Metal Forming Research Articles

Composition-Dependent Voltage-Driven OFF-ON Switching of Ferromagnetism in Co-Ni Oxide Microdisks.

Magneto-ionics, which refers to the modification of the magnetic properties of materials through electric-field-induced ion migration, is emerging as one of the most promising methods to develop nonvolatile energy-efficient memory and spintronic and magnetoelectric devices. Herein, the controlled generation of ferromagnetism from paramagnetic Co-Ni oxide patterned microdisks (prepared upon thermal oxidation of metallic microdisks with dissimilar Co-Ni ratios, i.e., Ni25Co75 and Ni50Co50) is demonstrated under the action of voltage. The effect is related to the partial reduction of the oxide phases to their metallic forms. Samples richer in Co show stronger magneto-ionic activity, which manifests in lower-onset threshold voltages, faster switching rates, and larger values of the attained saturation magnetization. By means of scanning electron microscopy, a cobalt segregation phenomenon has been experimentally observed upon thermal oxidation, which has been theoretically discussed from the diffusivities' viewpoint. X-ray diffraction characterization has revealed transitions between purely mixed Ni and Co oxides, in the OFF state, to a mixture of oxide and metallic phases, in the ON state, because of the oxygen ion motion outward/inward the Co-Ni oxide microdisks, depending on the voltage polarity. Ab initio calculations reveal that the energy barrier for oxygen vacancy migration is lower in CoO than in NiO, in agreement with the obtained magneto-ionic responses. The observation of magneto-ionic effects in patterned disks (and not only in archetypical continuous films) is a step further for the practical utilization of this phenomenon in real miniaturized devices.

Characteristics and Predictive Analysis of Heavy Metal Pollution in Typical Municipal Solid Waste Landfill Soil

ABSTRACT Due to the excavation of landfill sites, the safe disposal of high-content humus soil and the control of secondary heavy metal pollution have become urgent issues to be addressed. Exploring the forms of heavy metals in humus soil is crucial for a comprehensive and accurate assessment of the characteristics and toxic effects of heavy metal pollution. The present study analyzed the pollution characteristics and ecological risks of heavy metals in humus soils obtained from three typical municipal solid waste landfills in Zhejiang Province, China. The results indicated elevated concentrations of Cu, Zn, Cr, and Pb in the three landfills, with maximum concentrations reaching 5041, 6093, 2756, and 3576 mg/kg, respectively. The RAC (Risk Assessment Code) Risk Index and Potential Ecological Risk Index methods indicate that Cd in landfills has a high ecological risk and high bioavailability. Five machine learning models of Logistic Regression (LR), Random Forest (RF), Extreme Gradient Boosting (XGBoost), Support Vector Machine (SVM), and Multi-Layer Perception (MLP) were employed to predict the concentrations of heavy metals. The RF model showed the best performance for predicting Cu with an average Area Under the Curve (AUC) of 0.99, while the MLP model performed the best for predicting the concentration of Hg. This study provides a scientific basis and practical guidance for the effective control and resource utilization of heavy metal pollution in landfill humus soil.

Numerical Study on Continuous-Bending-Under-Tension of 3rd Generation Steel

Sheet metal forming is one of the key processes in the manufacturing of parts for several industries, such as automotive, aerospace and packaging. However, it is often constrained by the onset of plastic instability, which limits uniform deformation. To address this challenge, considerable attention has been given to methods that enhance strength, formability, and energy absorption during forming processes. One such method is the continuous-bending-under-tension (CBT) deformation mechanism, which has shown potential in mitigating localized instability during plastic deformation. This study presents a numerical investigation of the CBT process using Abaqus 2017 to evaluate the forces generated in both the CBT equipment and material when processing high-strength materials. The reference material used is the USS CR980XG3™ AHSS, a third-generation, high-strength, high-elongation steel grade with retained austenite (980T/600Y). The study systematically analyzes the effects of key parameters, such as roll diameter, distance between rolls, depth setting, specimen thickness, and the number of deformation cycles, on the evolution of forces during the CBT process. The results demonstrate that both the forces applied by the rolls and those experienced by the specimen are significantly influenced by the distance between rolls, depth setting, and specimen thickness. In contrast, the roll diameters have minimal influence. These findings contribute to the optimization of the CBT process and provide valuable insights for future studies aimed at enhancing the performance and formability of various materials.

