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Low- pressure casting and high-pressure casting processes are the most common liquid-based technologies used to produce aluminum components. Processing conditions such as cooling rate and pressure level greatly influence the microstructure, mechanical properties, and heat treatment response of the Al alloys produced through these casting techniques. The performance of heat treatment depends on the alloy’s chemical composition and the casting condition such as the vacuum required for high-pressure casting, thus, highlighting the low-pressure casting application that does not require a vacuum. The level of pressure applied to fill the mold cavity can affect the formation of gas porosities and oxide films in the cast. Moreover, mechanical properties are influenced by the microstructure, i.e., secondary dendritic arm spacing, grain size, and the morphology of the secondary phases in the α-matrix. Thus, the current study evaluates the most current research developments performed to reduce these defects and to improve the mechanical performance of the casts produced by low- and high-pressure casting.

Ru attracted considerable attention as a candidate to replace TaN as a diffusion barrier layer for Cu interconnect metallisation. The addition of W improves the diffusion barrier properties of Ru but appears to weaken the adhesion strength between the barrier and Cu and the direct (seedless) electroplatability behaviour. Although Cu can be directly electroplated on near equimolar Ru-W thin films, no complete substrate coverage is obtained. The understanding of Cu electrocrystallisation on Ru–W is essential to develop methods of fabricating thin, continuous, and well adherent films for advanced interconnect metallisation, where Ru–W thin films could be used as diffusion barriers. This work studies the effect of ultrasonic agitation on the growth of Cu films electroplated on Ru–W, namely on the impact on substrate coverage. Film structure, morphology and chemical composition were evaluated by digital and scanning and transmission electron microscopies, and X-ray diffraction. The results show that Cu particles decrease with increasing current density, but when no electrolyte agitation is applied, substrate coverage is incomplete in the central region, with openings around larger Cu particles, regardless of current density. Under ultrasonic agitation, substrate coverage is remarkably improved. An active particle detachment mechanism is proposed as responsible for attaining improved substrate coverage, only possible at intermediate current density. Lower current densities promote growth over nucleation, whereas higher currents result in extensive hydrogen reduction/formation. Ultrasonic agitation also enhances a preferential Cu growth along direction.

Micro hot embossing is a well-established technology to produce polymer microdevices and parts. This technology on metal powder/binder feedstocks is an innovator challenge that fits into the sustai...

Additive manufacturing (AM) is one of the most trending technologies nowadays, and it has the potential to become one of the most disruptive technologies for manufacturing. Academia and industry pay attention to AM because it enables a wide range of new possibilities for design freedom, complex parts production, components, mass personalization, and process improvement. The material extrusion (ME) AM technology for metallic materials is becoming relevant and equivalent to other AM techniques, like laser powder bed fusion. Although ME cannot overpass some limitations, compared with other AM technologies, it enables smaller overall costs and initial investment, more straightforward equipment parametrization, and production flexibility.This study aims to evaluate components produced by ME, or Fused Filament Fabrication (FFF), with different materials: Inconel 625, H13 SAE, and 17-4PH. The microstructure and mechanical characteristics of manufactured parts were evaluated, confirming the process effectiveness and revealing that this is an alternative for metal-based AM.

In recent years some progress has been made about the addition of Carbon Nanotubes (CNTs) in the stainless steel metal matrix by pulsed Gas Tungsten Arc Welding (P-GTAW). Despite that, there is lack of information regarding to microstructural modifications induced by CNTs in dissimilar welding. In this sense, we present the welding of nanocomposite based on Nickel/Carbon Nanotubes-stainless steel 316L alloy (Ni/CNTs-SS 316L), as the welding metal, on carbon-manganese (C-Mn) non-alloyed structural steel, as the base metal. The microstructure of manufactured specimens with/without nanocomposite was characterized by: optical microscopy; Raman spectroscopy; scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS) and electron backscattering diffraction (EBSD). Moreover, Vickers tests were performed from the welding metal (WM) to the base metal (BM) before/after temper treatment in order to investigate the microhardness changes. The results show that dilution rate and grain size for specimen with nanocomposite was higher than without nanocomposite; the CNTs affected the misorientation angle and texture of the WM; the topside microhardness from WM with Ni-CNTs was on average 30.40% higher than BM; and, in transverse cross-section microhardness was 31% higher than control sample on average at fusion line zone. These results indicate that addition of CNTs in the metallic matrix by dissimilar welding is a fertile ground for new studies applicable to manufacturing industry.

