Metals, Volume 13, Issue 8 (August 2023) – 175 articles

For the purpose of determining the interaction parameters between Mn and Al, and the influence of Mn on Al₂O₃ inclusions formation in the Fe-Mn-Al-O melts with high Mn and Al contents, three groups of Fe-Mn-Al-O melts with the initial Al content of 3, 5, and 7 mass% and different Mn contents were equilibrated with pure solid Al₂O₃ in an Al₂O₃ crucible at 1873 K and Ar-H₂ atmosphere. Then, the interaction parameters between Mn and Al were deduced using the WIPF (Wagner’s Interaction Parameter Formalism) and the R-K polynomial (Redlich-Kister type polynomial), respectively. From the WIPF, the first- and second-order interaction parameters, $e_{\mathrm{Al}}^{\mathrm{Mn}}$ and $r_{\mathrm{Al}}^{\mathrm{Mn}}$, were determined to be 0.0292 and −0.00016, respectively. From the R-K polynomial, the binary interaction parameters, $\Omega _{\mathrm{Mn}-\mathrm{Al}}^0$ and $\Omega _{\mathrm{Mn}-\mathrm{Al}}^1$, were determined to be 73,439 J/mol and −34,919 J/mol, respectively. The applicability of the WIPF to high Mn and Al content Fe-Mn-Al-O melts was investigated by comparing the Al activity calculated by the WIPF and the R-K polynomial using the obtained data. The results showed that WIPF can be used in high Mn and Al content melts in the current concentration range. Further from the iso-activity contours of Al, the activity of Al increases with increasing Al or Mn content. Finally, the thermodynamic calculations show that the addition of Mn decreases the equilibrium O content at the same Al content, making the formation of Al₂O₃ inclusions easier. Full article

The study aims to investigate the influence of fraction of coarse undeformed particles on the microstructure evolution and mechanical properties of alloys processed by isothermal multidirectional forging (MDF). For this purpose, Al-Mg-Ni-Sc-Zr-based alloys with different Ni concentrations and a fraction of Al₃Ni particles of solidification origin phase were subjected to MDF at 350 °C. Precipitates of the L1₂-structured Al₃(Sc,Zr) phase retained their structure, morphology, and size after MDF and were coherent with the aluminum matrix. The Al₃Ni phase particles stimulated the nucleation of recrystallized grains and contributed significantly to the formation of an ultrafine-grained structure. The uniformity of the grain structure increased, and the average grain size decreased with an increase in the fraction of Al₃Ni particles. A fine-grained structure with a mean grain size of 2.4–3.4 µm was observed after MDF with a cumulative strain of 12. The results demonstrate that a bimodal particles size distribution with a volume fraction of nanoscale f~0.1% and microscale f~8% particles provided for the formation of a homogenous fine-grained structure after MDF and improved the mechanical properties. Full article

In the present study, an approach of determining the standard Gibbs energy of formation of Fe_3–xV_xO₄ was proposed firstly, then the standard Gibbs energies of formation of a variety of Fe_3–xV_xO₄ were determined experimentally, and finally, a calculating model of the standard Gibbs energy of formation of Fe_3–xV_xO₄ was established. The detailed results are as follows: (1) the standard Gibbs energy of formation of Fe_3–xV_xO₄ can be determined successfully by two steps; the first is to measure the chemical potential of Fe in Fe_3–xV_xO₄ under fixed oxygen partial pressure, the second is to derive the chemical potential of V in Fe_3–xV_xO₄ by Gibbs–Duhem relation; (2) the standard Gibbs energies of formation of Fe_3–xV_xO₄ are mainly decided by the Fe/V molar ratio, and almost not influenced by the oxygen partial pressure in the range from 2.39 × 10⁻¹² to 3.83 × 10⁻¹¹ atm; (3) in this oxygen partial pressure range, the standard Gibbs energies of formation of Fe_3–xV_xO₄ can be calculated satisfactorily by the following model: ${\Delta }_f{G}_{F{e}_{3-x}{V}_x{O}_4}^{\theta }\left(J/mol\right)=\left(1-x/2\right){\Delta }_f{G}_{F{e}_3{O}_4}^{\theta }+\left(x/2\right){\Delta }_f{G}_{Fe{V}_2{O}_4}^{\theta }+\left(1-x/2\right)RTln\left(1-x/2\right)+\left(x/2\right)RTln\left(x/2\right)$$- 168627.48\left(1-x/2\right)\left(x/2\right)$. Full article

