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Nickel-based coatings obtained by laser melting are broadly applied for surface modification owing to their high bond strength and exceptional wear resistance. Nickel-based laser cladding coatings are also extensively employed in high temperature wear environments. In this paper, the research progress on improving the high temperature wear resistance of laser cladding nickel-based composite coatings was reviewed by introducing a hard ceramic phase, adding solid lubricants and rare earth elements. On this basis, the material system to enhance the high temperature wear resistance of coating was summarized from the perspectives of the type, addition amount, morphology and distribution law of the hard ceramic phase, etc. The synergistic effect of various lubricants on improving the high temperature wear resistance of coating was discussed, and the action mechanism of solid lubricants in the high temperature extreme environment was analyzed. Finally, this paper summarizes the main difficulties involved in increasing the high temperature wear resistance of nickel-based coatings and some problems worthy of attention in the future development.

This paper proposes a new silver nanoscale joining material, silver nanowire film, as an alternative joining approach for high-power and large-size chip packaging. The silver nanowire film was prepared by pressing filtration with silver nanowire that was synthesized using the polyol method. We found that the tensile strength of the film reached 3.40 MPa and the content of the silver reached up to 99.0 wt%. This paper further studies the influence of the size of silver nanowires on the performance of silver nanowire film. The experimental results show that the silver nanowire films prepared with silver nanowires with longer lengths and smaller diameters displayed better performances. The silver nanowire film with the best performance was prepared using silver nanowire with a diameter of 88 nm and a length of 29 μm. The thermal resistance of the sintered silver nanowire film that was hot-pressed at 250 °C 10 MPa was only 1.28 K∙W−1. The shear strength of the sintered joint was 56.4 MPa, and the fracture that occurred in the sintered silver nanowire film displayed a good plasticity.

Composite materials such as Fiber Metal Laminates (FMLs) have attracted the interest of the aerospace and automotive industries due to their high strength to weight ratio, but to use them as structures it is necessary to master the manufacturing and wiring techniques of these materials. Therefore, this paper aims to address and summarize the drilling and milling processes in FMLs based on a literature review of papers published from 2000 to 2023. Parameters used in multi-material manufacturing and machining such as drilling and milling, tool geometry, tool coating, lubricants and coolants published by researchers were analyzed, compared and discussed. Machining process parameters related to sustainability were also analyzed. A SWOT analysis was carried out and discussed to identify opportunities for improvement in the machining process. There are opportunities to develop the surface treatment of aluminum alloys, such as testing other combinations than those already used, testing non-traditional surface treatments and manufacturing modes, and developing sustainable techniques during the FML manufacturing process. In the area of tooling, the opportunities are mainly related to coatings for tools and changing machining parameters to achieve an optimum finished part. Finally, to improve the sustainability of the process, it is necessary to test coated drills under cryogenic conditions to reduce the use of lubricants during the machining process.

The adjustment of sintering raw materials has a decisive influence on the composition of blast furnace slag and the properties of sinter. In order to smelt high-quality molten iron in the blast furnace, the composition of the sinter must be properly adjusted so that the composition of the blast furnace slag and the metallurgical properties of the sinter are optimal for the quality of the iron and are conducive to the smooth operation of the blast furnace. In view of the huge difference in the quality and price of sintering raw materials, this paper proposes an automatic sintering ore blending model to quickly configure sintering raw materials according to the requirements of the production line. This method is based on the calculation process of blast furnace charge, combined with the constraints of process composition and cost performance, to establish a multi-decision sintering ore blending model based on the OLS(Ordinary least squares) algorithm to automatically screen from available raw materials and give the sinter that meets the requirements of the furnace. The plan finally makes TFe, CaO, MgO, SiO2, TiO2, Al2O3, P, Mn, Na2O, K2O, Zn, and other components meet the requirements of the production line, and meet the cost performance requirements of the enterprise for sinter. The model can complete the screening and proportioning of 43 kinds of raw materials within 10 s, and its performance can meet the requirements of the production of variable materials. Combined with an example, a comparative analysis experiment is carried out on the accuracy and practicability of the designed sintering and ore blending model. The experimental results show that the accuracy and efficiency of the method proposed in this paper are higher than those of the current ore blending scheme designed by enterprise engineers. This method can provide an effective reference for the stable operation of the sintering production line.

Twinning is a major mechanism of plastic deformation in hexagonal close-packed (hcp) structures. However, a mechanistic understanding of twin nucleation and growth has yet to be established. This paper reviews the recent progress in the understanding of twinning in hcp materials—particularly the newly discovered phase transformation-mediated twinning mechanisms—in terms of crystallographical analysis, theoretical mechanics calculations, and numerical simulations. Moreover, the relationship between phase transformation-mediated twinning mechanisms and twinning dislocations are presented, forming a unified understanding of deformation twinning. Finally, this paper also reviews the recent studies on transformation twins that are formed in hcp martensite microstructures after various phase transformations, highlighting the critical role of the mechanical loading in engineering a transformation twin microstructure.

Thin-walled structures are widely used in anti-collision devices for various vehicles due to their light weight and high energy absorption. Offset collision is a common scene in various traffic accidents. Because the commonly used thin-walled structures do not consider this complex collision method, the energy absorption effect of the structure cannot meet the requirements. In this paper, a C-shaped frame structure composed of thin-walled steel tubes is proposed. The configuration of the structure is studied through theoretical analysis and numerical simulation, and it is found that the structure can absorb energy stably in the offset collision. The offset experiment and simulation were carried out, and the crashworthiness of the structure was investigated to verify the accuracy and feasibility of the numerical analysis method. A large-scale parameter simulation analysis was carried out, and the influence characteristics of the structure configuration, different materials and different sections were investigated. Based on the above test and numerical analysis results, an optimal design method for improving the crashworthiness of structures considering offset collisions is proposed. This paper can provide theoretical and technical support for the related research on the integrated anti-climbing energy-absorbing parts of rail trains under offset collision.

