The use of aluminium alloys continues to grow in many applications to mention a few aerospace, automotive, electronics, electricity, construction and food packaging. With so much demand there is a new interest in welding of dissimilar aluminium alloys. Some of the welding techniques used to join dissimilar aluminium alloys include friction stir welding and TIG welding. The welding of dissimilar alloys affects the mechanical properties negatively due to porosity and cracking during the welding. This then suggests that there should be a process which can be used to improve the dissimilar alloys mechanical properties post its production. Friction stir processing was found to be one of the mechanical techniques that could be used to improve the mechanical properties of the material. This paper reports on the literature on the friction stir welding, TIG welding and friction stir processing techniques published so far, with the aim to identify the gap in the use of friction stir process as a post processing technique of the weld joints.

Cellular substructure has been widely observed in the sample fabricated by selective laser melting, while its growth direction and the crystallographic orientation have seldom been studied. This research tries to build a general model to construct the substructure from its two dimensional morphology. All the three Bunge Euler angles to specify a unique growth direction are determined, and the crystallographic orientation corresponding to the growth direction is also obtained. Based on the crystallographic orientation, the substructure in the single track is distinguished between cell-like dendrite and cell. It is found that, with the increase of scanning velocity, the substructure transits from cell-like dendrite to cell. The critical growth rate of the transition can be around 0.31 ms^-1.

This article presents the copper ions adsorption process using an activated carbon from winemaking wastes. The pH, temperature, activated carbon amount and initial copper concentration were varied based on a full factorial 2^k experimental design. Kinetic and thermodynamic studies were also carried out. The adsorption kinetics was found follow a pseudo-second-order model. The adsorption data fit better to the Langmuir isotherm. The ANOVA demonstrated that both pH of the solution and activated carbon dosage had the greatest influence on copper adsorption. The activation energy was -32 kJ·mol^-1 suggesting that the copper adsorption is a physic-sorption process. The best fit to a linear correlation was the moving boundary equation that controls the kinetics for the adsorption copper ions onto the activated carbon. The X-ray photoelectron spectroscopy (XPS) results reveal the existence of different copper species (Cu²⁺, Cu⁺ and or Cu⁰) on the surface of the carbonaceous adsorbent after the adsorption, which could suggest a simultaneous reduction process.

By using hydrogen quench continuous annealing technology, Stelco Inc. has developed a suite of Advanced High Strength Steel (AHSS) grades with tensile strength greater than 1000MPa to meet standard automotive specifications and for unique customer requirements. These grades were optimized by correlating chemical composition and processing parameters with microstructures and mechanical properties. Dual-Phase 980 (Stelco trademarked STELMAXTM 980DP), Multi-Phase 1180 (STELMAXTM 1180MP), Martensitic Steel 1300 (STELMAXTM 1300M) and 1500 (STELMAXTM 1500M) products met strength and formability requirements with excellent flatness and surface quality. Hydrogen quench continuous annealing technology not only ensures all developed AHSS grades have consistent mechanical properties across the entire strip length (from strip head to tail) and width (from edge to edge), but also produces high product yield compared with other continuous annealing processes.

A multi-strand composite welding wire was applied to join high nitrogen austenitic stainless steel, and microstructures and mechanical properties were investigated. The electrical signals demonstrate that the welding process using a multi-strand composite welding wire is highly stable. The welded joints are composed of columnar austenite and dendritic ferrite and welded joints obtained under high heat input and cooling rate have a noticeable coarse-grained heat-affected zone and larger columnar austenite in weld seam. Compared with welded joints obtained under the high heat input and cooling rate, welded joints have the higher fractions of deformed grains, high angle grain boundaries, Schmid factor and the lower dislocation density under the low heat input and cooling rate, which indicate a lower tensile strength and higher yield strength. The rotated goss (G_RD) orientation of a thin plate and the cube (C) orientation of a thick plate are obvious after welding, but the S orientation at 65° sections of Euler’s space is weak. The δ-ferrite was studied based on the primary ferrite solidification mode. It is observed that low heat input and high cooing rate result in the increasing of δ-ferrite and high dislocation density was obtained in grain boundaries of δ-ferrite. M₂₃C₆ precipitates due to low cooling rate and heat input in weld seam and deteriorates the elongation of welded joints. The engineering stress-strain curves also show the low elongation and tensile strength of welded joints under low heat input and cooling rate, which is mainly caused by the high fraction of δ-ferrite and the precipitation of M₂₃C₆.

One ambitious objective of Integrated Computational Materials Engineering (ICME) is to shorten the materials development cycle by using computational materials simulation techniques at different length scales. In this regard, the most important aspects are the prediction of the microstructural evolution during material processing and the understanding of the contributions of microstructural features to the mechanical response of the materials. One possible solution to such a challenge is to apply the Phase Field (PF) method because it can predict the microstructural evolution under the influence of different internal or external stimuli, including deformation. To accomplish this, it is necessary to take into account plasticity or, specifically, non-homogeneous plastic deformation, which is particularly important for investigating the size effects in materials emerging at the micron length scale. In this work, we present quasi-2D simulations of plastic deformation in a face centred cubic system in a finite strain formulation. Our model consists of dislocation-based strain gradient crystal plasticity implemented into a PF code. We apply this model to study the influence of grain size on the mechanical behavior of polycrystals, which includes dislocation storage and annihilation. Furthermore, the initial state of the material before deformation is also considered. The results show that a dislocation-based strain gradient crystal plasticity model can capture the Hall-Petch effect in many aspects. The model reproduced the correct functional dependence of the flow stress of the polycrystal on grain size without assigning any special properties to the grain boundaries. However, the predicted Hall-Petch coefficients are significantly smaller than those found typically in experiments. In any case, we found a good qualitative agreement between our findings and experimental results.

There is a high iron content in the nickel slag that mainly exists in fayalite phase. Basic Oxide can destroy the stable structure of fayalite which is beneficial to the treatment and comprehensive utilization of nickel slag. The reseach was based on the composition of the raw nickel slag, taking CaO-SiO₂-FeO-MgO system as the object and CaO as a modifier. The effect of basicity on the melting characteristics, viscosity and structure of CaO-SiO₂-FeO-MgO system was studied. The relationship between the viscosity and structure of CaO-SiO₂-FeO-MgO system was also explored. The results show as follows. (1) When the basicity is 0.38~0.90, the phase of primary crystal is olivine at argon atmosphere, while it is monoxide at the basicity of 0.90~1.50. The liquidus temperature, softening temperature, hemispherical temperature, and flow temperature all reach the lowest value at the basicity of 0.90. (2) With the increase of basicity, critical viscosity temperature of CaO-SiO₂-FeO-MgO system decreases first and then increases. Critical viscosity temperature is the lowest at the basicity of 0.90, which is 1263 ℃. (3) When the slag system is heterogeneous, the viscosity of the molten slag increase rapidity because of the type and quantity of solid phase precipitated from CaO-SiO₂-FeO-MgO system. And critical viscosity temperature of the slag system is also significantly affected. (4) When the slag system is in a homogeneous liquid phase, the molar fraction of O0 decreases with the increase of basicity and the mole fraction of O^- and O^2- increases continuously at the basicity of 0.38~1.50. The silicate network structure is gradually depolymerized into simple monomers, resulting in the degree of polymerization is reduced and the viscosity is reduced, too.

In article questions of development low-waste technologies of processing of steel-smelting slag are considered, gland allowing by extraction and its connections from steel-smelting slag to receive additional raw materials for production became, and the remains to use in building industry. Studying of gravitational methods of enrichment of steel-smelting slag and heat treatment the ore-fuel of pellets is the basis for work. Proceeding from it, in work modern physic-mechanical, chemical and physical and chemical methods of researches (UV-spectroscopy, electronic microscopy, the granulometric analysis) are used.

In this study, the effect of heat treatment was investigated to influence the occurrence of fracture during manufacturing process of Alloy B steel with boron contents as high as 130 ppm. As the content of boron increases, it affects the phase transformation temperature and texture. The development of {111}<uvw> components in the γ-fiber is affected depending on the austenite fraction after phase transformation. The Alloy B steel indicated that the increase in the boron content increased the α to γ phase transformation temperature such that sufficient transformation did not occur in the normalizing condition. The cracks occurred at the point of the transition from elastic to plastic deformation in the ND direction during the rolling process, thereby resulting in failure. Therefore, it is necessary to avoid the intermediate heat treatment condition in which γ-fiber does not fully develop, i.e., an imperfect normalization.

