Search Results (389)

As emergent material candidates for extreme environments, refractory high-entropy alloys (HEAs) or refractory multi-principal-element alloys (RMPEAs) comprising refractory metals feature qualities such as high radiation tolerance, corrosion resistance, and mechanical strength. A set of MoNbTi-based RMPEA samples with Al, Cr, V, and Zr additions are prepared by spark plasma sintering and investigated for their response to irradiation using 10 MeV Si⁺ ions with a dose of $1.43\times {10}^{15}$ ions/cm². Positron annihilation spectroscopy and transmission electron microscopy are employed as atomic- and meso- scale techniques to reveal how chemical complexity, nanotwinning, and phase fractions play an important role in radiation-induced defect accumulation and damage tolerance. The study provides experimental evidence of nanotwinning acting as an effective sink for radiation-induced point defects. Full article

Injection molding is widely used for mass-producing plastic components, demanding precise thermal control to optimize cycle times and part quality. Traditional CNC-machined molds limit design flexibility and restrict advanced cooling features like conformal cooling channels (CCCs). Integrating CCCs improves cooling performance, reduces cycle times, and offers more efficient, cost-effective designs. Additive manufacturing (AM), especially Metal-Fused Filament Fabrication (Metal-FFF), offers geometries unattainable by machining. While most mold research focuses on Laser Powder Bed Fusion (LPBF), the feasibility of Metal-FFF molds remains underexplored. This study presents the design, fabrication, and experimental evaluation of an injection mold produced via Metal-FFF with integrated CCCs. The process included computational design, resistance simulations, fabrication, debinding, sintering, and post-processing, followed by testing under injection molding conditions. Results show that Metal-FFF molds with CCCs boost cooling efficiency, cutting cycle times by about 30% compared to conventional molds, while offering greater design freedom and economic benefits. Nonetheless, issues such as porosity and shrinkage need further refinement to fully leverage this technology for industrial use. Full article

Fuel layered-distribution sintering (FLDS) is a technology that can effectively reduce fuel consumption and achieve a more uniform temperature distribution within the sintering bed compared to traditional iron ore sintering. In this study, the melting quality index, combined with the maximum temperature and the duration of melting temperature, are used as performance indicators to investigate the effects of coke size and oxygen content on sintering characteristics under layered fuel distribution conditions. The results indicate that increasing the oxygen content can enhance the velocity of the flame front in the sinter pot, thereby accelerating the sintering process. However, excessive oxygen content may lead to fluctuations in the quality of the sinter. Small coke sizes provide higher melting quality in the upper region of the sinter pot, while large coke sizes perform better in the lower region. For a 600 mm sintering bed layer, an oxygen enrichment time of 6 min with oxygen concentration of 27% and coke particle diameter of 2.0 mm can balance sintered ore quality, sintering time, and flame front speed, ensuring the yield of sintered ore. These findings provide an effective pathway for energy saving and emission reduction in iron ore sintering plants. Full article

The fabrication of WC-based cemented carbides faced challenges including inhomogeneous composition and grain coarsening. To solve these problems, WC–Co cemented carbides were fabricated via spark plasma sintering (SPS) using core–shell WC–Co powders prepared by an electroless plating method. The effects of sintering pressure and Co content on the microstructure and mechanical properties of the cemented carbides were investigated. The results showed that, with increasing sintering pressure, the relative density of the sintered samples was improved (98.4–99.6%) while the grains were coarsened (0.94–1.07 μm). The optimal properties (fracture toughness 11.11 MPa·m^1/2, and hardness 2100.3 HV30) were obtained when sintered with a pressure of 20 MPa. Grain coarsening at higher pressure (30 MPa) reduced the toughness of the cemented carbides. When the Co content was increased from 3 wt.% to 8 wt.%, fracture toughness was improved while the hardness of the cemented carbides was reduced, attributed to the intrinsic high toughness and low hardness of the Co phase. The WC–8 wt.% Co cemented carbides exhibited optimized synergic mechanical performance (hardness of 1874.2 HV30 and fracture toughness of 13.77 MPa·m^1/2). This work elucidated the relationship between the key sintering parameters (pressure and Co content) and the microstructure and mechanical properties of the cemented carbides. The achievements obtained provide a theoretical foundation for high-quality fabrication of the WC–Co cemented carbides. Full article

