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The paper presents a simple and efficient method for identifying two-parametric isotropic pressure-independent yield criteria. The experimental procedure includes the upsetting of three types of specimens. The upsetting of cylinders and rings is used to evaluate the effect of friction. Together with the plane strain compression in a die, these tests provide two points of the yield locus on the π-plane. The experimental procedure is used in conjunction with the plasticity theory based on Hosford’s yield criterion. The plastic work is used to describe the hardening of the material. This hardening law can be reformulated in terms of the equivalent strain after the yield criterion is determined. The experimental/theoretical procedure above applies to steel C15E.

Compared with cubic Continuously Variable Crown (CVC), quintic CVC presents integrated control capability of quadratic and quartic crown. In order to take full advantage of quintic CVC and have better comprehensive control of the edge wave, center wave, high order wave and complex wave in practical application, it is necessary to further clarify the complicated profile control characteristics of quintic CVC. In this paper, quintic CVC technology in a 1500 mm continuous hot rolling mill production line has been taken as the research object and use finite element method to study its profile control characteristics. Through finite element simulation, an integrated model of rolls and strip was established to analyze the influence of the shifting, bending force and rolling force on strip profile with different strip widths. Both crown adjustment area and transverse stiffness are gained to study the control capability of quintic CVC. The simulation results show that the positive shifting and positive bending of CVC work roll reduce the quadratic crown and increase the quartic crown, and the controlling effect of shifting on both quadratic and quartic crown is more remarkable than that of bending. The control capability of the crown increases with the increase of strip width. That is, wider strip has a larger crown adjustment area. Meanwhile, there is a strong coupling relationship that the increase of quadratic crown can lead to the decrease of the quartic crown, which is not good for the flexible control of strip profile. With the increase of rolling force, the quadratic crown of strip increases significantly, while the quartic crown does not change obviously. Additionally, the increase of strip width significantly increases the transverse stiffness of mill.

In this paper, the effects of the skin pass technique on the residual stress and plastic strain fields generated in cold drawn pearlitic steel wires are analyzed. The aim is to find out the optimal conditions to be used in the design of a manufacturing process for obtaining more reliable structural components in terms of the main cause of failure: the hydrogen embrittlement (HE). To achieve this goal, diverse numerical simulations were performed by using finite elements (FE) and considering, on one hand, the first step of a real cold drawing chain, using (i) a conventional drawing die and (ii) modified drawing dies with different soft diameter reductions, and, on the other hand, numerical simulations by FE of the hydrogen diffusion assisted by stress and strain states to estimate the hydrogen distributions. Obtained results revealed the secondary reduction degree as a key parameter in the die design for reducing the drawing-induced residual stress. According to the results, low values of the reduction ratio cause radial distributions of residual stress with significant reductions at both the wire core and at the wire surface. In addition, the hydrogen accumulation at the prospective damage zone (near the wire surface) given by FE simulations is lower in the wires drawn with modified drawing dies including a skin pass zone.

In this work, bio-hydrometallurgy technology was employed and a novel two-stage method based on successive chemical and bio treatments was proposed to collaboratively utilize manganese–silver ore and silver-bearing pyrite. In the optimization research of the chemical leaching stage, the sensitive factors for the Mn leaching efficiency were screened by Plackett–Burman design, and central compound design was performed to settle the optimized parameters. A mixed strain of bacteria containing Sulfobacillus thermosulfidooxidans, At. caldus and Leptospirillum ferrooxidans was applied in the bioleaching stage. A conventional cyanidation process carried out with the Mn leaching residuals suggested an efficient recovery of Ag. Applying a two-stage method with the optimum conditions, the leaching efficiency of 95.3% (Mn) and 96.3% (Ag) were obtained with 284.94 kg/t silver-bearing pyrite addition and 277.44 kg/t sulfuric acid consumption with a temperature at 77.73 °C and stirring speed at 287.76 rpm. Mineral behaviors were investigated with XRD and SEM/EDS analysis, and it was revealed that the oxidation of sulfur is the crux in reducing the usage of reagents, and the presence of leaching bacteria enhanced the oxidation efficiently. Through optimization and mechanism study, this paper provides an opportunity to co-leach the manganese–silver ore and silver-bearing pyrite process in a more economical and environmental way.

