Microstructural Studies Research Articles

Experimental study of shielding gas concentration on mechanical properties of stainless steel alloy parts using wire and arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is an emerging three-dimensional fabrication technology that enables higher deposition rate, material savings, and near net-shape. In this study, various shielding gas concentration (SGC) of argon (Ar) and carbon-di-oxide (CO2) was employed to fabricate 316L using Cold Metal Transfer (CMT) WAAM process. Microstructure characteristics and mechanical properties of thick-walled parts were studied. Microstructure studies show a combination of columnar and equiaxed grains in various regions. Microhardness results exhibit the uneven distribution of hardness value from bottom to top region along the building direction and the values are ranging between185 and 240 HV. Tensile studies indicates the both horizontal and vertical direction samples secures the higher ultimate tensile strength (UTS), yield strength (YS) and elongation (EL) values and confirmed the isotropic properties. Fractography studies prove ductile fracture with the evidence of dimples and enough plastic deformation. From the experimental results, the SGC-2 possesses finer solidification structure and higher mechanical properties than the other samples. The as-fabricated WAAM parts possess higher mechanical properties than the 316L parts fabricated via casting and wrought parts.

Synthesis and Characterization of Recycled-TiC Reinforced AlZnMgCu Powder Metallurgy Composites.

Recycling's value in conserving scarce resources, avoiding environmental damage to the land, and reducing energy consumption is well known. This research aims to develop a composite that uses recycled reinforcement that was formed through an in situ method to build confidence in the usage of recycled materials. Thus, in connection with defense and aerospace industry applications, aluminum composite alloys receive more interest due to their light weight and high strength with improved mechanical properties; therefore, this research focuses on the fabrication of in situ-developed recycled TiC (r-TiC)-reinforced AlZnMgCu composites, i.e., new recycled materials. Experiments were conducted to determine the synthesized composites' microstructural, mechanical, tribological, and corrosion properties. The microstructural study showed that r-TiC was distributed uniformly along the grain boundaries until the addition of 12% r-TiC. However, the accumulation of reinforcements began at 14% r-TiC addition and became more aggregated with subsequent increases in the percentage addition of r-TiC. The mechanical and tribological tests showed that the composite with 14% r-TiC was superior to all other compositions, with 60% improved mechanical qualities and the lowest wear rate of 0.0007 mm3/m. Composites containing 2% r-TiC showed the best corrosion resistance, an increase of 22% over AlZnMgCu, without reinforcement.

Pillar-Supported 2D Layered MOFs with Abundant Active-Site Distributions for High-Performance Alkaline Supercapacitors.

The development of two-dimensional (2D) layered metal-organic frameworks (MOFs) through precise molecular-level design and synthesis has emerged as a prominent research endeavor. However, the utilization of MOFs in their pristine form as electrodes for supercapacitors poses a significant challenge due to their limited tolerance in alkaline environments. To address these issues, we have developed Co- and Cu-based pillar-layered MOFs by regulating the structure of their inner layers through introducing an alkaline N-containing "pillar" to enhance the performance of alkaline supercapacitor electrodes. From the microstructure study and theoretical calculation, the high-density redox centers and efficient chemical bonding modes of Co-MOF determine a unique electron conduction pathway, resulting in excellent energy storage performance. This study underscores the significance of chemical bonding modes and active-site distribution in enhancing the energy storage capabilities of pillar-layered MOFs in alkaline environments, presenting a promising approach for the development of high-performance MOF-based materials for supercapacitor applications.

Microstructural Characterization of Friction Stir Welds of Aluminum 6082 Produced with Bobbin Tool.