Using co-precipitation to synthesize (CeO2)0.95(Y2O3)0.05 (YDC) and solid reaction method to synthesize (CeO2)0.75(ZrO2)0.25 (ZDC), and the characterization for both crystal structure and micro-structure of the two materials was conducted with X-ray diffraction (XRD) and scanning electron microscope (SEM) methods. Prepare the YDC and ZDC based limited current O2 sensor by employing platinum pasting bonding method. Sensing characteristics of the sensor were obtained at different conditions and study on the impact of temperature, O2 concentration as well as water vapor pressure on the sensing characteristics had been conducted. XRD results show that the phase structure of both YDC and ZDC is cubic phase. SEM results show that both YDC and ZDC layers are dense layers, which are then qualified to be the composition materials of the sensor. This limited current O2 sensor shows good sensing performance and conforms to the Knudsen model. Log(IL•T) depends linearly on 1000/T with R2 of 0.9904, IL depends linearly on x(O2) with R2 of 0.9726 and sensing characteristics are not affected by p(H2O).

Titanium’s accelerating usage in global markets is attributable to its distinctive combination of physical and metallurgical properties. The key to best utilizing titanium is to exploit these characteristics, especially as they complement one another in a given application, rather than to just directly substitute titanium for another metal. Titanium alloy are extensively used in aerospace applications such as components in aero-engines and space shuttles, mainly due to their superior strength to weight ratio. For these demanding applications functionality and reliability of components are of great importance. To increase flight safety, higher sensitivity inspections are sought for rotating parts. Increased sensitivity can be applied at the billet stage, the forging stage, or both. Inspection of the forging geometry affords the opportunity to apply the highest sensitivity due to the shorter material paths when compared to those required for billet inspections. Forging inspection is typically performed for titanium (Ti) rotating parts with immersion inspection and fixed-focus, single-element transducers. Increased gain is required with depth because the ultrasonic beam attenuates with distance and diverges beyond the focus position that is placed near the surface. The higher gain that is applied with depth has the effect of increasing the UT noise with depth. The relationships between the UT noise, selection of the examination technique and the smallest detectable defect are presented in this material.

The microstructure and solidification behavior of nickel based GTD222 superalloy at different cooling rates are studied. The solidification of the GTD222 superalloy proceeds as follows: L→L+γ, L→L+γ+MC, L→L+(γ/γ ′)-Eutectic and L→η phase. The temperature of liquidus of GTD222 superalloy is 1360 °C while the solidus is slightly lower at 1310 °C, which due to the alloying elements redistribution. It was found that the dendrite arm spacing of the alloy decreased with the increase of cooling rate (From 200 μm at 2.5 K/min to 100 μm at 20 K/min).

Equiatomic CuZr alloy undergoes a martensitic transformation from the B2 parent phase to martensitic phases (P21/m and Cm) below 150 °C. We clarified the effect of the thermal cycling on the morphology and crystallography of martensite in equiatomic CuZr alloy using a transmission electron microscopy. The 10th cycled specimens consisted of different multiple structures at the maximum temperature of DSC measurement: 400 °C and 500°C, respectively. At the maximum temperature 400 °C of DSC measurement, it is composed of the fine plate-like variants, and a lamellar eutectoid structure consisting of Cu10Zr7 and CuZr2 phases on the martensitic variant. Concerning the maximum temperature 500 °C of DSC measurement, it is observed the martensitic structure and the lamellar structure in which the martensitic phase was completely eutectoid transformed. The formation of this lamellar eutectoid structure due to thermal cycling leads to the shift of forward and reverse transformation peaks to low and high temperature side. In addition, new forward and reverse transformation peaks indicating a new transformation appeared by thermal cycling, and the peaks remained around -20 °C. This new martensitic transformation behavior is also discussed.

Abstract: Microstructural and mechanical properties of the eutectic Sn58Bi and micro-alloyed Sn57.6Bi0.4Ag solder alloys were compared. With the addition of Ag micro-alloy, the tensile strength was improved and this is attributed to a combination of microstructure refinement and an Ag3Sn precipitation hardening mechanism. However, ductility is slightly deteriorated due to the brittle nature of the Ag3Sn intermetallic compounds (IMCs). Additionally, a board level reliability study of Ag micro-alloyed Sn58Bi solder joints produced utilising a surface-mount technology (SMT) process, were assessed under accelerated temperature cycling (ATC) conditions. Results reveal that micro-alloyed Sn57.6Bi0.4Ag has a higher characteristic lifetime with a narrower failure distribution. This enhanced reliability corresponds with improved bulk mechanical properties. It is postulated that Ag3Sn IMCs are located at the Sn-Bi phase boundaries and suppress the solder microstructure from coarsening during the temperature cycling, hereby extending the time to failure.

In this paper were analyzed the effects of double reduction and annealing during rolling process on texture evolution in an ultrathin sheet of low carbon steel. Experimental samples were obtained from each process stage. EBSD technique and correlated tools as orientation density functions and pole figures were used to analyze the microstructural changes and the texture. Results show that {111} recrystallized grains were formed during process, reducing dramatically gamma-fibre texture intensity and generating an adequate finished product for deep die stamping.

In recent years, it has been found in engineering practice that the service life of cemented carbide shield machine tools used in uneven soft and hard strata is substantially reduced. The study found that thermal stress is the main reason for the failure of cemented carbide shield tunneling tools when shield tunneling is carried out in uneven soft and hard soil. To maintain the hardness of cemented carbide, improving the thermal conductivity of the shield machine tool is of great importance for prolonging its service life and reducing engineering costs. In this paper, graphene and carbon nanotubes were mixed with WC-Co powder and sintered by SPS (Spark Plasma Sintering). The morphology was observed by using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). A Rockwell hardness tester and bending strength tester were used to test hardness, bending strength and thermal conductivity. The results show that adding trace graphene or carbon nanotubes can increase the bending strength of the cemented carbide by approximately 50% while keeping the hardness of the cemented carbide unchanged. The thermal conductivity of the cemented carbide can be increased by 10% with the addition of 0.12% graphene alone.

Thin Slab Casting and Directing Rolling (TSCDR) has become a major process for flat- rolled production. However, the elimination of slab reheating and limited number of thermomechanical deformation passes leave fewer opportunities for austenite grain refinement resulting in some large grains persist in the final microstructure. In order to achieve excellent Ductile to Brittle Transaction (DBTT) and Drop Weight Tear Test (DWTT) properties in thicker gauge high strength low alloy products, it is necessary to control austenite grain coarsening prior to the onset of thermomechanical processing. This contribution proposes a suite of methods to refine the austenite grain from both theoretical and practical perspective including: increasing cooling rate during casting, liquid core reduction, increasing austenite nucleation sites during the delta ferrite to austenite phase transformation, controlling holding furnace temperature and time to avoid austenite coarsening, and producing new alloy with two phase pinning to arrest grain coarsening. These methodologies can not only refine austenite grain size in the slab center, but also improve the slab homogeneity.

Plastic flow in body-centered cubic (bcc) alloys is governed by the thermally-activated screw dislocation motion. In bcc interstitial solid solutions, solute diffusion can occur at very fast rates owing to low migration energies and solute concentrations. Under mechanical loading, solutes may move on the same or similar time scale as dislocations glide, even at low temperatures, potentially resulting in very rich co-evolution processes that may have important effects in the overall material response. It is therefore important to accurately quantify the coupling between interstitial impurities and dislocations, so that larger-scale models can correctly account for their (co)evolution. In this paper, we use electronic structure calculations to obtain the energetics of oxygen diffusion under stress and its interaction energy with screw dislocation cores in bcc tungsten. We find that oxygen atoms preferentially migrate from tetrahedral to tetrahedral sites with an energy of 0.2 eV. This energy couples only weakly to hydrostatic and deviatoric deformations, with activation volumes of less than $0.02$ and $0.2b^3$, respectively. The strongest effect is found for the inelastic interaction between O atoms and screw dislocation cores, which leads to attractive energies on the order of 1.5 eV and a structural transformation of the screw dislocation core from an `easy' to a `hard' core configuration

Abstract: The Inconel 625 is a nickel-based alloy has been widely used in the high-temperature application. The Inconel 625 exhibits unstable plastic flow at elevated temperature characterized by serrated yielding, known as Portevin-Le Chatelier effect. The aim of this work is to evaluate the mechanical properties at high temperatures of the Inconel 625. The tensile tests were performed in the temperature range of room temperature until 1000 °C and strain rate of 2x10^-4 to 2x10^-3 s^-1. The creep tests were performed in the temperature range of 600-700 °C, in the stress range of 500-600 MPa in a constant load mode. The surface fracture was observed by optical and scanning electron microscopy. Serrated stress-strain behavior was observed in the curves obtained at 200 to 700 °C, which was associated with the dynamic strain aging effect. The yield strength and the elongation values show an anomalous behavior as a function of the test temperature. An intergranular cracking was observed specimen tensile tested at 500 °C that can be attributed to the decohesion of the carbides along the grain boundaries. The fracture surface of the specimen tensile tested at 700 °C showed the predominance of transgranular cracking with tear dimples with a parabolic shape.

