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Metal matrix composites (MMCs) are dynamic and fascinating materials as they can be designed to suit the end property requirements for any present and futuristic application [...]

Herein, A4 typing paper was used as a novel source to manufacture FeNi3 and NiCx coated carbon skeleton via facile routes. The product was examined for its ability to absorb electromagnetic emission which can be a health hazard. The impact of precursor concentration on the final electromagnetic wave absorption of samples was evaluated; the composite prepared under suitable concentration possesses outstanding multiband absorption ability of −34.64 dB and −26.7 dB at 2.32 GHz and 17.2 GHz, respectively, together with an ultra-wide effective absorption bandwidth of 9.58 GHz at only 3.9 mm. The strong dipole polarization and broad frequency range of preferable impedance matching, along with the coupling of other auxiliary mechanisms, are responsible for this excellent property. The as-prepared absorber has great potency for multiband absorption of electromagnetic waves.

As a basic mechanical component, the sealing ring is widely used in industrial, aerospatial, and other fields. In this study, an elastic metal C-shaped sealing ring with a wave structure was taken as an example, and its performance was analyzed theoretically and measured experimentally. First, an experimental study was performed on the C-ring seal. The proposed method for experimental measurement of the contact stress of the C-ring seal involved innovative use of a universal electronic testing machine and pressure sensitive paper, in conjunction with the hue⁻saturation⁻brightness (HSB) method. Based on the discoloration of the pressure sensitive paper after contact stress, computer software was used for analysis, the discoloration was digitized, and the contact stress was established. Second, a theoretical calculation model of the C-ring seal was established using ANSYS software, and a finite element theoretical calculation of the mechanical properties of the sealing ring was established. Finally, the contact stress results were compared with the model calculation results of the C-ring seal. The error between the two was small (4.8%), which proved the validity of the calculation model and the scientificity of the experimental method.

The failure of a proximal humerus internal locking system (PHILOS) used in a pantalar arthrodesis was investigated in this paper. PHILOS constructs are hybrids using locking and non-locking screws. Both the plate and the screws used in the fusion were obtained for analysis. However, only the plate failure analysis is reported in this paper. The implant had failed in several pieces. Optical and scanning electron microscopic analyses were performed to characterize the failure mode(s) and fracture surface. The chemical composition and mechanical properties of the plate were determined and compared to controlling specifications to manufacture the devices. We found that equivalent tensile strength exceeded at the locations of high stress, axial, and angular displacement and matched the specification at the regions of lower stress/displacement. Such a region-wise change in mechanical properties with in vivo utilization has not been reported in the literature. Evidence of inclusions was qualitatively determined for the stainless steel 316L plate failing the specifications. Pitting corrosion, scratches, discoloration and debris were present on the plate. Fracture surface showed (1) multi-site corrosion damage within the screw holes forming a 45° maximum shear force line for crack-linking, and (2) crack propagation perpendicular to the crack forming origin that may have formed due to the presence of inclusions. Fracture features such as beach marks and striations indicating that corrosion may have initiated the crack(s), which grew by fatigue over a period of time. In conclusion, the most likely mechanism of failure for the device was due to corrosion fatigue and lack of bony in-growth on the screws that may have caused loosening of the device causing deformity and pre-mature failure.

In the last decade, iron and magnesium, both pure and alloyed, have been extensively studied as potential biodegradable metals for medical applications. However, broad experience with these material systems has uncovered critical limitations in terms of their suitability for clinical applications. Recently, zinc and zinc-based alloys have been proposed as new additions to the list of degradable metals and as promising alternatives to magnesium and iron. The main byproduct of zinc metal corrosion, Zn2+, is highly regulated within physiological systems and plays a critical role in numerous fundamental cellular processes. Zn2+ released from an implant may suppress harmful smooth muscle cells and restenosis in arteries, while stimulating beneficial osteogenesis in bone. An important limitation of pure zinc as a potential biodegradable structural support, however, lies in its low strength (σUTS ~ 30 MPa) and plasticity (ε < 0.25%) that are insufficient for most medical device applications. Developing high strength and ductility zinc with sufficient hardness, while retaining its biocompatibility, is one of the main goals of metallurgical engineering. This paper will review and compare the biocompatibility, corrosion behavior and mechanical properties of pure zinc, as well as currently researched zinc alloys.

Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime applications. Understanding thermomechanical behavior during LHW DED of NAB is a critical step towards the production of high-quality NAB parts with desired performance and properties. In this paper, finite element simulations are first used to predict the thermomechanical time histories during LHW DED of NAB test coupons with an increasing geometric complexity, including single-layer and multilayer depositions. Simulation results are experimentally validated through in situ measurements of temperatures at multiple locations in the substrate as well as displacement at the free end of the substrate during and immediately following the deposition process. The results in this paper demonstrate that the finite element predictions have good agreement with the experimental measurements of both temperature and distortion history. The maximum prediction error for temperature is 5% for single-layer samples and 6% for multilayer samples, while the distortion prediction error is about 12% for single-layer samples and less than 4% for multilayer samples. In addition, this study shows the effectiveness of including a stress relaxation temperature at 500 °C during FE modeling to allow for better prediction of the low cross-layer accumulation of distortion in multilayer deposition of NAB.