Speciation of Trace Metals in the Bottom Sediments of the Mozhaisk Reservoir and the Moskva River

The speciation of heavy metaf Geology, ls (Mn, Fe, Co, Ni, Cu, Zn, Cd, and Pb) in the bottom sediments of the Mozhaisk Reservoir and the Moskva River is described. They were characterized using the Tessier sequential selective extraction procedure trace element concentrations determined by inductively coupled plasma–mass spectrometry (ICP-MS). The bottom sediments of the Mozhaisk Reservoir are characterized by higher concentrations of the examined metals compared to the channel alluvium of the Moskva River. In this case, the most widespread metal compounds in the bottom sediments of the Mozhaisk Reservoir are firmly bound (stable form) to the mineral matrix. High concentrations of the firmly bound forms of metals (Co, Ni, Cu, Zn, Cd, Pb, and Fe) in the bottom sediments are due to an increased proportion of the silt fraction (0.1–0.01 mm) entering the reservoir due to abrasion of its shores. The only exceptions are Mn and Cd, which are present in labile compounds with carbonates and hydroxides of iron and manganese. In the bottom sediments of the Moskva River, strongly bound forms prevail for most metals—for Ni, Zn, and Cd, they are complex compounds with Fe and Mn hydroxides; for Co, Cu, Pb, and Fe, they are compounds with stable silicate minerals. The proportion of labile bioavailable forms of metals in the bottom sediments of the Moskva River is higher than in the reservoir due to anthropogenic input. Among the labile forms of the metal compounds, carbonates predominate. The proportion of elements in the most mobile exchange form and in compounds with organic matter is not large and does not exceed 14% for most elements. The only exceptions are Co and Cd, for which the concentration of the exchange form reaches 25%.

Hybridizing 3D printing and electroplating for the controlled forming of metal structures within fused deposition modelled contours

Abstract An innovative approach for metal electroforming is presented, exemplified with proof-of-concept geometries and illustrated with an industrial application. The proposed production chain hybridizes 3D polymer printing and nickel electroplating for the design-controlled forming of metals within fused deposition modelled contours or patterns, which provide a selective functionalization of the substrate for metal deposition on demand. Applying the developed process, Ni electrodes for streamer discharge plasma generators are structured. These components stand out for their needle-like details, required for promoting streamer discharge phenomena, which would be challenging to obtain employing traditional milling processes. Current capabilities, main challenges and foreseen research directions, for this novel hybrid 3D printing and electroplating process and for its industrial applications, are discussed. Overall, the described process contributes to the already fruitful connections among additive manufacturing technologies and metal electrodeposition procedures, providing an interesting route towards accessible and straightforward electroforming of large components and structures.

Lead (Pb) Contamination in Soil and Plants at Military Shooting Ranges and Its Mitigation Strategies: A Comprehensive Review

Heavy metals, especially lead (Pb), is the major cause of pollution in the military shooting range soils. Bullets, which are primarily made of Pb, are a substantial source of this pollution. On speciation, this Pb is distributed into its different metal forms. Different physicochemical properties of the soil like pH, moisture content, cation exchange capacity (CEC), and organic matter play a very crucial role in the distribution, transformation, and bioavailability of the Pb. The concentration of Pb found in different shooting ranges is examined. Moreover, bullet weathering and the availability of contaminants in the soil are influenced by the physicochemical properties of the soil. For the management of firing range pollution, a variety of strategies have been investigated, including soil washing, phytoremediation, and chemical stabilization. This review focus on the pollution status of different shooting ranges, the impact of the physicochemical properties of soil on the distribution, speciation, and transformation of Pb, and different mitigation strategies to control Pb pollution in military shooting ranges.

