Directed energy deposition (DED) parameters were determined for near-β alloy Ti-55511 by employing statistical design of experiments (DOE) methods. Parameters resulting in fully dense freeform deposits were identified using two sequential DOEs. Single laser tracks were printed with several laser power, traverse rate, and powder feed rate settings in an initial DOE to identify promising build parameters. Capture efficiency and effective deposition rate were used to characterize and rank the single track deposits. The best parameters were then used to print solid cube with various X-Y and Z-overlaps (different hatch spacing, HS, and layer thickness, ZS) in a second DOE. Suitable deposition parameters were selected based on cube density and microstructure and were used to fabricate larger tensile samples for mechanical testing. Multiple parameter sets were found to provide dense Ti-55511 deposits with acceptable mechanical properties and parametric models showed statistical significance.

Melting, solidification and viscosity properties of a multicomponent Fe-Cu-Nb-Mo-Si-B alloys with low aluminum addition up to 0.42 at.% Al were studied using an oscillating cup viscometer. It is shown that melting and solidification are divided into two stages with a knee point at 1461 K. The temperature dependences of the liquid fraction between the liquidus and solidus temperatures during melting and solidification are calculated. It has been proven that aluminum accelerates the processes of melting and solidification and leads to an increase in liquidus and solidus temperatures. In the liquid state at temperatures above 1700 K in an alloy with a low aluminum content, the activation energy of viscous flow increases. This growth was associated with the liquid – liquid structure transition caused by the formation of large clusters based on the metastable Fe23B6 phase. Aluminum atoms attract iron and boron atoms and contribute to the formation of clusters based on the Fe2AlB2 phase and metastable phases of a higher order.

A new Mg-Zn-Zr-Ca alloy in powder state was obtained via mechanical alloying method, from pure elemental powder. Further, the obtained powder-alloy was processed by selective laser melting (SLM) procedure to obtain 3D printed samples for small biodegradable implants. A series of microstructural, mechanical and corrosion analysis were performed. The SEM analysis of powder-alloy reveal a good dimensional homogeneity, with uniform colored, no agglutinated and almost rounded particles, suitable for selective laser melting procedure. Further, the SLM samples reveal a robust and unbreakable morphology, with a suitable porosity and without undesirable balling effect. The tested Young’s modulus of the SLM samples, of 42 GPa, is close to cortical bone one, of 30 GPa. The corrosion tests performed in PBS (Phosphate-buffered saline) solution show that the corrosion parameters have a satisfactory evolution.

This study concerns calculation and comparison of Fe, Co, Ni and Cu deposition rates in tungsten codeposition process based on electrodeposition of numerous tungsten alloys. 8 different tungsten alloys containing from 2 to 5 metals were electrodeposited in constant conditions in order to compare exact reduction rates. Calculated rates enabled control of the alloy composition precise enough to obtain a high-entropy WFeCoNiCu alloy with well-balanced composition. Introduction of copper to form the quinternary alloy was found to catalyze the whole process, increasing deposition rates of all components of the high-entropy alloy.

Sr4Al6O12SO4 samples were obtained from the compound mixture formed by a solid–state reaction of Al2O3, SrSO4, and SrCO3. Samples were compacted at 100MPa to form pellets of 1 and 4cm in diameter and were sintered at 1400°C for 4 hours. The compound was analyzed by X–ray diffraction. Static immersion and wettability tests were performed to evaluate corrosion resistance in contact with Al–Si. Corrosion tests were carried out by immersion at 800, 900, and 1000°C for 24, 50, and 100 hours, while wettability was carried out at 900, 1000, and 1100°C for 2 hours. Subsequently, the samples were prepared metallographically. Samples were analyzed by optical microscopy, scanning electron microscopy, and image analysis. In general, reaction products consisting of alumina, spinel, oxides, and sulfates were found. The contact angles obtained were 124° to 135°. It is concluded that ceramic substrate Sr4Al6O12SO4 is resistant to corrosion by Al–Si alloy, since the slight thickness of the reaction products found in the samples (100μm) considering the severe conditions of the experiment: 1000°C and 100 hours of isothermal temperature. Furthermore, it can be said that Sr4Al6O12SO4 is not wettable by Al–Si alloys.

The article describes machine learning using artificial neural networks (ANN) to develop the parameters of the friction stir welding (FSW) process for three types of aluminum joints (EN AW 7075). A total of 608 experimental data were used to build the ANN. Two types of networks were built: the first one was used to classify good/bad connections with the MLP 7-19-2 topology, the second one was used to regress the tensile load-bearing capacity with the MLP 7-19-1 topology. Selected parameters of the FSW process were used as input data for ANN training: rotational speed, welding speed, joint and tool geometry. Based on a case study, the quality of the FSW joint was assessed in terms of microstructure and mechanical properties. The usefulness of both trained neural networks has been demonstrated. For the regression network, the quality of the validation set was approximately 93.6%. In the case of confusion matrix for the test set, errors never exceeded 6%. Only 184 epochs were needed to train the regression network. The quality of the validation set was approximately 87.1%. On their basis, predictive maps were developed and presented in the work allowing for the selection of optimal parameters of the FSW process for three types of joints.

The effect of defects and microstructure on mechanical properties of Ti-6Al-4V welds produced by tungsten inert gas welding, plasma arc welding, electron beam welding and laser beam welding was studied in the present work. The mechanical properties of the different weld types have been evaluated with respect to micro hardness, yield strength, ultimate tensile strength, ductility and fatigue at room temperature and at elevated temperature. Metallographic investigation was carried out to characterize the microstructures of different weld types and fractographic investigation to relate the effect of defects on fatigue performance. Electron and laser beam welding produced welds with finer microstructure, higher tensile ductility and better fatigue performance than tungsten inert gas welding and plasma arc welding. Large pores and pores located close to the specimen surface were found to be most detrimental to fatigue life.