Metallic materials are widely employed in engineering constructions, and one of the most common failure mechanisms in metals is fatigue failure. Even though metal fatigue has been studied for almost 160 years, many problems remain unsolved. Fatigue in metal occurs when the metallic material is subjected to varying loads, resulting in failure due to damage accumulation. The fatigue process consists of a buildup of damage that leads to crack initiation, followed by a period of crack growth until the critical flaw size is reached. The sum of a start phase and a propagation phase represents the total life. To better understand the fatigue phenomenon at its different stages and predict the fatigue life, various types of prediction models have been developed and reported in the literature. This paper reviewed the different models that include microstructure scale parameters that can be used to predict how fatigue cracks start under variable amplitude loading, including the Modified Tanaka-Mura Model, Acoustic Second Harmonic Generation, and the Probability of Crack Initiation on Defects. For perfect life prediction under variable amplitude loading, a stress-based approach, a strain-based approach, and a continuum damage mechanics approach are reviewed. The purpose of this paper is to get overview of the current state of approaches to the life prediction of fatigue crack initiation with variable amplitude. Finally, gaps in knowledge about the prediction of fatigue crack initiation under variable loading at high temperatures are pointed out.

The concept of repair and restoration using additive manufacturing (AM) is to build new metal layers on a broken part. It is beneficial for complex parts that are no longer available in the market. Optimization methods are used to solve product design problems to produce efficient and highly sustainable products. Design optimization can improve the design of parts to improve the efficiency of the repair and restoration process using additive manufacturing during the end-of-life (EoL) phase. In this paper, the objective is to review the strategies for remanufacturing and restoration of products during or at the EoL phase and facilitate the process using AM. Design optimization for remanufacturing is important to reduce repair and restoration time. This review paper focuses on the main challenges and constraints of AM for repair and restoration. Various AI techniques, including the hybrid method that can be integrated into the design of AM, are analyzed and presented. This paper highlights the research gap and provides recommendations for future research directions. In conclusion, the combination of artificial neural network (ANN) algorithms with genetic algorithms as a hybrid method is a key solution in solving limitations and is the future for repair and restoration using additive manufacturing.

Ultrasonic-assisted wire–arc additive manufacturing (WAAM) can refine microstructures, enhancing performance and improving stress concentration and anisotropy. It has important application prospects in aerospace, weaponry, energy, transportation, and other frontier fields. However, the process parameters of ultrasonic treatment as an auxiliary technology in the WAAM process still have an important impact on product performance indicators, such as the amplitude of the ultrasonic tool, the distance between the points of action of the product, and the scanning speed. The number of ultrasonic impacts influences the performance indexes. Therefore, these parameters must be optimized. This paper describes the advantages and the defects of WAAM components, as well as the principle and development status of ultrasonic treatment technology. Subsequently, this paper also briefly describes how ultrasonic-assisted technology can refine the crystal and improve the mechanical properties of WAAM components. Finally, we review the influence of process parameters (such as ultrasonic amplitude, application direction, and impact times) on the product materials. In this paper, a comprehensive optimization method for ultrasonic parameters is proposed to improve the mechanical properties of WAAM components.

With multiple principal components, high entropy alloys (HEAs) have aroused great interest due to their unique microstructures and outstanding properties. Recently, the corrosion behavior of HEAs has become a scientific hotspot in the area of material science and engineering, and HEAs can exhibit good protection against corrosive environments. A comprehensive understanding of the corrosion mechanism of HEAs is important for further design of HEAs with better performance. This paper reviews the corrosion properties and mechanisms of HEAs (mainly Cantor alloy and its variants) in various environments. More crucially, this paper is focused on the influences of composition and microstructure on the evolution of the corrosion process, especially passive film stability and localized corrosion resistance. The corrosion behavior of HEAs as structural materials in nuclear industry applications is emphasized. Finally, based on this review, the possible perspectives for scientific research and engineering applications of HEAs are proposed.

Numerous studies indicate that the hardening behaviors of materials are closely related to their deformation history. In the forming processes with loading path changes, such as sheet metal forming, anisotropic hardening behaviors are universally observed. In this situation, selecting or constructing a suitable anisotropic hardening model is essential. This paper presents a review of the phenomenological modeling of the deformation-induced anisotropic hardening behaviors. At the beginning, the deformation-induced hardening behaviors are introduced together with the relevant experiments. Different from other published review works, this paper is not laid out according to the description of a series of models. Instead, the modeling is emphasized by generalizing the main mathematical modeling ideas among various hardening models and sorting out the description methods for the decomposed anisotropic hardening behaviors. Some prospective development directions for the modeling of anisotropic hardening behaviors are suggested at the end of this work. This review work tries to provide the researchers with an instruction on how modeling for the anisotropic hardening behaviors according to the materials and forming processes.

This paper proposes a combined microwave and ultrasonic technique that aims to extract the refractory mineralogical properties of complex zinc ore. This technique consists of two steps: microwave-assisted phase transformation and ultrasonic-assisted complexation leaching. During the microwave-assisted phase transformation step, the refractory zinc phases transform into manageable phases using doping oxidation agents. In the ultrasonic-assisted complexation leaching step, the effect of NTA3 on Zn2+ species distribution is explored. The results show that microwave roasting with 20% Na2O2 at 600 °C for 15 min adequately transforms ZnS, ZnCO3 and Zn2SiO4 into ZnO and avoids the generation of Zn2SiO4. Further, 0.5 mol/L NTA3− (nitrilotriacetic acid) is especially effective as a complex additive for complexes with Zn2+ as Zn (NTA)24−. The ultrasonic technique can reduce the diffusion resistance and open the products in the leaching process, improving zinc leaching by 4.7%. The degree of zinc recovered from zinc ore can reach 91.4% when leach is assisted with 225 W ultrasonic force at 80 °C for 75 min. This paper shows great potential for the green extraction of non-traditional zinc-containing resources.

The purpose of this paper is to develop a new technology for controlling the quenching deformation of light cast aluminum alloy wheels. First, based on the existing wheel heat treatment process, a gas–liquid–solid multi-phase flow coupling model was established through the ANSYS Workbench platform to analyze the gas–liquid phase change, heat exchange on wheel surface and quenching deformation characteristics during the process of wheel immersion into the water. The results show that heat exchange characteristics of the wheel surface are comprehensively affected by wheel structure, quenching fluid flow field and gas–liquid phase transition. There are a lot of non-uniform heat exchange areas in the outer rim, spoke area and center area, which affect the overall deformation characteristics. Affected by spoke structure, the maximum deformation occurs at the outer and inner rim end faces farthest away from the wheel. Based on the above research, this paper independently develops a new deformation control strategy of spray and water immersion composite step process. Through spraying, the influence of spoke structural stiffness on the overall deformation characteristics of the wheel is effectively reduced, and the wheel deformation control is realized by meeting the mechanical properties of the wheel, with the maximum deformation reduction of 39.2%. This study provides a new option for the integrated control of deformation and mechanical properties of aluminum alloy wheels.