The Ti-6Al-4V alloy is widely used in the manufacture of components that should have low density, high corrosion resistance, and fatigue strength. The fatigue strength can be improved by surface modification. The aim of this study was to determine the influence of plasma nitriding on the fatigue behavior of Ti-6Al-4V alloy with a lamellar microstructure (Widmanstätten type). Nitriding was executed at 720 °C for 4 hours in an atmosphere with N₂, Ar and H₂. Samples microstructure characterization was carried out by X-ray diffraction analysis, optical microscopy and scanning electron microscopy. The average roughness of the specimens was determined, and fatigue tests were executed in a bending-rotating machine with reverse tension cycles (R= -1). X-ray diffraction analysis revealed the matrix phases α and β, and the phases Ɛ-Ti₂N and δ-TiN in the nitrided alloy. A nitrogen diffusion layer was formed between the substrate and the titanium nitrides. Plasma nitriding resulted in an increase in low cycle fatigue strength, whereas at high cycles, both conditions exhibit similar behavior. The fracture surface of the fatigue tested specimens clearly revealed the lamellar microstructure. The fracture mechanism appears to be due to cracking at the interface of α and β phases of the lamellar microstructure.

Bulk metallic glass matrix composites have emerged as competent structural material of future bearing potential structural applications. However, the optimum percentage of crystallinity required to produce enough toughness that it can serve as structural component is still a matter of debate. In this study, an effort is made to address this problem by inoculation. A controlled amount of carefully selected inoculant is introduced in Zr_47.5Cu_45.5Al₅Co₂ bulk metallic glass matrix composite during melting and solidification. Its effect in promoting crystallinity is checked by detailed electron back scatter diffraction (EBSD) mapping. Proper pattern capture, background correction, binning, Hough space transformation, step size selection, indexing and matching with well-defined crystal structure files have shown to reflect upon map quality. This shows and bears direct relation with effect of inoculation. Results from two independent laboratories are reported. Inoculation treatment is shown to be advantageous.

A overview on application of CO2 in the ironmaking and steelmaking process is presented. Study on resource utilization of CO2 is significant for the reduction of CO2 emissions and the coping with global warming. The paper introduces the research progress of CO2 utilization in the sintering, Blast Furnace, Converter, secondary refining, Continuous Casting and smelting process of stainless steel in recent years in China. According to the foreign and domestic research and application status, the paper analyzes the feasibility and metallurgical effects of the CO2 utilization in the ferrous metallurgy process. The paper mainly introduces such new techniques as 1) flue gas circulating sintering, 2) blowing CO2 through Blast Furnace tuyere and CO2 as a pulverized coal carrier gas, 3) top and bottom blowing CO2 in the converter, 4) Ladle Furnace and Electric Arc Furnace bottom blowing CO2, 5) CO2 as Continuous Casting shielding gas, 6) CO2 for stainless steel smelting, and 7) CO2 circulation combustion. CO2 has a very wide application prospect in ferrous metallurgy process and the quantity of CO2 utilization is expected to be 100kg per ton of steel. It will effectively facilitate the progress of metallurgical technology and strongly promote the energy conservation of metallurgical industry.

Synthesis of poly(o-phenylenediamine) (PoPD) and poly(o-phenylenediamine)-ZnO (PoPD-ZnO) nanocomposites on carbon steel by in-situ polymerization with HCl acid as doping acid Material coating. The composition and structure of PoPD-ZnO nanocomposites were characterized by Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD) and scanning electron microscopy (SEM). The corrosion protection ability of polymer coatings in 3.5% NaCl was studied by potentiodynamic polarization curves and electrochemical impedance spectroscopy. It can be seen from the electrochemical corrosion experimental data that PoPD-WPU coating (PWC) and PoPD-ZnO-WPU coating (PZWC) can effectively improve the corrosion resistance of the carbon steel substrate, and the corrosion rate is reduced by 2-3 orders of magnitude compared with carbon steel. The conclusion demontrates that PoPD can effectively extend the service life of carbon steel substrates. In addition, it is advantageous to form a compact and low-defect coating when added nano-particle ZnO, which is advantageous for the POPD film to develop its good barrier property and corrosion resistance.

Duplex Stainless Steels (DSS) and Superduplex Stainless Steels (SDSS) are an important class of stainless steels because they combine the benefits of austenite and ferrite phases, resulting in steels with better mechanical properties and higher corrosion resistance. Due to these characteristics are widely employed in various industries. However, the appearance of deleterious phases in their microstructure impairs the properties of DSS and SDSS. Among the deleterious phases, the main one is the sigma phase (σ), which can be nucleated when the steel is exposed to the temperature range between 650 °C and 900 °C, reducing its toughness and resistance to corrosion. In a previous work, Fonseca and collaborators used two descriptors of the microstructural path to analyze the formation of sigma phase (σ), SV, interfacial area per unit volume between sigma phase and austenite, and <λ>, mean chord length of sigma, both in function of the VV, volume fraction of sigma, known in the literature as microstructural partial path (MP). In this work, the contiguity ratio is applied for the first time to describe the microstructural path in the study of sigma phase precipitation in SDSS. The contiguity ratio showed that the distribution of the ferrite/sigma boundaries is homogeneous. Thus, it is reasonable to infer that one has a uniform distribution of sigma phase nuclei within the ferrite. About the kinetics of sigma phase formation, the DSS can be described by the classical JMAK equation, whereas for the SDSS, the kinetics tends to follow the Cahn model for grain edge nucleation. Finally, we present the 3D reconstruction of the sigma phase in SDSS. The results demonstrate that the sigma phase nucleates at the edges of the ferrite/austenite interfaces. Moreover, the sigma phase grows consuming the ferrite, but it is not fully interconnected.

The aim of this work is to assess the influence of Friction Stir Welding (FSW), process parameters, optimized tool traveling speed, and corrosion resistance of the 0.95 Mg-Al-alloy and pure copper weldment. Samples of aluminum-copper with and without deformation were characterized to investigate the metallurgical effects created during the welding deformation process. Effect of process parameters on microstructure and corrosion rate have been investigated for all the samples. All the electrochemical and polarization tests were done in 3.5 wt.% NaCl solution. Scanning Kelvin Probe (SKP) was done to detect the localized corrosion on the surface. Optical micrography observation indicated that the primary α-Al phase, which was formed during solidification can effectively limit the growth of Cu₉Al₄ phase. Finer acicular α-Al precipitates were observed in CuAl matrix during joining process that tends to coarser with the increase in tools travel speed. The electrochemical and polarization results showed that among all the tool travelling speed the specimen joined at tool travelling speed of 40 mm/min shows the best non-corrosive property.

Using nanoindentation under various strain rates, the mechanical properties of a selective laser melted (SLM) SKD61 at the 800 mm/s scan speed was investigated and compared to SLM H13. No obvious pile-up due to the ratio of the residual depth (h_f) and the maximum depth (h_max) being lower than 0.7 and no cracking were observed on any of the indenter surfaces. The nanoindentation strain-rate sensitivity (m) of SLM SKD61 was found to be 0.034, with hardness increasing from 8.65 GPa to 9.93 GPa as the strain rate increased between 0.002 s⁻¹ and 0.1 s⁻¹. At the same scan speed, the m value of SLM H13 (m = 0.028) was lower than that of SLM SKD61, indicating that the mechanical behavior of SLM SKD61 was more critically affected by the strain rate compared to SLM H13. SLM processing for SKD61therefore shows higher potential for advanced tool design than for H13.

Direct-to-blister copper flash smelting slag contains up to 14% of copper and 2-4% of lead. Considering this fact, this material is subjected to the high-temperature reduction process. After this, converting process is performed on the Cu-Pb-Fe alloy being the product of decopperization process in electric furnace. An alternative to the presently used processing of flash smelting slag would be its hydrometallurgical treatment and selective recovery of Pb and Cu. This paper presents the results of laboratory tests on flash smelting slag leaching with citric acid solutions. The experiments performed allowed to determine the process parameters at which the Pb concentration in the post-leaching sediment reached the value of 0.41-0.6% while the Pb content in flash smelting slag was 3.05%. Analogous values for copper were 11.5-11.8% (after leaching) and 12.44% (before). Material after leaching in citric acid solutions can be processed, in the second step, using sulfuric acid solutions, and it could lead to the recovery of almost all copper contained in it.

ASTM A743 CA6NM alloy is a martensitic stainless steel typically used in energy industry -runners and hydraulic turbine components- due to its superior toughness, yield and fatigue properties. In both the manufacturing, shielded metal arc welding is applied to join for this grade steels. However, weldability of the steels is limited due to formation of hard and brittle phases such as untempered martensite during welding and post weld heat treatment processes. The formation causes a reduction in toughness. In this study, influence of post-weld heat treatment procedure (single tempering and double tempering) and parameters on microstructure and hardness of AWS410NiMo all weld metal. Hardness tests were conducted from weld metal. Microstructures of the all weld metals subjected to different heat treatment process were characterized.

