Microstructural Characterization Research Articles

Disclosing Connection Links between Microstructure and Mechanical Performance in Pulsating Current Gas Tungsten Arc Welding of Hastelloy B-2 Superalloy

In this study, welding a Ni-Mo-based superalloy (Hastelloy B-2) was examined in order to characterize the microstructure and mechanical performance of joints along with assessing the effects of current intensity on the microstructure and mechanical responses of different weld zones. The gas tungsten arc welding (GTAW) process was used to weld the samples using ERNiCrMo-2 filler metal. The pulsed current GTAW process was used to weld the superalloy sheets of thickness of 1 mm with background current (Ib) of 20 A and 40 A and peak current (Ip) of 80 A and 60 A. Tensile and Vickers microhardness tests were conducted to evaluate the effect of pulsed current on mechanical properties of the welds along with chemistry and microstructure characterizations. Finally, the fracture surfaces after the tensile test were studied using SEM fractography analysis. The results indicated that increasing Ib and decreasing Ip led to low heat input and high cooling rate resulting in a high thermal gradient. This caused microstructure transition from the columnar dendrites to the coaxial ones in the weld zone; molten metal convection in the fusion zone led to fine grains in the weld zone during welding time. Moreover, a significant decrease in the amount of molybdenum carbides at the interdendritic regions of the weld metal was observed under these conditions. The tensile strength of the weld metal was higher than that of the base metal resulting in the fracture of all welds from the base metal. Additionally, the microhardness results indicated a significant increase for the weld metal compared to both heat-affected zone (HAZ) and base metal. The higher mechanical properties of the weld metal is attributed to the increase in background current and decrease in peak current leading to a fine grain microstructure. Fractography following the tensile test showed a completely ductile fracture.

Exposure behavior and drilling efficiency of basalt fiber composite impregnated diamond bits in hard granite

Impregnated diamond bits (IDBs) are widely used for drilling in hard formations. To improve the drilling efficiency and exposure behavior of IDBs in granite, three types of Cu-based basalt fiber (BF) composite IDBs were designed and prepared by using the medium-frequency induction hot-pressing and sintering method, in which 0 wt.% BF and 25 vol.% diamond were used in 0BF25D IDB, 1 wt.% BF and 25 vol.% diamond were used in 1BF25D IDB, 1 wt.% BF and 20 vol.% diamond were used in 1BF20D IDB. The drilling efficiency of each IDB was tested under different drilling pressures (WOB), and the exposure behavior of IDBs was investigated by scanning electron microscopy and ultra field microstructural characterization. Results show that drilling granite with grade 9 drillability, low drilling pressure can drill successfully with the addition of BF. The average rate of penetration (ROP) of 1BF20D IBD under 6 kN WOB was 4.78 m/h, which was improved by 60%∼80%, energy consumption decreased by 66% for each meter, torque (TOB) decreased, and rotational speed (RPM) was more stable during the drilling process. The addition of BF and reasonable diamond concentration enhanced the holding power of the diamond which promoted the exposure of the diamond. The average exposed height of the diamond in 1BF20D IDB reached 121.2 μm with 22% to 29% of the whole diamond.

Microstructure characterization and corrosion performance of Alloy 625 weld cladding deposited using TWF-GTAW and PTA-P

Microstructure characterization and corrosion performance of Alloy 625 weld cladding deposited using TWF-GTAW and PTA-P

MICROSTRUCTURE AND WEAR BEHAVIOR CHARACTERIZATION OF STIR-CAST ALUMINUM 6063 ALLOY AND ITS FOAM: A COMPARATIVE STUDY

In this research work, aluminum 6063 alloy foam was synthesized through stir casting using varying amounts of titanium hydride as a foaming agent. A comparative microstructural and wear behavior analysis of stir-cast aluminum 6063 alloy and its foam is presented. The oxide and aluminide phases present as intermetallic compounds in the stir-cast aluminum 6063 alloy foam ensure the stability of the synthesized foam. In order to optimize the effect of wear parameters on the tribological properties of stir-cast aluminum 6063 alloy foam, the L933 orthogonal array (OA) was designed and modeled statistically. The tribological properties of stir-cast aluminum 6063 alloy and its foam were evaluated by pin-on-disc tests. The optimal tribological properties of the synthesized foam are 0.29 coefficient of friction, 8.6 N frictional force, and 0.00025 mm3/N-m specific wear rate. The tribological properties of stir-cast aluminum 6063 alloy foam are superior to those of aluminum 6063 alloy and comparable to other aluminum foams described in the literature.