Aiming at the problems of large elastic deformation and low machining accuracy in cutting titanium alloy thin-walled parts, this paper establishes the finite element model of milling titanium alloy thin-walled parts, and simulates and analyses the milling process of titanium alloy thin-walled parts by the statics analysis module of ANSYS 15.0 software. The maximum deformation point of the workpiece in the milling process is determined. Then the combination of cutting parameters that can minimize the deformation is determined by the orthogonal experiments of four factors and four levels. This paper designs the single factor experiments, which study the distribution of the milling force and the deformation law of the parts in the milling process. Moreover, this paper carries out the optimal design of the cutting parameters by orthogonal experiments, which provides a reference for the selection of the cutting parameters for the bending thin-walled parts of titanium alloy.

A method of ultrasonic surface plastic deformation is widely used to change the properties of the surface layers of metal products. Under the influence of this type of treatment, the structure of the material changes, microhardness increases, roughness decreases, internal tensile stresses are removed, and compressive stresses are created. Now many types of ultrasonic surface plastic deformation have been developed, which differ in the degree of impact on the material. The object of this paper is to study the change in the microgeometry of steel 45 (ASTM M1044; DIN C45; GB 45) under the action of ultrasonic plastic deformation by a free deforming element (indenter in the form of a surface rolling ball). During the study, factors that have the greatest influence on the change in the microgeometry of the sample during treatment were identified. These include the initial roughness of the sample, the number of passes of the indenter, the feed of the indenter, the force with which the indenter is pressed to the treated surface, and the amplitude of the oscillations of the ultrasonic horn. The paper presents the dependences of changes in the main roughness parameters on the above factors. The value of the initial roughness at which it is possible to obtain a uniform surface microrelief is determined. The optimization of treatment parameters providing a change in the height and step parameters of roughness was carried out. Recommendations for choosing the most effective technological modes of ultrasonic treatment of steel 45 with a surface rolling ball are given.

Aiming at the problems of the blurred image defect contour and the surface texture of the aluminum strip suppressing defect feature extraction when collecting photos online in the air cushion furnace production line, we propose an algorithm for the surface defect enhancement and detection of aluminum strips based on the Retinex theory and Gobar filter. The Retinex algorithm can enhance the information and detail part of the image, while the Gobar algorithm can maintain the integrity of the defect edges well. The method first improves the high-frequency information of the image using a multi-scale Retinex based on a Laplacian filter, scales the original image and the enhanced image, and enhances the contrast of the image by adaptive histogram equalization. Then, the image is denoised, and texture suppressed using median filtering and morphological operations. Finally, Gobar edge detection is performed on the obtained sample images by convolving the sinusoidal plane wave and the Gaussian kernel function in the null domain and performing double-threshold segmentation to extract and refine the edges. The algorithm in this paper is compared with histogram equalization and the Gaussian filter-based MSR algorithm, and the surface defects of aluminum strips are significantly enhanced for the background. The experimental results show that the information entropy of the aluminum strip material defect image is improved from 5.03 to 7.85 in the original image, the average gradient of the image is improved from 3.51 to 9.51 in the original image, the contrast between the foreground and background is improved from 16.66 to 117.53 in the original image, the peak signal-to-noise ratio index is improved to 24.50 dB, and the integrity of the edges is well maintained while denoising. This paper’s algorithm effectively enhances and detects the surface defects of aluminum strips, and the edges of defect contours are clearer and more complete.

Connecting a variable groove weldment is always challenging, and it is necessary to monitor the course of the work and optimize the welding process parameters in real time to ensure the final welding forming quality. Welding penetration is an important index to appraise the welding forming quality; the visual sensing method for molten pool is the main method for detecting the weld penetration, but its detection accuracy is affected by the arc light. In this paper, a welding penetration sensing method for variable groove weldments based on the welding temperature field distribution is proposed. Firstly, a set of temperature field measurement system for a weldment is developed by means of an infrared sensor. Secondly, in the direction perpendicular to the welding direction, a linear temperature distribution feature extraction algorithm based on Gaussian fitting is studied; in the direction parallel to the welding direction, the linear temperature distribution feature extraction algorithm based on the thermal cycle parameters is studied, and the feasibility of using the extracted linear temperature distribution features to identify the weld penetration of a variable groove weldment is analyzed. Finally, taking the extracted linear temperature distribution features as input, using an artificial neural network, the prediction model for the welding penetration of a variable groove weldment is established. The experimental results showed that the weld penetration sensing method put forward in this paper can realize high-precision weld penetration sensing and has high reliability, which solves the problem that weld penetration sensing is affected by arc light to a great extent.

Closed-cell aluminum foam has a porous structure and metal properties due to its unique composition. As a structural material, it has the advantages of being lightweight, having a large specific surface area, and having high specific strength and stiffness. As a functional material, it can be used for sound and noise reduction, heat insulation, electromagnetic shielding, damping, and energy absorption, but it also has poor mechanical properties and poor surface flatness, and can be easily corroded. Considering the abovementioned problems, researchers have gradually extended their research on foam materials. Under the research of many international scholars, studies have shifted from simple aluminum foam preparation to improving and optimizing aluminum foam composite structures (AFCSs). From the perspective of development prospects, AFCSs have better application prospects than single aluminum foam. In this paper, the research progress on the preparation technology of AFCSs in recent years was reviewed based on the performance enhancement mechanism of aluminum matrix composites and the structural characteristics of aluminum foam. The morphology and pore structures of closed-cell AFCSs under different preparation methods were summarized. However, due to the limitations of existing experimental conditions, this paper only considered the advantages and disadvantages of AFCS preparation methods. The improvement of AFCS preparation technology, the development of the potential properties of AFCSs, and the promotion of AFCS industrial applications were also considered.

The joint is a key component of the aviation piping system, with severe performance requirements and better requirements for connection technology. With a focus on the manufacturing demand of AA6061 aerospace pipe joints, as well as the characteristics of EMP forming technology, this paper investigates the deformation behavior of the EMP forming on AA6061 aerospace pipe joints, the influence of process parameters on the deformation behavior, and the deformation mechanism of the tube wall. The results show that under the conditions of this paper, with an increase in the initial tube-sleeve gap and discharge voltage, the degree of local deformation of the AA6061 tube wall and the trench embedding rate increase. Keeping the width and depth of the grooves as 1.14 mm and 0.23 mm, the embedding rate of the grooves is less than 85% under the clearance conditions of 0.11 mm and 0.5 mm, while the lowest voltage for the embedding rate of the grooves to reach more than 85% under the clearance conditions of 1 mm, 1.5 mm and 2 mm is 7 kV, 6 kV, and 5 kV, respectively. The metallographic organization of the deformation area shows that the tube is deformed by the intense shear at the edge of the groove of the tube sleeve, thereby showing streamlined organization characteristics and deformation characteristics. The electromagnetic pulse forming process of the AA6061 tube is mainly divided into two stages: free bulging and local deformation; the inertia of high-rate deformation causes the groove filling to exhibit volume deformation characteristics in the local deformation stage.

