TiC particles were prepared from Ti and C powders, and TiC-reinforced Cu-based composites were prepared by powder metallurgy with SPS sintering. The effects of SPS sintering temperature and TiC particle reinforcement phase content on the electrical and mechanical properties of Cu-based composites were investigated. The reinforcement of TiC particles by thermal mismatching at increasing sintering temperature has a significant strengthening effect on the composites, but the high temperature causes softening of the Cu matrix and the growth of grains reduces the properties of the composites. In this study, the effects of porosity and density on the composite properties were not significant.

Effects of oxygen content on microstructure and creep property of FGH96 superalloy were investigated. When oxygen content increased from 135ppm to 341ppm, prior particle boundary (PPB) rose from degree 2 to degree 3, and the size of γ′ phase on PPB enlarged from 1.07μm to 1.27μm, and MC carbide size grew from 77.4nm to 104.0nm. Meanwhile, the steady creep rate accelerated form 4.34×10-3 h-1 to 1.87×10-2 h-1, and the creep rupture life shortened from 176h to 94h, and the creep rupture mode transferred from intergranular and transgranular mixed fracture to along PPB fracture. During creep, the micro-twins formation and gliding will be restrained by ∑3 boundaries. FGH96 superalloy with higher oxygen content contains less ∑3 boundaries and its micro-twins cross slipped instead of single direction slip in lower oxygen content superalloy. Consequently, specimen with higher oxygen content creeped faster and raptured earlier.

Nano Silicon carbide reinforced aluminum (Al/nanoSiC) metal matrix composites are attractive because of their superior properties such as high strength and stiffness, Application of aluminum in technological and structural application is growing steadily. The major limitation for metal matrix nano composites, however, is their propensity to brittle fracture. The new technologies and new materials are two basic aims for companies. In this research, the effect of addition Al/SiC nano particles on microstructure and mechanical properties of pure aluminum has been investigated. Pure aluminum powder and various fractions of SiC particles with an average diameter of 50 nm were milled by a high-energy planetary ball mill to produce nanocrystalline Al–SiC nanocomposite powders. Pressing and sintering applied to consolidate powders to tablet shape. Then the samples were rolled to cylindrical shape. The nano SiC Percentage were 0%, 2.5%, 5%, 7.5%, 10% , 12,5% and 15%. Mechanical tests such as tensile, hardness, fracture toughness and young’s modules measurement carried out to study the mechanical behavior of each alloy. Scanning electron microscopy was used to study the morphology and microstructure of nanocomposite powders and bulk samples. The role of wt% fraction of SiC nanoparticles was investigated. The results shows that the addition of SiC nano particles has significant influence on the microstructure and mechanical properties of composites and usually the optimum properties depends on wt% SiC.

In this study one of the most innovative sintering techniques up to date was evaluated: Electro-Sinter-Forging (ESF). Despite it has been proved to be effective in densifying several different metallic materials and composites, bearing steels such as 100Cr6 have never been processed so far. Pre-alloyed Astaloy CrM powders have been ad-mixed with either graphite or graphene and then processed by ESF to produce a 100Cr6 equivalent composition. Porosity has been evaluated by optical microscopy and compared to that one of 100Cr6 commercial samples. Mechanical properties such as hardness and transverse rupture strength were tested on samples produced by employing different process parameters and then submitted to different treatments (machining, heat treatment). The experimental characterization highlighted that porosity is the factor mostly affecting mechanical resistance of the samples, correlating linearly to the transverse rupture strength. Hardness on the other side does not correlate to the mechanical resistance because process related cracking has a higher effect on the final properties. Promising results were obtained that give room to the sinterability by ESF of materials difficult to sinter by conventional press and sinter techniques.