The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based in light structures, requiring light weight concepts and light materials, while at the same time avoiding dependence towards the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully cover the requirements of many structural applications, however their production requires from bauxite and other Critical Raw Materials (CRM), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp element and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low performance applications. The present work analyses the effect that the use of scrap has in the quantity of inclusions present in the alloy and in other properties relevant for the material processing. The study was carried out for common alloys belonging to 3 of the most common aluminium processes used in the car manufacturing industry: High Pressure Die Casting (HPDC) (EN AC-43500), extrusion (6063) and sheet metal forming (5754 and 6181). Reference alloy were mixed with different level of scrap (0, 20, 40, 60, 80 and 100%) trying to keep the chemical composition as unaffected as possible. The inclusions level of the alloy was characterized with the Prefil Foot-printer® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties to assess the formability quality of the alloys for the corresponding transforming process, were obtained: flowability test for HPDC alloy and high temperature compression for extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related with an important lost of flowability, but do not have a noticeable impact on microstructure.

Research on the development of new lightweight Al-Li alloys using selective laser melting pro-cess has great potential for industrial applications. This paper reports on the development of novel aluminum-lithium alloys using selective laser melting technology. Al-Cu-Li-Mg-Ag-Sc-Zr pre-alloyed powders with lithium contents of 1 wt.%, 2 wt.% and 3 wt.%, respectively, were prepared by inert gas atomization. After SLM process optimization, the microstructure and me-chanical properties of the as-formed specimens were investigated. The densification of the three newly developed alloys are 99.51 %, 98.96 % and 92.01 %, respectively. They all have good form-ability, with the lithium loss rate about 15 %. The as-formed alloy with 1% Li content presents good comprehensive properties with a yield strength of 412.6 ± 16.0 MPa, an ultimate tensile strength of 461.1 ± 11.7 MPa, and an elongation of 13.6 ± 1.1%. The three alloys exhibit a layered molten pool stacking morphology and have a typical heterostructure. The columnar crystals and equiaxed fine grains are alternately arranged, and most of the precipitated phases are enriched at the grain boundaries. The change of Li content mainly affects the precipitation of Cu-containing phase. When the Li content is 1 wt.%, there are θ phase, T1 phase and TB phase. When Li increased to 2 wt.%, T1 and T2 phases precipitated together. When Li reaches 3 wt.%, δ' phase precipitates with T2 phase. This study provides useful guidance for the future SLM form-ing of new crack-free and high-strength Al-Li alloys.

Thin twin-roll cast strips from a model Al-Cu-Mg-Li-Zr alloy with a small addition of Sc were prepared. A combination of a fast solidification rate and a favorable effect of Sc microalloying impacts the size and distribution of primary phase particles and the dimension of eutectic cells. Small interdendritic spacing in the range of 10-15 um enables substitution of the initial long-term homogenization annealing by a two-step annealing at 300 and 450 °C and a short solution treatment at 530 °C before quenching and the final age-hardening procedure. A dense dispersion of small Al3(Sc,Zr) precipitates intensively inhibiting recrystallization forms during this treatment. Further refining and fragmentation of the structure were performed using constrained groove pressing before the solution treatment. Small pre-straining of quenched specimens and subsequent age-hardening simulating T8 temper were used to promote the formation of a homogeneous distribution of strengthening particles and to suppress preferential heterogeneous precipitation on subgrain and grain boundaries. Microstructural features and microhardness evolution during annealing were critically examined and confronted with microstructural characteristics observed on reference mold cast alloy or alloys without Sc alloying. The proposed treatment represents a model near net shape procedure for manufacturing thicker sheets for the aerospace industry.

Keywords: liquid alloys, microstratification, dispersed particles, spontaneous dispersion, criteria for true (entropic) spontaneous dispersion, mechanisms of quasi-spontaneous dispersion, methods and results for assessing size of dispersed particles.

CuAl8Fe5Ni4Zn4Sn1 (OF 2238) is a new lead-free copper alloy for plain bearing applications that was first officially presented in a scientific journal in 2020. Soon after its invention, the use of the alloy for connecting rod bushings in heavy duty internal combustion engines was promoted and validated with customers. The aim of this article is to describe the material properties of the new alloy in more detail than previously and explain how the advantageous properties of CuAl8Fe5Ni4Zn4Sn1 are generated. At the beginning of the article, the general development trends in the field of copper alloys for sliding applications are presented. This is followed by a presentation of the latest research results about CuAl8Fe5Ni4Zn4Sn, before concluding with a brief summary and future outlook, emphasizing on the fact that recent trends in copper-based sliding applications show great additional potential for further material developments.

The excavations carried out by the Ephorate of Antiquities of Piraeus and Islands at the cemetery in the Phaleron Delta, Attica (late 8th - 4th century B.C.), have uncovered in total 1961 burials of various types, among which the Burial 923 is of particular importance as it is the only case of secondary cremation inside a copper alloy lebes. The use of such a valuable bronze vessel, symbolizing prestige, social status and wealth, as a cinerary urn indicates the importance of this find for the interpretation of issues related to the use of the cemetery and the ritual customs of the period and makes imperative the need to preserve the object despite its significant erosion. In this paper, we will present issues related to the lifting and conservation of the bronze vessel, that was found buried within a coastal and sandy depositional environment. Also, the condition of the vessel was scientifically investigated using optical microscopy (OM), portable X-ray fluorescence (p-XRF) and X-ray diffraction (XRD) techniques. The results showed a completely mineralized bronze artefact with tin corrosion products in the core, which indicate decuprification of the copper alloy.