The interconnecting solder is a key control factor for the reliability of electronic power packaging because it highly affects the junction temperature of insulated-gate bipolar transistor (IGBT) modules and is prone to plasticity, creep, and other failure behaviors under temperature-change environments. In this paper, the interconnecting performance and fatigue life of five different kinds of solders such as SAC305, sintered silver, Au80Sn20, sintered copper, and pure In under direct current (DC), power cycle, and electro-thermal coupling complex environments were studied based on electro-thermal multi-physical field coupling finite element simulation method, respectively. Results show that the sintered silver owns the most outstanding thermal reliability and the DC operating junction temperature of the IGBT module after utilizing sintered silver solder is only 90.2 °C, which is nearly 15 °C lower than that of the IGBT module utilizing SAC305 solder. Furthermore, in the power cycle reliability test, the fatigue life of Au80Sn20 solder reaches a maximum of 3.26 × 107 cycles while the life of indium presents only 5.85 × 103 cycles, a difference of nearly four orders of magnitude. Finally, under the complex environment of electro-thermal coupling, the fatigue life of Au80Sn20 solder is also the largest at 1.9 × 106 cycles, while the smallest life of solder becomes SAC305 solder at 4.44 × 102 cycles. The results of this paper can provide a theoretical basis for solder selection and life prediction of the IGBT module, which is of great significance in improving the reliability of power electronic packaging.

Hot isostatic pressing (HIP) is a near-net shape powder metallurgy (PM) technique, which has emerged as an efficient technique, offering precise control over the microstructure and properties of materials, particularly in high-performance alloys. This technology finds applications across a wide range of industries, such as aerospace, automotive, marine, oil and gas, medical, and tooling. This paper provides an overview of powder metallurgy and hot isostatic pressing, covering their principles, process parameters, and applications. Additionally, it conducts an analysis of PM-HIPed alloys, focusing on their microstructure and fatigue behavior to illustrate their potential in diverse engineering applications. Specifically, this paper focuses on nickel-based superalloys and martensitic tool steels. The diverse microstructural characteristics of these alloys provide valuable insights into the PM-HIP-induced fatigue defects and properties.

As a novel type of metal material emerging in recent years, high-entropy alloy boasts properties such as a simplified microstructure, high strength, high hardness and wear resistance. High-entropy alloys can use laser cladding to produce coatings that exhibit excellent metallurgical bonding with the substrate, thereby significantly improvement of the wear resistance of the material surface. In this paper, the research progress on improving the high-temperature wear resistance of high entropy alloy coatings (LC-HEACs) was mainly analyzed based on the effect of some added alloying elements and the presence of hard ceramic phases. Building on this foundation, the study primarily examines the impact of adding elements such as aluminum, titanium, copper, silicon, and molybdenum, along with hard ceramic particles like TiC, WC, and NbC, on the phase structure of coatings, high-temperature mechanisms, and the synergistic interactions between these elements. Additionally, it explores the potential of promising lubricating particles and introduces an innovative, highly efficient additive manufacturing technology known as extreme high-speed laser metal deposition (EHLMD). Finally, this paper summarizes the main difficulties involved in increasing the high-temperature wear resistance of LC-HEACs and some problems worthy of attention in the future development.

The welded joints of high/medium entropy alloys (H/MEAs) have shown sound mechanical properties, indicating high promise for the industrial application of this new type of metal alloy. However, these joints possess either relatively low strength or low ductility. In this paper, we used ultrasonic-assisted laser welding to weld CrCoNi MEA with the nitrogen as shielding gas. The results showed that the tensile strength of the joint at room and cryogenic temperature is 686 MPa and 1071 MPa, respectively. The elongation at room and cryogenic temperature is 26.8% and 27.7%, respectively. The combination of the strength and ductility in our joints exceeds that of other welded H/MEA joints. We attributed this excellent combination to the refined dendrite, the solution of nitrogen into the matrix, and the low stacking fault energy of the CrCoNi MEA. The findings in this paper not only provide a novel way to weld H/MEAs with high strength and ductility, also are useful for additively manufacturing the high-performance component of H/MEAs.

The corrosion of steel rebars is a prevalent factor leading to the diminished durability of reinforced concrete structures, posing a significant challenge to the safety of structural engineering. To tackle this issue, extensive research has been conducted, yielding a variety of theoretical insights and remedial measures. This review paper offers an exhaustive analysis of the passivation processes and corrosion mechanisms affecting steel rebars in reinforced concrete. It identifies key factors such as chloride ion penetration and concrete carbonization that primarily influence rebar corrosion. Furthermore, this paper discusses a suite of strategies designed to enhance the longevity of reinforced concrete structures. These include improving the concrete protective layer’s quality and bolstering the rebars’ corrosion resistance. As corrosion testing is essential for evaluating steel rebars’ resistance, this paper also details natural and accelerated corrosion testing methods applicable to rebars in concrete environments. Additionally, this paper deeply presents an exploration of the use of X-ray computed tomography (X-CT) technology for analyzing the corrosion byproducts and the interface characteristics of steel bars. Recognizing the close relationship between steel bar corrosion research and microstructural properties, this paper highlights the pivotal role of X-CT in advancing this field of study. In conclusion, this paper synthesizes the current state of knowledge and provides a prospective outlook on future research directions on the corrosion of steel rebars within reinforced concrete structures.