This study utilized a bobbin tool to friction stir weld aluminum 6082 workpieces under two sets of process parameters: a tool rotation speed of 280 rev/min with a weld velocity of 280 mm/min (280/280) and a tool rotation speed of 450 rev/min with a weld velocity of 450 mm/min (450/450). The weld microstructures were characterized through optical microscopy utilizing polarized light and through transmission electron microscopy (TEM) and scanning electron microscopy (SEM) coupled with chemical analysis by energy dispersive spectroscopy and electron back scatter diffraction. The microstructural studies were supplemented by hardness measurements (Vickers) performed on the same sections as the metallographic examinations. The produced weldments were free from cracks and any discontinuities. Fine, equiaxed grains that were several microns in size characterized the stir zones (SZs), and the advancing (AS) and retreating (RS) sides revealed distinct microstructural features. On the AS, the transition from the thermo-mechanically affected zone to the SZ was well defined and sharp, but on the RS, the transition appeared as a continuous, gradual change in microstructure. The lower weld energy (280/280) produced lower hardness in the stir zone than the higher energy weld (450/450), ~95 HV1 versus ~115 HV1; however, the 280/280 welds showed higher tensile strengths than the 450/450 welds, ~238 MPa as opposed to ~172 MPa. These behaviors in mechanical performance correlated with the temperature histories produced by each set of weld parameters in relation to the precipitation behavior of the alloy. The fracture characteristics of the weldments were notably different with the 450/450 sample fracturing in a quasi-brittle manner with slight plastic deformation and the 280/280 sample fracturing ductilely. A numerical simulation supported the investigation by elucidating the temperature and material flow behavior during the joining process.

TRIBOLOGICAL AND CORROSION PROPERTIES OF 45 AND 65G STEELS USED IN AGRICULTURAL MACHINERY AFTER ELECTROLYTIC-PLASMA HARDENING

The article examines the effect of electrolytic plasma hardening on the wear resistance and corrosion resistance of steels 45 and 65G, which are used in the production of agricultural machinery components. The presented results demonstrate the improvement of the surface properties of steel through the application of electrolytic plasma hardening. This technology provides rapid heating and cooling, which contributes to the formation of a fine-grained and hardened surface layer, as evidenced by microstructural studies conducted using an optical metallographic microscope. Tribological tests showed an improvement in wear resistance after electrolytic plasma hardening: the wear volume for steel 45 was 3,03×10-4 mm³, and for steel 65G it was 6,17×10-5 mm³, which is 7 and 4,5 times less than the wear volume for the initial samples, respectively. The analysis of polarization curves showed that the corrosion current density decreased compared to the initial sample. For steel samples 45 and 65G after three cycles of electrolytic plasma hardening, the corrosion current densities were 6,87×10^-6 A/cm² and 1,61×10^-7 A/cm², respectively. Additionally, a shift in the corrosion potential towards more positive values was noted, indicating an increase in corrosion resistance. The results of the study demonstrate significant improvements in the tribological and corrosion properties of steels 45 and 65G after electrolytic plasma hardening, providing valuable data for industrial applications.

Optical and microstructural studies of erbium-doped TiO2 thin films on silicon, SrTiO3, and sapphire

Optical and microstructural studies of erbium-doped TiO2 thin films on silicon, SrTiO3, and sapphire

Durability assessment of blended slag-fly ash geopolymer concrete in field conditions after 5 years

This study investigated the durability performance of a blended slag-fly ash geopolymer concrete slab exposed to outdoor field conditions for five years. The performance of the geopolymer slab was periodically assessed at two different intervals. During the assessment, ultrasonic pulse velocity (UPV) was performed to analyze the structural soundness. The cores were extracted and tested for strength, carbonation depth and transport parameters. With time, the UPV was improved from 4.17 km/s to 4.39 km/s which suggests densification of microstructure and correlated well with the reduction in the water permeability depths. Degradation of strength or efflorescence was not observed over time and the pH of the concrete was found to be 10.9 after five-year exposure. Microstructural studies revealed the formation of needle-like structures and the densification of the matrix with age. The investigation of the durability performance of geopolymer concrete is essential for the development of standard specifications for wider industrial applications.

