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Materials (Basel, Switzerland) Jun 2024The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by...
The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out-In or In-Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design.
PubMed: 38930281
DOI: 10.3390/ma17122912 -
Materials (Basel, Switzerland) Jun 2024Additive manufacturing, commonly referred to as 3D printing, is a fabrication method characterized by a layer-by-layer deposition process [...].
Additive manufacturing, commonly referred to as 3D printing, is a fabrication method characterized by a layer-by-layer deposition process [...].
PubMed: 38930274
DOI: 10.3390/ma17122905 -
Materials (Basel, Switzerland) Jun 2024Medium-entropy alloys (MEAs) have attracted considerable attention in recent decades due to their exceptional material properties and design flexibility. In this study,...
Medium-entropy alloys (MEAs) have attracted considerable attention in recent decades due to their exceptional material properties and design flexibility. In this study, lightweight and non-equiatomic MEAs with low density (~5 g/cm), high strength (yield strength: 1200 MPa), and high ductility (plastic deformation: ≧10%) were explored. We fine-tuned a previously developed Ti-rich MEA by microalloying it with small amounts of Ni (reducing the atomic radius and increasing the elastic modulus) through solid solution strengthening to achieve a series of MEAs with enhanced mechanical properties. Among the prepared MEAs, Ti65Ni1 and Ti65Ni3 exhibited optimal properties in terms of the balance between strength and ductility. Furthermore, the Ti65Ni3 MEA was subjected to thermo-mechanical treatment (TMT) followed by cold rolling 70% (CR70) and cold rolling 85% (CR85). Subsequently, the processed samples were rapidly annealed at 743 °C, 770 °C, 817 °C, and 889 °C at a heating rate of 15 °C/s. X-ray diffraction analysis revealed that the MEA could retain its single-body-centered cubic solid solution structure after TMT. Additionally, the tensile testing results revealed that increasing the annealing temperature led to a decrease in yield strength and an increase in ductility. Notably, the Ti65Ni3 MEA sample that was subjected to CR70 and CR85 processing and annealed for 30 s exhibited high yield strength (>1250 MPa) and ductility (>13%). In particular, the Ti65Ni3 MEA subjected to CR85 exhibited a specific yield strength of 264 MPa·cm/g, specific tensile strength of 300 MPa·cm/g, and ductility of >13%.
PubMed: 38930268
DOI: 10.3390/ma17122900 -
Materials (Basel, Switzerland) Jun 2024This study presents the design, preparation, and characterization of thirty new medium-entropy alloys (MEAs) in three systems: Al-Ti-Nb-Zr, Al-Ti-Nb-V, and Al-Ti-Nb-Hf....
This study presents the design, preparation, and characterization of thirty new medium-entropy alloys (MEAs) in three systems: Al-Ti-Nb-Zr, Al-Ti-Nb-V, and Al-Ti-Nb-Hf. The hardness of the alloys ranged from 320 to 800 HV. Among the alloys studied, AlTiNbZr exhibited the highest-reversible hydrogen storage capacity (1.03 wt.%), with an H/M value of 0.68, comparable to LaNi, but with a reduced density (5.11 g·cm) and without rare earth elements. This study further reveals a strong correlation between hardness and hydrogen absorption/desorption; higher hardness is responsible for reduced hydrogen uptake. This finding highlights the interplay between a material's properties and hydrogen storage behavior in MEAs, and has implications for the development of efficient hydrogen storage materials.
PubMed: 38930265
DOI: 10.3390/ma17122897 -
Materials (Basel, Switzerland) Jun 2024The effects of Si addition on the microstructures and properties of CoCrNi medium-entropy alloy (MEA) were systematically investigated. The CrCoNiSi MEA possesses a...