Density-based phase-field (DPF) methods have emerged as a technique for simulating grain boundary thermodynamics and kinetics. Compared to the classical phase-field, DPF gives a more physical description of the grain boundary structure and chemistry, bridging CALPHAD databases and atomistic simulations, with broad applications to grain boundary and segregation engineering. Notwithstanding their notable progress, further advancements are still warranted in DPF methods. Chief among these are the requirements to resolve its performance constraints associated with solving fourth-order partial differential equations (PDEs) and to enable the DPF methods for simulating moving grain boundaries. Presented in this work is a means by which the aforementioned problems are addressed by expressing the density field of a DPF simulation in terms of a traditional order parameter field. A generic DPF free energy functional is derived and used to carry out a series of equilibrium and dynamic simulations of grain boundaries in order to generate trends such as grain boundary width vs. gradient energy coefficient, grain boundary velocity vs. applied driving force, and spherical grain radius vs. time. These trends are compared with analytical solutions and the behavior of physical grain boundaries in order to ascertain the validity of the coupled DPF model. All tested quantities were found to agree with established theories of grain boundary behavior. In addition, the resulting simulations allow for DPF simulations to be carried out by existing phase-field solvers. Full article

The fatigue crack propagation behaviour of Q550E high-performance steel (HPS) is studied in this paper. Static tensile testing and fatigue crack propagation testing were carried out, and the results were compared with those of Q235. Finite element models were developed and verified against the experimental results. The impacts of the initial crack angle, crack depth ratio, stress ratio, thickness, and corrosion pitting on the fatigue crack propagation behaviour of the HPS were analysed. The results show that the fatigue life of Q550 was reduced by 18% due to the corrosion pitting, but it did not change the crack propagation path. When the stress intensity factor is higher than a certain value, the fatigue performance of Q235 is better than that of Q550E. The initial crack angle of 52.5° is the critical angle of the crack stress intensity factor. The steel tends to fracture as the crack depth ratio increases, and more attention should be paid to the effective crack length in engineering practice. An increasing stress ratio leads to a smaller stress intensity factor, and the thickness affects the stress intensity factor in the later stage. The crack stress intensity factor around the corrosion pits gradually decreases along the thickness direction, and the crack tips around the corrosion pits tend to reach the yield state initially, accelerating the fatigue fracture of the specimen and ultimately leading to a decrease in fatigue life. Full article

The evolution of the microstructure, the precipitation behavior, and the mechanical performances of Nb-V-Ti micro-alloyed steel prepared under different tempering time were studied using transmission electron microscopy (TEM), X-ray diffraction (XRD), and mechanical tests. It was found that the width of the martensite laths increases with the increasing tempering time. Several kinds of carbides, including M₃C, M₂C, M₂₃C₆, M₇C₃, and MC particles, were identified after tempering. The MC carbides remain stable during tempering, but the transformation behavior of other carbides was identified. The transformation sequence can be summarized as: M₃C → M₂C → M₇C₃ → M₂₃C₆. The strength decreases and the Charpy impact toughness increases gradually with the increase in the tempering time. The ultimate strength (UTS) decreases from 1231 to 896 MPa, and the yield strength (YS) decreases from 1138 to 835 MPa. The −40 °C Charpy impact toughness increases from 20 to 61 J as the tempering time increases from 10 min to 100 h. The evolution of carbides plays an important role in their mechanical performances. Full article