Feasibility study on the preparation of ternary blended cements with low-kaolinite calcined coal gangue and limestone

This paper presents a feasibility study on the production of ternary blended cements with low-kaolinite calcined coal gangue (CCG) and limestone, considering kaolinite contents varying from 11.7 % to 40.6 % in coal gangue (CG). The ternary systems were designed with 15 %, 30 %, 45 % and 60 % by mass of cement replaced by CCG and limestone with a fixed mass ratio of 2:1. The fluidity and compressive strength of the mortars were measured, followed by the strength efficiency analysis combined with CO2 emission. The potential hydration mechanism was revealed by analysing the hydration kinetics, hydrates and microstructural evolution of these ternary pastes. The results showed that it is possible to use low-kaolinite CCG and limestone to prepare ternary blended cements with adequate mechanical strength that can fulfill the 28-day strength requirement of 32.5 or 42.5 grade cement. In addition, Increasing the kaolinite content in CG can increase the substitution of cement up to 60 %. Microstructural studies indicated that the compressive strength of these ternary mortars at 3 and 7 days was mainly dominated by cement hydration and the pozzolanic reaction between CCG and portlandite (CH), respectively. The precipitation of carboaluminates from the synergy of CCG and limestone significantly reduced critical pore size and increased the volume fraction of fine capillary pores from 7 days, well supporting the strength development of the ternary mortar. The findings of this work underscores the potential of using low-kaolinite CCG as a supplementary cementitious material (SCM) to reduce carbon footprint in the field of construction, and also in contributing to a high-value green utilization of solid waste.

Microstructural Study of the Coloring Variation of Chinese Sauce Glaze Replications

ABSTRACTSauce glazed wares of Yaozhou kilns are famous for their high gloss and distinctive glaze color palette varying from yellowish‐brown to reddish‐brown. In this work, sauce glazes were successfully replicated using the traditional technology of Yaozhou kilns. Micro‐Raman spectroscopy, combined with optical microscopy, scanning electron microscopy, x‐ray fluorescence, and reflective spectroscopy, was systematically applied to analyze the chemical composition, nature and distribution of crystals, and the coloration of the glazes. The results show that the yellowish‐brown glaze is mainly original from dendritic ε‐Fe2O3 crystals, whereas the reddish‐brown color is mainly derived from dendritic hematite crystals. Such dendritic structure could account for slightly color variations of the glaze surface observed in different angles, which also reported in Japanese Bizen ceramics. The principal component analysis (PCA) was further applied to study the Raman spectra of these iron oxides. The PCA results effectively indicates the structural disorders of these crystals introduced by ion substitutions. These substitutions could not only stabilize the crystals but also darken the crystals color. Besides, high Mg in the raw materials was found to benefit the growth of magnesioferrite crystals. The relative low level of Fe2O3, high level of SiO2, and CaO may relate to the formation of ε‐Fe2O3 crystals.

Effect of non-covalently bound alkaline amino acids on the structural characterization, microstructure, and rheological properties of whey protein emulsion gel

The objective of this study was to explore the impact of L-arginine (Arg) and L-lysine (Lys) on the structural changes and rheological properties of whey protein isolate (WPI) emulsion gels through the utilization of multi-spectroscopic techniques and rheological analysis. The results indicated that the incorporation of Lys/Arg caused WPI molecules to become unfolded, thus exposing hydrophobic amino acids and altering the microenvironment of aromatic amino acids. Microstructural studies revealed that WPI emulsion gels containing 0.5% Lys or 2% Arg resulted in a more uniform and compact network structure. This phenomenon could be attributed to the capability of Lys/Arg to improve the hydrophobic interactions and hydrogen bonding between molecules during gel formation, ultimately leading to a network structure characterized by excellent rheological properties, textural properties, and water-holding capacity. These findings provide a theoretical for the development of emulsion gels with improved structural and rheological properties.