: The effect that the microstructure exerts on the TRIP phenomenon and on the mechanical properties in a multiphase steel was studied. Samples of an initially cold-rolled ferrite-pearlite steel underwent different intercritical annealing treatments at 750 °C until an equal fractions of austenite/ferrite was reached; the intercritical treatment was followed by isothermal bainitic treatments before cooling the samples to room temperature. Samples in the first treatment were heated  directly to the intercritical temperature, whereas other samples were heated to either 900 or 1100 °C to obtain a fully homogenized, single phase austenitic microstructure prior to the conducting the intercritical treatment. The high temperature homogenization of austenite resulted in the decrease in its stability, so a considerable austenite fraction transformed into martensite by cooling to room temperature after the bainitic heat treatment. Most of the retained austenite transformed during the tensile tests, and as a consequence, the previously homogenized steels showed the highest UTS. In turn, the steel with a ferritic-pearlitic initial microstructure, exhibited higher ductility than the other steels and texture components that favor forming processes.     

Vanadium titano-magnetite is a significant resource in China, and in this study, we characterize its isothermal reduction mechanisms in the mixture of H₂, CO, and N₂ where the variables considered here include reduction time, reduction temperature, gas composition, and pellet size. The kinetics of the reduction process are mainly studied, which follows a shrinking core model. The results indicate that the reduction degree of oxidized VTM pellets increases with the increase of reduction time, reduction temperature but decreases with the increase of pellet size. Moreover, we found that an increase of H₂/(H₂+CO) ratio induces an increase of the reduction degree. Then the transformation of main Ti-bearing mineral phases is discussed, and the most probable reaction mechanism is revealed. In the whole reduction process, the kinetic results confirm the existence of an early stage and a latter stage, which are controlled by interface chemical reaction and diffusion, respectively. Furthermore, the results show that the diffusion-control step can be observably shortened with the decrease of pellet size because a thinner product layer is formed during the reduction process. Our study thus provides a valuable technical basis on the VTM industrial application.

The aim of this paper is to at first evaluate the influence of three key parameters including weld current, weld time and electrode force on nugget diameter and tensile strength in resistance projection welding. Then, a 2-D axis-symmetric finite element model is developed to simulate the projection welding and predict the nugget diameter. Finally, the FEM results are compared to experimental data to verify the simulation model and simulated results. In the finite element model, the temperature-dependent material properties were taken into account.  

The formability and failure behavior of TRIP steel blanks were investigated through various stress states. The forming limit diagram (FLD) at fracture is constructed both experimentally and numerically. Numerical studies are performed to evaluate the applicability of different damage criteria in predicting the FLD as well as complex cross-die deep drawing process.  The fracture surface and numerical results revealed that the material failed in a different mode for different strain path. Therefore, Tresca model which is based on shear stress accurately predicted the conditions where shear had the profound effect on the damage initiation, whereas Situ localized necking criterion was able to calculate the conditions which localization was dominant.

In this paper, firstly, experiments are carried out to evaluate the influence of three key parameters including weld current, weld time and electrode force in nugget diameter and tensile strength in projection welding. Then, a 2-D axis-symmetric finite element model is developed to simulate the projection welding and predict the nugget diameter. Finally, the FEM results are compared to experimental data to verify the simulation model and simulated results. In the finite element model, the temperature-dependent material properties are taken into account.

This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO₂ emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one), to correctly describe the lateral gas feed and cooling gas outlet. This model relies on a detailed description of the main physical–chemical and thermal phenomena, using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. We also take into account eight heterogeneous and two homogeneous chemical reactions. The local mass, energy, and momentum balances are numerically solved, using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished, according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion.

The rapidly evolving field of additive manufacturing requires a periodic assessment of the progress made in understanding the properties of metallic components. Although extensive research has been undertaken by many investigators, the data on properties such as hardness from individual publications are often fragmented. When these published data are critically reviewed, several important insights that cannot be obtained from individual papers become apparent. We examine the role of cooling rate, microstructure, alloy composition, and post process heat treatment on the hardness of additively manufactured components. Hardness data for steels and aluminum alloys processed by additive manufacturing and welding are compared to understand the relative roles of manufacturing processes. Furthermore, the findings are useful to determine if a target hardness is easily attainable either by adjusting AM process variables or through appropriate alloy selection.

The purpose of this work was analysing the compaction of a cohesive material using different DEM simulators to determine the equivalent contact models and identify how some parameters of the simulations affect the compaction results (maximum force and compacts appearance) and computational costs. For that purpose, three cohesion contact models were tested (‘linear cohesion’ in EDEM; ‘SJKR’ and ‘SJKR2’ in LIGGGHTS). The influence of the particle size distribution (PSD) on the results was also investigated. Further assessments were performed on the effect of selecting different timesteps, using distinct conversion tolerances for exporting the 3D models to STL files and moving the punch with different speeds. Consequently, it was possible to determine that a timestep equal to a 10% Rayleigh timestep, a conversion tolerance of 0.01 mm and a punch speed of 0.2 m/s are adequate for simulating the compaction process using the contact models in this work. In addition, the results determined that the maximum force was influenced by the PSD because of the rearrangement of the particles. The PSD was also related to the computational cost because of the number of simulated particles and their sizes. Finally, an equivalence was found between the linear cohesion and SJKR2 contact models

Bauxite residue (BR) is a well promising resource for critical metals and especially scandium (Sc), a rare and expensive metal with increasing applications in advanced technology. Particularly, Greek BR’s composition indicates a sound possibility for a commercially viable recovery of Sc under the conditions of an optimized leaching process and the subsequent use of advanced separation techniques. Leaching with mineral acids emerges as the dominant selection with comparison to other techniques. This study investigates an optimized leaching condition set on Sc recovery, using sulfuric acid as the most suitable among different acids tested, in the context of process economics and environmental constraints. Several variables were studied individually or combined in order to achieve high Sc concentration in the leachate as well as to ensure selectivity, especially in respect to iron. The most significant parameters proved to be the solid to liquid ratio (S/L), the final pH value as well as the use of recycling of leachate on fresh BR batches. The proposed process, using sulfuric acid at low acid molarities under ambient conditions was integrated rapidly leading to high and selective Sc recovery. A flow diagram of the developed leaching process in industrial scale was proposed based on continuous operation.

In this paper, we present a comprehensive 4D study of the early stage of plastic deformation in a polycrystalline binary AlLi alloy. The entire microstructure is mapped with X-ray diffraction contrast tomography and a set of bulk grains is further studied via X-ray topotomography during mechanical loading. The observed contrast is analyzed with respect to the slip system activation and the evolution of the orientation spread is measured as a function of applied strain. The experimental observations are augmented by the mechanical response predicted by crystal plasticity finite element simulations to analyze the onset of plasticity in details. Simulation results show a general agreement of the individual slip system activation during loading and that comparison with experiments at the length scale of the grains may be used to fine tune the constitutive model parameters.

This paper addresses the modeling of the iron ore direct reduction process in the context of the reduction in CO₂ emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one) to correctly describe the lateral gas feed and the cooling gas outlet. This model relies on a detailed description of the main physical-chemical and thermal phenomena using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. Eight heterogeneous and two homogeneous chemical reactions are taken into account. The local mass, energy and momentum balances are numerically solved using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion.

The mining wastes generated during the last decades in the mining region of Pachuca-Real del Monte in Mexico, still contains silver values of interest. For this reason, the present work is a preliminary study of the leaching kinetics of silver contained in these residues, using as a leaching reagent the thiosemicarbazide-oxygen system, with the aim of proposing this leaching system as a less toxic alternative than cyaniding process. Previous the leaching process, representative samples were wholly characterized, finding 56 g of Ag and 0.6 g of Au per ton. For the kinetic study in the mentioned system, were evaluated the reagent concentration, temperature, partial pressure of oxygen, pH and stirring rate. According the experimental results found, it was observed that [CH5N3S] concentration showed a significant effect on the leaching rate, obtaining a reaction order of n = 0.93, in the range of 20 - 40 mol CH5N3S ⋅ m-3, getting so a silver recovery up to 76.9%. The effect of temperature gave an activation energy of Ea = 45.55 KJ mol-1, which was indicative of a chemical reaction control. Finally, partial pressure of oxygen has a notable effect on leaching rate, but pH and stirring rate have not apparent effect.