This paper studies the integration of direct reduced iron (DRI) and hot briquetted iron (HBI) into the steelmaking process via an electric arc furnace (EAF). Considering a variety of DRI production techniques distinguished by different reactor types, this paper provides a comparative overview of the current state. It delves into significant challenges, such as the susceptibility of DRI to reoxidation and the necessity of thorough handling to maintain its quality. The effectiveness of several reoxidation mitigation strategies, including the application of thin oxide layers, briquetting, various coatings, and nitride formation in ammonia-based reduction processes, is evaluated. Most existing studies have primarily focused on the reoxidation of DRI rather than on HBI, despite the fact that HBI may undergo reoxidation. The importance of DRI/HBI in offering an alternative to the integrated steelmaking route is highlighted, focusing on how it changes the EAF process compared to those for melting scrap. This paper also identifies several research prospects for further DRI/HBI applications in steel production.

Fretting wear in the contact area between the aero-engine blade tenon and turbine disk mortise has an important influence on the performance of the aero-engine. In this paper, the tenon joint structure of the DZ125/FGH99 superalloy material is taken as the research object, and the finite element model of the fir-tree tenon joint structure is established. Through subroutine invocation and mesh adaptive control technology, the fretting wear problem of dissimilar material contact pairs under composite load is numerically studied. The results show that for the specific tenon joint structure and load and boundary conditions studied in this paper, the maximum wear occurs on the contact surface of the first tooth, and the surface will show different partial slip states in different load cycles. The slip region always extends from the two contact edges to the interior, and the upper side has a larger range. Wear has a significant effect on the stress distribution and stick–slip state of the contact surface. The second and third teeth have a small amount of wear and are basically in a stick state during the entire wear process. Therefore, wear has little effect on the stress distribution and the stick–slip state of the contact surface. This study reveals the coupling relationship between the fretting wear and contact state of the tenon joint structure.

This review offers a comprehensive analysis of thermal barrier coatings (TBCs) applied to metallic materials. By reviewing the recent literature, this paper reports on a collection of technical information, involving the structure and role of TBCs, various materials and coating processes, as well as the mechanisms involved in the durability and failure of TBCs. Although TBCs have been successfully utilized in advanced applications for nearly five decades, they continue to be a subject of keen interest and ongoing study in the world of materials science, with overviews of the field’s evolution remaining ever relevant. Thus, this paper outlines the current requirements of the main application areas of TBCs (aerospace, power generation and the automotive and naval industries) and the properties and resistance to thermal, mechanical and chemical stress of the different types of materials used, such as zirconates, niobates, tantalates or mullite. Additionally, recent approaches in the literature, such as high-entropy coatings and multilayer coatings, are presented and discussed. By analyzing the failure processes of TBCs, issues related to delamination, spallation, erosion and oxidation are revealed. Integrating TBCs with the latest generations of superalloys, as well as examining heat transfer mechanisms, could represent key areas for in-depth study.

Selective laser melting (SLM) technology used for the design and production of porous implants can successfully address the issues of stress shielding and aseptic loosening associated with the use of solid implants in the human body. In this paper, orthogonal experiments were used to optimize the process parameters for SLM molding of Ti-6Al-4V (TC4) material to investigate the effects of the process parameters on the densities, microscopic morphology, and roughness, and to determine the optimal process parameters using the roughness as a judging criterion. Based on the optimized process parameters, the mechanical properties of SLM-formed TC4 alloy specimens are investigated experimentally in this paper. The main conclusions are as follows: the optimal combination of roughness is obtained by polar analysis, the microhardness of SLM-molded TC4 alloy molded specimens is more uniform, the microhardness of specimens on the side and the front as well as the abrasion resistance is higher than that of casting specimens, the yield strength and tensile strength of specimens is higher than that of ASTM F136 standard and casting standard but the elongation is not as good as that of the standard, and the elasticity and compressive strength of porous specimens are higher than that of casting specimens at different volume fractions. The modulus of elasticity and compressive strength are within the range of human skeletal requirements. This work makes it possible to fabricate high-performance porous femoral joint implants from TC4 alloy SLM-molded materials.

This paper presents a review on the formability evaluation of AHSS, enhancing necking-based failure criteria limitations. Complementary fracture/damage constitutive modeling approaches specifically tailored to formability evaluation, validated through numerical and experimental methods, are also subjects of research. AHSS are widely processed through sheet metal forming processes. Although an excellent choice when lightweight, high-strength, and ductility are critical factors, their multi-phase microstructure accentuates forming challenges. To accurately model forming behavior, necking-based failure criteria as well as direct fracture models require improvements. As a necking-based failure model, the conventional forming limit diagram/curve (FLD/FLC) presents limitations in estimating direct fracture (surface cracks, edge cracks, shear cracks), as well as deformation histories under non-linear strain paths. Thus, significant research efforts are being made towards the development of advanced fracture constitutive models capable of predicting fracture scenarios without necking, which are more frequently observed in the realm of AHSS. Scientific community research is divided into several directions aiming at improving the forming and fracture behavior accuracy of parts subjected to sheet metal forming operations. In this review paper, a comprehensive overview of ductile fracture modeling is presented. Firstly, the limitations of FLD/FLC in modeling fracture behavior in sheet metal forming operations are studied, followed by recent trends in constitutive material modeling. Afterwards, advancements in material characterization methods to cover a broad range of stress states are discussed. Finally, damage and fracture models predicting failure in AHSS are investigated. This review paper supplies relevant information on the current issues the sheet metal forming community is challenged with due to the trend towards AHSS employment in the automotive industry.