The microstructure and properties of non-linear friction stir welded lap joints of the AA6061-T6 aluminum alloy were investigated, with a particular focus on the influence of corner curvature on the formability and mechanical properties of the joints. The research results indicate that for the 6061-T6 aluminum alloy lap joint friction stir welding with a smaller radius (R < 7 mm), there is a more severe accumulation of welding material. When the radius exceeds 7 mm, good macroscopic joint formation can be achieved. Various regions at the joint corners are composed of α-Al and intermetallic precipitations β phases. The microstructure of the heat-affected zone (HAZ) appeared relatively coarse, the weld nugget zone (WNZ) had the finest grain, and partial dissolution of the β phase occurred. The grain size in the middle WNZ at the corner was larger than at the ends, and the grain size on the inner side of the corner was larger than on the outer side. The hardness distribution of the joint exhibited a “W” shape, with the lowest hardness in the inner HAZ. When R ≤ 7, with an increase in R, the shear strength of the friction stir welded joints increased, and then the change became relatively small. The maximum shear strength of the joint was 101.32 ± 6.89 MPa at R = 7, and the fracture mode was primarily a ductile mixed fracture. Full article

The aim of the present research was to examine the process of bioleaching and the application of a combined process for the recovery of copper and nickel from industrial sand deposits. The investigated sample of sands finer than 0.1 mm in size contained 0.32% Ni and 0.22% Cu. Industrial sands were processed by bioleaching in flasks on a thermostatically controlled shaker. In addition, sand roasting experiments were carried out with ammonium sulfate. An attempt was also made to use a combined process, including low-temperature roasting of the sands mixed with ammonium sulfate, water-leaching of the roasted mixture, and subsequent biological after-leaching of the residue. In the process of roasting the industrial sands in a mixture including ammonium sulfate at a temperature of 400 °C, more than 70% of the non-ferrous metals were recovered. We examined the possibility of recovering non-ferrous metals using a combined process including low-temperature roasting of industrial sands and the additional recovery of non-ferrous metals by bioleaching using the Acidithiobacillus ferrivorans bacterial strain, which was found to increase the recovery of non-ferrous metals to up to 90%. Full article

In order to reduce the ignition temperature and improve the combustion efficiency of aluminum powder, three aluminum-based alloy fuels, Al–Mg, Al–Zn, and Al–Si–Mg, were prepared by the atomization method. The oxidation, ignition, and combustion performance of alloy fuels were investigated, and the results showed that, using pure aluminum powder as a reference, the weight gain of alloy fuels increased from 10% to 84%, the reaction activation energy decreased from 582 kJ·mol⁻¹ to 208 kJ·mol⁻¹, the alloy fuels containing Mg had good ignition response, and aluminum-based alloy fuels showed high calorific value and efficient combustion as a whole. In order to investigate the combustion behavior of alloy fuels in the solid propellant, tests were conducted on the mechanics, safety, process, and combustion properties of propellant according to the national standard, and the test results showed that, compared with the propellant made of aluminum powder with same quality, the propellant made of alloy has better mechanical properties, higher frictional sensitivity, lower electrostatic sensitivity, comparable process performance, and increased combustion calorific value and combustion speed. Engine test results confirmed that Al–Zn and Al–Si–Mg alloy fuels could effectively improve the specific impulse efficiency of the solid propellant and reduced the residual rate of the engine. Full article

Over the past decade, relentless efforts have brought lightweight high-temperature γ-TiAl-based intermetallic alloys into real commercialisation. The materials have found their place in General Electric’s (GE) high bypass turbofan aircraft engines for the Boeing 787 as well as in the PW1100GTF engines for low-pressure turbine (LPT) blades. In service, the alloys are required to withstand hostile environments dominated by cyclic stresses or strains. Therefore, to enhance the fatigue resistance of the alloys, a clear understanding of the alloys’ response to fatigue loading is pivotal. In the present review, a detailed discussion about the low-cycle fatigue (LCF) behaviour of γ-TiAl-based alloys in terms of crack initiation, propagation and fracture mechanisms, and the influence of temperature and environment on cyclic deformation mechanisms and the resulting fatigue life has been presented. Furthermore, a comprehensive discussion about modelling and prediction of the fatigue property of these alloys with regard to the initiation and propagation lives as well as the total fatigue life has been provided. Moreover, effective methods of optimising the microstructures of γ-TiAl-based alloys to ensure improved LCF behaviour have been elucidated. Full article