Cu-containing steels can suffer from hot shortness unless Ni is added to protect them but whether this problem also influences the straightening operation is not clear. Previous work on hot ductility has found that only when the tensile samples from Cu-containing steels are oxidised can any deleterious influence of copper be found. However, this paper shows that oxidation is not essential. It is more complex than that and, as Cu has been suggested for TRIP steels at levels up to 2.5% Cu to increase their strength and ductility, a greater understanding is required, both of hot shortness and cracking during straightening. The present paper explores the hot ductility behaviour of steels alloyed with Cu and Ni in the straightening temperature range, 700–1000 °C, when tested in air and in an argon atmosphere. Segregation of Cu to the sulphides and grain boundaries occurred allowing the formation of fine Cu2S particles at the austenite grain boundaries favouring intergranular failure and this was more pronounced under oxidising conditions and required strain. It was concluded that a Cu addition, as well as causing hot shortness at higher temperatures will also cause cracking problems in the straightening temperature range in the more sensitive to cracking grades of steel and although the problems are different they are nevertheless interrelated and provided there is sufficient Ni, both may be avoided.

The objective of the study is to improve understanding of the practical role of niobium (Nb) in the case of industrial inconsistent rolling processes such as the rolling of heavy gauge plates where a lower stored energy rolling practice will result in a less stable and less repeatable static recrystallization (SRX) activation that prevents complete recrystallization. In the current study, these variabilities are validated by comparing the mean flow stress (MFS) indirectly determined from the rolling force measured on a reverse four-high rolling mill stand. The material resistance to deformation and grain size evolution of a C-Mn steel during hot rolling was observed and validated with and without Nb addition. The pre-defined rolling schedule was predicted to exhibit incomplete recrystallization in the roughing phase due to the limited stored energy of deformation that resulted from low rolling loads and a higher number of rolling passes. The prior austenite grain size (PAGS) distribution was predicted and compared to the measured effective ferrite grain (FG) size distribution after the completion of hot rolling and phase transformation achieved using natural air plate cooling. Both the predicted PAG and measured FG distributions revealed the presence of multimodality, and both distributions were used for grain size reduction factor determination for γ → α transformation for the current study with 1.96 for 0 Nb and 1.70 for 240 Nb. The results presented in this paper are not only limited to the rolling schedule used in this paper because instabilities resulting in incomplete austenite conditioning are also observed when evaluating the cross-sections of other heavy plates and various steel grades utilizing different processing routes with comparable compositions such as modern lean abrasion-resistant steels, regular line pipe steels, and other similar grades.

This paper evaluates the effect of stress-relieving heat treatment on the AlSi10Mg alloy prepared by additive manufacturing using the Laser Powder Bed Fusion (L-PBF) with print parameters: 370 W, 1400 m/s, and 50 μm. The as-built state and four different annealing modes (240 °C/2 h, 240 °C/6 h, 300 °C/2 h, and 300 °C/2 h/water-quenched) are investigated. To determine the effect of the annealing mode on the mechanical properties of the L-PBF AlSi10Mg alloy, heat-treated samples were compared with the as-built state and with each other. The mechanical properties of the samples were determined by tensile and hardness tests. The strength in the as-built state is 488 MPa, depending on the method of heat treatment, the strength values range from 296 MPa to 417 MPa, and the HV10 hardness values are in accordance with the measured strength values. Furthermore, the microstructure of the samples was investigated by scanning electron microscopy (SEM) analysis, which was then linked to the measured mechanical properties. The composition of the microstructure of the alloy and its influence on the mechanical properties were determined by energy dispersive spectroscopy (EDS) analysis. Furthermore, the differences between the individual heat treatments in comparison with the as-built state were analyzed and the phenomenon of decomposition of the silicon network after reaching specific temperatures was discussed and confirmed. The paper evaluates the effect of dwelling time on stress relief annealing. It was found that if annealing at intermediate temperatures of 240 and 300 °C is applied, changes in structure and mechanical properties are more temperature- than dwell-time-dependent.

This paper presents a 0.25 scale quasi-three-dimensional hydraulic model experiment of transient fluid flow phenomena during continuous casting of steel. The relationship between the continuous casting process and the hydraulic jump phenomenon is established. The casting process in the mold is divided into four stages (I–IV) from the beginning to the end of continuous casting. The filling process involves stages I–II and is investigated by high-speed camera. The filling process is part of the cast start. In this paper, the hydraulic jump behavior varies and is controlled by different spring and iron chips arrangement on the dummy bar during the filling process. A filling coefficient is proposed to judge the best filling conditions and apply them to the whole filling process. There is an optimal spring and iron chip arrangement, which can adjust the hydraulic jump to optimize the initial flow field during the filling process, even the whole continuous casting process.

In this paper, the research progress on the strengthening of copper and copper alloy is reviewed. The research shows that traditional strengthening methods are often accompanied by the decrease of plasticity, and there are limitations in size, cost, and other aspects in the process. The in-situ nanoparticle strengthening and plasticizing technology proposed in recent years can avoid the above problems. In this paper, the idea of in-situ nanoparticle strengthening is introduced to realize the simultaneous enhancement of strength and ductility of as-cast pure copper and tin bronze alloys. The effects of in-situ precipitation of iron-rich nanoparticles on the microstructure, and mechanical properties of different copper alloy systems, are systematically elucidated based on the former characterization and mechanical testing results. The results show that the in-situ introduction of iron-rich nanoparticles in the copper systems induces the formation of a nano precipitate-fine grain (NPFG) structure, which greatly improves the strength and ductility of copper alloys. The evolution of size, distribution, number density, morphology evolution in iron-rich nanoparticles, and the formation mechanism of NPFG structure, as well as the mechanism of NPFG strengthening and toughening, are summarized. An industrial-applicable casting process is proposed to prepare bulk NPFG structured copper alloys with complex shape, high strength, and high ductility.

