities in the weld seam. Full article

Tube/Pipe (TP) 304 stainless steel has been widely used in industry, but a change in its microstructures may endanger its service safety, and it is essential to evaluate its microstructural evolution. In this work, a pulse-echo nonlinear method is proposed to characterize the microstructural evolution of the TP304 stainless steel. The detailed pulse-echo nonlinear experimental process is presented, and it is shown that the absolute nonlinear parameter can be determined when the effect of attenuation is taken into account. The microstructural evolution of TP304 stainless steel is artificially controlled by annealing treatments before it is evaluated by using nonlinear ultrasonic method and metallographic method. The results show that the grain sizes increase as the annealing time increases, which leads to the performance degradation of the TP304 steel and an increase in the nonlinear parameters, with the reason discussed considering the variation in the microstructure. The present pulse-echo nonlinear method is easier to conduct than the traditional transmission-through method and the absolute nonlinear parameter can be determined for quantitative characterization. The variation in determined nonlinear parameters provides a reference to evaluate the microstructural evolution of TP304 stainless steel. Full article

In this work, iron oxide nanoparticle loaded carbon fibers were prepared by electrohydrodynamic co-casting a polymer and particle mixture followed by carbonization. The precursor used to generate carbon fibers was a linear molecular chain polymer: polyacrylonitrile (PAN). A solution containing iron (II, III) oxide (Fe₃O₄) particles and the PAN polymer dissolved in dimethylformamide (DMF) was electrohydrodynamically co-cast into fibers. The fibers were stabilized in air and carbonized in hydrogen at elevated temperatures. The microstructure and composition of the fibers were analyzed using scanning electron microscopy (SEM). A quantitative metallographic analysis method was used to determine the fiber size. It was found that the iron (II, III) oxide particles distributed uniformly within the carbonized fibers. Photosensitivity of the particle containing fibers was characterized through measuring the open circuit potential of the fiber samples under the visible light illumination. Potential applications of the fibers for photovoltaics and photonic sensing were discussed. Full article

Extrudability of aluminum alloys of the 6xxx series is highly dependent on the microstructure of the homogenized billets. It is therefore very important to characterize quantitatively the state of homogenization of the as-cast billets. The quantification of the homogenization state was based on the measurement of specific microstructural indices, which describe the size and shape of the intermetallics and indicate the state of homogenization. The indices evaluated were the following: aspect ratio (AR), which is the ratio of the maximum to the minimum diameter of the particles, feret (F), which is the maximum caliper length, and circularity (C), which is a measure of how closely a particle resembles a circle in a 2D metallographic section. The method included extensive metallographic work and the measurement of a large number of particles, including a statistical analysis, in order to investigate the effect of homogenization time. Among the indices examined, the circularity index exhibited the most consistent variation with homogenization time. The lowest value of the circularity index coincided with the metallographic observation for necklace formation. Shorter homogenization times resulted in intermediate homogenization stages involving rounding of edges or particle pinching. The results indicated that the index-based quantification of the homogenization state could provide a credible method for the selection of homogenization process parameters towards enhanced extrudability. Full article

6063 aluminum anodized extrusions may exhibit a common surface defect known as streaking, characterized by the formation of narrow bands with a surface gloss different from the surrounding material. The origin of this banding lies in the differential surface topography produced after etching during the anodizing stage, shown to be connected to certain microstructural characteristics. The present study has attempted to determine the origin of these defects and measure the mechanical properties in these zones, properties which were either barely acceptable or did not meet the specification’s requirements. Quantitative metallography and mechanical testing, both tensile and microhardness, were used for materials assessment at the different steps of the process of manufacturing 6063 anodized extrusions. The results of this research show that nonequilibrium solidification rates during billet casting could lead to the formation of coarse eutectic Mg₂Si particles which have a deleterious effect on both mechanical properties and surface appearance in the anodized condition. However, differences in the size and density of the coarse Mg₂Si particles have been found to exist in the streak profile compared to the surrounding zones. The study revealed the importance of these particles in explaining the origin of the marginal or sub-marginal properties and anodizing surface defects found. Full article