The present work aims to boost our understanding of factors governing the grain-refining efficiency of inoculation treatments by comparing the grain-refining efficiencies of two inoculators: Ti nanoparticles and LaB₆ nanoparticles, in a 2024 Al alloy during additive manufacturing (AM). Experimental results obtained by scanning electron microscopy show that the LaB₆ nanoparticle possessed almost no refining effect on the alloy, with the addition content ranging from 0.5 wt.% to 2 wt.%. Conversely, the Ti nanoparticle resulted in a more pronounced refinement and a fine, fully equiaxed microstructure at 1 wt.% Ti addition. Based on transmission electron microscopy analysis, the higher refining efficiency of Ti inoculation was ascribed to the incorporation of both Ti solute and the in situ-formed L1₂-Al₃Ti nucleation particles. The former significantly increased the overall undercooling ahead of the growing Al grain, which ensured the activation of heterogeneous nucleation on the L1₂-Al₃Ti nanoparticles, leading to grain refinement. This work highlights that despite the addition of nucleation particles, the incorporation of appropriate solutes to generate sufficient undercooling is the prerequisite for the activation of heterogenous nucleation in AM. Full article

To understand the secondary transfer performances of residual prestress after the anchoring failure of end-anchored steel wire strands due to corrosion fracture, six steel wire strand components of post-tensioning prestress were designed and fabricated. One-side fast corrosion was applied to the steel wire strand components using the electrochemical method until anchoring failure was reached. The sphere of influence, stress changes, and the retraction and swelling effect of broken beams after failure were investigated. The influences of factors such as concrete strength, stirrup area, and the length of the component on the secondary transfer length of residual prestress were discussed. Based on the deformation relationship between prestressed steel wire strands and concrete in the stress transfer zone, a stress equation was established and solved through a bond constitutive model. A prediction model of the effective stress transfer length of prestressed steel wire strand after failure was proposed. The results demonstrated that residual prestress can have a secondary transfer after the corrosion fracture of end-anchored steel wire strands, but some effective prestress may be lost. Moreover, the loss of prestress is inversely proportional to concrete compressive strength. When the specimens are relatively short, the prestress loss increases significantly. Concrete strength has significant influences on the length of secondary transfer. The proposed simplified calculation method of the secondary transfer length of residual prestress has a relatively high accuracy, with an average error of 2.9% and a maximum error of 5.2%. Full article

CrC and NbC carbide coatings both have good mechanical properties, wear resistance, and corrosion resistance. The present study seeks to combine the two coating systems in order to further enhance their properties. NbCrC_x and NbCrC_xN_y coatings (where x and y denote the atomic percentages of carbon and nitrogen, respectively) were deposited on SKH51 substrates using a radio-frequency unbalanced magnetron sputtering system. The mechanical, tribological, and corrosive properties of the coatings were investigated and compared. Among the NbCrC_x coatings, the NbCrC₆₁ coating showed high levels of hardness, excellent adhesion strength, and good wear resistance. Among the NbCrC_xN_y coatings, the NbCrC₅₅N₅ coating showed high adhesion strength and hardness and excellent tribological properties. However, for nitrogen contents greater than 16 at%, the adhesion strength was dramatically reduced, resulting in poor tribological performance. Among all of the coatings, the NbCrC₄₉ coating showed the best corrosion resistance due to its enhanced crystallinity, high adhesion strength, moderate surface roughness, and high sp³ C-C bonding ratio. Full article

Development of metallic glasses is hindered by the difficulties in manufacturing bulk parts large enough for practical applications. Spark plasma sintering (SPS) has emerged as an effective consolidation technique in the formation of bulk metallic glasses (BMGs) from melt-spun ribbons. In this study, Mg₆₅Zn₃₀Ca₅ melt-spun ribbons were sintered at prolonged sintering times (15 min to 180 min) via SPS under a pressure of 90 MPa and at a temperature of 150 °C (which is below the crystallization temperature), to provide an insight into the influence of sintering time on the consolidation, structural, and biodegradation behavior of Mg-BMGs. Scanning Electron Microscopy was used to characterize the microstructure of the surface, while the presence of the amorphous phase was characterized using X-ray diffraction and Electron Backscatter Diffraction. Pellets 10 mm in diameter and height with near-net amorphous structure were synthesized at 150 °C with a sintering time of 90 min, resulting in densification as high as 98.2% with minimal crystallization. Sintering at extended durations above 90 min achieved higher densification and resulted in a significant amount of local and partial devitrification. Mechanical properties were characterized via compression and microhardness testing. Compression results show that increased sintering time led to better structural integrity and mechanical properties. Notably, SPS150_90 displayed ultimate compressive strength (220 MPa) that matches that of the cortical bone (205 MPa). Corrosion properties were characterized via potentiodynamic polarization with Phosphate Buffered Solution (PBS). The results suggest that the sintered samples have significantly better corrosion resistance compared to the crystalline form. Overall, SPS150_90 was observed to have a good balance between corrosion properties (10× better corrosion resistance to as-cast alloy) and mechanical properties. Full article