As the lightest structural materials, Mg alloys show great effectiveness at energy saving and emission reduction when applied in the automotive and aerospace fields. In particular, Zr-bearing Mg alloys (non-Al containing) exhibit high strengths and elevated-temperature usage values. Zr is the most powerful grain refiner, and it provides fine grain sizes, uniformities in microstructural and mechanical properties and processing formability for Mg alloys. Due to the importance of Zr alloying, this review paper systematically summarizes the latest research progress in the grain refinement effects of Zr on Mg alloys. The main points are reviewed, including the alloying process of Zr, the grain refinement mechanism of Zr, factors affecting the grain refinement effects of Zr, and methods improving grain refinement efficiency of Zr. This paper provides a comprehensive understating of grain refinement effects of Zr on Mg alloys for the researchers and engineers.

Be-Al alloy is a type of in situ metal matrix composite composed of a primary Be phase for strength and stiffness and a continuous Al matrix for ductility and toughness. Be-Al alloy (AlBe-Cast®910) has the characteristics of low density (2.17 g/cm3), high elastic modulus (193 GPa) and specific stiffness (88.94 GPa/(g/cm3)) as a preferred material for lightweight aerospace products. Investment casting technology can be employed to prepare the components with thin-walled complex structures for aerospace; however, the wide solidification range for Be-Al leads to difficulty in feeding a casting and results in extensive shrinkage and porosity in cast parts. In this paper, the characteristics of Be-Al alloy are introduced first. Secondly, the mechanisms of influence of adding elements on the casting process, mechanical properties (strength increases more than 20% by adding elements) and microstructure evolution are explained in detail. In addition, the heat treatment technology (strength increases at least 10% after heat treatment) and the repair of defects by electron beam welding are discussed. Finally, Be-Al alloy is a new type of composite material, and China is a major research and application country; this paper introduces its research status and analyzes existing problems and shortcomings and points out the direction of Be-Al alloy development in China in the next few years.

Vision-based welding seam tracking is an important and unique branch of welding automation. Active vision seam tracking systems achieve accurate feature extraction by using an auxiliary light source, but this will introduce extra costs and the real-time performance will be affected. In contrast, passive vision systems achieve better real-time performance and their structure is relatively simple. This paper proposes a passive vision welding seam tracking system in Plasma Arc Welding (PAW) based on semantic segmentation. The BiseNetV2 network is adopted in this paper and online hard example mining (OHEM) is used to improve the segmentation effect. This network structure is a lightweight structure allowing effective image feature extraction. According to the segmentation results, the offset between the welding seam and the welding torch can be calculated. The results of the experiments show that the proposed method can achieve 57 FPS and the average error of the offset calculation is within 0.07 mm, meaning it can be used for real-time seam tracking.

Several additive manufacturing processes are capable of fabricating three-dimensional parts with complex distribution of material composition to achieve desired local properties and functions. This unique advantage could be exploited by developing and implementing methodologies capable of optimizing the distribution of material composition for one-, two-, and three-dimensional parts. This paper is the first effort to review the research works on developing these methods. The underlying components (i.e., building blocks) in all of these methods include the homogenization approach, material representation technique, finite element analysis approach, and the choice of optimization algorithm. The overall performance of each method mainly depends on these components and how they work together. For instance, if a simple one-dimensional analytical equation is used to represent the material composition distribution, the finite element analysis and optimization would be straightforward, but it does not have the versatility of a method which uses an advanced representation technique. In this paper, evolution of these methods is followed; noteworthy homogenization approaches, representation techniques, finite element analysis approaches, and optimization algorithms used/developed in these studies are described; and most powerful design methods are identified, explained, and compared against each other. Also, manufacturing techniques, capable of producing functionally graded materials with complex material distribution, are reviewed; and future research directions are discussed.

Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., “LAMMPS Molecular Dynamics Simulator,” or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help.

In recent decades, the electromagnetic induction quenching approach has been widely applied in the surface treatment process of steel engine parts such as crankshafts. In this paper, the strengthening effect of this approach was selected to be the object of study. First, the multi-physics coupling phenomenon was established by a 3D finite element simulation approach. Then, the fatigue property of the crankshaft was predicted based on the combination of the residual stress field obtained in the previous step and a chosen multi-axial fatigue damage model. Finally, a corresponding experiment verification was carried out to check the accuracy of the prediction. The results showed that the method proposed by this paper can provide high enough accuracy in predicting the fatigue property of two types of commonly used steel crankshafts.

Nowadays, advanced turning processes are extensively being adopted to perform different types of turning operations such as straight turning, taper turning on Hastelloy, Nimonic, and Inconel, stainless steel, and tool steel to fabricate better quality cylindrical and rotating parts such as miniature-bars, miniature-pins, miniature-electrodes, and miniature-tools. This paper presents a review of the previous research conducted on the turning of miniature cylindrical bars using thermoelectric-erosion based turning processes namely thermoelectric-erosion turning (TET) and wire-assisted thermoelectric-erosion turning (WTET). It also highlights work and tool electrode materials, types of dielectrics, detailed specifications of turning, types of turning, process parameters, performance measures, advantages and limitations, and key findings. The paper ends with conclusions and future research directions. This paper aims to facilitate researchers and scholars by highlighting the potential and capabilities of TET and WTET processes and providing relevant information for ease of fabrication of miniature parts and components from a wide range of difficult-to-machine materials.

Porous materials have significant advantages, such as their light weight and good specific energy absorption. This paper presents the designs of two ordered Voronoi structures, a truncated octahedron (Octa) and a rhombic dodecahedron (Dodeca), based on spatial Voronoi tessellation. Through a numerical analysis, the dynamic behavior, deformation and energy absorption of the two porous structures under different impact energies were explored. According to the energy-absorption index, the effects of porosity, rotating unit cell and unit-cell shape on the energy absorption of the porous structures were quantitatively evaluated. The study shows that, for Dodeca and Octa structures subjected to various impact energies, the force-displacement curves exhibit three modes. The porosity, rotational unit cell and unit-cell shape play a crucial role in affecting the impact resistance of porous structures. The work in this paper proposes an effective way to improve the energy-absorption capacity of porous structures under different impact energies. At the same time, a new understanding of the deformation mechanism of Octa and Dodeca was obtained, which is significant for the impact-resistance design and energy-absorption evaluation of porous structures.