The effects of Si addition on the microstructures and properties of CoCrNi medium-entropy alloy (MEA) were systematically investigated. The CrCoNiSi MEA possesses a single face-centered cubic (FCC) phase when x is less than 0.3 and promotes solution strengthening, while the crystal structure shows a transition to the FCC+σ phase structure when x = 0.4 and the volume fraction of the σ phase increases with a microstructure evolution as the Si content increases. The Orowan mechanism from σ precipitation effectively enhances the strength, hardness, and stain hardening of CrCoNiSi MEA, which also exhibits superior hardness at high temperatures. Furthermore, a large amount of σ phase decreases the wear resistance because of the transformation of the main wear mechanism from abrasion wear for σ-free CrCoNiSi MEA to adhesion wear for σ-contained CrCoNiSi MEA. This work contributes to the understanding of the effect of Si addition on FCC structured alloys and provides guidance for the development of novel Si-doped alloys.
PubMed: 38930262
DOI: 10.3390/ma17122893 -
Materials (Basel, Switzerland) Jun 2024In this study, two-mm-thick dual-phase LA103Z Mg-Li and 6061 Al alloys, known for their application in lightweight structural designs, were joined using dynamic support...
In this study, two-mm-thick dual-phase LA103Z Mg-Li and 6061 Al alloys, known for their application in lightweight structural designs, were joined using dynamic support friction stir lap welding (DSFSLW). The microstructural evolution and mechanical properties of dissimilar joints were investigated at different welding speeds. The analysis revealed two distinct interfaces: the diffusion interface and the mixed interface. The diffusion interface, characterized by a pronounced diffusion zone, is formed under slower welding speeds. The diffusion zone height, the effective lap width, and the interface layer thickness decrease with increasing welding speed due to low plastic deformation capacity and weak interfacial reactions. Conversely, the mixed interface, associated with higher welding speeds, contained large Al fragments. The extremely high microhardness values (130.5 HV) can be ascribed to the formation of intermetallic compounds (IMCs) and strain-hardened Al fragments. Notably, the maximum shear strength achieved was 175 N/mm at a welding speed of 20 mm/min. The fracture behavior varied significantly with the interface type; the diffusion interface showed enhanced mechanical strength due to better intermetallic reactions and interlocking structures, while the mixed interface displayed more linear crack propagation due to weaker IMCs and the absence of hook structures. Fracture surface analysis indicates that fractures are more likely to propagate through the Al matrix and interface layers.
PubMed: 38930252
DOI: 10.3390/ma17122883 -
Materials (Basel, Switzerland) Jun 2024The sluggish kinetics of oxygen reduction reactions (ORRs) require considerable Pd in the cathode, hindering the widespread of alkaline fuel cells (AFCs). By alloying Pd...
The sluggish kinetics of oxygen reduction reactions (ORRs) require considerable Pd in the cathode, hindering the widespread of alkaline fuel cells (AFCs). By alloying Pd with transition metals, the oxygen reduction reaction's catalytic properties can be substantially enhanced. Nevertheless, the utilization of Pd-transition metal alloys in fuel cells is significantly constrained by their inadequate long-term durability due to the propensity of transition metals to leach. In this study, a nonmetallic doping strategy was devised and implemented to produce a Pd catalyst doped with P that exhibited exceptional durability towards ORRs. PdP with an average size of 6.41 nm was synthesized by the heat-treatment phosphorization of Pd nanoparticles followed by acid etching. After P-doping, the size of the Pd nanoparticles increased from 5.37 nm to 6.41 nm, and the initial mass activity (MA) of PdP/NC reached 0.175 A mg at 0.9 V, slightly lower than that of Pd/C. However, after 40,000 cycles of accelerated durability testing, instead of decreasing, the MA of PdP/NC increased by 6.3% while the MA loss of Pd/C was 38.3%. The durability was primarily ascribed to the electronic structure effect and the aggregation resistance of the Pd nanoparticles. This research also establishes a foundation for the development of Pd-based ORR catalysts and offers a direction for the future advancement of catalysts designed for practical applications in AFCs.
PubMed: 38930248
DOI: 10.3390/ma17122879 -
Materials (Basel, Switzerland) Jun 2024Friction stir processing (FSP) was performed on an AZ91 magnesium alloy cladding layer fabricated by a cold metal transfer (CMT) technique. Electrochemical properties...