Aluminum matrix nanocomposites have been the subject of much attention due to their extraordinary mechanical properties and thermal stability. This research focuses on producing and characterizing an aluminum matrix reinforced with silicon carbide (SiC) nanometric particles. The conventional powder metallurgy route was used to produce the nanocomposites, and the dispersion and mixing process was carried out by ultrasonication. The conditions of the dispersion and the volume fraction of the SiC were evaluated in the production of the nanocomposites. Microstructural characterization was carried out using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD). Mechanical characterization was carried out using hardness and tensile tests. The dispersion agent was investigated, and isopropanol leads to better dispersion with fewer agglomerates. Increasing the volume fraction of the reinforcement improves the hardness of the nanocomposites. However, greater agglomeration of the reinforcement is observed for larger volume fractions. The greatest increase in hardness (77% increase compared to the hardness of the Al matrix) is obtained with 1.0 vol % of SiC, corresponding to the sample with the best dispersion. The mechanical characterization through tensile tests attests to the effect of the reinforcement on the Al matrix. The main strengthening mechanisms identified were the load transfer, the texture hardening, Orowan strengthening, and the increase in the density of dislocations in the nanocomposites.

Real-time closed-loop control of metallurgical processes is still in its infancy, mostly based on simple models and limited sensor data, challenged by extreme temperature, harsh process conditions. Contact-free thermal imaging-based measurement approaches thus appear to be particularly suitable for process monitoring. With the potential to generate vast amounts of accurate data in real-time, combined with artificial intelligence methods to enable real-time analysis and integration of expert knowledge, thermal spectral imaging is identified as a promising method offering more robust and accurate identification of key parameters, such as surface temperature, morphology, composition and flow rate.

The material undergoes high temperature and high strain rate deformation process during cutting process, may induce the dynamic recrystallization behavior and result the evolution of dynamic mechanical properties of the material to be machined. In this paper, the modified Johnson-Cook(J-C) model for Nickel based powder metallurgy superalloy considering dynamic recrystallization behavior in high strain rate and temperature is proposed. The dynamic mechanical properties of the material under different strain rates and temperature conditions are obtained by quasi-static compression test and split Hopkinson pressure bar (SHPB) test. The coefficients of the modified J-C model are obtained by linear regression method. The modified model is verified by comparison with experimental and model prediction results. The results show that the modified J-C model proposed in this paper can accurately describe the mechanical properties of nickel-based powder metallurgy superalloys at high temperature and high strain rate. Which provides help for studying the cutting mechanism and finite element simulation of nickel-based powder metallurgy superalloy.

The issues of metallic scrap management and its utilization in manufacturing plants are nowadays intensely considered to address essential sustainability guidelines. Efficient recycling procedure for shop floor metallic scrap is not yet available because of abundance and contamination of nonmetallic constituents. Other ferrous metallic scrap are melted and purified during secondary steelmaking to get products in the form of blooms and billets are obtained. This study illustrates the potential of powder technology (powder metallurgy (PM) and metal injection molding (MIM)) based process for solid-state recycling and attainment of usable products. Industrially downgraded grinding sludge is pulverized and used as a raw material. Results showed properties of sintered parts are significantly improved due to in-situ reduction and densification during sintering. Recyclability Index (RI) was created to compare the effect of process variables on obtained products. Based on RI, recycled ferrous parts have about 70% comparable properties with equivalent pure iron parts. Complex reduction and sintering behavior in MIM, particularly, diffusion and pore volume kinetics limits applicability of MIM with this recycling approach. However, few industrial parts were developed and manufactured by PM based approach to validate the applicability of this novel recycling-cum-manufacturing process for the production of porous parts.

The welding performance of shipbuilding steel under large heat input could be improved greatly by the Mg addition to the steel, but the impact toughness of the HAZ is not stable. According to the three different thickness steel plates obtained in the industrial experiment, the large heat input welding was carried out by different heat input, and the impact toughness analysis, impact fracture analysis, metallographic microstructure analysis and inclusions analysis were carried out. The results showed that, the HAZ of three kinds of thickness plates induced a lot of IAF, with Mg addition, the inclusion dimension had been reduced effectively, and the IAF induced ability of the inclusions had also been improved. The difference of HAZ impact toughness with different welding heat input and different impact temperature is significant, in consideration of the influence of welding heat input and metallographic microstructure on impact toughness of HAZ, the welding heat load had far greater effect than metallographic microstructure on ductile-brittle transition temperature. At the same time, if the original metallographic microstructure of steel was coarse, the pinning effect of the inclusions would be reduced significantly, and the microstructure of HAZ would be coarsened and the impact toughness of HAZ would be decreased, so there is a certain matching relationship between the metallographic microstructure and the inclusion dimension.