Due to the insufficient durability (wear resistance) of guides made of 50SiCr4 steel tempered to a hardness of 400 HB, 14 variants of the yarn guide manufacturing process were developed. The ring spinner yarn guides were manufactured from three types of steel, from Al99.5% and its alloys, as well as from porcelain, Al₂O₃ sinter, and WC 94% + Co 6% tungsten carbide. The unit manufacturing cost and six manufacturing quality criteria were used as evaluation criteria: four parameters of the geometric structure of the surface and the maximum surface hardness, as well as the depth of hardening of the surface layer. The presented variants were then evaluated against the seven criteria, determining a set of optimal solutions in the Pareto sense. This set consisted of 12 variants. A distance function was then used to select the best manufacturing process variant, corresponding to the smallest value of the distance function. In this study, this is the process variant for which the semi-finished product is a drawn bar ø6 mm of C45 steel tempered to a hardness of 350 HB with a glazed porcelain insert. The alternative process, with a slightly higher distance function value, is the variant with the Al₂O₃ ceramic sinter insert. Full article

Additive manufacturing (AM) has emerged as a transformative technology in dentistry, enabling the production of patient-specific dental applications with reduced costs and fabrication times. Despite the growth of applications, a consolidated understanding of current 3D printing technologies, materials, and performance in dental settings remains fragmented. Here, we perform a Systematic Literature Review (SLR) using the PRISMA protocol, retrieving 19 closely related primary studies. The evidence is synthesized across three axes: application domain, AM technology, and critical quality parameters. Dental restorations, prosthetics, crowns, and implants are the most common applications, while fused deposition modeling, stereolithography, digital light processing, selective laser sintering, and laser-directed energy deposition are the most used technologies. AM materials include polymers, metals, and emerging biomaterials. Key quality determinants include dimensional accuracy, wear and corrosion resistance, and photosensitivity. Notably, biocompatibility and cytotoxicity remain underexplored yet critical factors for ensuring long-term clinical safety. The evidence also suggests a lack of in vivo studies, insufficient tribological and microbiological testing, including limited data degradation pathways of AM materials under oral conditions. Understanding that there are disconnects between the realization of the clinical and the economic benefits of 3D printing in dentistry, future research requires standardized testing frameworks and long-term biocompatibility validation. Full article

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological parameters of the laser irradiation process are characterized, which determine the range of laser processing modes within which no oxidation and crack formation occur, and a high-quality composite with specified geometrical parameters is formed. It has been proven that composites consisting of synthetic diamond grains and a metal bond do not lose strength under the condition that the temperature during laser heating does not exceed 1600 °C and the exposure time is 0.3 s. Electron microscopy and X-ray diffractometry were used for experimental studies of the microstructure and phase composition of the sintered layers. A new design and manufacturing method for a drum-type abrasive tool with replaceable diamond inserts for grinding large-sized aircraft and shipbuilding products are proposed. Components of a laser technological complex for the implementation of the process of sintering the diamond-containing layer of the abrasive inserts of the drum have been developed. Full article

This article explores the issue of surface modification through tumbling and vaporisation of 3D-printed materials, and its impact on the electrolytic deposition of metal coatings on previously non-conductive materials. Plastic materials represent an affordable alternative, but their surface treatment, in the form of post-coating, achieves properties comparable to those of metal parts while saving expensive metal material. Samples prepared by selective laser sintering (SLS) with different surface treatments were used. Polyamide 12 (PA12) was chosen as the base material and copper (Cu) as the metallic coating. Graphite was sprayed on the samples to ensure conductivity. The Cu coating was electrodeposited from an acidic copper electrolyte. The quantitative analysis of the surface was carried out using standard ISO parameters. The thickness of the deposited copper layer was determined using destructive measurements on a digital microscope. The results show that surface modification has a significant effect on the functional properties of the surface quality and the thickness of the deposited copper layer. Full article