The dehydration of titanium dioxide, which is the carrier for denitration catalysts, is a crucial control step in the preparation of functional materials and has an impact on the performance of the product. In this study, the kinetics of the dehydration behavior and reaction mechanism of titanium dioxide were investigated under different atmospheres by measuring the thermal analysis curve of titanium dioxide at different heating rates. The results indicate that the dehydration behavior of the catalyst carrier titanium dioxide is closely related to the calcination atmosphere. The dehydration rate differed for oxygen and no-oxygen atmospheres. Dehydration began quickly in an oxygenated atmosphere and then slowed down towards the end of the reaction, completing slowly in an oxygen-free atmosphere. Kinetic calculations were carried out using modeless and mode function methods. The results show that dehydration of titanium dioxide is consistent with the Avrami–Erofeev equation in an oxygen-containing atmosphere and with the power function rule in an oxygen-free atmosphere, with the process of dehydration being influenced by the formation and growth of crystal nuclei. Full article

In order to explore the relationship between welding thermal cycles and the thermal field during the repair process of dies, a numerical simulation software (SYSWELD) was employed to construct a thermo-mechanical coupled model. The influence of various inter-layer cooling times was investigated on heat accumulation, residual stress, and deformation of the repaired component. The results showed that the numerical simulation results agreed well with experimental data. The temperature within the cladding layer gradually rose as the number of weld beads increased, leading to a more pronounced accumulation of heat. The residual stress exhibited a double-peak profile, where the deformation of the repaired component was large at both ends but small in the middle. The less heat was accumulated in the cladding layer with a prolonged cooling time. Meanwhile, the residual stress and deformation in the repaired component experienced a gradual decrease in magnitude. The numerical simulation results demonstrated that the microstructure of the repaired component predominantly consisted of martensite and residual austenite at the optimal cooling time (300 s). Furthermore, the microhardness and wear resistance of the cladding zone significantly surpassed those of the substrate. In conclusion, this study suggested the prolonged cooling time mitigated heat accumulation, residual stress, and deformation in repaired components, which provided a new direction for future research on the die steel repairments. Full article

The present paper reports the results of the comparative study of mechanical properties of sintered disperse-strengthened Al–40Sn alloy depending on the method of reinforcing particle introduction. The study is performed on two mixtures of aluminum and tin powders: one is admixed with 5.5–14.6 wt% of pure iron powder and the other contains the same amount of iron, but as a component of aluminide Al₃Fe powders. The volume fraction of tin remains unchanged in all mixtures, being equal to 20%, and the concentration of hard particles increases due to a decrease in the volume fraction of the aluminum phase. Green compacts are sintered in the vacuum furnace at a temperature above the melting point of aluminum. The sintered material is a composite containing three phases: α-Al, β-Sn, and Al₃Fe, in which the tin volume fraction is constant. Testing of the sintered composites for compression shows that the addition of finished Al₃Fe particles has a more beneficial effect on their mechanical properties as compared to the addition of pure iron powders. In the latter case, aluminides are formed during sintering. The ultimate strength of composites reaches 180 MPa. Mechanisms of sintering of composites and the related structure and mechanical properties are discussed. Full article