Ferrite body is the origin of crack and corrosion initiation of steels. Distribution and density of ferrite in seven steel ingots were examined by light optical microscopy and computational modeling in the study to explore the correlation of ferrite formation to chemical composition and mushy zone temperature in ingot forming. The central segregation phenomenon in ferrite distribution was observed in all the examined steel specimens except 0Cr17Ni4Cu4Nb stainless steel. No significant difference was found in distribution and density of ferrite amongst zones of the surface, ½ radius and core in neither risers nor tails of 0Cr17Ni4Cu4Nb ingots. Additionally, fewer ferrite was found in 0Cr17Ni4Cu4Nb compared to other examined steels. The difference of ferrite formation in 0Cr17Ni4Cu4Nb elicited a debate on the traditional models explicating ferrite formation. Considering the compelling advantages in mechanical strength, plasticity and corrosion resistance, further investigation on the unusual ferrite formation in 0Cr17Ni4Cu4Nb would help understand the mechanism to improve steel quality. In summary, we observed that ferrite formation in steel was correlated with mushy zone temperature. The advantages of 0Crl7Ni4Cu4Nb in corrosion resistance and mechanical stability could be resulted from that fewer ferrites formed and distributed in a scattered manner in microstructure of the steel.

The mining wastes generated during the last decades in the mining region of Pachuca-Real del Monte in Mexico, still contains silver values of interest. For this reason, the present work is a preliminary study of the leaching kinetics of silver contained in these residues, using as a leaching reagent the thiosemicarbazide-oxygen system, with the aim of proposing this leaching system as a less toxic alternative than cyaniding process. Previous the leaching process, representative samples were wholly characterized, finding 56 g of Ag and 0.6 g of Au per ton. For the kinetic study in the mentioned system, were evaluated the reagent concentration, temperature, partial pressure of oxygen, pH and stirring rate. According the experimental results found, it was observed that [CH₅N₃S] concentration showed a significant effect on the leaching rate, obtaining a reaction order of n = 0.93, in the range of 20 - 40 mol CH₅N₃S × m^-3, getting so a silver recovery up to 76.9%. The effect of temperature gave an activation energy of Ea = 45.55 KJ mol^-1, which was indicative of a chemical reaction control. Finally, partial pressure of oxygen has a notable effect on leaching rate, but pH and stirring rate have not apparent effect.

The diameter of a H13 steel tool with M6 threads and a pin diameter of 5.9 mm and a pin length of 5 mm was measured after each 25.4 mm length of friction stir processing (FSP) of 6061-T6 extrusions. The change in pin diameter with FSP time or distance did not exhibit any steady state and was found to have two distinct regions. Metallographic analysis of two tools subjected to FSP for 60 and 120 seconds showed that (i) threads fractured in early stages of FSP, (ii) a built-up layer formed between the threads, and (iii) threads progressively wore with processing time. The metallographic analysis of an embedded tool showed the presence of a fractured piece of the tool in the stir zone. These points are discussed in detail in the paper.

There are many welded structures in the world such as bridges and viaducts that are subject to fatigue. These structures, generally made of non-alloy or low-alloy steels, have been put into operation some of them with many years ago and have accumulated a large number of variable load cycles over the time. For this reason the occurrence of fatigue phenomenon is inevitable and consists in the occurrence of failures at stresses applied to the structure, below the yield limit of the material. These stresses under the static loads would not cause the failures to appear..This paper will investigate whether two reconditioning techniques “weld toe grinding” and “WIG remelting weld toe”, influences favorably the behavior of welded structures made from HSLA steel, in static and variable loads and therefore if the application of these techniques is justified in both cases. In the paper will be presented the chemical composition and mechanical properties of the base and filler materials, micro and macrostructures, graphics with the variation of microhardness, static and fatigue tensile tests will be performed, and it will be rised durability curve in case of fatigue tests.

Ferrite body is the origin of crack and corrosion initiation of steels. Distribution and density of ferrite in seven steel ingots were examined by light optical microscopy and computational modeling in the study to explore the correlation of ferrite formation to chemical composition and mushy zone temperature in ingot forming. The central segregation phenomenon in ferrite distribution was observed in all the examined steel specimens except 0Cr17Ni4Cu4Nb stainless steel. No significant difference was found in distribution and density of ferrite amongst zones of the surface, ½ radius and core in neither riser nor tail of 0Cr17Ni4Cu4Nb ingot. Additionally, fewer ferrite was found in 0Cr17Ni4Cu4Nb compared to other examined steels. The bizarreness of ferrite formation observed in 0Cr17Ni4Cu4Nb elicited a debate on the traditional concepts explicating ferrite formation. Considering the compelling advantage in the mechanical strength, plasticity and corrosion resistance, further investigation on the unusual ferrite forming occurrence in 0Cr17Ni4Cu4Nb would help develop steels with improved quality. In summary, we observed that ferrite formation was correlated to mushy zone temperature, Cr:Fe and Cu:Fe ratios. We originally assume that Fe, the major component of steel could play an unrecognized role via proportion to other chemical components in ferrite formation.

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.

The present work shows a novel physical-mathematical model to estimate the average corrosion resistance index from the crystallographic texture in API 5L steels. The crystallographic texture of the studied steels was measured by means of the X-ray diffraction technique. The model, based on the symmetric spherical surface harmonics for a BCC structure, is capable of describing the anisotropy surface of anodic dissolution resistance of the crystal and establishing a straightforward relationship between crystallographic texture, surface roughness, and metal corrosion behavior. The predictions of the average corrosion resistance index made from the crystallographic texture were in good agreement with those obtained from potentiodynamic polarization curves for the investigated steels. This agreement validates the capacity of this model and opens the possibility of applying it as a novel criterion for the material selection and design stages in order to combat metal corrosion problems.

This paper studies the combined effect of corrosion and fatigue on the growth of cracks in aircraft and on the effect of skin corrosion and stress corrosion cracking on the load bearing capacity of rib stiffened aircraft wings. In this context it is shown that the growth of cracks from surface pitting, and also from intergranular cracking at a fastener hole, can be accurately computed using the Hartman-Schijve variant of the NASGRO crack growth equation. The examples studied support the lead crack approach, that has been independently developed by the USAF and the Australian Defence Science Technology Group, in which the growth of lead cracks is often exponential. In the case of skin corrosion it is shown that to be consistent with the US Joint Service Structural Guidelines (JSSG2006) assessment of its effect on the load bearing capacity of the wing should involve an assessment of whether at 115% DLL the remaining material exceeds the yield stress of the material.

In this study, a 5vol. % (TiBw+TiCp)/Ti composite pancake with a diameter of 260mm was prepared by casting followed by open die forging in (α+β) phase region. The microstructures of the composite pancake are inhomogeneous, in terms of both matrix microstructure and distribution of reinforcements. The matrix microstructures were gradually refined from the periphery to centre of the pancake. The TiBw and TiCp reinforcements tend to be uniformly distributed in the centre region and. It is suggested that the microstructure difference can be mainly ascribed to the temperature variation from the periphery to the centre. Additionally, tensile testing results showed that the centre region of the composite pancake exhibits higher strength than the peripheral region. The strengthening mechanism and the softening behavior of the composite pancake with temperature is discussed.

The post-weld heat treatment (PWHT) cracking susceptibility of a coarse grain heat-affected zone (CGHAZ) in SA213-T23 (2.25Cr-1.6W steel), used for boiler tubes employed in thermal power plants, was investigated using a Gleeble thermal cycle simulator. The PWHT cracking susceptibility test was performed at 650℃, 700℃ and 750℃, and it can be judged that the lower the reduce of area, the more susceptible it is to PWHT cracking. The results of the test also showed higher cracking susceptibility at 650℃ and 700℃, mostly involving intergranular fracture, while at 750℃, transgranular fracture was exhibited. Therefore, the PWHT cracking susceptibility is considered to be closely related to grain boundary. The microstructure of the simulated CGHAZ and PWHT at 650℃, 700℃and 750℃ was observed after etching with nital and alkaline sodium picrate etchants. Alkaline sodium picrate etched microstructures showed a white band at the grain boundary at 650℃, 700℃ and 750, that did not appear in nital etching. Analysis of the white band using EPMA, TEM and nanoindentation revealed that it was intergranular ferrite depleted with C, W and Cr as compared to that in the matrix. Based on these results, we investigated the mechanism of intergranular ferrite formation during PWHT and its effect on PWHT cracking susceptibility at 650℃, 700℃ and 750℃.

Current progress in the prediction of mechanical behavior of solids requires understanding of spatiotemporal complexity of plastic flow caused by self-organization of crystal defects. It may be particularly important in hexagonal materials because of their strong anisotropy and combination of different mechanisms of plasticity, such as dislocation glide and twinning. These materials often display complex behavior even on the macroscopic scale of deformation curves, e.g., a peculiar three-stage elastoplastic transition, the origin of which is a matter of debates. The present work is devoted to a multiscale study of plastic flow in α-Ti, based on simultaneous recording of deformation curves, 1D local strain field, and acoustic emission (AE). It is found that the average AE activity also reveals three-stage behavior, but in a qualitatively different way depending on the crystallographic orientation of the sample axis. On the finer scale, the statistical analysis of AE events and local strain rates testifies to an avalanche-like character of dislocation processes, reflected in power-law probability distribution functions. The results are discussed from the viewpoint of collective dislocation dynamics and are confronted to predictions of a recent micromechanical model of Ti strain hardening.