The Scalable and Expeditious Additive Manufacturing (SEAM) process is an advanced additive manufacturing (AM) technique that relies on the optimization of metal powder suspensions to achieve high-quality 3D-printed components. This study explores the critical role of dispersants in enhancing the performance of stainless steel (SS) 420 metal powder suspensions for the SEAM process by improving powder loading, recyclability, flowability, and consequent final part density. The addition of dispersant allows for increased powder contents while preserving stable rheological properties, thereby enabling higher powder loading without compromising the rheological characteristics required in the SEAM process. Previously, our team implemented a two-step printing strategy to address the segregation issues during printing. Nonetheless, the semi-cured layer was not recyclable after printing, resulting in a significant amount of waste in the SEAM process. This, in turn, leads to a considerable increase in material costs. On the other hand, the addition of a dispersant has been shown to enhance suspension stability, enabling multiple cycles of reuse. This novel approach has been demonstrated to reduce material waste and lower production costs. The enhanced flowability guarantees uniform suspension spreading, resulting in defect-free layer deposition and superior process control. Moreover, the dispersant’s ability to impede particle agglomeration and promote powder loading contributes to the attainment of a 99.33% relative density in the final sintered SS420 parts, thereby markedly enhancing their mechanical integrity. These findings demonstrate the pivotal role of dispersants in refining the SEAM process, enabling the production of high-density, cost-effective metal components with superior material utilization and process efficiency. Full article

This in vitro study aimed to compare the effects of various surface treatments and hydrothermal aging on the phase composition, microstructure, and compressive strength of dental zirconia (ZrO₂). Forty-eight zirconia cubes (8 × 8 × 8 mm) were fabricated using CAD/CAM from two materials: infrastructure zirconia (Group S1) and super-translucent multilayered monolithic zirconia (Group S2). Four samples of each material were analyzed in their pre-sintered state (S1-0, S2-0). The remaining specimens were sintered and assigned to sub-groups based on surface treatment: untreated, sandblasted with 30 µm or 50 µm Al₂O₃, polished, or polished and glazed. Characterization was performed using EDX, SEM, XRD with Rietveld refinement, Raman spectroscopy, and compressive testing before and after accelerated hydrothermal aging, according to EN ISO 13356:2015. EDX revealed a higher yttria content in monolithic zirconia (10.57 wt%) than in infrastructure zirconia (6.51 wt%). SEM images showed minimal changes in polished samples but clear surface damage after sandblasting, which was more pronounced with larger abrasive particles. XRD and Raman confirmed that sandblasting promoted the tetragonal (t-ZrO₂) to monoclinic (m-ZrO₂) phase transformation (t→m), amplified further by hydrothermal aging. The polished groups showed greater phase stability post-aging. Compressive strength decreased in all treated and aged samples, with monolithic zirconia being more affected. Polished samples displayed the best surface quality and structural resilience across both materials. These findings underline the impact of clinical surface treatments on zirconia’s long-term mechanical and structural behavior. Full article

Background and Objectives: Bone regeneration (BR) is a cornerstone technique in reconstructive dental surgery, traditionally using either barrier membranes, titanium meshes, or perforated non-resorbable membranes to facilitate bone regeneration. Recent advancements in 3D technology, including CAD/CAM and additive manufacturing, have enabled the development of customized scaffolds tailored to patient needs, potentially overcoming the limitations of conventional methods. Materials and Methods: A scoping review was conducted according to the PRISMA guidelines. Electronic searches were performed in MEDLINE (PubMed), the Cochrane Library, Scopus, and Web of Science up to January 2025 to identify studies on digital technologies applied to bone augmentation. Eligible studies encompassed randomized controlled trials, cohort studies, case series, and case reports, all published in English. Data regarding digital workflows, software, materials, printing techniques, and sterilization methods were extracted from 23 studies published between 2015 and 2024. Results: The review highlights a diverse range of digital workflows, beginning with CBCT-based DICOM to STL conversion using software such as Mimics and Btk-3D^®. Customized titanium meshes and other meshes like Poly Ether-Ether Ketone (PEEK) meshes were produced via techniques including direct metal laser sintering (DMLS), selective laser melting (SLM), and five-axis milling. Although titanium remained the predominant material, studies reported variations in mesh design, thickness, and sterilization protocols. The findings underscore that digital customization enhances surgical precision and efficiency in BR, with several studies demonstrating improved bone gain and reduced operative time compared to conventional approaches. Conclusions: This scoping review confirms that 3D techniques represent a promising advancement in BR. Customized digital workflows provide superior accuracy and support for BR procedures, yet variability in protocols and limited high-quality trials underscore the need for further clinical research to standardize techniques and validate long-term outcomes. Full article