Design and Construction of Magnetic Support Construction Separator on Track V 33 BC-5 at Greenzone 2

The process of shredding and sorting waste in the Pre Processing method is one of PT Solusi Bangun Indonesia's contributions in overcoming waste and pollution problems. The waste will be shredded into certain sizes and put into the cement kiln. The processing place is called a green zone. In this process, sometimes the material transport contains impurities in the form of metal and the like. This distribution has the potential to cause foreign material to be carried because there is no sorting of waste content. Belt conveyors and dynamic disc screens are often damaged by the metal material. This problem can be overcome with a magnetic separator to separate foreign metals from waste that is channeled using a belt conveyor. The magnetic separator provides protection for the dynamic disc screen and conveyor operating process from foreign material so that the potential for wear on the dynamic disc screen and torn belt conveyor can be avoided. The installation of the magnetic separator position uses a construction based on the optimal position. This study discusses the design and construction of the green zone belt conveyor magnetic separator installation. The construction installation for the magnetic separator aims to facilitate access to maintenance and cleaning, also provide access to dispose of foreign materials and protect the material transport system in the green zone. Before redesign magnetic sparator, the company spent Rp. 389,000,000 maintenance cost from November 2023 to February2024 period. After redesign, it’s can reducing maintenance and repair costs during the period March 2024 to July 2024 with no maintenance related to metal separation.

A Combined Approach to Solving Applied Metal Forming Problems

A Combined Approach to Solving Applied Metal Forming Problems

An Icosahedral 55-Atom Iron Hydride Cluster Protected by Tri-tert-butylphosphines.

Nanoclusters are nanometer-sized molecular compounds characterized by significant metal-metal bonding and low average oxidation states, and they exhibit unique properties distinct from those of small metal complexes or nanoparticles. Unlike noble metals stable in metallic forms, the synthesis of nanometer-sized iron clusters has been precluded by the relatively weak iron-iron bonds and the high reactivity of low oxidation state iron, despite the extensive history of molecular iron compounds. Here, we report the synthesis and characterization of a cationic 55-atom iron cluster with a 1.2 nm icosahedral core. Its 12 vertices are occupied by tri-tert-butylphosphines, while multiple hydrides cover the surface. This core can be viewed as a substructure of the face-centered cubic (fcc), in contrast to the body-centered cubic (bcc) for the stable bulk phase. This work reveals a stable structure and fundamental properties of a nanometer-sized iron cluster, which have remained elusive for decades, and the simple synthetic protocol provides a route to explore molecular nanochemistry.

Sheet metal forming processes: Development of an innovative methodology for the integration of the metal forming and structural analysis

Sheet metal forming processes: Development of an innovative methodology for the integration of the metal forming and structural analysis

Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming

This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing.

The Real-Time Prediction of Cracks and Wrinkles in Sheet Metal Forming According to Changes in Shape and Position of Drawbeads Based on a Digital Twin

In the automotive industry, extensive research has been conducted to eliminate factors negatively impacting product quality, such as wrinkles, cracks, and thickness distribution in components. The application of drawbeads often relies on the experience of field workers, leading to considerable trial and error before stabilizing the production process. Therefore, to efficiently transform these inefficiencies related to time and cost, there is a need for real-time predictive technology for forming quality based on the position of drawbeads and the bead force. This study proposes a method for predicting formability in real-time, based on a digital twin framework that considers the position of drawbeads and holder force. A digital twin was developed to predict the sheet metal forming process using Support Vector Machine, Random Forest, Gradient Boosting Machine, and Artificial Neural Networks. The machine learning models were trained using finite element analysis data corresponding to the position and bead force of drawbeads, enabling the real-time prediction of wrinkles and crack occurrences. The accuracy of the machine learning models was demonstrated, achieving 100% accuracy in determining crack occurrence, with a mean squared error (MSE) of 0.141 for wrinkle prediction and 0.038 for crack prediction, thereby ensuring the accuracy of the forming prediction model based on drawbead applications. Based on these predictive models, a user-friendly GUI has been developed, which is expected to reduce design time and costs while facilitating real-time predictions of forming quality, such as wrinkles and cracks, on-site.