The residual stress in low-alloy hot-rolled strips seriously affects the use and processing of products. Reducing residual stress is important for improving the product quality of hot-rolled strips. In this paper, the changes in grain size and residual stress of hot-rolled strips under different cooling processes were investigated via thermal simulation experiments and electron backscatter diffraction. It was found that the optimum cooling process solution for single-objective optimization of grain size was a final rolling temperature of 875 °C, a laminar cooling speed of 50 °C/s, and a coiling temperature of 550 °C. When single-objective optimization of residual stress was carried out, the optimal cooling process scheme was 900 °C for final rolling temperature, 20 °C/s for laminar cooling speed, and 625 °C for coiling temperature. The significance of the effect of cooling processes on grain size and residual stress was analyzed based on the extreme deviation of the effect of each cooling process on grain size and residual stress in orthogonal experiments. The results show that the coiling temperature was the most influential factor on grain size and residual stress among the cooling process parameters. The difference was that grain size increased with increasing coiling temperature, and residual stress decreased with increasing coiling temperature. Using both grain size and residual stress as evaluation indicators, a multi-objective optimization of the cooling process for hot-rolled strips was carried out via the gray correlation analysis method. The optimized solution was 875 °C final rolling temperature, 30 °C/s laminar cooling speed, and 625 °C coiling temperature. At this time, the grain size was 4.8 μm, and the KAM (Kernel Average Misorientation) was 0.40°. The grain size under the actual production process scheme was 4.4 μm with a KAM of 0.78°. Compared to the actual production process solution, the multi-objective optimization solution showed little change in grain size, with only a 9% increase and a 49% reduction in KAM. The optimization scheme in this paper could significantly reduce the level of residual stresses while ensuring the fine grain size of hot-rolled strips, thus improving the overall quality of hot-rolled strips.

Inclusions are important phases affecting material properties in complicated ways. In this paper, a quantitative study of the addition of HfO2 inclusions to DZ125 nickel-based superalloys was performed. Experimental results showed that the introduction of HfO2 inclusions caused a loss of strength and ductility. The carbide morphology also changed significantly from skeletal-shaped to block-shaped, resulting in a remarkable discrepancy in the fracture behavior under quasi-in-situ tensile testing. The SEM dynamic observations showed that cracks were initiated from the skeletal carbides and almost failed to propagate into the matrix. In contrast, the damage behavior of block-shaped carbides also involved internal cracking but with a tendency to form interconnected microcracks during propagation. A crystal plasticity finite element model (CPFEM) method was further developed to study the stress/strain behavior during the deformation process, considering the crystal orientations and microstructure morphologies from the EBSD data. Those elastoplastic parameters were determined through nanoindentation experiments. Simulation results verified that blocky carbides produced a pronounced strain concentration at the interface of the carbides and matrix, thereby increasing the tendency of crack formation. This paper provides a fundamental understanding of the role of inclusions in material recycling applications.

Nickel-based alloys that contain chromium are widely used in corrosion-resistant applications in industry, but they are sensitive to the environment when the passive chromium oxide layer is damaged. In Ni600 and Ni625 alloys, precipitates can deplete the surface layer of chromium oxide. To better characterize and analyze the nickel alloy surfaces and their chromium carbides, chemical etching with different etchants and electrolytic etching were applied to sample surfaces. This paper revealed their efficacy in etching various carbides within the nickel alloys, and orange phases ranging from 2 to 20 μm in optical micrographs were identified as titanium-containing compounds. Carbides located on the grain boundaries were determined to be Cr23C6 and were surrounded by chromium-depleted zones. The findings and figures in this paper provide a more intuitive reference for future analysis of carbides and titanium nitrides, enhancing the understanding of their impact on the corrosion resistance of these alloys, which will not only contribute to the material science field but also aid in developing the Ni-based alloys for industrial applications.

This paper presents the results of research focused on increasing the lifespan of HPDC moulds for casting aluminium alloys by applying duplex PVD coatings in combination with laser texturing the base material before the coatings’ deposition. This article describes the HPDC process and the degradation mechanisms of the moulds that arose during this process. The PVD nanostructured coatings utilised, the methods of their deposition, and the evaluation of their wear resistance are defined in this paper. The surface texturing process is described alongside the description of the analysis of the wear of the functional parts of the mould after decommissioning, which was carried out by visual inspection and optical and light microscopy. Three types of PVD duplex coatings were analysed during our study. The coatings were deposited using the LARC technology method (lateral rotating cathode). Subsequently, the procedure of laser texturing in the form of dimple textures using a laser was proposed. The quality of the coatings was evaluated under tribological conditions by means of the “Ball on disc” method. Based on the experimental results, recommendations for practice are established.

The paper presents the results of experimental research and surface characteristics after the process of roller burnishing of macro-asperities of the surface. As part of the work, the possibility of plastic shaping of the surface macrostructure with indentations (plateau structure), which will show anti-wear properties through appropriate surface shaping and the compressive stress state in the product’s top layer, was investigated. The essence of the paper is to present the analysis of the surface roughness parameters and carry out analysis of SEM, AFM and metallographic results for the burnished surface. The main objective of the work is to develop an adequate outline of the surface to receive the required parameters and characteristics of the surface after burnishing. The results of dependencies of roughness parameter after turning and after burnishing from the vertical angle of asperities are presented, as well as SEM, AFM and metallographic analysis for the surface with a vertical angle of 60 ÷ 150 degrees.