Investigating the Effects of Boron Nitride on Mechanical Properties of CoCrFeNiMn Composites

High‐entropy alloys (HEAs) are gaining attention for their exceptional properties but achieving precision and surface quality in powder metallurgy (PM) can be challenging. This study investigates the mechanical properties of CoCrFeNiMn HEAs produced through the flake powder metallurgy (FPM) technique and laser powder bed fusion (LPBF) preservative industrial, which established outstanding antiwear properties. To assess the enhancement of mechanical behavior and wear resistance by incorporating boron nitride (BN) into CoCrFeNiMn composites is fabricated via FPM. By incorporating BN into the composites, the mechanical behavior is significantly enhanced, leading to improved resistance against wear. Furthermore, the study delivers comprehensions into the serration behavior microstructure and shear localization in a high‐strain‐rate‐deformed CoCrFeMnNi entropy‐high alloy produces through metallurgy in powder. The serration behavior of the CoCrFeMnNi HEA is discussed concerning strain rate and temperature. Accordingly, the study employs the LPBF technique to fabricate the CoCrFeMnNi alloy from the prepared flakes. Microstructural characterization using scanning electron microscopy and X‐ray diffraction techniques to explore phase distribution, grain size, and possible segregation in the CoCrFeMnNi alloy produced through FPM‐LPBF is performed. In this particular investigation, a gradient microstructure is achieved through fusion in a laser‐powder bed of CoCrFeMnNi HEA onto highly deformed equal‐atomic HEA sheets. The resulting combination of partially recrystallized regions, exhibiting elevated yield strength, and fully recrystallized regions, demonstrates enhanced strain hardenability and elongation, and yields superior mechanical properties. The results obtained from the FPM‐LPBF CoCrFeMnNi alloy will be compared with those of conventionally processed CoCrFeMnNi to highlight the advantages and improvements achieved through the proposed method. The study findings reveal that the fundamental understanding of HEAs’ behavior under LPBF with FPM affords valuable insights into optimizing the processing parameters and achieving superior mechanical attributes.

Stepwise Optimization of Thermoelectric Performance in n‐Type SnS

AbstractTin sulfide (SnS) has been developed as an earth‐abundant and eco‐friendly compound that exhibits promising thermoelectric (TE) performance. While significant achievements are achieved in p‐type SnS, the development of its n‐type counterpart remains at a nascent stage, making it rather essential for developing n‐type SnS to ensure good compatibility in SnS‐based TE devices. In this study, Br is selected as the aliovalent dopant for realizing n‐type transport in SnS. Subsequently, isoelectronic Se alloying and vacancy compensation are utilized to further promote the TE performance for n‐type SnS. Se alloying can effectively narrow the bandgap of SnS for enhancing carrier concentration and diminishing thermal conductivity by strain and mass field fluctuations, while the excess Sn further compensates intrinsic Sn vacancies, thus optimizing carrier concentration and mobility simultaneously. These results are well verified by microstructure characterization and defect formation energy calculations. Consequently, the maximum ZT value of ≈0.7 and quality factor B of ≈1.02 at 823 K can be obtained after stepwise optimization, which is currently the highest value for n‐type SnS thermoelectrics. This study presents a significant progress for n‐type SnS and lays an important foundation for constructing all‐SnS‐based TE devices.

The role of magnesium oxide addition in densification of AlON transparent ceramics by pressureless sintering

AbstractPressureless sintering processing was adopted to fabricate transparent aluminum oxynitride (AlON) ceramics by using magnesium oxide (MgO) as a sintering additive into synthetic single phased aluminum oxynitride powder. Under the condition of adding 0.6 wt% magnesium oxide, the relative density of aluminum oxynitride ceramics increased from 98.67% with no addition to 99.9% after being held at 1800°C for 24 h, coupled by a reducing of average grain size from 190 µm to 130 µm. The optical linear transmittance of the AlON ceramic sample (thickness 1.2 mm) reached 84.2% at the wavelength of 1100 nm. The microstructural characterizations by energy dispersive spectroscopy and atom probe tomography indicated that the doping Mg element was uniformly dispersed inside aluminum oxynitride grains of as‐sintered ceramics. It was demonstrated that magnesium oxide played a key role in inhibiting the movement of grain boundaries, eliminating pores, leading to the fully densification of aluminum oxynitride ceramics.

