Search Results (13,476)

Electric discharge machining (EDM) stands out for its ability to perform no-contact machining of materials with desired forms by multi-pulse discharges. In this investigation, the machinability of drilling on Ti₅₆Zr₁₈Cu₁₂, metallic glass, for micro-hole is investigated with renewable dielectrics in the EDM process. Machinability is investigated by examining performance indicators including material removal rate (MRR), overcut, edge deviation, and energy efficiency per volume (EEV) in relation to the process parameters, such as electrical and non-electrical parameters. The edges of the drilled holes are examined to investigate the micro-structural changes that occur in metallic glass as a result of micro-machining. The experimental results show that the maximal value of MRR of 0.0103 mm³/min is achieved when the pulse-on time of 30 μs and sunflower oil renewable dielectric is selected, and the minimum overcut and edge deviation of micro-hole drilling in Ti₅₆Zr₁₈Cu₁₂ is 39.99 and 9.41 μm, respectively. Minimum overcut and edge deviation are obtained for colza oil, optimized by 38% and 70%, respectively, over the worst-case conditions. Multi-objective optimization on the basis of ratio analysis (MOORA) results in a 70% reduction in energy consumption of EEV compared to the conventional paraffin media process. In addition, a range of pulse-on time, pulse duty cycle, and renewable dielectric are identified using the MOORA technique while EDM drilling in metallic glass Ti₅₆Zr₁₈Cu₁₂. Full article

Hydrogen, as a clean energy source, has gradually become an important choice for the energy transformation in the world. Utilizing existing natural gas pipelines for hydrogen-blended transportation is one of the most economical and effective ways to achieve large-scale hydrogen transportation. However, hydrogen can easily penetrate into the pipe material during the hydrogen-blended transportation process, causing damage to the properties of the pipe. The heat-affected zone (HAZ) of the weld, being the weakest part of the pipeline, is highly sensitive to hydrogen embrittlement. The microstructure and properties of the grains in the heat-affected zone undergoes changes during the welding process. Therefore, this paper divides the HAZ of X80 welded pipes into three sub-HAZ, namely the coarse-grained HAZ, fine-grained HAZ, and intercritical HAZ, to study the hydrogen behavior. The results show that the degree of hydrogen damage in each sub-HAZ varies significantly at different strain rates. The coarse-grained HAZ has the highest hydrogen embrittlement sensitivity at low strain rates, while the intercritical HAZ experiences the greatest hydrogen damage at high strain rates. By combining the microstructural differences within each sub-HAZ, the plastic damage mechanism of hydrogen in each sub-HAZ is analyzed, with the aim of providing a scientific basis for the feasibility of using X80 welded pipes in hydrogen-blended transportation. Full article

In this investigation, it was found that the co-addition of Er and B causes both the modification and refinement of the Al-7Si alloy. The B element mainly forms a small amount of the AlB2 phase within the alloy, which can be used as a nucleation site for grains during casting, so the addition of B can significantly reduce the grain size of the Al-7Si alloy. However, the number density of AlB2 phase is too low, so its effect on improving the eutectic Si size and reducing the secondary dendrite arm spacing (SDAS) is not significant. The addition of 0.1 wt% Er can form a large amount of Al3Er phase within the alloy, which mainly serves as a nucleation site for eutectic Si during casting, so the addition of Er can significantly reduce the SDAS, eutectic Si size and morphology of Al-7Si alloys. However, due to the existence of a certain degree of mismatch between the Al matrix and the Al3Er phase, the relative grain refinement effect of Al3Er is not significant. In addition to this, we also observe the enrichment of Er at eutectic Si, which suggests that Er can interact with Si and thus inhibit the growth of eutectic Si. Therefore, Er can modulate eutectic Si through the Al3Er phase and the enrichment of Er. The co-addition of Er and B to Al-7Si alloys has better refining and modification effects than the addition of Er or B alone, mainly due to the modification effect of the Er element and the refining effect of the AlB2 phase. Unlike the Er-containing alloys, where the Al3Er phase plays a modifying role, the modification of the co-addition Er and B alloys is mainly caused by the enrichment of Er within the alloy. Full article