This paper presents the results of experimental data analysis, which indicate an increased resistance of heterogeneous multilayer clad composites to dynamic loading destruction compared with homogeneous materials. The reason for this is the crack retardation caused by lamination at the boundary of the layers. The destruction of heterogeneous compact composite samples by cyclic off-center stretching also occurs with crack retardation, with the fractogram clearly demonstrating the transverse tightening of the sample section. We argue that crack nucleation plays a decisive role in the process of dynamic destruction of heterogeneous composites obtained by both multilayer cladding and explosion welding. This study presents generalized calculated data confirming the influence of the sign and magnitude of residual stresses (the appearance of a stress discontinuity) on the conditions of fatigue surface crack nucleation and propagation. Unlike homogeneous materials obtained by casting, forging (rolling), or cladding, which are characterized by a linear dependence of the crack propagation velocity on the dynamic stress intensity coefficient, for multilayer composites consisting of strong and viscous layers, a sharp crack deceleration is observed. This is due to the transition of the crack boundary between the strong and viscous layers. This paper presents studies of the corresponding properties of adjacent layers on the integral characteristics of the deposited composite.

There is a long process to transform bauxite, a critical raw material, into a substance with the required properties of cast aluminum alloys for use in electro automotive parts. Thanks to its unique properties, aluminum has become the material of choice for clean technology manufacturers in applications such as use in the automotive industry, renewable energy, batteries, electrical systems, resource-saving packaging, energy efficient buildings and clean mobility. Restructuring of the economy, the oil crisis, air pollution and global warming are some of the factors that have moved the automotive industry towards electrification since the beginning of the 21st century. This paper aims to highlight the required properties of cast aluminum alloys applied to the production of electro automotive parts, such as their mechanical and thermophysical properties, dimensional stability, corrosion resistance, electromagnetic compatibility and crashworthiness. Furthermore, this paper discusses which of the cast aluminum–silicon alloys, as well as the heat treatments and casting processes, are most suitable.

In Part II of this series of review papers, the reaction mechanisms, thermodynamics, slag chemistry and process flowsheets are analyzed concerning cases where the TSL bath smelter has found its application. These include the primary and secondary production routes of five non-ferrous metals (tin, copper, lead, nickel, zinc), ironmaking and two waste-processing applications (spent pot lining and municipal solid waste/related ash treatment). Thereby, chemistry and processing aspects of these processes are concisely reviewed here, allowing for clear and in-depth overview of related aspects. In contrast to Part I, the focus lies on a holistic analysis of the metallurgical processes themselves, especially the particularities induced by carrying them out in a TSL reactor rather than on the respective equipment and auxiliaries. The methodology employed per metal/application is presented briefly. Firstly, the feed type and associated statistical information are introduced, along with relevant process goals, e.g., the secondary metallurgy of copper involves the recovery of platinum group metals (PGMs) from waste from electrical and electronic equipment (WEEE). Subsequently, associated chemistry is discussed, including respective chemical equations, analysis of the reaction mechanisms and phase diagrams (especially of associated slag systems); these are redrawn using FactSage 8.1 (databases used: FactPS, FToxid, FTmisc, FTsalt and FTOxCN) and validated by comparing them with the literature. Then, based on the above understanding of chemistry and thermodynamics, the flowsheets of several industrial TSL plants are introduced and discussed while providing key figures associated with process conditions and input/output streams. Finally, this article culminates by providing a concise overview of the simulation and digitization efforts on TSL technology. In light of the foregoing discourse, this paper encapsulates basic principles and operational details, specifically those pertaining to TSL bath smelting operations within the non-ferrous industry, thereby offering valuable insights intended to benefit both scholarly researchers and industry professionals.

As a type of metallurgical solid waste with a significant output, chromium-containing metallurgical dust and slag are gaining increasing attention. They mainly include stainless steel dust, stainless steel slag, ferrochrome dust, and ferrochrome slag, which contain significant amounts of valuable elements, such as chromium, iron, and zinc, as well as large amounts of toxic substances, such as hexavalent chromium. Achieving the harmless and resourceful comprehensive utilization of chromium-containing metallurgical dust and slag is of great significance to ensuring environmental safety and the sustainable development of resources. This paper outlines the physicochemical properties of stainless steel dust, stainless steel slag, ferrochrome dust, and ferrochrome slag. The current treatment technologies of chromium-containing metallurgical dust and slag by hydrometallurgy, the pyrometallurgical process, and the stabilization/solidification process are introduced. Moreover, the comprehensive utilization of resources of chromium-containing metallurgical dust and slag in the preparation processes of construction materials, glass ceramics, and refractories is elaborated. The aim of this paper is to provide guidance for exploring effective technology to solve the problem of chromium-containing metallurgical dust and slag.

This paper discusses a method of finish turning Inconel 718 alloy to compare machining performance of a naturally aged and used metalworking fluid (MWF), which had been conventionally managed through its life cycle, with the same new unaged product. The MWF concentrate was a new-to-market bio-ester oil, diluted with water to produce an emulsion. In the experiments, 50 mm diameter bars were turned down with multiple passes at a 250 μm depth of cut to reach a tool flank wear of 200 μm. The machining was interrupted at several stages to measure the flank wear and compare the chip forms for the aged and unaged MWF. The method of finish turning used a small tool nose radius and a small depth of cut that was found to be sensitive in detecting a difference in the flank wear and chip forms for the aged and unaged MWF. On the chemistry, the findings suggest that higher total hardness of the aged MWF was the cause of reduced lubricity and accelerated flank wear. This paper discusses the state of the art with the insights that underpin the finish turning method for the machinability assessment of MWFs. The findings point to stabilization of the MWF chemistry to maintain machining process capability over an extended sump life.