In the motorsport industry, the choice of material for manufacturing the heat resistant components often falls on titanium alloys. In most cases, the production flow for this kind of part involves CNC machining and subsequent assembly by welding process, to other parts obtained by cold plastic forming and possibly made using different titanium alloys. Hence, the alloying element-content in the joint area can be extremely heterogeneous and variable point-by-point. To investigate this topic further, dissimilar welding of the alpha/beta alloy Ti6Al4V and of the oxidation-resistant alpha alloy KS-Ti 1.2 ASN-EX was made by GTAW technology and using different filler metals. Chemical and mechanical properties of the welds were investigated by XRD, SEM-EDS, microhardness maps, and tensile and bending tests. Results show that, despite the different alloying elements present in the two filler wires investigated, static properties of the welds are similar. Results also show that the local V/Al content ratio affects the microhardness as it is responsible for the creation of supersaturated alpha phases during the cooling of the weld beads. Full article

As a metal of strategic value, tungsten plays an important part in civil and military applications. Currently, China is the biggest tungsten producer all over the world, and the metallic smelting technologies for tungsten are well established. However, the harmless recovery and treatment procedures for tungsten residue remain rather underdeveloped. The treatment of tungsten residue generally includes the recovery of valuable metals (e.g., scandium, tantalum, and niobium) and the solidification of toxic elements (e.g., arsenic, lead, and chromium), which may control the transfer of these elements and metals. If treated improperly, the resource of tungsten residue may be wasted, and potential environmental risks could arise. Therefore, the safe disposition of tungsten residue has become the limit factor and an urgent problem to be solved for the sustainable development of tungsten-related industries. In this regard, we reviewed the industrial background of tungsten and the composition and toxicity characteristics of tungsten residue. In addition, particular attention was paid to the harmless utilization processes and technologies for tungsten residue, which were then systematically compared in terms of the applicable situations as well as their advantages and shortcomings. Finally, the development trend for the harmless utilization of tungsten residue was discussed, and some proposals for further studies were provided. Full article

A mathematical model was developed to determine the order of failure of layers in a two-layer ceramics composite and to determine the conditions for achieving the maximum limit load under three-point loading. The model was set in the space of three “bilayer parameters”: the ratio of the thickness of the lower layer to the whole thickness of the beam, the ratio of Young’s moduli of the lower layer to the upper layer, and the ratio of flexural strengths of the materials of the lower layer to the upper layer. The adequacy of the model obtained was confirmed by experimental results on the three-point bending of the experimental specimens. The experimental samples were two-layer composites consisting of a cermet layer TiB/Ti and a layer of α-Ti. The samples were obtained by free self-propagating high-temperature synthesis (SHS) compression and with varying their thickness. The results obtained make it possible to predict in advance which layer, based on the specific bilayer parameters, will trigger the brittle fracture mechanism as well as to set the maximum destructive load of bilayer composites. Full article

Stainless steel is one of the most commonly used structural materials in industry for the transportation of liquids such as water, acids, and organic compounds. Corrosion is a major concern in industry due to the use of strong mineral acids, feedstock contamination, flow, aqueous environments, and high temperatures. Stainless steel is the most commonly used material in the petrochemical industry because of its characteristics of self-protectiveness, offered by thin passive oxides, and its metallurgical composition. However, chlorides and mineral acids attack the stainless steel continuously, consequently breaking down the passivation film, causing a continuous challenge from corrosion. The corrosion in stainless steel is influenced by many factors including flow rate, temperature, pressure, ethanol concentration, and chloride ion content. This review describes the impact of organic compounds and organic acids on the degradation behavior of stainless steel. The review also summarizes the commonly used organic compounds and their applications. It has been demonstrated that organic acid concentration, temperature, and halide impurities have significant effects on susceptibility to pitting corrosion by damaging the passivation film. The phenomenon of corrosion in stainless steel is quite different in immersion tests and electrochemical potentiodynamic polarization. This review article discusses the importance of organic compounds and their corrosion behavior on steel. The article also puts emphasis on the roles of corrosion inhibitors, monitoring methods, corrosion management, and forms of corrosion. Full article