This study seeks to investigate the local reinforcement of low carbon cast steel specimens with WC–metal matrix composites (WC–MMCs), to obtain a new material effective in competing with hard alloy steels. For this purpose, a powder compact of tungsten carbide (WC) and iron (Fe) was prepared and placed in the mold cavity before casting. The reactions that occurred with the molten steel led to the formation of the WC–MMC and, consequently, to the local reinforcement of the steel. The microstructure of the WC–MMC reinforcement was characterized by scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), and electron backscatter diffraction (EBSD). The results showed a microstructural variation throughout the depth of the reinforcement. In the surface region, most of the original WC particles retain their polygonal morphology, but towards the base metal, the dissolution of the WC particles increased with the formation of (Fe,W)6C carbides. Closer to the base metal, dendritic eutectic carbides of (Fe,W)6C and fine (Fe,W)23C6 precipitates in a matrix of martensite were formed. The mechanical properties of the reinforcement were evaluated by hardness and ball-cratering abrasion tests. The results revealed a significant increase in hardness, being three times harder than the base metal, and a decrease of 39% in the wear rate.

Metal powder hot embossing (MPHE) is a low-cost micromanufacturing technique that can produce metallic parts with aspects in micron scale. In this study, scanning electron microscopy (SEM) is employed for evaluating the shape retention and the homogeneity of microstructure of replicated geometries into AISI 316L powder feedstock by the secondary electron imaging (SEI) and the backscattered electron imaging modes, the distribution of chemical composition by the electron-dispersive spectroscopy (EDS) mapping, and grain structures by the electron backscatter diffraction technique. Moreover, the SEI and EDS techniques completed the failure analysis of tensile tests. Nanoindentations were also performed to assist phase identification analysis in the densified microstructure. Different geometries in the micron scale (micro wall half-reservoirs, micro channel half-flanges, convex and concave micro gear configurations, and micro tensile specimens) were selected for replication. Shaping limitations were attributed to the geometry, convex or concave, and the stiffness of the die. Micro gear and micro wall configurations were shaped using a stiffer elastomer (T = 230 °C and P = 11.3 to 14 MPa for 45 min) and a metallic die (T = 170 °C and P = 11.3 MPa for 10 min), respectively. The shaping of concave geometries was achieved regardless of the metal powder concentration, 60 and 65 vol.%. Densified parts retained the replicated micro configurations after long periods of thermal debinding and sintering, with densification above 95%. The chemical composition in sintered parts was homogeneous. The microstructure was principally composed of austenitic grains. The 316L stainless steel sintered part produced through MPHE presented an ultimate tensile strength of 458 ± 15 MPa, similar to that of a wrought AISI 316L alloy; the fracture type in the micro tensile specimen was ductile.

The current research focuses on the shaping of aluminum feedstock by micro powder hot embossing. This method includes a mixture of powder with binder material for feedstock preparation. Then, shaping is accomplished by embossing, debinding and sintering. Micro powder hot embossing can be interested in the fabrication of parts when small series production is intended. The embossing step, to provide the designed configuration, is challenging and carried out using an elastomer die and uniaxial compaction. We evaluated the shaping process using aluminum feedstock and two geometries with similar aspect ratios (micro-channel half-flanges and micro-wall half-reservoirs). The micro-channel, half-flanges and half-reservoirs configurations were shaped using elastomer die; the micro-wall configuration was attained by the application of metallic die. For each die, the processing conditions (temperature, compaction and holding time) and shaping steps were selected to ensure the replicability and homogeneity of the green parts. The green parts were thermally debound and successfully sintered at a relatively high sintering temperature in a low-pressure atmosphere. The sintered parts retained their shapes and showed shrinkage.

For decades, Ta/TaN has been the industry standard for a diffusion barrier against Cu in interconnect metallisation. The continuous miniaturisation of transistors and interconnects into the nanoscale are pushing conventional materials to their physical limits and creating the need to replace them. Binary metallic systems, such as Ru-W, have attracted considerable attention as possible replacements due to a combination of electrical and diffusion barrier properties and the capability of direct Cu electroplating. The process of Cu electrodeposition on Ru-W is of fundamental importance in order to create thin, continuous, and adherent films for advanced interconnect metallisation. This work investigates the effects of the current density and application method on the electro-crystallisation behaviour of Cu. The film structure, morphology, and chemical composition were assessed by digital microscopy, atomic force microscopy, scanning and transmission electron microscopies, energy-dispersive X-ray spectroscopy, and X-ray diffraction. The results show that it was possible to form a thin Cu film on Ru-W with interfacial continuity for current densities higher than 5 mA·cm−2; however, the substrate regions around large Cu particles remained uncovered. Pulse-reverse current application appears to be more beneficial than direct current as it decreased the average Cu particle size.