What can machine learning help with microstructure-informed materials modeling and design?

AbstractMachine learning (ML) techniques have been widely employed as effective tools in addressing various engineering challenges in recent years, particularly for the challenging task of microstructure-informed materials modeling. This work provides a comprehensive review of the current ML-assisted and data-driven advancements in this field, including microstructure characterization and reconstruction, multiscale simulation, correlations among process, microstructure, and properties, as well as microstructure optimization and inverse design. It outlines the achievements of existing research through best practices and suggests potential avenues for future investigations. Moreover, it prepares the readers with educative instructions of basic knowledge and an overview on ML, microstructure descriptors, and ML-assisted material modeling, lowering the interdisciplinary hurdles. It should help to stimulate and attract more research attention to the rapidly growing field of ML-based modeling and design of microstructured materials. Graphical abstract

Microstructural and hardness characterization of stainless steel 316-Inconel 718 multimaterial developed by wire-based Directed Energy Deposition

Microstructural and hardness characterization of stainless steel 316-Inconel 718 multimaterial developed by wire-based Directed Energy Deposition

Accurate quantification of dislocation loops in complex functional alloys enabled by deep learning image analysis

In-depth statistics of individual defects observed during transmission electron microscopy (TEM) experiments are essential for the thorough characterization of materials. In this study, we aim to quantitatively characterize the population of dislocation loops in ion-irradiated CrFeMnNi alloys. To this end, we propose an efficient guideline to prepare TEM micrographs dataset for deep learning analysis, adapted for accurate characterization of microstructures produced by thousands of overlapping defects, a very common situation in TEM images, unfeasible by previous existing methods. To reduce human effort, we annotate only a few images and complement the database through a two-step process: initially, singular value decomposition to normalize image background, followed by a controlled data augmentation. The performed analysis provides precise quantitative information about the number of loops of different types, as well as their spatial distribution, their size, and the inter-object distances. These characteristics provide insights into the nucleation, mobility, and growth of dislocation loops, as well as the elastic anisotropy of the material. Our results emphasize how accurate analysis of complex microstructures can provide insights into the physical properties of materials and open up many perspectives for attaining quantitative information on materials properties based solely on their image analysis.

Alumina ceramic insulation layer for strain sensor fabricated by direct laser deposition

ABSTRACT Strain sensors are often used to monitor the use of critical components. The bond strength between the strain sensor and the gear teeth is particularly critical. There is a problem of insufficient bond strength between separated strain sensors and parts. The strain sensor is prone to loosening and flaking in the working environment. Therefore, a method of preparing the ceramic insulation layer of the strain sensor by direct laser deposition (DLD) is proposed. The effects of laser scanning trajectories, laser power, and scanning speed on forming quality were investigated experimentally. In addition, the phase analysis, microstructure characterization, and insulation properties of the insulating layers prepared at different overlap rates were researched. The research shows that the ceramic insulation layer has good insulation properties and hardness. The maximum hardness can reach 2405.74MPa, and the insulation resistance increases with the number of layers. The surface of the ceramic insulation layer is dense and has no cracks.

Extracting ductile cast iron microstructure parameters from fracture surfaces: A deep learning based instance segmentation approach

This study investigates the deep-learning based microstructural analysis from SEM images of ductile cast iron fracture surfaces. A Mask R-CNN model was trained, achieving 70% precision and 75% recall in graphite particle detection. Combined with a fracture surface reconstruction using the.4-quadrant backscattered electron signal, key parameters, including the particle size, shape and distance were extracted accurately. Compared to micrograph analysis, following probabilistic simulations showed the impact of the higher microstructural variance for the fracture surfaces on crack initiation, leading to higher scatter and elevated crack resistance curves. This highlights the potential of deep-learning based analysis for comprehensive microstructural characterization.

The Dependence of Electrochemical Behavior and Discharge Performance on the Zn/Gd Ratio of Mg-Li-Zn-Gd Anodes for Mg-Air Batteries