The effects of laser powder bed fusion (LPBF) parameters, such as power (200 to 350 W) and scan speeds (from 200 to 2000 mm/s), on the microstructure and mechanical properties of high-strength, low-alloy (HSLA) AISI 4340 steel were examined. A wide range of volumetric energy density (VED) between 93 and 162 J/mm³ produced samples with relative densities greater than 99.8%. The optimal parameter set was identified with laser power = 200 W, scan speed = 600 mm/s, hatch spacing = 0.12 mm, and slice thickness = 0.03, corresponding to VED = 92.6 J/mm³. Scanning electron microscopy revealed a predominantly martensitic microstructure for all processing parameters examined, although X-ray diffraction revealed the minor presence of retained austenite within the as-fabricated 4340 steel. Using the optimized LPBF parameters, the as-fabricated 4340 steel exhibited a yield strength of 1317 MPa ± 16 MPa, ultimate tensile strength of 1538 MPa ± 22 MPa, and 18.6 ± 1% strain at failure. These are similar to wrought 4340 steel quenched and tempered between 400 and 600 °C. Full article

NiTi alloy has been widely used due to its excellent shape memory effect, superelasticity, and high damping performance. These excellent properties are mainly derived from its unique phase structure. In order to further explore the effect of different phase ratios on the performance of NiTi alloy, this study successfully prepared NiTi alloys with different atomic ratios by controlling the wire feeding speed to control the atomic ratio in the alloy. The results of TEM showed that the alloy with a lower Ni atomic ratio is enriched with Ti element, while the alloy with a higher Ni atomic ratio has a coexistence of NiTi phase and NiTi₂ phase. At the same time, the compression performance showed that the increase in Ni atomic ratio can improve the compression performance of the alloy. In addition, by constructing a molecular dynamics model of NiTi alloys with different phase ratios, the unloading recovery behavior and phase transformation characteristics of the alloy under external force were analyzed. The results showed that with the increase of the NiTi₂ phase ratio in the alloy, the irrecoverable strain also increases, exceeding the elastic strain limit of the NiTi₂ phase, resulting in the generation of disordered structure and plastic deformation in the late deformation stage. In addition, with the increase of the NiTi₂ phase ratio, the energy dissipation area of the hysteresis curve increases, reflecting a greater energy loss. Full article

This paper presents the results of experimental and numerical analysis of fracture mechanics testing of ductile metallic materials using a non-standard procedure with PRNT (pipe ring notched tensile) ring-shaped specimens, introduced in previous publications through analysis of 3D-printed polymer rings. The main focus of this research is the determination of the values of the plastic geometry factor η_pl since the specimen is not a standard one. Toward this aim, the finite element software package Simulia Abaqus was applied to evaluate the J-integral (by using the domain integral method) and the F-CMOD curve so that the plastic geometry factor η_pl can be evaluated for different values of the ratio of crack length to specimen width (a₀/W = 0.45 ÷ 0.55). In this way, a procedure and the possibility of practical implementation on the thin-walled pipelines are established. Full article

Precise control of forging and heat treatment parameters is essential to achieve microstructural homogeneity in turbine disks, ensuring optimal mechanical performance for aerospace applications. This study examines the influence of the hot deformation temperatures on the grain size and γ’ phase characteristics of U720Li alloy following subsequent heat treatments. Samples extracted from a hot-extruded U720Li billet were subjected to isothermal compression within the temperature range of 1100–1130 °C, followed by holding at 1100 °C and 1120 °C for 4 h and air cooling. The results demonstrate that increasing the deformation temperature from 1100 °C to 1120 °C reduces the γ’ phase volume fraction at grain boundaries from 13% to 5%, weakens pinning effects, promotes grain growth during deformation, elevates grain boundary energy, and diminishes stored deformation energy, despite maintaining an equivalent degree of dynamic recrystallization. When the sub-solvus heat treatment temperature was 20 °C below the effective deformation temperature, Ostwald ripening dominated, resulting in a multimodal γ’ phase distribution after cooling. Conversely, when the sub-solvus heat treatment temperature 20 °C exceeded the effective deformation temperature, a significant portion of the intergranular γ’ phase dissolved, leaving a bimodal distribution comprising both large- and small-sized particles. Full article