This study characterizes the microstructure and its associated crystallographic features of bulk maraging steels fabricated by selective laser melting (SLM) combined with a powder bed technique. The fabricated sample exhibited characteristic melt pools in which the regions had locally melted and rapidly solidified. A major part of these melt pools corresponded with the ferrite (alpha) matrix, which exhibited a lath martensite structure with a high density of dislocations. A number of fine retained austenite (gamma) with a <001> orientation along the build direction was often localized around the melt pool boundaries. The orientation relationship of these fine gamma grains with respect to the adjacent alpha grains in the martensite structure was (111) gamma // (011) alpha and [-101] gamma // [-1-11] apha (Kurdjumov–Sachs orientation relationship). Using the obtained results, we inferred the microstructure development of maraging steels during the SLM process. The results depict that new and diverse high-strength materials can be used to develop industrial molds and dies.

The article presents tests aimed to verify the possibility of making T-joints in TMCP steel using laser. The tests involved the use of 10 mm thick high yield point steel S700MC obtained in an industrial manufacturing process. The joints made in the tests were single and double-sided. Subsequent non-destructive tests revealed that the joints obtained in the tests represented quality level B in accordance with PN-EN ISO 13919-1. Single-sided welding performed using the laser beam having a power of 11 kW enabled the obtainment of 8 mm deep penetration without visibly deforming the web of the joint. The double-sided welded joints were characterised by proper geometry and the presence of gas pores in the welds not compromising the requirements of quality level B (strict requirements). The weld structure was bainitic-ferritic. The weld hardness was by approximately 60 HV1 higher than that of the base material (280 HV1). The HAZ area was slightly softer than the base material. The tests of thin foils performed using a high-resolution scanning transmission electron microscope revealed that, during welding, an increase in the content of the base material in the weld was accompanied by an increase in contents of alloying microagents Ti and Nb, particularly near the fusion line. The above-named alloying microagents, in the form of fine-dispersive (Ti,Nb)(C,N) type precipitates, could reduce plastic properties of joints.

2.25Cr-1Mo steel with high strength at high temperatures and good hydrogen resistance is widely used for power generation boiler material in high temperature and pressure use environments. Following the test evaluation of the ASME Boiler and Pressure Vessel Code, specimens from the base metal of a boiler pipe were found to have impact toughness values of 285 and 21 ft-lb, which are drastically different values. The analysis of the fracture surface of the 21 ft-lb test specimen revealed MnS inclusions, and it was found that cracks initiated at the inclusions. Observation of the cross-section of the crack propagation front revealed that cracks propagated along the ferrite regions and precipitate voids. Inclusions were also found in the 285 ft-lb impact specimen; however, the volume fraction of the inclusions was significantly less than that of the 21 ft-lb specimen. It was also found that the ferrite and carbide content of the 285 ft-lb specimen was less than 21 ft-lb specimen. The reason that the inclusions, ferrite, and carbide content differed in the two adjacent impact test specimens was analyzed. The effects of micro-segregation, such as MnS inclusions on ferrite and carbide, were compared and analyzed.

The precipitate phases often play an important influence on the corrosion resistance of 2205 Duplex stainless steel (DSS). In the presented paper, the microstructure and corrosion resistance in the hot-rolled and cold-rolled 2205 DSS aging for different time at 850 °C was investigated by XRD, SEM and potentiodynamic polarization. It has been found that the Chi(χ) phase and Sigm(σ) phase were precipitated in turn after aging treatment of hot-rolled and cold-rolled materials, but the precipitate amount in cold-rolled material is much more than that of hot-rolled samples. The corrosion resistance of the solution-annealed cold-rolled material is similar to the hot-rolled material, but the corrosion resistance of cold-rolled material with precipitate is weaker than that of hot-rolled material after aging treatment. Pitting initiates preferentially in the Cr-depleted region from σ phase in aged hot-rolled 2205, and severe selective corrosion occurs on sigma/ferrite interfaces aged for a long aged lime. However, the initiation of pitting corrosion may take place at the phase boundary, defect and martensite in the aged cold-rolled 2205. The σ phase is further selectively dissolved by electrochemical method to investigate the difference of microstructure and corrosion behavior in hot-rolled and cold-rolled 2205 duplex stainless steel.

Cogging is a key part in the production process of superalloy, but inclusions affect the performance of superalloy. It is therefore particularly important to study the effects of cogging on the inclusions in superalloy. In our study, the superalloy GH4738 was made by double vacuum smelting. Cogging was performed by unidirectional drawing, upsetting and drawing, and upsetting/drawing with radial forging. The types and distributions of the inclusions after the three cogging processes were analyzed using scanning electron microscopy, energy dispersive spectroscopy, and software such as Image Pro Plus. The results showed that double vacuum smelting essentially determined the types of the inclusions in the GH4738 superalloy. Four types of inclusions were found in the experiments: TiC-TiN-Mo-S composite, TiC-TiN composite, Ce-Mo-S composite, and SiC inclusions. In the case of cogging by unidirectional drawing, the average size of the inclusions first decreased and then increased, from the center to the edge. In the case of upsetting and drawing, and upsetting/drawing with radial forging, the average size of inclusions decreased from the center to the edge.

Among all the processing technologies of heat-treatable aluminum alloys like 2219 aluminum alloy, using friction stir welding (FSW) as the joining technology and using electromagnetic forming (EMF) for plastic forming technology both have obvious advantages and successful applications. Therefore, there is a broad prospect for the compound technologies which can be used on the 2219 aluminum alloy to manufacture the large-scale thin-wall parts in the astronautic industry. The microstructure and mechanical properties of 2219 aluminum alloy under the process compounded of FSW, heat treatment, and EMF were investigated by means of tensile test, optical microscope (OM), and scanning electron microscope (SEM). The results show that the reduction of strength, which was caused during the FSW process, can be recovered effectively by the post-welding heat treatment composed of solid solution and aging, while the ductility was still reduced after heat treatment. Under the compound technology of FSW, heat treatment, and EMF, the forming limit of 2219 aluminum alloy decreased distinctly due to the poor ductility of the welding joint. A ribbon-pattern, which was formed due to the banded structure caused by FSW process, was found on the fracture surface of welded 2219 aluminum alloy after EMF treatment. During the EMF process, because of the effects of induced eddy current, a unique structure, which was manifested as a molted-surface appearance under the SEM observation, was formed as the material fractured.

CuO-ZnO-Al2O3 catalysts are designed for the low-temperature shift conversion in the process of hydrogen and ammonia synthesis gas production. The paper presents the results of research on recovery of copper and zinc from spent catalysts using pyrometallurgical and hydrometallurgical methods. Under reducing conditions, at high temperature, having appropriately selected the composition of the slag, more than 66% of copper in metallic form and about 70% of zinc in the form of ZnO can be extracted from this material. Hydrometallurgical processing of the catalysts was carried out using two leaching solutions: alkaline and acidic. Almost 62% of the zinc contained in the catalysts has been leached to the alkaline solution and about 98% of copper has been leached to the acidic solution. After the hydrometallurgical treatment of the catalysts, insoluble residue was also obtained in the form of pure ZnAl2O4. This compound can be reused to produce catalysts, or it can be processed under reducing conditions at high temperature to recover zinc. The recovery of zinc and copper from such a material is consistent with the policy of sustainable development and helps to reduce the environmental load of stored wastes.

CuO-ZnO-Al2O3 catalysts are designed for the low-temperature shift conversion in the process of hydrogen and ammonia synthesis gas production. The paper presents the results of research on recovery of copper and zinc from spent catalysts using pyrometallurgical and hydrometallurgical methods. Under reducing conditions, at high temperature, having appropriately selected the composition of the slag, more than 66% of copper in metallic form and about 70% of zinc in the form of ZnO can be extracted from this material. Hydrometallurgical processing of the catalysts was carried out using two leaching solutions: alkaline and acidic. Almost 62% of the zinc contained in the catalysts has been leached to the alkaline solution and about 98% of copper has been leached to the acidic solution. After the hydrometallurgical treatment of the catalysts, insoluble residue was also obtained in the form of pure ZnAl2O4. This compound can be reused to produce catalysts, or it can be processed under reducing conditions at high temperature to recover zinc. The recovery of zinc and copper from such a material is consistent with the policy of sustainable development and helps to reduce the environmental load of stored wastes.

A metastable β-Ti alloy, Ti–10V–3Fe–3Al (wt.%), was subjected to thermos-mechanical processing including the compression test at 725°C, which is below the β transus temperature (780°C), and at strain rate of 10-3s-1. The presence of phases was determined using transmission electron microscopy and X-ray diffraction. Although the dynamic recovery took place together with slip, both deformation-induced α˝ martensite and ω were detected as other operating mechanisms for the first time in metastable-β Ti alloys deformed in α+β region. The volume fraction of stress-induced α˝ was higher than that of the same alloy deformed at room temperature due to higher strain applied. Stress-induced twinning was not operational, which could be related to the priority of slip mechanism at high temperature resulted from thermally-assisted nucleation and lateral migration of kink-pairs.