Aluminum base alloys containing chromium (Cr) and zinc (Zn) were produced using extrusion and heat treated powder metallurgy. Cr addition ranged between 5 to 10 wt. % while Zn was added in an amount between 0 to 20 wt. %. Heat treatment processes were performed during powder metallurgy process at different temperatures followed by water quenching. Similar alloys were extruded, with an extrusion ratio of 4.6 to get proper densification. Optical microscopy was used for microstructure investigations of the produced alloys. The element distribution microstructure study was carried out using the Energy Dispersive X-ray analysis method. Hardness and tensile properties of the investigated alloys have been examined. Wear resistance tests were carried out and the results were compared with these of the Al-based bulk alloys. Results showed that the aluminum base alloys containing 10wt. % Chromium and heat treated at 500°C for one hour followed by water quenching exhibited the highest wear resistance and better mechanical properties.

The main purpose of the work was to determine the powder composition and properties of iron-based sinters used as a matrix in metallic diamond tools. The FeCuSnNi sinters obtained from a mixture of commercial powders were used for research. The material was subjected to milling in a ball mill and sinter have been performed with the hot-pressing technique in a graphite mold. The physical and mechanical properties of the sinters were tested. The investigations of obtained sinters concerned density, porosity, hardness, oxygen content, static tensile test and analysis of microstructure. The static tensile test was carried out with the use of a universal testing machine UTS-100. The study of the microstructure of sinters was performed using the JSM-7100F scanning electron microscope. The sinters are characterized by a high coefficient of thermal expansion and good mechanical properties. The FeCuSnNi sinter revealed a complex phase structure. Spot chemical analysis revealed the presence of Fe solution, Cu solution and the presence of iron oxides oxides. Nickel atoms were present throughout the sinter volume. The obtained results indicate that the presented material can be used as a matrix of a diamond-metal composite in diamond tools for the processing of natural stones and building materials.

The influence of the hot isostatic pressing (HIP) post-processing step on structural and phase changes, porosity healing and mechanical strength in a powder metallurgy Ti35Nb2Sn alloy was studied. Powders were pressed at room temperature at 750 MPa, and then sintered at 1,350°C in a vacuum for 3 h. The standard HIP process at 1,200°C and 150 MPa for 3 h was performed to study its effect on a Ti35Nb2Sn powder metallurgy alloy. The influence of the HIP process and cold rate on density, microstructure, the quantity of interstitial elements, mechanical strength and Young's modulus was investigated. HIP post-processing for 2 h at 1,200°C and 150 MPa led to greater porosity reduction and a marked retention of the β phase at room temperature. The slow cooling rate during the HIP process affected phase stability, with a large amount of α”-phase precipitate, which decreased the titanium alloy’s yield strength.

Commercially pure (c.p.) iron powders with a deliberate high degree of oxidation were consolidated by medium-frequency electrical resistance sintering (MF-ERS). This is a consolidation technique where pressure, and heat coming from a low-voltage and high-intensity electrical current, are simultaneously applied to a powder mass. In this work, the achieved densification rate is interpreted according to a qualitative microscopic model, based on the compacts global porosity and electrical resistance evolution. The effect of current intensity and sintering time on compacts was studied on the basis of micrographs revealing the porosity distribution inside the sintered compact. The microstructural characteristics of compacts consolidated by the traditional cold-press and furnace-sinter powder metallurgy route are compared with results of MF-ERS consolidation. The goodness of MF-ERS versus the problems of conventional sintering when working with oxidized powders is analyzed. The electrical consolidation allows to obtain higher densifications than the traditional route under non-reducing atmospheres.