In this study, the electrochemical performance and discharge behavior of Mg-Li-Zn-Gd alloys with α-Mg and β-Li-based anode material are investigated, with the aim to improve the anode performance of Mg-air batteries. The experimental anode alloys with detailed Mg-8Li-xZn-yGd (x = 1, 2, 3; y = 1, 2, 3 wt.%) components are prepared, and extrusion deformation is carried out on these alloys. Simultaneously, scanning electron microscope (SEM), X-ray diffractometer (XRD), electrochemical workstation, and constant current discharge systems are applied for microstructure characterization, corrosion, and discharge performance testing. The results show that the experimental alloys are composed of an α-Mg and β-Li dual matrix, with W-Mg3Gd2Zn3, Mg3Gd, and MgLiZn second phases. Meanwhile, extrusion deformation promotes the recrystallization process through the particle-induced nucleation mechanism. The corrosion resistance is improved with the increasing Zn/Gd ratio, and the extruded Mg-8Li-2Zn-1Gd (LZG821) alloy exhibits the optimum corrosion resistance, with a corrosion rate of 0.493 mm·year−1. In addition, the extruded Mg-8Li-1Zn-1Gd (LZG811) alloy has the optimal discharge performance, with a discharge specific capacity of 1371.04 mA·g−1 at a current density of 40 mA∙cm−2, and its anode efficiency reaches nearly 70%. The poorer discharge properties of the Mg-8Li-2Zn-1Gd (LZG821) and Mg-8Li-2Zn-3Gd (LZG823) alloys are attributed to their refined grains, which could bring severe intergranular corrosion while increasing the grain boundary density.

Understanding the grain refinement and residual stress formation mechanisms of a Ni-based alloy during machining processes

Ni-based alloys are important materials for many industries, microstructure of the sub-surface regions of these alloys can be refined during machining processes, affecting both their machinability and service performance. Several mechanisms have been proposed to explain the machining-induced microstructure refinement of these alloys, however, sound evidences to support them are still lacking. In this research, microstructure characterization with an emphasis on the micro-texture and defects was conducted on milled surfaces of a Ni-based alloy, to promote in-depth understanding of the grain-refinement process. A nano-crystalline layer consisted a topmost region with randomly-orientated grains and annealing nano-twins and a textured region beneath it with deformed microstructure was observed in the cross-section of the alloy with the help of high resolution orientation determination techniques. These observations provide additional evidences to support the recrystallization induced grain-refinement mechanism of the nano-grains. It is also suggested that recrystallization was a by-product of the shear deformation occurred during the milling process, supported by the observation of the clear boundary between the nano-grain layer and its beneath deformed region. The deformed region was refined as a result of mechanical twining and twin-intersections, leading to significant fluctuations of the residuals stresses.

Experimental Study of the Microstructural Characterization of Microbial Induced Calcite Precipitation (MICP) Bio-Cement Concrete

Experimental Study of the Microstructural Characterization of Microbial Induced Calcite Precipitation (MICP) Bio-Cement Concrete

Covalent Pectin/Arabinoxylan Hydrogels: Rheological and Microstructural Characterization.

This research aimed to evaluate the gelation process of ferulated pectin (FP) and ferulated arabinoxylan (AXF) in a new mixed hydrogel and determine its microstructural characteristics. FP from sugar beet (Beta vulgaris) and arabinoxylan from maize (Zea mays) bran were gelled via oxidative coupling using laccase as a crosslinking agent. The dynamic oscillatory rheology of the mixed hydrogel revealed a maximum storage modulus of 768 Pa after 60 min. The scanning electron microscopy images showed that mixed hydrogels possess a microstructure of imperfect honeycomb. The ferulic acid content of the mixed hydrogel was 3.73 mg/g, and ferulic acid dimer 8-5' was the most abundant. The presence of a trimer was also detected. This study reports the distribution and concentration of ferulic acid dimers, and the rheological and microstructural properties of a mixed hydrogel based on FP and AXF, which has promising features as a new covalent biopolymeric material.

Microencapsulated carotenoids from orange sweet potato: Degradation kinetics and physicochemical properties

AbstractThe use of natural pigments in the food industry has increased due to their health benefits. Carotenoids are natural pigments that carry the disadvantage of sensitivity to temperature, light and the presence of enzymes and oxygen. Microencapsulation technology is widely used to protect these compounds against degradation, preserving their physicochemical characteristics. The research objective was to obtain the kinetics of carotenoid degradation of a microencapsulated extract of orange‐fleshed sweet potato (Ipomoea batatas L.) and to establish its physicochemical properties. The sweet potato extract was obtained using ultrasound and then microencapsulated by spray drying using maltodextrin as the wall material. The microencapsulate obtained was subjected to degradation kinetics at 30, 40 and 50°C. Carotenoid quantification analysis, colour, rehydration properties, antioxidant capacity, Fourier‐transform infrared (FTIR) and RAMAN spectroscopy and microstructural characterisation were performed on the microencapsulated carotenoids. From the kinetic analysis, the activation energy of the sweet potato extract was 16.31 kJ/mol while that of the microencapsulated sweet potato extract was 10.27 kJ/mol. Thus, it can be concluded that the microencapsulation process improved the stability of carotenoids subjected to thermal conditions. FTIR and RAMAN spectra confirmed the microencapsulation of the carotenoids. The microencapsulated powder showed a hygroscopicity of 0.22 g/100 g, wettability of 49 s and high solubility. The results obtained in the kinetics are a useful tool to predict losses during the process of heating the carotenoids from sweet potato, thus allowing improvement and selection of the products to which this powder can be applied, in either thermal or cold processes.