The microstructure evolution and grain refinement kinetics of a solution treated Cu – 0.1Cr – 0.06Zr alloy during equal channel angular pressing (ECAP) at a temperature of 673 K via route B_C were investigated. The microstructure change during plastic deformation was accompanied by the microband formation and an increase in the misorienations of strain-induced subboundaries. The refinement of initial coarse grains was considered as a result of continuous dynamic recrystallization. The dynamic recrystallization kinetics was discussed in terms of grain/subgrain boundary triple junction evolution. The strain dependence of the triple junctions of high-angle boundaries can be expressed by a modified Johnson-Mehl-Avrami-Kolmogorov relationship with a strain exponent of about 1.49. Severe plastic deformation by ECAP led to substantial strengthening of the Cu-0.1Cr-0.06Zr alloy. The yield strength increased from 60 MPa in the initial state to 445 MPa after the total strain of 12.

Cyanex 301 and LIX 63 can seletively extract Pd(II) over Pt(IV) from strong hydrochloric acid solutions. Therefore, solvent extraction experiments have been performed by extractant mixtures containing either Cyanex 301 or LIX 63 and the extraction behavior of Pd(II) was compared. Among the mixture of Cyanex 301, the highest synergistic enhancement coefficient was achieved by mixing Cyanex 301 and TOPO. However, it was very diffiuclt to strip the Pd(II) from the loaded mixture. Among the mixture of LIX 63, the mixture of LIX 63 and Alamine 336/TOPO enhanced the extraction of Pt(II). Although the synergistic coefficient by Cyanex 301 + TOPO was higher than that by LIX 63 + Alamine 336, the Pd(II) in the loaded mixture of LIX 63 and Alamine 336 was easily stripped by thiourea.

In some sour reservoirs and tertiary oil recovery blocks, SO₄^2- in solution can cause the corrosion and corrosion fatigue of the sucker rods. In this paper, the corrosion behaviors of super-strength sucker rod FG20 (16Mn2SiCrMoVTiA) steel in the well fluid are investigated by electrochemical measurements, and electron probe micro-analyzer (EPMA) analysis. The results show that FG20 steel has a favorable corrosion resistance in neural solutions. When the hydrogen ion content increases, the hydrolysis of SO₄^2- greatly accelerates the corrosion of FG20 steel. The energy dispersive X-ray(EDX)results demonstrate that the corrosion process of FG20 steel in neural well liquid is an oxygen concentration process, and the protective FeCO₃ and Fe₂O₃ on the surface of the samples can prevent further corrosion. With the increase of the acidity in the well liquid, the corrosion process converts into a sulphide concentration process, and the sloppy FeS and mackinawite film cannot provide effective protection for the specimens, resulting in the increase of corrosion rate.

This paper investigates the evolution of microstructures and precipitations of an ultra-low iron alloy 625 subjected to long term aging treatment by scanning electron microscope (SEM) and X-ray diffraction(XRD). Use ASTM G28A acid Fe3(SO4)2 erosion to represent intergranular corrosion weightlessness and corrosive morphology. The result shows that alloy at 750C by aging treatment for 40h, precipitated γ'' phase in the grain boundary. In high density area of γ'' phase, occurs γ'' phase to δ phase degeneration transformation by aging treatment for 200h and the needle-like δ phase becomes more with time prolonged. And γ'' phase degenerated to δ phase completely until treated for 1000h. The sample which has aging treatment tends to have intergranular corrosion and mainly because alloy element spreading leads to dilution area and grain boundary precipitated phase, plus interlaced δ phase’s dissolving, which makes sample grain particle fall off and this results in apparent weightlessness. The weightlessness rate(WLR) is related with precipitated volume score. With aging sensitization time change, can be described by Johnson-Mehl-Avrami equation, i.e.: $WLR=44.32\left[1-\text{exp}\left(-\frac{t}{10.99}\right)\right]+44.62\left[1-\text{exp}\left(-\frac{t}{327.8}\right)\right]+1.267 \left(mm/a\right)$

This work focuses on the study of the microstructure, hardening and stiffening effect caused by the secondary phases formed in titanium matrices. These secondary phases were originated from reactions between the matrix and boron particles added in the starting mixtures of the composites. Not only was the composite composition studied as an influencing factor in the behaviour of the composites, but also different operational temperatures. Three volume percentages of boron content were tested (0.9, 2.5 and 5 vol % of amorphous boron). The manufacturing process used to produce the composites was inductive hot pressing, which operational temperatures were between 1000 °C to 1300 °C. Specimens showed optimal densification. Moreover, microstructural study revealed the formation of TiB in various shapes and proportions. Mechanical testing confirmed that the secondary phases had a positive influence on the properties of the composites. In general, adding boron particles increased the hardness and stiffness of the composites; however rising temperatures resulted in greater increases in stiffness than in hardness.

Semi-solid feedstock of AZ80 magnesium alloy modified by minor rare-earth Y element (0, 0.2, 0.4, 0.8 wt.%) were fabricated by strain induces melting activated (SIMA) in the form of extrusion and partial remelting. The effect of Y addition on the microstructure evolution of extruded and isothermal treated alloy was observed by optical microscope (OM), scanning electron microscope (SEM), X-ray diffraction (XRD) and quantitative analysis. The results show that the Y addition can refine the microstructure and make the β-Mg17Al12 phases agglomerating. During the subsequent isothermal treatment at 570℃, the average solid grain size, shape factor and liquid fractions increased with prolonged soaking time. Smaller spheroidal solid grains and the larger shape factor were obtained due to Y addition. The coalescence and Ostwald ripening of solid grains operated the coarsening process simultaneously. The coarsening rate constants of AZ80M1 (0.2 wt.% Y addition) of 164.22 μm3s-1 was approximately four times less than the un-modified AZ80 alloy of 689.44 μm3s-1. In contrast, the desirable semi-solid structure featured by fine, well globular solid grains and appropriate liquid fractions and shape factor was achieved in AZ80M1 alloy treated at 570℃ for 20-30 min.

The thorough description of the peculiarities of additively manufactured structures represents a current challenge for aspiring freeform fabrication methods, such as the selective laser melting (SLM). All of which have an immense advantage in the fast fabrication (no special tooling or moulds required), the geometrical flexibility in the design of components, and their efficiency when only low quantities are required. However, designs demand the precise knowledge of the material properties, which in case of additively manufactured structures are anisotropic and, under certain circumstances, in addition of an inhomogeneous nature. Furthermore, these characteristics are highly dependent on the fabrication settings. Within this study, the anisotropic tensile properties of selective laser melted stainless steel (1.4404, 316L) are investigated: The Young’s modulus ranged from 148 GPa to 227 GPa, the ultimate tensile strength from 512 MPa to 699 MPa and the breaking elongation ranged, respectively, from 12% to 43%. The results were compared to related studies, in order to classify the influence of the fabrication settings. Furthermore, the influence of the chosen raw material was addressed by comparing deviations on the directional dependencies reasoned by differing microstructural developments during manufacture. Stainless steel was found to possess its maximum strength at a 45° layer versus loading offset, which is precisely where AlSi10Mg was previously reported to be at its weakest.

Non-uniform grain boundary sliding can induce strain and rotation incompatibilities at perfectly planar interfaces. Explicit analytic expressions of stress and lattice rotation jumps are thus derived at a planar interface in the general framework of heterogeneous anisotropic thermo-elasticity with plasticity and grain boundary sliding. Both elastic fields are directly dependent on in-plane gradients of grain boundary sliding. It is also shown that grain boundary sliding is a mechanism that may relax incompatibility stresses of elastic, plastic and thermal origin although the latter are not resolved on the grain boundary plane. This relaxation may be a driving force for grain boundary sliding in addition to the traditionally considered local shears on the grain boundary plane. Moreover, the obtained analytic expressions are checked by different kinds of bicrystal shearing finite element simulations allowing grain boundary sliding and where a pinned line in the interface plane aims at representing the effect of a triple junction. A very good agreement is found between the analytic solutions and the finite element results. The performed simulations particularly emphasize the role of grain boundary sliding as a possible strong stress generator around the grain boundary close to the triple line because of the presence of pronounced gradients of sliding.