Catalytic Performance of Ti-MCM-22 Modified with Transition Metals (Cu, Fe, Mn) as NH3-SCR Catalysts

In the presented work, titanosilicate with the MWW structure (Ti-MWW) was hydrothermally synthesized using boron and titanium precursors, with piperidine as a structure-directing agent. The resulting layered zeolite precursor, with a Si/Ti molar ratio of 50, was treated in an HNO3 solution to remove extraframework Ti and B species. The acid-modified zeolite was functionalized with transition metal cations (Cu2+, Fe2+, Mn2+) and trinuclear oligocations (Fe(3) and Mn(3)). The application of this catalytic system is supported by the presence of titanium in the catalytic support structure—similar to a commercial system, V2O5–TiO2. The obtained samples were characterized with respect to their structure (P-XRD, DRIFT), textural parameters (low-temperature N2 sorption), surface acidity (NH3-TPD), transition metal content (ICP-OES) and form (UV–vis DRS) as well as catalyst’s reducibility (H2-TPR). Ti-MWW zeolite samples modified with transition metals were evaluated as catalysts for the selective catalytic reduction of NO with ammonia (NH3-SCR). The effective temperature range for the NO conversion varied depending on the type of active phase used to functionalize the porous support. The catalytic performance was influenced by transition metal content, its form, and accessibility for reactants as well as interactions between the active phase and titanium-containing support. Among the catalysts tested, the copper-modified Ti-MWW zeolite showed the most promising results, maintaining 90% NO conversion rates across a relatively broad temperature range from 200 to 325 °C. This catalyst meets the requirements of modern NH3-SCR installations, which aim to operate in the low-temperature region, below 250 °C.

Efficient amine-assisted CO2 hydrogenation to methanol co-catalyzed by metallic and oxidized sites within ruthenium clusters

Amine-assisted two-step CO2 hydrogenation is an efficient route for methanol production. To maximize the overall catalytic performance, both the N-formylation of amine with CO2 (i.e., first step) and the subsequent amide hydrogenation (i.e., second step) are required to be optimized. Herein, a class of Al2O3-supported Ru catalysts, featuring multiple activated Ru species (i.e., metallic and oxidized Ru), are rationally fabricated. Density functional theory calculations suggest that metallic Ru forms are preferred for N-formylation step, whereas oxidized Ru species demonstrate enhanced amide hydrogenation activity. Thus, the optimal catalyst, containing unique Ru clusters with coexisting metallic and oxidized Ru species, efficiently synergize the conversion of CO2 into methanol with exceptional selectivity (>95%) in a one-pot two-step process. This work not only presents an advanced catalyst for CO2-based methanol production but also highlights the strategic design of catalysts with multiple active species for optimizing the catalytic performances of multistep reactions in the future.

Selected Metal (Au, Ag, and Cu) Complexes of N-heterocyclic Ligands as Potential Anticancer Agents: A Review.

Nitrogen-based organic heterocyclic compounds are an important source of therapeutic agents. About 75% of drugs approved by the FDA and currently available in the market are N-heterocyclic organic compounds. The N-heterocyclic organic compounds like pyridine, indole, triazoles, triazine, imidazoles, benzimidazoles, quinazolines, pyrazoles, quinolines, pyrimidines, porphyrin, etc. have demonstrated significant biological activities. These heterocyclic organic compounds also coordinate with various metal ions and form coordination compounds. Most of them have shown improved biological activities. The research on the metal complexes of these compounds reported their significant biological activities. N-heterocyclic-based metal complexes showed outstanding anticancer activities against different cancer cell lines, including VEGFR-2, HT-29, MDA-MB-231, MCF-7 K562, A549, HepG2, HL60, A2780, WI-38, Colo-205, PC-3, and other cancer cell lines. Some of these compounds showed better anticancer activity than cisplatin. In this review, we summarized the anticancer properties of N-heterocyclic-based gold (Au), silver (Ag), and copper (Cu) complexes and explored the mechanisms of action and potential structure-activity relationships (SAR) of these complexes. Our goal is to assist researchers in designing highly potent N-heterocyclic-based Au, Ag, and Cu complexes for the potential treatment of various cancers.