This study focuses on the preparation of fine-grained WC/Co composite powder using rolling ball milling and spray drying techniques. The cemented carbide composition achieved through low-pressure sintering technology was WC-10Co-0.5${\mathrm{Cr}}_3{\mathrm{C}}_2$-1TaC-0.5Ru (wt.%). To study the effect of sintering temperature on the microstructure and mechanical properties of WC-10 wt.% cemented carbide, the microstructure and phase constituents of the material were analyzed using X-ray diffractometry and scanning electron microscopy. Additionally, the physical and mechanical properties of the material were examined. The results indicate that as the sintering temperature increased from 1390 °C to 1450 °C, the grain size of WC in the alloy increased, resulting in a slight decrease in hardness, an increase in fracture toughness, and the transverse fracture strength increasing first and then decreasing. The sintered hard alloy prepared at 1410 °C exhibited fewer pores and a uniform and fine grain size, reaching a density of 99.98%, a hardness of 91.8 HRA, a fracture strength of 3962 MPa, and a fracture toughness of 14.7 $\mathrm{MPa}\cdot {\mathrm{m}}^{1/2}$ Full article

In this study, the constitutive equation of the high-strength Mg-Gd-Y-Zn-Zr alloy sheet was established by tensile tests at different temperatures and different tensile rates. The U-shape bending forming process of the sheet was simulated under different process conditions by the DEFORM software. The variation rules of the stress field, strain field and free bending force of the formed parts were analyzed, and the accuracy of the finite element simulation was verified by the U-shaped bending test. Studies have shown that the equivalent stress, equivalent strain and free bending force decreased with the increase in forming temperature. With an increase in the stamping speed, the equivalent stress and free bending force increased, while the equivalent strain did not change significantly. Notably, the maximum difference in the free bending force between the test and simulation was less than 10%. The results of this study can provide guidance for the stamping forming of high-strength Mg-Gd-Y-Zn-Zr alloy sheets. Full article

The 25Cr7Ni stainless steel alloy system is gaining increasing interest in the oil and gas industry because of its combination of high strength and corrosion resistance properties. However, very few studies on the effects of starting powder attributes and chemical composition on the as-printed properties of 25Cr7Ni stainless steel fabricated through laser-powder bed fusion (L-PBF) exist in the literature. This study examined the influence of powder attributes and chemical composition on the samples from gas atomized and water atomized 25Cr7Ni stainless steel powders, fabricated through L-PBF, on their as-printed microstructure and properties. The mechanical properties that were examined included ultimate tensile strength (UTS), elongation (%), and hardness. The corrosion behavior was also studied using linear sweep voltammetry in 3.5 wt.% NaCl solution. The evolved phases were characterized using optical and scanning electron microscopy, as well as through X-ray diffraction. The gas atomized powders, with their spherical and uniform morphology, yielded as-printed parts of higher relative densities when compared to water atomized powders, with irregular morphology due to better powder bed compaction. The higher densification obtained in the L-PBF samples from gas atomized powders translated into the highest UTS, hardness, and yield strength among the L-PBF samples from water atomized powders and wrought–annealed 25Cr7Ni stainless steel. The presence of higher amounts of N and Mn in the chemical composition of the gas atomized powders over water atomized powders promoted the presence of retained austenite in the corresponding L-PBF samples. Higher amounts of Mo, combined with austenite content, yielded a higher corrosion resistance in the L-PBF samples from the gas atomized powder than in the L-PBF samples from the water atomized powders. The latter part of the work is focused on the evaluation of simulation parameters for analyzing the fabrication procedure for the L-PBF process using Simufact software. For a given set of process parameters, Simufact provides the distortion and internal stresses developed in the printed parts as output. The present study sought to evaluate the process simulation by comparing the experimental observations in terms of the part distortion achieved in a stainless steel cube fabricated through L-PBF with Simufact process simulation obtained using the same set of process parameters. Full article

Electromigration is one of the most important research issues affecting the reliability of solder joints. Current-induced Joule heating affects the electromigration behavior of solder joints. Solder joints with different cross-sectional areas were designed to obtain different Joule heating properties. The effects of the interfacial intermetallic compound (IMC) and mechanical properties of Sn58Bi/Cu solder joints were studied for different Joule heating properties. The results showed that as the cross-sectional area of the Sn58Bi/Cu solder joints increased, the Joule heating of the joint increased. The anode IMC thickness of the joint thickened and transformed into a planar shape. The Bi migrated to the anode region to form a Bi-rich layer and gradually increased in thickness. The cathode IMC thickness first increased, then decreased, and gradually dissolved. The Sn-rich layer formed near the solder side and gradually increased in thickness, with microcracks occurring when the cross-sectional area of the joint increased to 0.75 mm². The joint shear fracture path moved from the soldering zone near the cathode IMC layer to the interfacial IMC layer. The fracture mechanism of the joint changed from a mixed brittle/tough fracture, dominated by deconstruction and secondary cracking, to a brittle fracture dominated by deconstruction. The joint shear strength was reduced by 60.9% compared to that in the absence of electromigration. Full article