The increased utilization of pellets in blast furnaces is one of the directions for low-carbon ironmaking. As a result, the low slag rate may affect the desulfurization of the hot metal and the removal of alkali in the blast furnace. Effective desulfurization and the removal of alkali in the low slag ironmaking process have become the focus of the steel industry. In this paper, the effects of slag quantity, temperature, reaction time and slag composition on the desulfurization and removal of alkali were studied using the slag-metal reaction method. It was found that the slag quantity had the same influence trend on the desulfurization and the removal of alkali. The greater the slag quantity, the more effective the desulfurization and the removal of alkali. The slag composition, temperature and reaction time had the opposite effect on the desulfurization and the removal of alkali. High temperature, long reaction time, high MgO concentration, high CaO/SiO2 ratio and low Al2O3 concentration increased the desulfurization of hot metal but reduced the removal rate of alkali from the blast furnace. Applications of the experimental results on high-proportion pellet blast furnace operation are discussed.

The repair of structural elements for the prestressing of reinforced concrete is necessary when existing prestressing wires are damaged or after a certain period of time. The objective of this paper is to describe the methodology for the life assessment of corroded prestressing wires, sampled from prestressed concrete elements after a few decades of use. The aim of the presented research was to determine the real properties of corroded wire in terms of the evaluation of remaining load capacity using the Theory of Critical Distances (TCD). The methodology also includes spatial 3D characterization of corroded surfaces, determination of mechanical properties, and Finite Element Analysis (FEA) of a model of wire with corrosion pits. The final goal of the presented methodology is to enable more efficient evaluation of repair range and options for the elements of mechanical prestressing systems within various structures. The results and conclusions indicate that the developed methodology, based on the interdisciplinary approach and implementation of state-of-the-art methods, has a high applicability potential for both static and fatigue fracture prediction in the case of prestressed wires. The proposed method has a huge potential for simple and fast prediction of the life assessment of engineering structures, particularly for damaged elements with arbitrary geometry features.

In this paper, the fatigue resistance of superelastic NiTi shape memory alloy (SMA) wires was improved by combining mechanical training and nanocrystallization. Fatigue tests were performed after mechanical training with a peak stress of 600 MPa for 60 cycles of nanocrystalline (NC) NiTi wires, and the associated microscopic mechanism was investigated by using transmission electron microscopy (TEM) and transmission Kikuchi diffraction (TKD). The results showed that stress-controlled training effectively improved the functional stability (the accumulated residual strain decreased by 83.8% in the first 5000 cycles) of NC NiTi SMA wires, as well as increased the average structural fatigue life by 187.4% (from 4538 cycles to 13,040 cycles). TEM observations and TKD results revealed that training-induced dislocations resulted in lattice rotation and preferential grain orientation. The finite element method (FEM) simulation results indicated that the training-induced preferential grain orientation tended to decrease the local stress concentration and strain energy density. Combined with fractography analysis, the uniform deformation caused by mechanical training changed the crack growth mode from multi-regional propagation to single-regional propagation, improving the structural fatigue life.