Aluminum is a critical element of the circular economy as it can be recycled several times. Moreover, Al recycling is a more economically and environmentally efficient procedure than the primary Al production from ores. Secondary aluminum alloys are mostly used in casting applications since it is possible to accommodate their chemical composition through secondary manufacturing processes. However, the quality of the alloys may be considerably altered during the different steps of the recycling process. Inadequate waste sorting might result in excessive contamination. Iron is the most dangerous contaminant because it causes brittle and fragile intermetallic phases, which significantly impacts the mechanical characteristics of alloys. In addition, the microstructure of the alloy changes significantly after multiple cycles of remelting. These issues lead to the downcycling of aluminum, i.e., in other words, the reduction in the overall quality of the alloys. Thus, it has been shown that a number of procedures, including ultrasonic melt treatment and microalloying with rare earths, can somewhat alter the shape of the Fe-rich phases in order to reduce the shortcomings of downcycling. However, a solid mechanical characterization is still missing in order to improve the Fe-rich phase alteration.

In this work, austenitic stainless steel specimens were locally reinforced with WC particles. The reinforcements were fabricated via an ex situ technique based on powder technology. Mixtures of WC, Fe, and M0101 binder were cold-pressed to obtain powder compacts. After debinding and sintering, the porous WC–Fe inserts were fixed in a mold cavity, where they reacted with liquid metal. Microstructural analysis was conducted for characterization of the phases constituting the produced reinforcement zone and the bonding interface. The results revealed that the reinforcement is a graded material with compositional and microstructural gradients throughout its thickness. The zone nearest to the surface has a ferrous matrix with homogeneously distributed WC particles and (Fe,W,Cr)6C and (Fe,W,Cr)3C carbides, formed from the liquid metal reaction with the insert. This precipitation leads to austenite destabilization, which transforms into martensite during cooling. A vast dissolution of the WC particles occurred in the inner zones, resulting in more intense carbides formation. Cr-rich carbides ((Fe,Cr,W)7C3, and (Fe,Cr,W)23C6) formed in the interdendritic regions of austenite; this zone is characterized by coarse dendrites of austenite and a multi-phase interdendritic network composed of carbides. An interface free of discontinuities and porosities indicates good bonding of the reinforcement zone to stainless steel., This research was funded by FEDER through the program P2020|COMPETE, Projetos em Copromoção (project POCI-01-0247-FEDER-033417), and the program P2020|Norte2020, Programas doutorais (NORTE-08-5369-FSE-000051).

Functionally graded material (FGM) based on Inconel 625 and AISI 431 stainless steel powders was produced by applying the direct laser deposition (DLD) process. The FGM starts with layers of Inconel 625 and ends with layers of 431 stainless steel having three intermediate zones with the composition (100-X)% Inconel 625-X% 431 stainless steel, X = 25, 50, and 75, in that order. This FGM was deposited on a 42CrMo4 steel substrate, with and without preheating. Microstructures of these FGMs were evaluated, while considering the distribution of chemical composition and grain structure. Microstructures mainly consisted of columnar grains independent of preheating condition, epitaxial growth was observed. The application of a non-preheated substrate caused the formation of planar grains in the vicinity of the substrate. In addition, hardness maps were produced. The hardness distribution across these FGMs confirmed a smooth transition between deposited layers, however, the heat-affected zone was greatly influenced by the preheating condition. This study suggests that an optimum Inconel 625/AISI 431 FGM obtained by DLD should not exceed 50% AISI 431 stainless steel.