Precipitation behavior of Al-Zn-Mg-Cu alloys with the coupled soft/hard micro-scale areas and its effect on properties

A novel thermomechanical processing route was developed to prepare Al-Zn-Mg-Cu alloys containing heterostructures with coupled soft/hard micro-scale areas. The heterostructure gives an effect on the subsequent precipitation behavior of alloys. Importantly, the tensile strengths, elongation and corrosion resistance of grain boundaries of the #3 alloy with an appropriate coupled distribution of soft/hard micro-scale areas are all greatly improved compared with the alloy with the homogeneous structure. Based on the detailed microstructure characterization, the corresponding strengthening and corrosion resistance mechanisms of alloys with heterostructure have been established in this paper.

Low-cost flash graphene from carbon black to reinforce cementitious composites for carbon footprint reduction

With the merits of high quality, cost-effectiveness, and high yield efficiency, flash Joule heating (FJH) emerges as an efficient means for mass production of flash graphene (FG). It creates prerequisites for the large-scale application of graphene in reinforcing cementitious composites, thus opening innovative possibilities for curbing carbon emissions and fostering the sustainable evolution of cementitious composites. In this study, two types of FGs, including high-purity FG (FG-G) and conductive FG (FG-D), are successfully synthesized via FJH process using carbon black as the carbon source. FG-G features a low ID/IG of 0.52, and exhibits higher graphitization and structural orderliness with fewer defects compared to the FG-D. The addition of 0.25 wt% FG-D increases the compressive strength, flexural strength, and flexural ultimate strain of cementitious composites by 16.48 MPa/16.8%, 1.43 MPa/37.2%, and nearly 2600 με/550%, respectively. The microstructure characterization results reveal that FG reduces the matrix defects, enhances both the matrix microstructure and calcium silicate hydrate gel nanostructure, which is advantageous for matrix refinement, inhibition of microcrack aggregation and propagation, and load transfer efficiency. Its disorderly stacked turbine structure also contributes to robust interface bonding and friction with cement matrix, thus facilitating the strengthening and toughening of cementitious composites. This study introduces a potential avenue to develop widely applicable and versatile silicon-based cementitious composites with high performance and low CO2 emission by using small carbon-based graphene as reinforcement.

Deformation behavior of Gd alloyed CoCrFeNi high entropy alloy at high temperature under the influence of local nano-ordered structure and misorientation

The thermomechanical processing (TMP), which is an industrial process that includes deformation and heat treatment, represents a novel approach to enhancing the mechanical properties of metallic materials. However, it requires extensive research on the high-temperature deformation behavior of alloys during its application process. The present study conducts hot compression tests at 700 °C and 800 °C, as well as detailed microstructural characterization of the deformed material after hot deformation, to comprehensively discuss the mechanical properties and deformation behavior at high temperature of the (CoCrFeNi)100-xGdx (x = 0, 0.5, 1, 2, 3 at.%) HEAs. The (CoCrFeNi)100-xGdx HEAs exhibit an excellent combination of strength and plasticity in high temperature. The original dendritic microstructure in the (CoCrFeNi)100-xGdx HEAs was completely fractured and transformed into a mass of deformed structures during thermal deformation. The mechanical properties at high temperature of the alloy system originate from the misorientation in the microstructure. Dislocation slip is the main deformation mechanism of the alloy system at high temperature. The coordinated deformation of the soft orientation for FCC phase and the hard orientation for HS phase affects the dislocation morphology in the microstructure. Dynamic recovery (DRV) plays a dominant role in the flow behavior of the alloy at high temperature, and work hardening is the main strengthening mechanism during plastic deformation. The correlation between microstructure evolution and mechanical properties of Gd alloyed CoCrFeNi HEAs during hot deformation has been established through comprehensive studies on deformation behavior.