Turning is a complex machining process that can be characterized by a number of performances for a given machining system, workpiece material, cutting tool, and selected cutting regime. In addition to the characteristics of the machined surface quality, the estimation of machining time is particularly important for manufacturers, since machining time is directly related to other important performances of the turning process, such as productivity, cost, and energy consumption. In this paper, a model for estimation of total operation time in turning of a part with continuous profile, made of polyoxymethylene copolymer (POM-C), using a polycrystalline diamond (PCD) cutting tool, was developed. Face centred central composite design (CCD) and Box–Cox transformation approaches were applied for that purpose. The developed model was then used as the objective function in the proposed optimization model, which also included three practical constraints related to quality of the machined surface (surface roughness and workpiece deflection) and machinability aspects of the workpiece material (favourable chip forms). Nonlinear and linear models, used as constraints, were developed based on the results of experimental investigation of turning of POM-C using a PCD cutting tool. The total operation time estimation model showed good agreement with the results of tool path simulations in CAM software and validation experimental trial in real manufacturing environment. By applying the optimal solution, 44% of the total time being saved for machining of a single part can be achieved, compared to the recommended cutting parameter values, which indicates significant optimization benefits in turning industrial plastics.

In the context of the use of AM, particularly in the L-PBF technique, the printability characterization of material occurs through the identification of its printability map as a function of printing process parameters. The printability map identifies the region where the powder melting is optimal and ensures a dense and defect-free material. Identifying the zones affected by physical phenomena that occur during the printing process which lead to material defects such as keyhole, lack of fusion and balling mode is also possible. Classical methods for the characterization of material and the identification of its printability map require the printing of a large number of specimens. The analysis of the specimens is currently time-consuming and costly. This paper proposed a methodology to identify optimal process parameters in L-PBF using an integrated single and multi-tracks analyses embedded in an overall algorithm with detailed metrics and specific factors. The main scope is to speed up the identification of printability window and, consequently, material characterization, reducing the number of micrographic analyses. The method is validated through an experimental campaign assessing the material microstructure in terms of porosity and melt pool evaluation. The case study on IN718 superalloy shows how the application of the proposed method allows an important reduction of micrographic analysis. The results obtained in the case study are a reduction of 25% for the complete definition of the printability map and more than 90% for identifying the zone with a high productivity rate.

Due to its excellent performance, 90-10 cupronickel has been widely used as a pipeline for marine engineering. However, due to the harsh service conditions of flowing seawater, the problem of corrosion leakage is extremely serious. One of the most common locations is the welding joint. In this paper, electrochemical impedance spectroscopy, surface morphology analysis techniques (scanning electron spectroscopy, energy disperse spectroscopy, three-dimensional microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy) are used to study the corrosion resistance of 90-10 cupronickel (MZ), heat affected zone (HAZ) and welding zone (WZ). The experimental results show that MZ, HAZ and WZ can form protective corrosion product film in flowing seawater, and that the corrosion resistance increases with the experiment time increasing and achieves the maximum value after 20 days. However, the corrosion resistance of HAZ is smallest due to the low adhesion density of corrosion production formed on HAZ. HAZ is preferentially corroded for minimum corrosion resistance and galvanic corrosion between WZ and HAZ.

This paper studies the shear strength of an anti-rust bolt with a spiral oil-guiding slot and oil-bearing hole by conducting a simulation and experiment. A finite element model with the bolt and the clamp tool is developed for simulating the shearing of the bolt in progressive failure analyses. An indirect method is proposed to generate a spiral entity that can produce excellent spiral elements. A clamp tool is designed for the shear experiment of the bolt. Moreover, a substitute calculation method is presented for the shear strength analysis of the special bolt, and the effect of using the oil-guiding slot on shear strengths is considered by reducing the bolt’s radius. The study results show the following: The results of the simulation are in good agreement with the experimental results. One side of the bolt with the oil-bearing hole is first cut off, and the deviation between the result obtained by using the substitute calculation and the experiment’s result is 7.97%.