As a necessary part of all electronic devices, equipment and systems, electronic components play a vital role in the global economy. Since the corrosion of a single electronic component may directly affect the normal operation of the entire electronic system, the failure of electronic components has now become the most important cause of electrical system failure and has become a major obstacle to China’s transformation into a scientific and technological power. Therefore, it is urgent to study the corrosion failure process of electronic components and the means of effective protection. In this paper, starting from the corrosion types and influencing factors of electronic components, especially chips, we introduce the influence of humidity, temperature, salt spray, and environmental particles, as well as the device’s own surface roughness, material adhesion, semiconductor materials, metal coupling system, and lead-free solder system on corrosion performance in the environment. Subsequently, this paper summarizes how to protect electronic components during processing, and sums up the types of electronic component protections, and the specific corrosion protection process for the three commonly used types of chips, namely, the indium antimonide InSb chip, the IC chip, and the Sn–Zn solder chip, for reference. Finally, future development trends in the corrosion protection of electronic components are anticipated and summarized.

Hardfacing is an efficient and economical surfacing technique widely used by heavy industries to remediate worn components in service or to enhance the component’s wear characteristics components prior to use. Efficient hardfacing for any targeted application requires precise consideration and understanding of the deposition process, consumables, and substrates. It is also essential to understand the process variables and issues that can occur during the deposition processes, such as dilution and defects in the deposit, including residual stress-induced cracking. Significant research has been published over many years on several aspects of hardfacing, primarily focusing on abrasive wear, corrosion, and impact characterisation using different welding methods and alloy compositions. This paper primarily focuses on reviewing the prior hardfacing literature to systematically summarise the considerations and selection criteria for hardfacing processes and materials. It also presents a discussion on key process variables, such as welding parameters and number of surfacing layers, highlighting their influences during the hardfacing deposition procedure. This paper further discusses issues and challenges in hardfacing practices, such as dilution and cracking. One significant issue investigated is the thermal damage to high-strength steel substrates, with the measurement and characterisation of the damage being key elements. The focus of this investigation is to discuss the optimisation of hardfacing high-strength steel substrates and to communicate potential research areas and prospective applications in the hardfacing industry.

Lead-cooled fast reactors (LFRs) are considered one of the most promising technologies to meet the requirements introduced for advanced nuclear systems. LFRs have higher neutron doses, higher temperatures, higher burnup and an extremely corrosive environment. The failure studies of claddings play a vital role in improving the safety criteria of nuclear reactors and promoting research on advanced nuclear materials. This paper presented a comprehensive review of the extreme environment in LFRs based on the fuel performance analyses and transient analyses of reference LFRs. It provided a clear image of cladding failure, focusing on the underlying mechanisms, such as creep, rupture, fatigue, swelling, corrosion, etc., which are resulted from the motions of defects, the development of microcracks and accumulation of fission products to some extent. Some fundamental parameters and behavior models of Ferritic/Martensitic (F/M) steels and Austenitic stainless (AuS) steels were summarized in this paper. A guideline for cladding failure modelling was also provided to bridge the gap between fundamental material research and realistic demands for the application of LFRs.

Discrete Dislocation Dynamics (DDD) simulations are a powerful simulation methodology that can predict a crystalline material’s constitutive behavior based on its loading conditions and micro-constituent population/distribution. In this paper, a 3D DDD model with spiral dislocation sources is developed to study size-dependent plasticity in a pure metal material (taken here as Aluminum). It also shows, for the first time, multipole simulations of spirals and how they interact with one another. In addition, this paper also discusses how the free surface of a crystalline material affects the plasticity generation of the spiral dislocation. The surface effect is implemented using the Distributed Dislocation Method. One of the main results from this work, shown here for the first time, is that spiral dislocations can result in traditional Frank–Read sources (edge or screw character) in a crystal. Another important result from this paper is that with more dislocation sources, the plastic flow inside the material is more continuous, which results in a lowering of the flow stress. Lastly, the multipole interaction of the spiral dislocations resulted in a steady-state fan-shaped action for these dislocation sources.

The technology of casting with crystallization under pressure-squeeze casting belongs to unconventional pressure-casting methods. The melt or material in a semi-solid state is pressed under pressure until the casting solidifies completely. The input parameter, whose influence was mainly observed in this paper, is the state of the material entering the filling process. The alloys were in a molten and semi-solid state. The influence of casting thickness from 3.15 mm to 8 mm was also observed. Alloy AlSi7Mg0.3 was used because of the wide solidification interval and the significant influence of pressure during solidification. Consequently, alloy AlSi12 was subjected to experimental work because processing in the semi-solid state is not sufficiently examined for this material. A significant influence of the cooling rate in different cross-sections on the structure and mechanical properties of castings made using squeeze casting technology was confirmed. The difference in mechanical properties was approximately 35% for both eutectic and hypoeutectic alloys. When processed in a semi-solid state, it was confirmed that the network of dendrites has a significant influence on the filling of the mold cavity. The paper also focuses on the effect of input material morphology on the final product properties. The change in morphology was achieved by metallurgical intervention, thermal and technological processing.