The dynamic effects observed in collisions represent a specific area of high-energy interaction located at the boundary of mechanics, hydrodynamics, shock wave physics, and alternating high-pressure regions. The paper shows that in the volume of a solid metal body, as a result of dynamic alloying by a high-speed stream of powder particles in the super-deep penetration mode (SDP), fibre structures of altering material arise, forming the framework of the composite material. The stream of powder particles in the metal obstacle following the path of least resistance and the impact of shock waves on particles results in a volumetric framework from the products of interaction between the injected and matrix materials. When using SDP, defective structural elements (channelled) - germs of reinforcing fibres arise. At the subsequent heat treatment, there is an intensive diffusion. The growth process of reinforcing fibres shifts to higher temperatures (as compared to the standard mode), leading to an increase in the bending strength of the fibre material up to 13 times for high-speed tool W6Mo5Cr4V2 steel. As a result of the completion of the growth of reinforcing fibres in the volume of the W6Mo5Cr4V2 steel, the material's bending strength in 1.2 times is realised. Simultaneously, it provides an increase of wear resistance 1.7-1.8 times.

With the ever-growing emphasis on global decarbonization and rapid increases in the power density of electronics equipment in recent years, new methods and lightweight materials have been developed to manage heat load as well as interfacial stresses associated with Coefficient of Thermal Expansion (CTE) mismatch between components. The Al-Si system provides an attractive combination of CTE performance and high thermal conductivity whilst being a very lightweight option. Such materials are of interest to industries where thermal management is a key design criterion, such as aerospace, automotive, consumer electronics, defense, EV and space. This paper will describe the development and manufacture of a family of high-performance hypereutectic Al-Si alloys (AyontEX™) by a powder metallurgy method. These alloys are of particular interest for structural heat sink applications that require high reliability under thermal cycling (CTE of 17μm/(m·°C)) as well as reflective optics and instrument assemblies that require good thermal and mechanical stability (CTE of 13μm/(m·°C)). Critical performance relationships are presented, coupled with the microstructure, physical and mechanical properties of these Al-Si alloys.

The study of co-fusion was one of the essential topics in the history of metallurgy in China. Simulation experiments had been an essential concept in the study of the co-fusion steelmaking process. This paper mainly studied the simulation experiments of co-fusion from two aspects: the replication of co-fusion swords by three different methods, and the micro-analysis of the co-fusion samples. The experimental results indicated that several co-fusion swords could be made by different processes, but the carbon content and surface hardness were quite different. During repeated forging welded, the microstructure of the samples transformed from laminated to homogenized, finally the steel with a uniform carbon content was obtained. It was challenging to find the characteristics of co-fusion from the homogenized samples. The results prompted people to rethink the microstructure characteristics of ancient co-fusion artifacts.

The study focuses on a novel porous TiNi-based material for ophthalmic orbital implants which was produced by self-propagating high-temperature synthesis (SHS) and, after proper surface modification, possesses a specific microstructure of its surface pores, which makes it attractive for biomedical use in implants. After preparation via SHS, the obtained porous TiNi material was etched in acidic environment, to get rid of its surface Ti2Ni secondary-phase particles. This was found to improve the material’s surface morphology, adding micro-roughness to its macro-rough pores. As a result, cell growth tests conducted on the material demonstrated improved cell adhesion and growth kinetics on such a porous material with improved roughness. Finally, the material was tested in vivo as an ophthalmic orbital implant, demonstrating good biocompatibility, good degree of biointegration with surrounding eyeball tissues, and no signs of rejection after as long as 180 days. Thus, the novel porous TiNi-based material shows promise for its use in ophthalmic implantology, for instanse for manufacturing musculoskeletal stumps of the eyeball after evisceration, as it is biocompatible, has a high tissue-implant integration potential and demonstrates reduced risks of exposure and rejection of the implant.