In this paper, four array patterns were first designed by observing the structural features of the surface microstructures of pig bones and tree frog paws on the titanium alloy surface bionically. Then, the optimal parameters for laser processing were determined experimentally, and the optimized processing parameters were used to prepare micron-scale bumps on the titanium alloy surface and to investigate the relationship between the weaving height and the processing times. Finally, multiple acid etching was used to prepare nanoscale holes on the surface of the titanium alloy. It was found that the multiple acid etching could not only prepare nanoscale holes on the surface of the titanium alloy, but could also well eliminate the slag left on the surface of titanium alloy by laser ablation. Based on the above study, this paper also analyzed the effect of micro-nano structure on the friction properties of the titanium alloy surface from three aspects—theory, hardness test and friction coefficient test—and experimentally analyzed the effect of single-factor and multi-factor coupling of structural features on the friction properties of the titanium alloy surface. It was found that the optimal mean friction coefficient was 0.0902, corresponding to the characteristic values of 0.66 for the shape, 200 μm for the edge length and 60 μm for the height.

To date, scholars’ research on the stability behavior of the arch structure mainly focuses on solid–web section arches, steel tubular truss arches and concrete-filled steel tubular arches, but the stability behavior of the novel spatial grid arch structure, which integrates the characteristics of grid structure and arch structure, is not yet clear. Based on the Eye of the Yellow Sea pedestrian bridge project in Rizhao, China, the stability behavior of this large-span spatial grid arch structure was studied, in this paper, by the project’s structure design team. The project is a glass covered steel arch pedestrian bridge with a span of 177 m, a height of 63.5 m, an elliptical section with a long axis of 18 m, and a short axis of 13.5 m. The elastic and the nonlinear elasto-plastic stability behavior considering different initial geometric imperfections, was analyzed by the ABAQUS finite element model. The buckling modes and the full-range load-displacement curve of the structure were analyzed, and the stress distribution, deformation mode and overall structural performance during the whole loading process were analyzed. The effects of initial imperfections, geometric nonlinearity and material nonlinearity on the ultimate load-carrying capacity of the structure were studied. The stability behavior of large-span spatial grid arch structure was studied in this paper, which provides an important reference for the design and analysis of such structures.

The paper proposes partially connected steel plate shear walls, in which the infill plates and frames are connected by discretely distributed fish plates at the corners and at the centers. The high lateral resistance of a steel plate shear wall has led to its widespread use in the design of structural shear resistance. In this paper, finite element models of the partially connected steel plate shear walls are established by the finite element method, and the effect of the different partial connections on the shear strength is firstly investigated. Moreover, the variation of the shear strength with the plate-to-frame connectivity ratio is analyzed numerically, and the effect of the connectivity ratio on the development of the tensile field is studied. Based on the numerical analysis results, the effect of the connectivity ratio on shear strength is evident at low levels. When the connectivity ratio is over 80%, the shear strength of the partially connected steel plate shear wall can reach 95% of that of the fully connected steel plate shear wall. When the connection ratio is at a low level, the advantages of the central connection on the shear strength of the structures are higher than those with corner connections. Furthermore, the fitting formula for the partially connected steel plate shear wall is obtained by changing the connectivity ratio and width-to-height ratio of the examples, which can predict the shear capacity of the partially connected steel plate shear wall with different partial connections.

In this paper, a new low-carbon alloy gear steel is designed via Si/Al alloying. The carburizing and austempering, at a temperature slightly higher than the martensitic transformation point (Ms) of the surface and much lower than the Ms of the core, for different times, were carried out on the newly designed gear steel. After heat treatment, a series of different microstructures (superfine bainitic ferrite + retained austenite, superfine bainitic ferrite + martensite + retained austenite, and martensite + retained austenite) were obtained on the surface, whilst the low-carbon lath martensitic microstructure was obtained in the core. The microstructure of the surface was examined using optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The phase composition was analyzed using X-ray diffraction (XRD). The hardness and wear resistance of the surface as well as the hardness distribution of carburizing layer of the samples with different microstructures were studied. The results show that the Si/Al-rich gear steel, after carburizing and austempering at 200 °C for 8 h, not only has excellent mechanical properties but also has high wear resistance, which meets the technical requirements of heavy-duty gear steel. The research work in this paper can provide a data reference for the application of carburized steel with mixed microstructures of bainitic ferrite and martensite in the design of heavy-duty gear.

Titanium-containing carbide slag (TCS) is the product obtained by high-temperature carbothermal reduction in Titanium-bearing blast furnace slag (TBFS), which contains a large amount of TiC phase with excellent electrical conductivity. In this paper, conductive cement mortar was prepared with TCS as an aggregate and graphite as a conductive phase. The content of graphite on the compressive strength and electrical resistivity of the prepared cement mortar was investigated. The results showed that the replacement of standard sand with TCS as an aggregate not only significantly reduced the electrical resistivity of the cement mortar, but also improved its compressive strength. When the graphite content was 10 wt%, the cement mortar with TCS as the aggregate exhibited excellent comprehensive performance with the 28d compressive strength of 34.0 MPa and the electrical resistivity of 2.9 Ω m in dry condition, respectively. The results of this paper provided a new way both for the utilization of TBFS and the preparation of conductive cement mortars.

Milling with minimum quantity lubrication (MQL) is now a commonly used machining technique in industry. The application of the MQL significantly reduces the temperature on the machined surface, while the cost of the lubricants is limited and the pollution caused by the lubricants is better controlled. However, the fast prediction of the milling temperature during the process has not been well developed. This paper proposes an analytical model for milling temperature prediction at the workpiece flank surface with MQL application. Based on the modified orthogonal cutting model and boundary layer lubrication effect, the proposed model takes in the process parameters and can generate the temperature profile at the workpiece surface within 1 min. The model is validated with experimental data in milling AISI D2 steel. With an average absolute error of 10.38%, the proposed model provides a reasonable temperature prediction compared to the experimental results. Based on the proposed model, this paper also investigates the effect of different cutting parameters on the cutting temperature. It is found that the application of the MQL decreases the temperature at the cutting zone, especially at the flank surface of the workpiece, which is due to the heat loss led by air-oil flow.