Bioremediation of Heavy Metal-Contaminated Solution and Aged Refuse by Microbially Induced Calcium Carbonate Precipitation: Further Insights into Sporosarcina pasteurii.

Recently, the ability of microbial-induced calcium carbonate precipitation (MICP) to remediate heavy metals has been widely explored. Sporosarcina pasteurii was selected to remediate heavy metal-contaminated solution and aged refuse, exploring the feasibility of Sporosarcina pasteurii bioremediation of heavy metals and analyzing the changes in heavy metal forms before and after bioremediation, as well as the mechanism of remediation. The results showed that Sporosarcina pasteurii achieved remediation rates of 95%, 84%, 97%, and 98% for Cd, Pb, Zn, and Cr (III) in contaminated solution, respectively. It also achieved remediation rates of 74%, 84%, and 62% for exchangeable Cd, Pb, and Zn in aged refuse, respectively. The content of exchangeable Cr (III) before bioremediation was almost zero. The content of heavy metals with exchangeable form and carbonate-bounded form in aged refuse decreased after bioremediation, while the content of heavy metals with iron-manganese oxide binding form and residual form increased. Simultaneously, the presence of Fe and Al components in aged refuse, as well as the precipitation of calcium carbonate produced during the MICP process, jointly promotes the transformation of heavy metals into more stable forms.

The use of artificial neural networks to the analysis of lubricating performance of vegetable oils for plastic working applications

Sheet metal forming is the basic method of processing of deep-drawing quality steel sheets used in the automotive industry. A properly planned technological process of forming should include guidelines for friction conditions, or rather the coefficient of friction. Determination of the coefficient of friction is carried out using various methods. In this article, the strip drawing test was used to analyse the friction of low-carbon DC04 steel sheets. The tests were carried out at different contact pressures and with the use of different vegetable-oil based biolubricants. The most common edible and non-edible oils were selected for the tests: sunflower, rape-seed, moringa and karanja. The analysis of the experimental results was carried out using multilayer artificial neural networks (ANNs). Different learning algorithms and different transfer functions were considered in ANNs. Based on the analysis of experimental data, it was noticed that the coefficient of friction decreased with increasing contact pressure. The lowest values of the coefficient of friction, in the entire range of analysed pressures, were observed during lubrication with karanja oil. It was also found that Levenberg-Marquardt training algorithm with log-sigmoid transfer function provided the lowest values of performance errors and at the same time the highest value of the coefficient of determination R2 = 0.94719.

Tribological Performance of Borided Tool Steel with Minimum Bio-Lubrication for Sheet Metal Forming Applications

Tribological Performance of Borided Tool Steel with Minimum Bio-Lubrication for Sheet Metal Forming Applications

Correlating crystallographic texture with anisotropic properties and sheet metal forming of aluminium alloys

Correlating crystallographic texture with anisotropic properties and sheet metal forming of aluminium alloys

Monitoring of chrome and nickel contents in agroecosystems of Central Chernozem region of Russia

The research was carried out within the framework of the state agroecological monitoring program. The goal was to conduct an environmental assessment of chromium and nickel content in agroecosystems of the southwestern part of the Central Chernozem region using the example of the Belgorod region. All analytical studies were carried out in an accredited testing laboratory using generally accepted methods. During the research, it was found that the average gross content of chromium and nickel in the arable layer in leached chernozems is 19.8 and 24.5, in typical chernozems – 20.0 and 24.9, in ordinary chernozems – 20.9 and 26.6 mg/kg, respectively. The average content of mobile forms of chromium in the studied soils was in the range of 0.13–0.14, nickel – 0.37–0.41 mg/kg. Exceeding the levels of the approximately permissible amount of nickel and the maximum permissible concentration of mobile forms of these heavy metals in soils was not detected. In the agroecosystems of the Belgorod region, chromium and nickel are mainly supplied with organic fertilizers, but this does not pose a risk for soil contamination and crop production. The highest average chromium content (0.45 mg/kg) was observed in sunflower seeds, and the lowest (0.22 mg/kg) in corn grain. Soybean grain is characterized by an abnormally high nickel content (4.81 mg/kg), and the lowest concentration (0.63 mg/kg) is observed in corn grain.