Abnormal operating modes in the iron ore sintering process often lead to reduced productivity and inferior sinter quality. The timely early warning of such modes is therefore essential in maintaining stable production and ensuring product quality. To this end, we develop an early warning approach that integrates cross-sectional image features from the discharge end. First, an edge detection-based scheme is designed to isolate and analyze the red fire layer in the image. Second, a random forest feature importance ranking is employed to select process variables. Third, a Bayesian neural network is trained on both selected process variables and visual features extracted from the red fire layer to construct the early warning model. Finally, the burn-through point is adopted as the classification criterion, and experiments are carried out on raw data collected from an industrial plant. The results demonstrate that the proposed method enables the accurate early detection of abnormal operating modes, achieving accuracy of 94.07%, and thus holds strong potential for industrial application. Full article

Iron ore sintering is a critical process in steelmaking, where the produced sinter is the main raw material for blast furnace ironmaking. The quality and yield of sinter ore directly affect the cost and efficiency of iron and steel production. Accurately predicting the burn-through point (BTP) temperature is of paramount importance for controlling quality and yield. Traditional BTP temperature prediction only utilizes data from bellows, neglecting the information contained in sinter images. This study combines color temperature information extracted from the cross-sectional frame at the discharge end with bellows data. Due to the non-stationarity of the BTP temperature, a hybrid prediction model of the BTP temperature integrating bidirectional long short-term memory and extreme gradient boosting is presented. By combining the advantages of deep learning and tree ensemble learning, a hybrid prediction model of the BTP temperature is established using the color temperature information in the cross-sectional frame at the discharge end and time-series data. Experiments were conducted with the actual running data in an iron and steel enterprise and show that the proposed method has higher accuracy than existing methods, achieving an approximately 4.3% improvement in prediction accuracy. The proposed method can provide an effective reference for decision-making and for the optimization of operating parameters in the sintering process. Full article

Microwave dielectric ceramics are indispensable in modern communication technologies, playing a pivotal role in components such as filters, oscillators, and antennas. Among these materials, ZnAl₂O₄ ceramics have garnered attention for their excellent quality factor (Q × f) and low dielectric constant (ε_r). However, their high sintering temperature (~1650 °C) limits practical applications. This study investigates ZnAl_2-x(Zn_0.5Si_0.5)_xO₄ (ZAZS) (x = 0.1–0.9) ceramics, where [Zn_0.5Si_0.5]³⁺ substitutes Al³⁺, to reduce sintering temperature while maintaining high-performance microwave dielectric properties. ZAZS ceramics were synthesized via the solid-state reaction method and characterized for their structural, morphological, and dielectric properties. X-ray diffraction analysis confirmed the formation of a single-phase solid solution up to x = 0.8, with minor secondary phases appearing at x = 0.9. The substitution increased lattice parameters and enhanced material densification, as observed through SEM and relative density calculations. Microwave dielectric measurements showed that ZAZS ceramics achieved a maximum Q × f of 20,200 GHz and a τ_f value reduced to −62 ppm/°C at x = 0.8, while ε_r decreased from 7.90 to 6.98. Bond-valence calculations reveal that the reduction of the average Al/Zn/Si–O bond valence weakens octahedral rigidity, systematically tuning τ_f toward zero. These results demonstrate that ZAZS ceramics, with a reduced sintering temperature of 1400 °C, exhibit excellent potential for application in low-loss microwave devices. Full article

Part defects in additive manufacturing (AM) operations like laser sintering (LS) can negatively affect the quality and integrity of the manufactured parts. Therefore, it is important to understand and mitigate these part defects to improve the performance and safety of the manufactured parts. Integrating machine learning to detect part defects in AM can enable efficient, fast, and automated real-time monitoring, reducing the need for labor-intensive manual inspections. In this work, a novel approach incorporating a lightweight Visual Geometry Group (VGG) structure with soft attention is presented to detect powder bed defects (such as cracks, powder bed ditches, etc.) in laser sintering processes. The model was evaluated on a publicly accessible dataset (called LS Powder bed defects) containing 8514 images of powder bed images pre-split into training, validation, and testing sets. The proposed methodology achieved an accuracy of 98.40%, a precision of 97.45%, a recall of 99.40%, and an f1-score of 98.42% with a computation complexity of 0.797 GMACs. Furthermore, the proposed method achieved better performance than the state-of-the-art in terms of accuracy, precision, recall, and f1-score on LS powder bed images, while requiring lower computational power for real-time application. Full article