Ti-6Al-4V (Ti64) alloy is one of the most widely used orthopedic implant materials due to its mechanical properties, corrosion resistance, and biocompatibility nature. Porous Ti64 structures are gaining more research interest as bone implants as they can help in reducing the stress-shielding effect when compared to their solid counterpart. The literature shows that porous Ti64 implants fabricated using different additive manufacturing (AM) process routes, such as laser powder bed fusion (L-PBF) and electron beam melting (EBM) can be tailored to mimic the mechanical properties of natural bone. This review paper categorizes porous implant designs into non-gradient (uniform) and gradient (non-uniform) porous structures. Gradient porous design appears to be more promising for orthopedic applications due to its closeness towards natural bone morphology and improved mechanical properties. In addition, this paper outlines the details on bone structure and its properties, mechanical properties, fatigue behavior, multifunctional porous implant designs, current challenges, and literature gaps in the research studies on porous Ti64 bone implants.

Repairing the worn surfaces of wear-resistant workpieces, such as rollers, is one of the main application fields of surface treatment, but the repairing time is often not considered. In fact, the repairing time is very important, since it affects the repair quality and service life of wear-resistant workpieces. In this paper, a remelted gradient coating was prepared on a ductile iron plate by plasma transferred arc to simulate the repair treatment of wear-resistant workpieces. First, two positions in the remelted gradient coating were defined, i.e., the top of the gradient remelted layer was defined as M1, and the position where the hardness was two-thirds of the top of the remelting layer was defined as M2. Next, the time taken to repair the workpiece when the working surface reached M2 was proposed. Finally this method was verified by a comparative study on the microhardness and wear resistance of the M1 and M2. In this paper, the M2 was located at a ~0.5 mm from the top of the remelted gradient layer. The results show that the microhardness of the position of the M1 was higher than that of the position of the M2. However, the wear resistance of the M1 was worse, as confirmed by the wear rates. At the same time, cracks and fragments were observed on the worn surface of the M1 and M2 positions. Furthermore, the coefficient of friction (COF) of the position of M1 was noted to be first higher and subsequently lower than that of the position of M2, owing to the grinding ball entering the substrate. The abrasion mechanisms of both regions were observed to be complex, including oxidative wear, adhesive wear, delamination wear, and/or fretting wear. The experimental data indicate that it is feasible to determine the repair time according to the microhardness of workpieces.

This paper aims to provide a better understanding regarding the effects of shot peening (SP), surface mechanical attrition treatment (SMAT), laser shock peening (LSP), surface mechanical rolling treatment (SMRT), and ultrasonic nanocrystal surface modification (UNSM) on the fatigue properties of metals in high-cycle fatigue (HCF) and very-high-cycle fatigue (VHCF) regimes. The work in this paper finds that SMRT and UNSM generally improve the high-cycle and very-high-cycle fatigue properties of metals, while SP, SMAT, and LSP can have mixed effects. The differences are discussed and analyzed with respect to the aspects of surface finish, microstructure and microhardness, and residual stress. SMRT and UNSM generally produce a smooth surface finish, while SP and SMAT tend to worsen the surface finish on metals, which is harmful to their fatigue properties. In addition to inducing a plastic deformation zone and increasing microhardness, surface treatments can also generate a nanograin layer and gradient microstructure to enhance the fatigue properties of metals. The distribution of treatment-induced residual stress and residual stress relaxation can cause mixed effects on the fatigue properties of metals. Furthermore, increasing residual stress through SP and SMAT can cause further deterioration of the surface finish, which is detrimental to the fatigue properties of metals.

Because the forming area involved in traditional reverse multistage incremental forming is only located inside the model, the sheet-metal thinning rate is relatively large. Particularly, the straight-wall parts with a narrow internal space cannot be formed using traditional multistage incremental forming. Therefore, a negative multistage incremental forming that extrudes the sheet from the forward and the reverse side of the straight-wall part is proposed in this paper. In this method, firstly, the auxiliary surface is generated to divide the straight-wall part model into three forming regions; secondly, the first- and second-stage forming are carried out from the forward side of the straight-wall part with support, respectively; Thirdly, the third-stage forming is carried out from the forward side of the straight-wall part without support. The software system for auxiliary-surface generation, the straight-wall parts partition, each intermediate-stage-forming model, and each stage-forming toolpath generation was developed by using C++, VC++, and OpenGL library. In order to verify the feasibility of the proposed method in this paper, the forming experiments of a 1060 aluminum sheet were conducted using traditional reverse multistage forming and the proposed method in this paper, and the forming effects were compared and analyzed. The results show that compared with traditional reverse multistage incremental forming with forward-side extrusion, the multistage incremental forming method with the forward and the reverse-sided extrusion proposed in this paper can increase the area of the sheet participating in the deformation and avoid the problem of excessive thinning of sheet thickness, especially suitable for the straight-wall part model with narrow internal space.

The paper presents a comparison of six recently introduced multiaxial fatigue strength estimation criteria to four methods, the large-scope validation of which has already been published. The results obtained for each newer method are analyzed and discussed. From the newer methods, only the criterion by Böhme reaches an estimation quality similar to the best performing criteria. The validation was performed on the FatLim data sets, but the primary focus of the paper is set to analyzing the validation on a smaller AMSD25 data set derived from it. The comparison shows that the application of AMSD25 for validation practice allows users to reduce the number of evaluated test cases, while generally preserving the worst cases showing the weaknesses of various estimation methods.

Titanium alloys are extensively used in the aerospace, chemical, and biomedical industries. However, it has always been a challenge in the manufacturing and machining of titanium alloys because they exhibit poor friction and wear characteristics, which results in serious problems and significantly restricts their further production and application. Therefore, in the present study, the wear contact between GCr15 steel and Ti6Al4V alloy is specifically studied by considering black phosphorus nanosheets (BP-NS) as water-based lubrication additives, which is expected to have a great potential application in manufacturing and machining titanium alloys. The influence of BP nanosheet size on the coefficient of friction (COF) and wear rate of Ti6Al4V alloy has been comprehensively studied, based on comparisons among adding large BP nanosheets (L-BP) (2–4 μm), medium BP nanosheets (M-BP) (300–500 nm), and black phosphorus quantum dots (BPQDs) (6–10 nm). Compared with ultrapure water, the COF and wear rate of Ti6Al4V alloy are reduced by 42.4% and 82.3%, respectively, when BPQDs are used as water-based lubrication additives. This paper also shows that a lower COF and wear rate is achieved with the addition of BPQDs than the other two BP nanosheet sizes. Derived from the friction tests and worn surface analysis of Ti6Al4V alloy, lubrication mechanisms of different-sized BP lubricants were proposed. The interlaminar shearing between BP-NS and the adsorbed films were the main mechanisms for L-BP and M-BP lubricants, while the adsorption, repair, and ball-bearing effects were mainly presented in the BPQD lubricants. The discoveries in this paper would be beneficial to developing novel lubricants for the manufacturing and machining of titanium alloys.