Steel surface defect detection is crucial for ensuring steel quality. The traditional detection algorithm has low detection probability. This paper proposes an improved algorithm based on the YOLOv5 model to enhance detection probability. Firstly, deformable convolution is introduced in the backbone network, and a traditional convolution module is replaced by deformable convolution; secondly, the CBAM attention mechanism is added to the backbone network; then, Focal EIOU is used instead of the CIOU loss function in YOLOv5; lastly, the K-means algorithm is used to cluster the Anchor box, and the Anchor box parameters that are more suitable for this paper are obtained. The experimental results show that using deformable convolution instead of traditional convolution can get more feature information, which is more conducive to the learning of the network. This paper uses the CBAM attention mechanism, and the heat map of the attention mechanism shows that the CBAM attention mechanism is beneficial for feature extraction. Focal EIOU is optimized in high and wide loss compared with the CIOU loss function, which accelerates the convergence of the model. The Anchor box is more favorable for feature extraction. The improved algorithm achieved a detection probability of 78.8% in the NEU-DET dataset, which is 4.3% better than the original YOLOv5 network, and the inference time of each image is only increased by 1 ms; therefore, the optimized algorithm proposed in this paper is effective.

The stochastic nature of tool wear during wood machining, owing to the dynamic properties of the biological material and its dependence on various factors, has raised significant industrial and research concerns in recent years. Explicitly, the tool wear is a product of the interaction between wood properties (such as hardness, density, and contamination level) and machining parameters (such as cutting speed, feed rate, and rake angle) alongside ambient conditions (such as temperature and humidity). The objective of this review paper is to provide an overview of recent advancements in the field of wood machining. To begin with, it highlights the important role of wood properties and ambient conditions influencing tool wear. Furthermore, the paper examines the various mechanisms involved in the wood-machining process and discusses their cost implications from an industrial perspective. It also covers technological advancements in the characterization of tool wear and explores the relationship between this parameter and other machining variables. It provides critical and analytical discussions on various methods for enhancing tool wear, including heat treatment, cryogenic treatment, thermochemical treatment, coating deposition, and hybrid treatments. Additionally, the paper incorporates statistical analysis to achieve two objectives. Firstly, it aims to identify the most significant wood property that affects tool wear and establish the correlation between this parameter and wood properties. Secondly, it investigates the effect of heat treatment parameters and carbide characteristics on tool wear as well as their correlation. Lastly, the review provides recommendations based on relevant literature for prospective researchers and industrial counterparts in the field. These recommendations aim to guide further exploration and practical applications in the subject matter.

Additive manufacturing (AM) represents the present and the future of manufacturing production, thanks to a new design paradigm that allows the customization of components based on the needs of the final application, all framed in a perspective of sustainable and on-demand production. It has become an increasingly popular method for manufacturing complex and custom parts, especially those made from metallic materials, such as AISI 316L. AISI 316L is a type of austenitic steel widely used in industries such as aerospace, medical, automotive, and marine due to its excellent corrosion resistance and high strength. Thanks to its physico-chemical properties, AISI 316L stainless steel is one of the most used metals for AM. In this paper, a critical review of printing technologies, microstructural defects, mechanical properties, as well as industrial applications of AISI 316L are presented based on the state of the art. Furthermore, the main challenges with AM AISI 316L techniques are discussed, such as the influence of printing parameters, surface quality, and other common problems identified in the literature. Overall, this paper provides a comprehensive overview of AISI 316L AM techniques, challenges, and future research directions.

Metastable austenitic stainless steels (MASS) are widely used in various industrial applications due to their exceptional compromise between mechanical properties and corrosion resistance. However, the mechanical properties of these materials can be further enhanced by surface treatments. This paper reviews various surface treatment methodologies used to improve the mechanical properties of MASS, with particular attention to laser treatments. The effects of these surface treatments on the microstructure and chemical composition in the thermal affected zone of the MASS are discussed, and their impact on the material’s mechanical properties, such as hardness, tensile strength, and fatigue life, are investigated in detail. Additionally, the paper highlights the limitations of these surface treatments and points out some areas where further research is needed. The findings presented can be used to guide the selection of appropriate surface treatment techniques for specific applications, ultimately improving the performance and lifespan of MASS in various industrial settings.

This paper first examines crack growth in a range of tests on additively manufactured (AM) and conventionally manufactured Inconel 718. It is shown that whereas when the crack growth rate (da/dN) is plotted as a function of the range of the stress intensity factor (ΔK), the crack growth curves exhibit considerable scatter/variability, when da/dN is expressed in terms of the Schwalbe crack driving force (Δκ), then each of the 33 different curves essentially collapse onto a single curve. This relationship appears to hold over approximately six orders of magnitude in da/dN. The same phenomenon also appears to hold for 20 room temperature tests on both conventionally and additively manufactured Inconel 625. Given that the 53 studies examined in this paper were taken from a wide cross section of research studies it would appear that the variability in the da/dN and ΔK curves can (to a first approximation) be accounted for by allowing for the variability in the fatigue threshold and the cyclic fracture toughness terms in the Schwalbe crack driving force. As such, the materials science community is challenged to address the fundamental science underpinning this observation.

This paper presents a comprehensive review of recent advancements in surface engineering of metals, encompassing techniques, characterization methods and applications. The study emphasizes the significance of surface engineering in enhancing the performance and functionality of metallic materials in various industries. The paper discusses the different techniques employed in surface engineering, including physical techniques such as thermal spray coatings and chemical techniques such as electroplating. It also explores characterization methods used to assess the microstructural, topographical, and mechanical properties of engineered surfaces. Furthermore, the paper highlights recent advancements in the field, focusing on nanostructured coatings, surface modification for corrosion protection, biomedical applications, and energy-related surface functionalization. It discusses the improved mechanical and tribological properties of nanostructured coatings, as well as the development of corrosion-resistant coatings and bioactive surface treatments for medical implants. The applications of surface engineering in industries such as aerospace, automotive, electronics, and healthcare are presented, showcasing the use of surface engineering techniques to enhance components, provide wear resistance, and improve corrosion protection. The paper concludes by discussing the challenges and future directions in surface engineering, highlighting the need for further research and development to address limitations and exploit emerging trends. The findings of this review contribute to advancing the understanding of surface engineering and its applications in various sectors, paving the way for future innovations and advancements.