Friction stir processing (FSP) was performed on an AZ91 magnesium alloy cladding layer fabricated by a cold metal transfer (CMT) technique. Electrochemical properties and immersion corrosion behavior of the cladding layer before and after FSP in 3.5 wt.% NaCl solution were investigated. After applying the FSP, the corrosion potential and corrosion current density of the cladding layer increased from -1.455 V to -1.397 V and decreased from 4.135 μA/cm to 1.275 μA/cm, respectively. The results of OM and SEM displayed the refinement of grains and the dispersion of β-MgAl second phase in the friction stir processed (FSPed) cladding layer and more severe corrosion of the unprocessed sample. The corrosion rate of the FSPed cladding layer was lower, and a more compact corrosion product film was formed on the surface of the FSPed cladding layer. EDS results and XRD patterns showed that the corrosion products was mainly composed of Mg(OH). The increase in Al content in the α-Mg matrix, grain refinement, and fragmentation and dispersion of the β-MgAl second phase induced by FSP were the main factors that led to the improvement in corrosion resistance of the cladding layer of the AZ91 magnesium alloy fabricated by CMT.
PubMed: 38930245
DOI: 10.3390/ma17122875 -
Materials (Basel, Switzerland) Jun 2024Ultrasonic frequency pulse assisted TIG welding (UFP-TIG) experiments were conducted to join Inconel 690 alloy (IN690) by adding Inconel 718 alloy (IN718) as the filler....
Ultrasonic frequency pulse assisted TIG welding (UFP-TIG) experiments were conducted to join Inconel 690 alloy (IN690) by adding Inconel 718 alloy (IN718) as the filler. The effect of the filler on the microstructure, mechanical properties, and ductility dip cracking (DDC) susceptibility of IN690 joints were investigated. The results show that a variety of precipitates, including MC-type carbide and Laves phases, are formed in the weld zone (WZ), which are uniformly dispersed in the interdendritic region and grain boundaries (GBs). The increase in the thickness of the IN718 filler facilitates the precipitation and growth of Laves phases and MC carbides. However, the formation of Laves phases in the WZ exhibits a lower bonding force with the matrix and deteriorates the tensile strength of IN690 joints. Due to the moderate content of Laves phases in the WZ, the IN690 joint with 1.0 mm filler reaches the maximum tensile strength (627 MPa), which is about 96.5% of that of the base metal (BM). The joint with 1.0 mm filler also achieves the highest elongation (35.4%). In addition, the strain-to-fracture tests indicate that the total length of cracks in the joint with the IN718 filler decreases by 66.49% under a 3.8% strain. As a result, the addition of the IN718 filler significantly improves the mechanical properties and DDC resistance of IN690 joints.
PubMed: 38930226
DOI: 10.3390/ma17122857 -
Materials (Basel, Switzerland) Jun 2024Bulk metallic glasses are modern engineering materials with unique functional properties. Zr-based alloys are particularly attractive as they exhibit high glass forming...
Bulk metallic glasses are modern engineering materials with unique functional properties. Zr-based alloys are particularly attractive as they exhibit high glass forming ability as well as good mechanical properties. Due to their relatively high thermal stability, reaching as much as 400 °C, they can be surface-treated in low-temperature plasma to further improve their mechanical properties. The subject of this study was to determine the influence of the technological parameters of nitriding in low-temperature plasma on the structure and mechanical properties of ZrCuAlAg bulk metallic glass. In the course of this study, the influence of the ion accelerating voltage on the structure and micromechanical properties of the bulk metallic glass was analyzed. The produced samples were characterized in terms of nanohardness, layer adhesion by using the scratch test, and wear resistance by using the ball-on-disc method. As a result of low-temperature plasma nitriding, a significant increase in the surface nanohardness of the ZrCuAlAg bulk metallic glass was obtained. The produced layers exhibited high adhesion to the substrate and they improved the wear resistance of the glass. The present study indicates the possibility of modifying the surface properties of bulk metallic glasses by using diffusion processes in low-temperature plasma without substrate crystallization.
PubMed: 38930219
DOI: 10.3390/ma17122850