Interdisciplinary barriers separating data scientists and geometallurgists have complicated systematic attempts to incorporate machine-learning into mine production management; however, experiences in excavating a vein-hosted gold deposit within the Alhué region of Chile have led to methodological advances, which is the subject of the current paper. These deposits are subject to several challenges, from increasing orebody complexity and decreasing gold grades to the significant geological uncertainty that is intrinsic to these systems. These challenges then translate to mineral processing, which is already dealing with increased environmental and technological constraints. Geological uncertainty causes stockout risks that can be mitigated by the approach that is developed within this paper, which features alternate operational modes and related control strategies. A digital twin framework based on discrete event simulation (DES) and a customized machine-learning (ML) model is proposed to incorporate geological variation into decision-making processes, including the setting of trigger point that induces mode changes. Sample calculations that were based on a simulated processing plant that was subject to mineralogical feed changes demonstrated that the framework is a valuable tool to evaluate and mitigate the potential risks to gold mineral processing performance.

The selective transfer phenomenon (STP) is based on physico-chemical processes occurring in the contact area of a friction pair, with an element from a copper alloy and allows the metallic transfer of particles of micro/nanometric size, forming a thin superficial tribologically performing layer under energy and relative motion conditions. During the formation of the layer, its crystalline network has an excess of defects and this makes the dislocations to come to the surface. The layer thickness is small, porous, and with comparable dimensions to those of the tensions field of the dislocations. This paper presents a review and analysis of the STP based on dislocations movement to establish and know the tensions field influence, the energy (about 0.25 J/m), and the linear tension of dislocations (~2.42 × 10−9 N) at the contact surfaces zone of a friction pair, by which we can ensure a low wear state (~4.16 × 10−5–2.16 × 10−4 g/min), and a reduced friction coefficient (~0.014–0.034). Therefore, the purpose of the paper is to analyze the STP based on the dislocations movement because is proves the existence (presence), importance, and utility of the dislocations, respectively, the dislocations movements during the conditions’ selective transfer, at the limit of the friction surfaces, under the action of a tensions field, whose components are determined analytically by modelling, together with energy and the linear tension. Also, the layer formed through STP has the property of ensuring during the deformation process an agglomeration of dislocations (structural defects) which protects it from destruction, and therefore, a self-regulation of the equilibrium processes, disturbed during the friction process, to maintain the friction and wear of the friction pairs within reduced limits.

The use of mini-CT specimens for the fracture characterization of structural steels is currently a topic of great interest from both scientific and technical points of view, mainly driven by the needs and requirements of the nuclear industry. In fact, the long-term operation of nuclear plants requires accurate characterization of the reactor pressure vessel materials and evaluation of the embrittlement caused by neutron irradiation without applying excessive conservatism. However, the amount of material placed inside the surveillance capsules used to characterize the resulting degradation is generally small. Consequently, in order to increase the reliability of fracture toughness measurements and reduce the volume of material needed for the tests, it is necessary to develop innovative characterization techniques, among which the use of mini-CT specimens stands out. In this context, this paper provides a review of the use of mini-CT specimens for the fracture characterization of ferritic steels, with particular emphasis on those used by the nuclear industry. The main results obtained so far, revealing the potential of this technique, together with the main scientific and technical issues will be thoroughly discussed. Recommendations for several key topics for future research are also provided.

This paper presents a study of microstructures and properties of pure copper and copper–fullerene-soot (Cu-FS) composite materials produced by mechanical milling followed by hot pressing. The electrochemical etching method was successfully applied to reveal the fragmented structure of the specimens produced by high-energy ball milling. It is shown the carbon nanoparticles are involved in the composite microstructure formation. Copper–fullerene-soot composite materials have a complex microstructure with a bimodal grain distribution. Both recrystallized (average 3 μm) and polygonized (155 nm) grains are observed in the microstructure. Thus, in the case of pure copper, due to the absence of carbon nanoparticles, only recrystallized grains are observed in the microstructure. The Cu-FS composite has a hardness up to 160 HV and thermal stability up to 700 °C.

Cu-Al composites are widely applied materials exhibiting advanced properties of both matrix metals. Controlling the brittle interfacial phases is a key factor in improving the interfacial strength of Cu-Al composites. This paper studied the interfacial formation process of Cu-Al composites fabricated by continuous composite casting. The phase formation sequence, growth direction and formation mechanism were clarified via element marking and thermodynamic calculations. The spatial distribution of the interfacial phases from the aluminum side to the copper side is as follows: the α + θ layer (α-Al + CuAl2), the θ layer (CuAl2) and the γ layer (Cu9Al4). Moreover, insular η phases (CuAl) and δ phases (Cu3Al2) exist in the γ phase sublayer. The formation sequence of interfacial phases is as follows: the θ phase, the η phase, the δ phase and the γ phase. The θ layer and α + θ layer are transformed from a liquid diffusion layer formed by scouring the surface of copper with liquid aluminum, the η and δ phases grow towards the θ layer and the γ phase simultaneously grows towards both the copper matrix and the θ layer.

Due to their higher strength and lighter weight compared to conventional metals, graphene-nickel (Gr-Ni) composites have recently gained growing interest for use in the automotive and aerospace industries. Homogeneous Gr dispersion, the metal powder dispersity and processing conditions play a key role in obtaining the desired grain size distribution, an amount of high angle grain boundaries thus reaching the desired balance between strength and plasticity of the composite. Here, we report an approach to fabricating graphene-nickel composites with balanced strength and ductility through the microstructure optimization of the nickel matrix. A graphite platelets (GP) content of 0.1–1 wt.% was used for the optimization of the mechanical properties of the material. In situ, conversion GP-to-Gr was performed during the milling step. This paper discusses the effect of bimodal nano- and micro-sized Ni (nNi and mNi) on the mechanical properties and microstructure of Gr-Ni composites synthesized using a modified powder metallurgy approach. Specimens with varied nNi:mNi ratios were produced by two-step compaction and investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), Raman spectroscopy, electron back-scattered diffraction (EBSD) and nanoindentation. The best combination of ultimate tensile strength (UTS), yield limit (YL), elongation and hardness were obtained for 100nNi and 50nNi matrices, and the best composites were those with 0.1% graphene. The addition of more than 0.5 wt.% GP to the nickel matrix induces the fracture mechanism change from tensile to brittle fracture. Dedicated to the 300th anniversary of the St. Petersburg University Foundation.