This work deals with a novel porous TiNi-based material for ophthalmic orbital implants that was produced by high-temperature synthesis (SHS) and possesses a specific microstructure of its surface pores, which makes it attractive for biomedical use in implants. After preparation via SHS, the obtained porous TiNi material was etched in acidic environment, to get rid of its surface Ti2Ni secondary-phase particles. This was found to improve the material’s surface morphology, adding micro-roughness to its macro-rough pores. As a result, cell growth tests conducted on the material demonstrated improved cell adhesion and growth kinetics on such a porous material with improved roughness. Finally, the material was tested in vivo as an ophthalmic orbital implant, demonstrating good biocompatibility, good degree of biointegration with surrounding eyeball tissues, and no signs of rejection after as long as 180 days. Thus, the novel porous TiNi-based material shows promise for its use in ophthalmic implantology, for instanse for manufacturing musculoskeletal stumps of the eyeball after evisceration, as it is biocompatible, has a high tissue-implant integration potential and demonstrates reduced risks of exposure and rejection of the implant.

TiNi alloys are very widely used materials for implant fabrication. When applied as rib replacement, they are required to be manufactured as combined porous-monolithic structure, ideally with a thin porous part well-adhered to its monolithic substrate. Additionally, good biocompatibility, high corrosion resistance and mechanical durability are also highly demanded. So far, all these parameters were not achieved in one material, which is why active search in the field is still underway. In the present work, we prepared new porous-monolithic TiNi materials by sintering a TiNi powder (0-100 µm) on monolithic TiNi plates followed by surface modification with high-current pulsed electron beam. The obtained materials were evaluated by a set of surface and phase analysis methods, after which their corrosion resistance and biocompatibility (hemolysis, cytotoxicity, and cell viability) were evaluated. Finally, cell growth tests were conducted. In comparison with flat TiNi monolith, the newly-developed materials were found to have better corrosion resistance, also demonstrating good biocompatibility and potential for cell growth on their surface. Thus, the newly-developed porous-on-monolith TiNi materials with different surface porosity and morphology show promise as potential new-generation implants for rib endoprostheses.

TiNbZrTa alloys are promising for multidisciplinary applications, such as refractory and biomedical purposes due to their high thermal stability and non-toxicity. Hardness and elastic modulus are among the key features for their adequate industrial applications. The influence of porosity and Ti/Ta ratio were investigated on TiNbZrTa alloys produced by three different processing routes, i.e., (i) blend element and posterior press and sintering (BE + P&S), (ii) mechanical alloying with press and sintering (MA + P&S), and (iii) arc melting and casting. Atomic diffusion was improved during processing, resulting in lower porosity in the following order: casting < MA + P&S < BE + P&S. Ta offered limited atomic diffusion due to its high melting point compared to other constituent elements. Thus, the total porosity of alloys increased with increasing the Ta contents, i.e., by lowering the Ti/Ta ratio. However, the Ti/Ta ratio did not considerably affect the bonding energy or the elastic modulus. Hardness was increased significantly in dense alloys compared to the porous ones. However, porosity and Ti/Ta ratio did not show a clear trend in hardness among the porous alloys.

Magnesium nanoparticles of various mean diameters (53 – 239 nm) were synthesized herein via Pulsed Laser Ablation in Liquid (PLAL) from millimeter sized magnesium powders within iso-propyl alcohol. It was observed via a 3x3 full factorial DOE that the processing parameters can control the nanoparticle distribution to produce three size-distribution types (bimodal, skewed and normal). Ablation times of 2, 5, and 25 minutes where investigated. An ablation time of 2 minutes produced a bimodal distribution with the other types seen at higher periods of processing. Mg nanoparticle UV-Vis absorbance at 204 nm increased linearly with increasing ablation time, indicating an increase in nanoparticle count. The colloidal density (mg/ml) generally increased with increasing nanoparticle mean diameter as noted via increasing UV-vis absorbance. High la-ser scan speeds (within the studied range of 3000 - 3500 mm/s) tend to increase the nanoparticle count/yield. For the first time, the effect of scan speed on colloidal density, UV-vis absorbance and nanoparticle diameter from metallic powder ablation was investigated and is reported herein. The nanoparticles formed dendritic structures after being drop cast on aluminum foil as observed via FESEM analysis. Dynamic light scattering was used to measure the size of the nanoparticles. Magnesium nanoparticles have promising use in the fabrication of wearables, such as in conductive tracks or battery electrodes, owing to their low heat capacity, high melting point and bio-compatibility.