Using pulsed double electrode-gas metal arc welding, aluminum wires are joined to copper plates with fillers of different fractions of silicon. Two layers of different microstructures are formed near the Al-Cu interface: one consists of a hypoeutectic microstructure of α (Al) + Al₂Cu, and the other consists of an intermetallic compound (IMC) of Al₂Cu. Increasing the heat input causes increases in the thicknesses of the IMC layer and the layer of the hypoeutectic microstructure. Si suppresses the growth of the IMC layer and assists the growth of the layer of the hypoeutectic microstructure. The effects of the interface microstructures and chemical compositions on the electric resistivity of the joints are analyzed. The electric resistivity of the joints increases with the increase in the thicknesses of the IMC layer and the layer of the hypoeutectic microstructure. The law of mixture is used to calculate the electric resistivity of the joints, which is in accordance with the experimental results. Full article

In this study, we investigated the nitriding and laser quenching composite modified layers of 42CrMo steel. MATLAB was used to fit the nitrogen concentration distribution during nitriding, and the laser temperature field was fitted using ABAQUS finite element simulation software. Two groups of simulation results were integrated to fit the modified layer depth under different processes, and the nitriding and laser quenching experimental results were compared with the simulation results, which indicated that the simulation results agreed well with the experimental results. The depth of the nitriding–laser quenching composite layer greatly improved compared with the nitriding or laser hardening layers. The austenitizing temperature of the 42CrMo steel was reduced to 577 °C by nitriding. Therefore, the depth of the austenitized layer of the 42CrMo steel heated with the same laser power significantly increased. Under the same laser process conditions, more austenitic phase transformation was observed in the nitriding layer than in the non-nitriding layer, so martensitic phase transformation was more likely to occur in the subsequent cooling process. After plasma nitriding at 460 °C for 16 h and laser quenching, the modified layer depth of the 42CrMo steel reached 990 μm, and the average surface hardness of the 42CrMo steel reached 625 HV_0.1. The friction coefficient of the modified layer was the lowest, with a value of 0.433, and the minimum wear value was 1.024 mm³. Double hardness and thickness of the modified layer could be obtained by nitriding and laser quenching composite processes. Full article

Double-sided self-pierce riveting (DSSPR) can be utilized as an alternative to self-pierce riveting (SPR) to produce butt joints through half-lap joints in dissimilar materials. The mechanical joining process makes use of tubular rivets with simple geometry that are here employed to join two sheets made from aluminium (Al) and copper (Cu). This research work analyses the influence of the stainless-steel rivet on both the electrical and mechanical performance of the joint. The electrical resistance variation of the joined assembly is measured at different temperatures and compared with conventional fastened joints made from the same material combination. The mechanical performance of the aluminium–copper connections is evaluated by means of shear tests and compared to the original fastened Al-Cu joint. An experimental approach is utilized to analyse the combined influence of different mechanical and electrical parameters to assess the performance of DSSPR in electrical applications. Full article

Compared with other forming processes, Pilger cold rolling exhibits unique process characteristics and a simple production method, making it highly advantageous in terms of high-precision, high-strength, and poor-plasticity alloys. Among them, the design parameters of the rolling mill play a significant role in the rolling results, with the key design parameters being the hole opening angle θ and the hole gap ΔK. In this study, a numerical simulation model for cold rolling an AZ31B magnesium alloy with variable cross-section three-roll Pilger cold rolling was established, and finite element simulation analysis was employed to obtain the comprehensive performance impact law of key design parameters on the cold-rolled AZ31B magnesium alloy. It can be concluded that when the hole opening angle is 10° and the hole gap is 1.2 mm, the equivalent stress and equivalent plastic strain of the billet reach a minimum, and the surface precision is excellent. Full article