This literature review aims to summarize the research conducted on the production of locally reinforced ferrous castings based on metal matrix composites reinforced with TiC (TiC-MMCs). One way to improve the wear resistance of cast components is to reinforce critical regions locally with metal matrix composites (MMCs) without changing the toughness of the component core. The in situ method of self-propagating high-temperature synthesis is one of the main approaches for the production of this enhanced material. Using this approach, the reinforcement is formed from a powder compact inserted in the mold cavity. The temperature of the liquid metal then produces the combustion reactions of the powders, which promote the formation of the ceramic phase. This paper focuses on eight powder systems used to synthesize TiC: Ti-C, Ni-Ti-C, Ni-Ti-B4C, Fe-Ti-C/Fe-Cr-Ti-C, Cu-Ti-B4C, Al-Ti-C, and Al-Ti-B4C, and provides an overview of the methodologies used as well as the effect of processing variables on the microstructural and mechanical characteristics of the reinforcement zones.

In this study, direct laser deposition (DLD) of nickel-based superalloy powders (Inconel 625) on structural steel (42CrMo4) was analysed. Cladding layers were produced by varying the main processing conditions: laser power, scanning speed, feed rate, and preheating. The processing window was established based on conditions that assured deposited layers without significant structural defects and a dilution between 15 and 30%. Scanning electron microscopy, energy dispersive spectroscopy, and electron backscatter diffraction were performed for microstructural characterisation. The Vickers hardness test was used to analyse the mechanical response of the optimised cladding layers. The results highlight the influence of preheating on the microstructure and mechanical responses, particularly in the heat-affected zone. Substrate preheating to 300 °C has a strong effect on the cladding/substrate interface region, affecting the microstructure and the hardness distribution. Preheating also reduced the formation of the deleterious Laves phase in the cladding and altered the martensite microstructure in the heat-affected zone, with a substantial decrease in hardness.

The use of Ta/TaN barrier bilayer systems in electronic applications has been ubiquitous over the last decade. Alternative materials such as Co-W or Ru-W alloys have gathered interest as possible replacements due to their conjugation of favourable electrical properties and barrier layer efficiency at reduced thicknesses while enabling seedless Cu electroplating. The microstructure, morphology, and electrical properties of Cu films directly electrodeposited onto Co-W or Ru-W are important to assess, concomitant with their ability to withstand the electroplating baths/conditions. This work investigates the effects of the current application method and pH value of the electroplating solution on the electrocrystallisation behaviour of Cu deposited onto a Co-W barrier layer. The film structure, morphology, and chemical composition were studied by X-ray diffraction, scanning electron microscopy and atomic force microscopy, as well as photoelectron spectroscopy. The results show that the electrolyte solution at pH 1.8 is incapable of creating a compact Cu film over the Co-W layer in either pulsed or direct-current modes. At higher pH, a continuous film is formed. A mechanism is proposed for the nucleation and growth of Cu on Co-W, where a balance between Cu nucleation, growth, and preferential Co dissolution dictates the substrate area coverage and compactness of the electrodeposited films., Portugal 2020 through European Regional Development Fund (FEDER) in the frame of Operational Competitiveness and Internationalisation Programme (POCI) and in the scope of the project USECoIN with grant number PTDC/CTM-CTM/31953/2017. This work was also supported by FCT, through IDMEC, under LAETA project UIDB/50022/2020

Carbon nanotube reinforced aluminum matrix composites are considered a promising solution for applications that require high specific mechanical properties. Even though there are numerous methods for their manufacturing, these are frequently based on powder metallurgy approaches, limiting the fabrication of components with significant volumes and complex shapes. Casting, as a manufacturing technique, is regarded as the most appropriate route to obtain complex-shaped components with a relative high microstructural quality. These techniques to obtain Al-CNT cast components is still challenging due to the agglomeration, lack of dispersion, reduced bonding and density of the CNTs in Al. To address these issues, CNTs are usually pre-processed by ball-milling with Al powder to promote bonding and disperse the reinforcement, however, these techniques are not really beneficial to casting approaches due to the increase of Al2O3 content that do not disperse within the Al alloy melts. This study proposes the use of Al spheres (~1 mm) in these ball milling techniques to prevent significant plastic deformation, the formation of Al flakes and the increase in Al2O3 content. It is shown that CNTs may be dispersed and bonded to the Al sphere surfaces. Results suggest that this is a promising novel technique to allow a successful implementation of casting-based routes to fabricate high-volume and complex-shaped Al-CNT components.