Porous metals are a new ultra-light material with high specific stiffness, specific strength, and good energy absorption properties. The elastic modulus and plateau stress of porous metals are essential parameters. There have been many studies on the effects of the matrix material, porosity, and pore size on the elastic modulus and plateau stress of porous metals, but few studies can be found on the impact of pore arrangement. The pore arrangement of porous metals cannot be quantitatively described, and the design space of a porous metal structure under the same porosity is vast. With the powerful learning and prediction ability of neural networks, the influence of pore arrangement can be better understood. In this paper, a convolutional neural network was used to explore the impact of pore arrangement on both the elastic modulus and plateau stress of a porous aluminum alloy. Firstly, a finite element method was used to simulate the compression of a porous aluminum alloy to obtain a training sample library. Secondly, a convolutional neural network was built to positively predict the elastic modulus and plateau stress of the porous aluminum alloy. Partial samples were used to select the best training model from five convolutional neural network candidates. Dropout, Batch Normalization, and L2 regularization methods were used to alleviate the over-fitting phenomenon in training. All data in the database were then trained and predicted, and the predicted goodness of fit of the elastic modulus and plateau stress were 0.8785 and 0.5922, respectively. A search method based on the convolutional neural network was then used to iteratively search the database. Under the condition of using a small amount of data, the pore structure with the best elastic modulus and plateau stress in the database could be determined, and the inverse design of a structure with high elastic modulus and plateau stress could be realized.

The damage mode of U75V rail steel in application is determined by its rolling wear behavior. In this paper, the pearlite microstructure of U75V steel is characterized to investigate the relationship between wear and fatigue behavior. The results show that, with decreasing of pearlite lamellar spacing, the wear resistance of the steel increases and the contact fatigue resistance decreases. The spacing decreasing causes the change of the wear mechanism from abrasive wear to adhesive wear, as well as the damage mode from wear damage to fatigue damage. The smaller the pearlite lamellar spacing is, the stronger the deformation of the cementite lamellar is. The thin cementite lamellar is hardly broken in the rolling friction to pile up a large number of dislocations in the ferrite matrix and the work hardening degree was improved. So, the plastic deformation layer is difficult to remove, and fatigue cracks are easy to initiate and extend to the interior of the material.

Studies have shown that the reduction of wustite is the limiting factor in the ironmaking process, whether in hydrogen-based shaft furnaces, hydrogen-rich blast furnaces or smelting reduction vessels. The study of the thermodynamic conditions for the reduction of molten wustite by hydrogen is of great significance for the optimization of the ironmaking process, energy saving and emission reduction. Previous studies have mostly focused on the thermodynamic study of the reduction at a lower temperature, but the data at high temperatures are different, which makes the calculation of thermodynamics difficult. Moreover, it is difficult to obtain experimental evidence for the data at high temperature, so calculation is needed to verify its feasibility. In this paper, a thermodynamic calculation model for the reduction of molten wustite by hydrogen based on the principle of minimum Gibbs free energy is developed. The enthalpy changes of the reaction at different temperatures and the partial pressure of hydrogen required for the reaction to occur are calculated, and the energy change during the reaction is analyzed. The results show that the partial pressure of hydrogen for the reduction of molten wustite by hydrogen at high temperatures decreases from 0.67 at 1650 K to about 0.65 at 2000 K. The enthalpy changes of reaction at 1873 K are only 1/4 to 1/3 of that at 1173 K compared with that at the corresponding temperature between hydrogen for the reduction of molten wustite (1873 K) and hydrogen-based shaft furnace reaction (1173 K). Interestingly, the thermodynamic calculations show that the effect of energy absorption in the gas–liquid reaction of hydrogen with wustite at high temperatures is much lower than in the gas–solid reaction zone at low temperatures. These results indicate that the energy change of the reduction of molten wustite by hydrogen at high temperatures is better than that of hydrogen reduction at low temperatures, and the thermodynamic conditions are more favorable, with slightly different results from different thermodynamic databases, but the general trend is the same. The results of this study will provide fundamental data to support new hydrogen metallurgy technologies in the future. If its correctness can be verified experimentally in the future, this result will be promoted to the development of a new alternative ironmaking technology, hydrogen-based smelting reduction.