Strain induced melt activation process (SIMA) creates a globular microstructure which improves the hardness and ultimate tensile stress (UTS) of 7075 aluminum alloys. But, at the grain boundaries of SIMA processed 7075 aluminum alloy, presence of continuous and brittle intermetallic compounds and the eutectic structure result in decreasing mechanical properties, such as elongation, formability and etc. Hence, in order to improve microstructure and formability of 7075 aluminum alloy respect to SIMA process, a new process was done that is called two-step strain induced melt activation (TSSIMA). This process, which has been mentioned in the experimental procedure section, both organized globular structure and significantly modified the microstructure of the alloy compared to that of the SIMA method. It promoted discontinuity and more homogeneity in distribution of the precipitates and, approximately removed the eutectic mixture. Performing the rolling process on the alloy also revealed that it is more effective in formability enhancement in comparison with SIMA process. Also, it increased the hardness of 7075 aluminum alloy respect to that of SIMA process.

Iron powders having average particle sizes of ~40µm are mechanically mixed thoroughly with aluminum powders ranging from 1 to 10 in wt.% with an average particle size of ~10µm. Two different powder metallurgical techniques cold and hot pressing are used to study the effect of the additive element powder on the mechanical properties, wear properties and the microstructure of the iron based alloys. The hot pressing technique was performed at a temperature up to 500°C at 445.6 MPa. The cold pressing technique was performed at 909 MPa in room temperature. By increasing the Al content to 10 wt. % in the base Fe-based matrix, the hardness was decreased from 780 to 690 MPa and the radial strength was decreased from 380 to 202 MPa with reductions of 11.5% and 40%, respectively. Improvement of the wear resistance with the increase addition of the Al powder to the Fe matrix up to 5 times was achieved compared to the alloy without Al addition for different wear parameters namely; wear time and sliding speed.

Medium-carbon steel is commonly used for the rail, wire ropes, tire cord, cold heading, forging steels, cold finished steel bars, machinable steel and so on. Its fatigue behavior analysis and fatigue life estimation play an important role in the machinery industry. In this paper, the estimation of fatigue life of medium-carbon steel with different surface roughness using established S-N and P-S-N curves is presented. To estimate the fatigue life, the effect of the average surface roughness on the fatigue life of medium-carbon steel has been investigated using 75 fatigue tests in three groups with average surface roughness (Ra): 0.4μm, 0.8μm, and 1.6μm respectively. S-N curves and P-S-N curves have been established based on the fatigue tests. The fatigue life of medium-carbon steel is then estimated based on Tanaka-Mura crack initiation life model, the crack propagation life model using Paris law, and material constants of the S-N curves. 6 more fatigue tests have been conducted to validate the presented fatigue life estimation formulation. The experimental results have shown that the presented model could estimate well the mean fatigue life of medium-carbon steel with different surface roughness

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.

Isothermal interrupted hot compression tests of 5754 aluminum were conducted on Gleeble-3500 thermo-mechanical simulator at temperature 350 °C and 450 °C, strain rate 0.1 s-1 and 1s−1. These tests simulated flat rolling to investigate how softening behaviors respond to controlled parameters, such as deformation temperature, strain rate and delay times. This data allowed the parameters for the hot rolling process to be optimized. The delay times during interrupted compression vary between 5s and 60s. The dynamic softening at each pass and metadynamic recrystallization at the intervals of deformation passes were analyzed in detail. 0.2% offset yield strength is applied to calculate the softening fraction undergoing metadynamic recrystallization. A kinetic model was developed to describe metadynamic recrystallization behaviors of the hot deformed 5754 aluminum alloy. Furthermore, the time constant for 50% recrystallization was expressed as functions related to the temperature and the strain rate. The experimental and calculated results were found to be in close agreement, which verified the developed model.

The scratch test consists in pushing a tool across the surface of a material at a given penetration depth or applied load. It has several applications in Science and Engineering including strength testing, damage and quality control of thin films and coatings. Despite numerous attempts in scientific literature, the application of scratch test to characterizations of fracture properties remains a heavily controversial topic. Therefore, this investigation arises as an experimental study in order to assess the fracture toughness using scratch test. A study on the effect of cryogenic treatment, performed after tempering, on fracture toughness, via scratch test experiments, of different tool steels has been made. A laboratory investigation on AISI D2, AISI M2 and X105CrCoMo18 steel confirms the possibility of increasing the fracture toughness by carrying out the cryogenic treatment after the usual heat treatment

This work investigated the isothermal holding time dependence of the densification, microstructure, weight loss and tensile properties of Fe-Mn-Si powder compacts. Elemental Fe, Mn and Si powder mixtures with a nominal composition of Fe-28Mn-3Si (in weight percent) were ball milled for 5h and subsequently pressed under a uniaxial pressure of 400 MPa. The compacted Fe-Mn-Si powder mixtures were sintered at 1200 ℃ for 0, 1, 2 and 3 h, respectively. In general, the density, weight loss and tensile properties increased with the increase of isothermal holding time. A significant increase in density, weight loss and tensile properties occurred in the compacts isothermally holding for 1 h, as compared to those with no isothermal holding. However, further extension of isothermal holding time (2 and 3 h) only played a limited role in promoting the density and tensile properties. The weight loss of the sintered compacts was mianly caused by the sublimation of Mn in Mn depletion region on the surface layer of the sintered Fe-Mn-Si compacts. The length of the Mn depletion region increased as isothermal holding time increased. A single α-Fe phase was detected on the surface of all the sintered compacts, and the locations beyond the Mn depletion region were comprised of a dual dominant γ-austenite and minor ε-martensite.

It is important to realize the transformation behavior of wüstite because it greatly affects the final structure of the oxide layer and the surface quality of the steel products. In the present study, the transformation behaviors of the wüstite layer are examined under nearly-oxygen-free conditions, to simulate the cooling processes after the hot rolled strip is coiled. As the single phase wüstite was prepared at 950˚C, the 460˚C transformed oxide layer was composed of a mixture of iron and magnetite formed through eutectoid reactions. For the 750˚C-fabricated wüstite, only magnetite was observed after transformation, without iron precipitates and residual wüstite. It is speculated that the unusual transformation behavior of the low-temperature-made wüstite results from the pseudo-structural intermediate phase transformation between wüstite and magnetite. This pseudo-structure is a pre-transformed wüstite and of various concentration of ferrous ion, which is determined by the fabrication conditions. During the hot strip mill process, the so-called wet scale, wüstite, is produced continuously from finish mill to laminar flow sections and ended at 570˚C. Consequently, the final eutectoid transformation below 570˚C is dominantly controlled by the surface temperature ranged from 750˚C to 950˚C for low carbon steel.

Aluminum alloy Al 2024-T3 were successfully joined using friction stir spot jwelding joining (FSSW). Satisfactory joint strengths were obtained at different welding parameters (tool rotational speed, tool plunge depth, dwell time) and tool pin profile (straight cylindrical, triangular and tapered cylindrical). Resulting joints were welded with welded zone. The different tools significantly influenced the evolution on the stir zone in the welds. Lap-shear tests were carried out to find the weld strength. Weld cross section appearance observations were also done. The macrostructure shows that the welding parameters have a determinant effect on the weld strength (x: the nugget thickness, y: the thickness of the upper sheet and SZ: stir zone). The main fracture mode was pull out fracture modes in the tensile shear test of joints. The results of tensile shear tests showed that the tensile-shear load increased with increasing rotational speed in the shoulder penetration depth of 0.2 mm. Failure joints were obrerved in the weld high shoulder penetration depth and insufficient tool rotation.

Aluminum wire is a common material for wire bonding due to its resistance to oxidation and low price. It does not melt when becoming a free air ball (FAB) during the electronic flame-off (EFO) process with wettability, and is applied by wedge bonding. This study used 20μm Zn-Coated Al-0.5wt.%Si (ZAS) wires to improve the FAB shape after the EFO process, while maintaining stability of the mechanical properties, including the interface bonding strength and hardness. In order to test circuit stability after ball bonding, the current-tensile test was performed. During the experiment, it was found that 80nm ZAS with wire bonding has lower resistance and higher fusing current. For the bias tensile test, the thicker Zn film diffused into the Al-Si matrix easily, after which the strength was reduced. The ball-bond interfaces had no change in their condition before and after the bias. Accordingly, ZAS could be a promising candidate for ball bonding in the future.

Fe-(9, 19, 28, 37)wt.% Cr alloys were corroded at 700 and 800 ^oC for 70 h under 1 atm of N₂, 1 atm of N₂/3.2%H₂O-mixed gas, and 1 atm of N₂/3.1%H₂O/2.42%H₂S-mixed gas. The corrosion rate of Fe-9Cr alloy increased with the addition of H₂O, and furthermore with the addition of H₂S in N₂ gas. Fe-9Cr alloy was always nonprotective. In contrast, Fe-(19, 28, 37) wt.%Cr alloys were protective in N₂ and N₂/H₂O-mixed gas because of formation of the Cr₂O₃ layer. They were, however, nonprotective in N₂/H₂O/H₂S-mixed gas because sulfidation dominated to form the outer FeS layer and the inner Cr₂S₃ layer containing some FeCr₂S₄.