In this study, the deposition of martensitic stainless-steel (Metco 42C) powder on 42CrMo4 structural steel by direct laser deposition (DLD) was investigated. Clads were produced by varying the laser power, scanning speed, feed rate, and preheating. The effect of these processing variables on the microstructure and microhardness of the clads was analyzed, as well as their soundness, yield (measured by dilution), and geometric characteristics (height, width, and depth). The complex interaction of the evaluated processing variables forced the application of complex parameters to systematize their effect on the clads. A genetic optimization algorithm was performed to determine the processing conditions warranting high-quality clads, that is, sound clads, metallurgically bonded to the substrate with required deposition yield.

The strengthening effect on aluminium (Al) by ultrafine particles of tungsten carbide (WC) after compacting and sintering was evaluated. The Al-1 vol.% WC mixture was prepared through a high-speed stirring technique, called assisted sonication. In this study, the effects of compacting, sintering temperature and holding time were evaluated by composite microstructural characterization and by mechanical tests. The characterizations involved electron dispersive spectroscopy and X-ray diffraction techniques for phase identification, electron backscattered diffraction for crystallographic analysis, backscattered electrons and secondary electrons imaging for failure and wear studies. In all composites, hardness was determined, for the hardest composite, the tensile strength, flexural strength and ball scattering wear resistance were also evaluated. The Al-1 vol.% WC composite produced by assisted sonication, densified by cold compacting at 152 MPa and sintered at 640 &deg, C for 2 h at 5 &times, 10&minus, 4 Pa (high vacuum) exhibited the highest hardness, associated with an acceptable ductile behavior. This strengthening was associated with the formation of Al12W and grain refinement.

High-chromium white cast iron (WCI) specimens locally reinforced with WC&ndash, metal matrix composites were produced via an ex situ technique: powder mixtures of WC and Fe cold-pressed in a pre-form were inserted in the mold cavity before pouring the base metal. The microstructure of the resulting reinforcement is a matrix of martensite (&alpha, &rsquo, ) and austenite (&gamma, ) with WC particles evenly distributed and (Fe,W,Cr)6C carbides that are formed from the reaction between the molten metal and the inserted pre-form. The (Fe,W,Cr)6C precipitation leads to the hypoeutectic solidification of the matrix and the final microstructure consists of martensite, formed from primary austenite during cooling and eutectic constituent with (Fe,Cr)7C3 and (Fe,W,Cr)6C carbides. The presence of a reaction zone with 200 &micro, m of thickness, between the base metal and the composite should guarantee a strong bonding between these two zones.

This research focuses on the microstructural characterization of nickel matrix composites reinforced by carbon nanotubes (CNTs). The nanocomposites were produced by a conventional powder metallurgy process and the dispersion of CNTs and mixture with nickel powders was performed in a single step by ultrasonication. Microstructural characterization of Ni–CNT nanocomposites was performed by scanning and transmission electron microscopy, electron backscattered diffraction, high-resolution transmission electron microscopy, selected area electron diffraction, and fast Fourier transform analyses. This characterization revealed CNTs embedded in the nickel grains and mainly presented as clusters at the grain boundaries. CNTs hinder recrystallization during sintering, and dislocation cells and subgrains form as a result of the recovery process.

Microstructural characterization of TiAl to Ti6Al4V dissimilar diffusion bonds assisted by reactive Ni/Al nanolayers was performed in this study. The nanolayers (alternated Al and Ni) were deposited onto the base material surfaces. Diffusion bonding was performed at 700 and 800 °C under pressures from 5 to 40 MPa and dwell times between 60 and 180 min. Microstructural characterization was performed using high-resolution transmission and scanning electron microscopies. The observations revealed that dissimilar TiAl to Ti6Al4V joints assisted by Ni/Al reactive nanolayers can be obtained successfully at 800 °C during 60 min using a pressure of 20 MPa. The bond interface is thin (less than 10 µm) and is mainly composed of NiAl grains. Thin layers of Al-Ni-Ti intermetallic compounds were formed adjacent to the base materials.

The spectroscopic signatures related to doping mechanisms in multiwall carbon nanotubes filled with aluminum carbide (Al 4 C 3 @MWCNTs) were studied and interpreted relative to changes in their electronic and phononic structures. Unfilled MWCNTs were used as standard samples to help interpreting the filling and the doping processes. The samples were characterized via scanning electron microscopy, transmission electron microscopy, X-ray diffraction and resonant Raman spectroscopy. The electron-phonon coupling mechanisms associated to the Raman intensities, frequencies and linewidths of the G- and G'-band Raman modes were analyzed and connected to the doping mechanism in these multi-walled systems. Our results indicate that the Al 4 C 3 particles transfer electrons to the MWCNTs. In order to shed light into the experimental findings, theoretical calculations were performed using two examples of filled and unfilled achiral MWCNTs and the results for the density of electronic states indicate that the two systems under consideration, exhibit metallic behavior, with aluminum carbide doping the carbon nanotubes, thereby supporting our experimental observations.