In steel structural engineering, artificial intelligence (AI) and machine learning (ML) are improving accuracy, efficiency, and automation. This review explores AI-driven approaches, emphasizing how AI models improve predictive capabilities, optimize performance, and reduce computational costs compared to traditional methods. Inverse Machine Learning (IML) is a major focus since it helps engineers to minimize reliance on iterative trial-and-error by allowing them to identify ideal material properties and geometric configurations depending on predefined performance targets. Unlike conventional ML models that focus mostly on forward predictions, IML helps data-driven design generation, enabling more adaptive engineering solutions. Furthermore, underlined is Explainable Artificial Intelligence (XAI), which enhances model transparency, interpretability, and trust of AI. The paper categorizes AI applications in steel construction based on their impact on design automation, structural health monitoring, failure prediction and performance evaluation throughout research from 1990 to 2025. The review explores challenges such as data limitations, model generalization, engineering reliability, and the need for physics-informed learning while examining AI’s role in bridging research and real-world structural applications. By integrating AI into structural engineering, this work supports the adoption of ML, IML, and XAI in structural analysis and design, paving the way for more reliable and interpretable engineering practices. Full article

Microwave dielectric (1 − x)CoTiTa₂O₈-xMgNb₂O₆ composite ceramics (x = 0.625–0.725) were fabricated through a two-step method and sintering techniques. The applied CoTiTa₂O₈ and MgNb₂O₆ powders were both synthesized by calcining stoichiometric mixtures of their respective metal oxides at 1000 °C for 3 h. The optimal sintering parameters were determined using visual high-temperature deformation analysis. The influence of the MgNb₂O₆ content on the phase composition, microstructure, and microwave dielectric properties of the obtained composite ceramics was comprehensively investigated. It was observed that an increase in the MgNb₂O₆ content resulted in a reduction in the dielectric constant (ε_r) and a significant enhancement in the quality factor (Q × f). The ceramics with a compositional value of x = 0.675, sintered at 1193 °C for 4.5 h, demonstrated a near-zero temperature coefficient of the resonant frequency (τ_f), exhibiting optimal microwave dielectric properties: ε_r = 28.4, Q × f = 33,055 GHz, and τ_f = −3.1 ppm/°C. These findings underscore the potential of the present CoTiTa₂O₈-MgNb₂O₆ composite ceramics for advanced microwave applications. Full article

In this study, FeCoNiCrAl high-entropy alloy (HEA) coatings were fabricated on Q235 steel surfaces using laser cladding (LC) to enhance corrosion resistance in harsh environments. The laser processing parameters (laser power, defocus distance, and scanning speed) were optimized using response surface methodology (RSM), establishing a mathematical model to guide the process. The optimized coatings demonstrated strong metallurgical bonding to the substrate, with a microstructure comprising Al-Ni-rich B2 phases and Cr-Fe-rich BCC phases. Elemental segregation was effectively mitigated as energy density decreased, leading to significant improvements in corrosion resistance. Electrochemical tests in 3.5 wt.% NaCl and 0.5 mol/L H₂SO₄ solutions showed that the optimized coating (laser power: 800 W, scanning speed: 450 mm/min, defocus: −15 mm) exhibited exceptionally low corrosion current densities of 1.78 × 10⁻⁷ A/cm² and 1.07 × 10⁻⁵ A/cm², respectively. The passive film on the optimized coating surface consisted of stable oxides, with low oxygen vacancy densities of 1.937 × 10²³ cm⁻³ in NaCl and 4.967 × 10²¹ cm⁻³ in H₂SO₄, significantly enhancing its resistance to localized and uniform corrosion. These results demonstrate the effectiveness of RSM-based optimization in producing HEA coatings with superior corrosion resistance suitable for applications in highly corrosive environments. Full article

This study comprehensively evaluates a non-weldable nickel-cobalt-based superalloy fabricated using laser powder bed fusion (LPBF) technology. The investigation systematically examined the impact of heat treatment, specifically solution treatment and solution treatment followed by aging treatment, on the microstructural characteristics and the evolution of residual stress within the alloy. The findings indicated that the as-built Ni-Co-based superalloy predominantly consists of equiaxed crystals and epitaxial columnar crystals, with no formation of the γ′ phase observed. After the solution treatment, the alloy experienced equiaxed columnar crystallization, recrystallization, and grain refinement. Additionally, a significant quantity of γ′ phases within the alloy exhibited a specific arrangement and precipitation. Following the aging treatment, there was an observed increase in the average dimensions of both the γ′ phase and the grains within the alloy. The evolution of residual stress distribution perpendicular to the construction direction in the alloy, both before and following heat treatment, was assessed using the contour method. The results showed that heat treatment progressively diminished the residual stress levels within the alloy. Furthermore, this study discusses the interrelationship between residual stress and the microstructural evolutions of nickel-cobalt-based superalloys throughout the heat treatment process. Full article