The present paper describes a study case of the failure investigation of duplex stainless steel (UNS S31803) on the tube and tube sheet sections of BEM TEMA-type shell and tube heat exchanger with seawater as the cooling medium. The heat exchanger’s shell design pressure was 22.6 MPa at 422 K, and the tube design pressure was 1 MPa at 339 K. Although UNS S31803 offers high strength, high resistance to chloride-induced SCC, and high resistance to pitting attack in chloride environments, the heat exchanger in this study experienced some material degradation after 28 months of use; 102 out of 270 tubes failed, 26 tubes leaked and were plugged on both sides, and scale plugged 76 tubes. The examination in this study case revealed the formation of white-colored biofilm inside the tubes; XRD examination revealed that the film contained CaCO3. Using microstructural examination on the inner surface of the tube, the austenite grains were shown to have been preferentially attacked; this phenomenon is typical in duplex stainless steel which fails due to crevice corrosion. According to the examination result, the failure in this case was caused by crevice corrosion between the substrate and surface deposits that was enhanced by microbiological-induced corrosion (MIC). Recommendations to avoid similar failures are also suggested in this paper.

The steadily growing demand for non-ferrous metals, a shift to heavier crude oil recovery and tightened environmental standards have increased the importance of heavy petroleum feedstock (HPF) as a raw source of metals. This paper reviews the recent developments in the recovery of vanadium and nickel from HPF. During crude oil processing and the application of its products, HPF is converted to various metal-enriched byproducts (“heavy oil”, petcoke, ashes and slags) from which the metals can be recovered. This paper briefly describes the sources and recovery pathways (both mainstream and exotic), and discusses the economic viability and possible future directions. Particular attention is paid to (i) the electrochemical recovery of metals from petrofluids and alternative approaches; (ii) pre-combustion metal recovery from petcoke; and (iii) metal reclamation from fly ash from heavy fuel oil or petroleum coke combustion: hydro- and pyro-metallurgical and bio-based techniques. The current stage of development and prospects for the future are evaluated for each method and summarized in the conclusion. Increasing research activity is mostly observed in traditional areas: metal extraction from fly ash and the reduction of metals from the ash to V–Fe and Ni–Fe alloys. Bioengineering approaches to recover vanadium from ashes are also actively developed and have the potential to become commercially viable in the future.

During the manufacturing of welded structures, some degree of residual stresses occurs. The classic approach to residual stress reduction is Post-Weld Heat Treatment (PWHT). In the case of structural grade mild steels, the thermal process is well established. In case of S690QL1 High Strength Steel (HSS), which is manufactured using the Quenching and Tempering (QT) process considered in this paper, only limited PWHT treatment is possible without deterioration of mechanical properties. Since this steel grade is susceptible to subsequent heat input, the challenge is to establish adequate PWHT parameters, achieving residual stress reduction while retaining sufficiently high mechanical properties. The paper considers X joint welded HSS steel plates with slightly overmatching filler metal. The welded coupon is prepared and subjected to PWHT treatment. The research on the influence of heat treatment was performed using the four different PWHT cycles and initial As-Welded (AW) material condition. The authors proposed those PWHT cycles based on available resources and the literature. Process holding temperature is considered the variable parameter directly related to the behaviors of material properties. The methodology of welded joint analysis includes experimental testing of mechanical properties, metallographic examination, and residual stress quantification. Testing of mechanical properties includes tensile testing, Charpy V-notch impact testing, and hardness testing in scope of complete welded joint (BM + HAZ + WM). Metallographic examination is performed in order to characterize the welded joint material in relation to applied PWHT cycles. In order to quantify residual stresses, all heat-treated samples were examined via the X-ray diffraction method. Mechanical properties testing determined that an increase in PWHT cycle holding temperature leads to degradation of tested mechanical properties. For specific zones of the welded joint, the decreasing trend from AW condition to Cycle D (max. 600 °C) can be quantified. Based on representative specimens comparison, strength values (BM ≤ 5.7%, WM ≤ 12.1%, HAZ ≤ 20%), impact testing absorbed energy (BM = 17.1%, WM = 25.8%, FL = 12.5%, HAZ = 0.6%), and hardness values (BM = 4.1%, WM = 3.2%, CGHAZ = 16.6%, HAZ = 24.2%) are all exhibiting decrease. Metallographic examination, using the light microscopy, after the exposure to PWHT thermal cycles, did not reveal significant changes in the material throughout all specific welded joint segments. Average relative reduction in residual stress in correlation with PWHT temperature can be observed (AW = 0%, Cycle A (max. 400 °C) = 72%, Cycle B (max. 530 °C) = 81%, Cycle C (max. 550 °C) = 93% and Cycle D (max. 600 °C) = 100% stress reduction). It can be concluded that S690QL1 HSS welded joints can generally be subjected to PWHT, while adhering to the limits of the material and process. In the authors’ shared opinion, it is advisable to use the PWHT Cycle C (max. 550 °C) with 93% RS reduction, while mechanical properties retain high values.

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.