Diffusion bonding of TiAl using reactive Ni/Ti multilayers was studied in this investigation. Alternated Ni and Ti layers were sputter deposited onto TiAl base material. These multilayers can be used to improve the diffusion bonding, since they increase the diffusivity at the interface. Bonding experiments were performed at 700 and 800 °C under a pressure of 10–50 MPa with a bonding time of 60 min. The interfaces were characterized by high-resolution scanning and transmission electron microscopies. Microstructural characterization reveals that joints can be obtained successfully with Ni/Ti multilayers. The interfaces exhibit slightly different microstructures depending on the bonding temperature and the multilayer bilayer thickness. For all joints, these are mainly composed of equiaxed grains of NiTi and NiTi2. The best mechanical response was achieved for joints processed at 800 °C for 60 min under a pressure of 10 MPa using Ni/Ti multilayers with 30 nm bilayer thickness, which exhibit a shear strength of 288 MPa.

The wires from aluminum alloy 6101 (AA-6101) used in power cables were covered by carbon nanotubes (CNTs) and graphite powders, and then they were subjected to solubilization heat treatment at a temperature of 550 °C and aged at 180 °C. The effects of the processing temperature on the mechanical and electrical properties of the wires based on CNTs@AA-6101 and graphite@AA-6101 composites were investigated by electron microscopes, thermogravimetric analysis, tensile tests, conductor tests and Raman spectroscopy. The results show that CNTs were successfully incorporated on the surface of aluminum wires; the tensile strength of CNTs@AA-6101 increased by 30% and 34% as compared to graphite@AA-6101 and standard AA-6101 wire without CNTs, respectively. Moreover, the resistivity had a decrease 13.7% less than conventional wires. The solubilization process added with the incorporation of CNTs represents a new way for manufacturing nanostructured power cables to achieve high-performance energy transmission lines.

This research focuses on the characterization of a metal matrix nanocomposite (MMNC) comprised of a nickel matrix reinforced by carbon nanotubes (CNTs). The aim of this study was to characterize Ni&ndash, CNTs nanocomposites produced by powder metallurgy using ball-milling. CNTs were initially untangled using ultrasonication followed by mixture/dispersion with Ni powder by ball-milling for 60, 180, or 300 min. The mixtures were cold-pressed and then pressureless sintered at 950 &deg, C for 120 min under vacuum. Their microstructural characterization was mainly performed by optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). The mechanical properties were evaluated by Vickers microhardness. The results indicate that combining ultrasonication and ball-milling can successfully produce Ni&ndash, CNTs nanocomposites. The ball-milling time has a significant effect on both the CNT dispersion and the final nanocomposite microstructure.

The development of metal nanocomposites reinforced by carbon nanotubes (CNTs) remains a focus of the scientific community due to the growing need to produce lightweight advanced materials with unique mechanical properties. However, for the successful production of these nanocomposites, there is a need to consolidate knowledge about how reinforcement influences the matrix microstructure and which are the strengthening mechanisms promoting the best properties. In this context, this investigation focuses on the study of the reinforcement effect on the microstructure of an Ni-CNT nanocomposites produced by powder metallurgy. The microstructural evolution was analysed by electron backscattered diffraction (EBSD). The EBSD results revealed that the dispersion/mixing and pressing processes induce plastic deformation in the as-received powders. The dislocation structures produced in those initial steps are partially eliminated in the sintering process due to the activation of recovery and recrystallization mechanisms. However, the presence of CNTs in the matrix has a significant effect on the dislocation annihilation, thus reducing the recovery of the dislocation structures.