With the increasing demand for premium-quality aluminum alloy castings that can be used as safety-critical structural components, as well as the rising urge to utilize sustainable materials during the manufacturing process, novel technologies need to be developed and implemented during the treatment of liquid alloys. Impurity and alloying elements accumulate in recycled aluminum alloys, which frequently results in the formation of coarse intermetallic compound (IMC) particles in the microstructure that have a detrimental effect on the ductility of cast products. One successful approach to alleviate this negative effect relies on affecting the phase selection and refinement of IMC phases. A growing body of literature has shown that the crystallization process of IMCs is affected by the native oxide phases present in the liquid alloys. It has also been demonstrated that by appropriate technologies, harmful oxide inclusion (like oxide bifilms) can be transformed into small-sized oxide particles that can be dispersed throughout the liquid alloy to serve as heterogeneous nucleation sites for different phases. In this way, the adverse effects of oxide inclusions and IMCs are simultaneously mitigated. This contribution aims to review the recent progress of experimental and theoretical work related to intermetallic particle refinement by oxide phases. Emerging technological solutions capable of refining intermetallics through transforming harmful oxide inclusions into numerous, well-dispersed heterogeneous nucleation sites are comprehensively reviewed. Besides analyzing the current state of these techniques, this discussion evaluates their future implications and the potential challenges that may arise in their application and development. Full article

A novel tera-dentate salen ligand and its Fe(III) complex was synthesized and characterized via several spectroscopic and physicochemical techniques. The corrosion rate inhibition of nickel and its alloys inspired the utilization of the L ligand and its FeL complex as vital and eco-friendly inhibitors. To assess their effectiveness, both Tafel plot analysis and electrochemical impedance spectroscopy were employed to examine the electrochemical properties of L and the FeL complex. The results show that corrosion current density (I_corr) steadily drops when the additive concentration is increased, but the inhibition efficiency increases. It has been observed that the efficiency of inhibition rises with temperature, particularly at high temperatures (55 °C) when 1 × 10⁻³ M of L and FeL are present as additives, with η = 90.5% and 92.7%, respectively. Additionally, the findings propose that the adsorption mechanism of both L and FeL additive reptiles follows the Langmuir design isotherm. Electrochemical impedance spectroscopy has also verified these findings. DFT calculations were employed to prove the structure of the investigated FeL complex and its activity as a corrosion inhibitor. Full article

This research reports on numerical simulations of the multi-pass laser forming process aimed at obtaining cylindrical surfaces from planar AISI 304 stainless-steel sheets. The effect of laser power, scanning speed, and distance between irradiation lines on the thermomechanical material response is assessed, with particular emphasis on the final curvature radius, maximum temperature, and final plastic deformation. To this end, a coupled thermomechanical finite element formulation is applied to the analysis of different experimental tests reported in the literature. The predictive capabilities of this model are demonstrated in the analysis of bent parts exhibiting a wide range of curvature radii, whose values were found in this work to inversely correlate with the total line energy input to the workpiece. In such situations, it was found that both the thermal response and the effective plastic strain values obtained in each test correlate directly with the line energy value. Furthermore, the distance between irradiation lines was identified as a key parameter in the formation of cylindrical surfaces, as it significantly influences the displacement and induced deformation. However, no significant impact of this parameter on the effective plastic strain was observed. Full article

In situ particle reinforced aluminum matrix composites have become an important development in the field of materials science due to their unique reinforced structure design and excellent mechanical properties. In this paper, in situ Al₂O₃ and AlSi₃Ti₂ particle reinforced Al12Si matrix composites were prepared via powder metallurgy. The microstructure and mechanical properties of the composites were analyzed systematically. With the increase in TiO₂ content, the grain size of the composites was refined, resulting in the composites exhibiting higher strength. The in situ generated AlSi₃Ti₂ phase has a higher Young’s modulus of elasticity compared to the Si phase. The in situ formed nano-Al₂O₃ and micrometer AlSi₃Ti₂ formed a strong interfacial bonding with the matrix, which ensured a good reinforcement effect. At the same time, the introduction of reinforced particles also changed the texture characteristics of extruded Al12Si, from <001>∥ED of Al12Si to <111>∥ED of composite. As a result, the strength of the Al12Si–7TiO₂ composite was 330 MPa, which is a 120% enhancement compared with that of the matrix. The hardness reached 107 HV, an increase of 80% compared to the matrix. This study can provide a reference value for the design of new multi-particle hybrid reinforced composites to enhance the material properties. Full article