The deformation mechanism is complex in the hot rolling process of clad plates, and head bending is a common defect. In this paper, an analytical computational mechanical model of a metal plate was established by the classical elastic mechanics method, and the relationship between uneven thickness extension and warpage was obtained. The hot rolling bonding process of dissimilar bimetallic plates of Ti/Steel was investigated. On this basis, the mechanical origins of the plate bending defects and the influence of various factors on the evolution of the plate bending defects of the metal plates were revealed. The results indicated that the rolling forces increased with the increase in reduction ratio and thickness ratio. As the total reduction ratios of the clad plates increased, the reduction ratio of each layer increased. Furthermore, it was found that the thickness reduction ratios of steel were larger than those of Ti at a certain total reduction ratio, which could reach up to 59.6%. When the reduction ratios were 0.4 and 0.45, the bending degree increased with the thickness ratio of the upper and lower plates increasing gradually. The maximum warpage could reach 0.349 m. The clad plate shape was better when the roll speed ratio was 1.02 and the reduction rate was 0.4. The present numerical results provide a valuable insight into the deformation behaviors and mechanisms involved in the hot rolling of clad plates.

The heating and impact of arc and droplet acting on the weld pool lead to the transfer of mass, heat, and momentum, which affects the dynamic behavior of the weld pool and the microstructure in the P-GMAW process. In this paper, an image processing program is used to extract the dynamic behavior characteristics of the droplet transition and the weld pool in high-speed photography. The influence of the current waveform on the arc pressure and the impact of the droplet is quantitatively analyzed with different parameters. The dynamic behavior of the weld pool and the microstructure under different current waveform conditions are further studied. The internal relation of current waveform parameters to weld pool behavior and weld microstructure was expounded. The results show that the droplet impact is positively correlated with the pulse peak current. The rectangular wave pulse has a more significant droplet impact than the exponential wave with the same waveform parameters. The impact of droplet transition on the weld pool enhances the convective intensity of the weld pool. It slows down the cooling rate of the solidified weld microstructure below the tail of the weld pool, increasing the grain size of the weld microstructure.

Rare-earth elements have been widely used in the field of functional materials, but their effects on the cold-stamping formability of high-strength automotive steels have rarely been studied. In this paper, the effect of the trace rare-earth element Ce on the microstructure and properties of cold-rolled medium manganese steel after ART (austenite-reverted transformation, ART) annealing was studied. The microstructure of the experimental steel was observed using SEM, and the mechanical properties were tested using a universal tensile testing machine. The volume fraction of the retained austenite and the texture of the steel were measured using XRD. The results showed that the original austenite grain size of the experimental steel was smaller after adding the trace rare-earth element Ce. After ART annealing, the grain size distribution of the experimental steel with rare-earth Ce was more uniform, and the comprehensive mechanical properties were better. Under the conditions of quenching at 800 °C for 5 min and annealing at 645 °C for 15 min, the maximum product of tensile strength and elongation was 28.47 GPa·%.

In this paper, a PtPd NC catalyst with a network structure of nanochains was prepared with KBr as a structure-directing agent, NaBH4 as a reducing agent, and modified multi-walled carbon nanotubes (MWCNTs) as a support. The experimental results show that the structure-directing agent KBr helps to form a particular type of nanochain with a network topology. PtPd NCs with various ratios (Pt:Pd = 2:1, 1:1, 1:2) have respective diameters of 30 nm, 35 nm, and 23 nm. With numerous structural flaws at the junctions, the nanochains’ distinctive network structure increases the number of active sites on the PtPd nanocenter surface. Electrochemical characterization results show that the current density of the PtPd NCs is about 658.5 mA mg−1, 1.5-times that of the Pt/C catalyst and 3.9-times that of the commercial Pd/C catalyst. Furthermore, it has better electrocatalytic stability for methanol oxidation than Pd/C and Pt/C catalysts.