Ni/Al multilayers are known to transform into NiAl in a highly exothermic and self-sustaining reaction. The fact that this reaction has a high heat release rate and can be triggered by an external impulse, are reasons why it has already attracted much research attention. There is a huge potential in the use of Ni/Al multilayers as a controllable and localized heat source for joining temperature-sensitive materials such as microelectronic components. The heat released and the phases resulting from the reaction of Ni and Al multilayers depend on the production methods, their composition, as well as the bilayer thickness and annealing conditions. The present research aims to explore the influence of these variables on the reaction of different multilayers, namely those produced by accumulative roll bonding (ARB) and sputtering. Structural evolution of Ni/Al multilayers with temperature was studied by differential scanning calorimetry, x-ray diffraction and scanning electron microscopy. Phase evolution, heat release rate and NiAl final grain size are controlled by the ignition method used to trigger the reaction of Ni and Al. The potential use of these multilayers in the diffusion bonding of TiAl was analyzed. The ARB multilayers allow the production of joints with higher strength than the joints produced with commercial multilayers (NanoFoil®) produced by sputtering. However, the formation of brittle intermetallic phases (Ni3Al, Ni2Al3 and NiAl3) compromises the mechanical properties of the joint.

The microstructure of similar and dissimilar diffusion bonds of metallic materials using reactive Ni/Ti interlayers was studied in this investigation. The base material surfaces were modified by sputter deposition of alternated Ni and Ti nanolayers. These nanolayers increase the diffusivity at the interface, enhancing the bonding process. Bonding experiments were performed at 800 °C under a pressure of 10 MPa with a bonding time of 60 min. The reaction zone was characterized by high-resolution scanning and transmission electron microscopies. Microstructural characterization reveals that similar (NiTi to NiTi and TiAl to TiAl) and dissimilar (NiTi to Ti6Al4V and TiAl to stainless steel) joints can be obtained successfully with Ni/Ti reactive nanolayers. The interfaces are thin (

Ni-Cr-Mo is a candidate to substitute Co binders in WC-based composites, where high corrosion resistance is required. This work focused on the effect of Cr on the corrosion susceptibility of WC-Ni-Cr-Mo composites, in acid media. Specimens were produced by powder metallurgy followed by microstructural, chemical and mechanical characterization. Open circuit potential measurements, potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) were employed to evaluate the corrosion susceptibility of WC-Ni-Cr-Mo alloys with different Cr content. The results highlight the greater aggressiveness of chloride medium compared to sulphate environment, and reveal that Cr can effectively decrease corrosion susceptibility without hampering the mechanical properties in both media, especially in chloride solution, where major improvements are observed.

In metal powder, shaping the preparation and characterization of the feedstock is an aspect commonly recognized as fundamental. An optimized composition is required to ensure the successful shaping of the feedstock. In this study, a commercial binder system, pure aluminum and 316L austenitic stainless-steel powders were used for micro hot embossing. The optimization process revealed that powder characteristics such as shape and the stability of the torque mixing, were important parameters. Manipulating the feedstock composition by adding multi-walled carbon nanotubes or stearic acid or using a higher powder concentration considerably influenced the torque mixing values. The steady state of torque mixing was achieved for all feedstocks. This torque behavior indicates a homogeneous feedstock, which was also confirmed by microscopic observations. Nevertheless, an extruding process was required for greater homogeneity of the aluminum feedstocks. The presence of the carbon nanotubes increased the homogeneity of green parts and reduced microcrack formation. The roughness was essentially dependent on the feedstock composition and on the plastic deformation of the elastomer die. Shaping the prepared feedstocks (with or without carbon nanotube) was achieved by the optimized powder concentrations and it did not increase by the stearic acid addition.

The homogeneity of dispersion and reinforcing of pure aluminium by multi-walled carbon nanotubes (MWCNT) through the application of a high speed sonication (340 Hz) assisted by ultrasonication (35 kHz) was evaluated, this method was termed “assisted sonication”. Other reinforcements (graphene, nanoalumina, and ultrafine tungsten carbide) were used for comparison with the MWCNT. The hardness measurement enabled us to evaluate the strengthening effect of the reinforcements. Raman analysis was the technique selected to evaluate the integrity of MWCNTs during dispersion. The scanning and transmission electron microscopies revealed the dispersion and microstructure of the nanoreinforcements and nanocomposites. After applying the assisted sonication, the MWCNTs were detangled without exfoliation. The integrity of MWCNTs was strongly influenced by the presence of the aluminum powder during dispersion. The application of the assisted sonication method reduced the size of the aggregates in the matrix, in comparison with the sonication technique. Ultrafine tungsten carbide, with a 1 vol. %, was the reinforcement that more effectively hardened aluminum due to a good dispersion of the reinforcement, grain refinement and the formation of Al12W phase.