Study of phase composition, microstructure and hardness of multicomponent zirconia-based ceramics

The manufacture of products from refractory ceramics requires high temperatures due to the high activation energies of the sintering process of refractory oxides. Processing temperatures for ceramics made of ZrO2, Al2O3, MgO can be reduced if a flux or glass-forming component is selected. Furthermore, in multicomponent ceramics it is possible to create more favorable thermoresistive properties. This study examines the synthesis, structural, phase and mechanical properties of multicomponent porous ZrO2-WO3-Al2O3-MgO ceramics with varying weight concentrations of components. Experimental samples were obtained by standard solid state reaction method. The analysis of fabricated samples was carried out using X-ray phase analysis, scanning electron microscopy and the Vickers microhardness test. In this work, a new approach to increasing the microhardness of porous refractory ceramics is presented, in which WO3-based flux forms a matrix composed of glass-like formations that “attach” particles of ZrO2 and MgAl2O4 phases. The obtained ceramics demonstrates high microhardness values HV0.05 for porous materials ranging from 500 to 600. Studies have shown that the selected composition of multicomponent ceramics (x = 0.10–0.25) can be used as a refractory material up to temperatures of ∼1300 °C. The fabricated refractory ceramics potentially possess chemical stability and optimal microhardness properties, which makes these materials promising as a heat insulating lining in the metals, ceramics and glass manufacturing, as well as for components in the chemical industry.

Impact of graphite on tribo‐mechanical, structural, and thermal behaviors of polyoxymethylene copolymer/glass fiber hybrid composites via Taguchi optimization

AbstractUnique hybrid thermoplastic composites based on polyoxymethylene copolymer (POM C), 10 wt.% glass fiber (GF) and graphite (Grt) filler at 1, 3, and 5 wt.% were developed using injection molding technique. According to the Taguchi L16 orthogonal array, present experiments were carried out with the aim of determining the coefficient of friction (COF) and specific wear rate (SWR) under a range of loads (namely, 5, 10, 20, and 30 N), sliding speeds (namely, 200, 400, 600, and 800 rpm), and run times (namely, 15, 30, 45, and 60 min) with varying wt.% of Grt (namely, 1, 3, and 5 wt.%) throughout the experiment. Analysis of variance (ANOVA) was used to evaluate the most significant factors that affect the output functions (viz., COF and SWR). The findings demonstrated that POM C/10GF composites' tribo‐mechanical, structural, and thermal properties were considerably improved upon by including Grt. Various microscopical methods were also employed to study the wear mechanisms of the composites and the surface morphology of the worn samples. The POM C/10GF with a 3 wt.% of Grt exhibited superior tribological properties owing to its enhanced interfacial bonding characteristics, resulting to increased wear resistance.Highlights Injection molded POM C/10GF hybrid composites with 1, 3, and 5 wt.% graphite (Grt) Structural, thermal, chemical, tribo‐mechanical and microstructural studies Design of experiment with variable loads, times, speeds, and Grt compositions COF and specific wear resistance as response Optimization of hybrid composite composition using Taguchi L16 orthogonal array

Mechanical Behavior Analysis of Lightweight Concrete Reinforced by Metalized Plastic Waste Fibers

This study evaluates the impact of adding metalized plastic waste (MPW) fibers to lightweight concrete that is used as a filler material in building slopes and bridge ramps. The goal is to open up new opportunities for recycling plastic waste and promote a more sustainable and productive construction industry. This study examined the mechanical behavior of lightweight concrete (LC) at 3, 28, and 90 days, both with and without MPW fiber (1%, 2%, and 3%). Compression tests, 3-point bending tests, and pull-out tests were used to measure the fibers' compressive strength, flexural strength, and maximum load-bearing capacity, respectively. According to the results, the compressive strength (CS) and elasticity modulus (MOE) decreased with increasing fiber content when MPW fiber was added. In the long term, the CS and MOE decrease for the LC containing 3% MPW fiber was 8% and 7%, respectively, lower than for the control concrete. At 90 days, the flexural strength of the LC with 1% MPW fiber was marginally higher than that of the control concrete, rising by 2.40%. After this initial rise, however, the flexural strength declined as the fiber concentration increased, eventually reaching an 8% reduction for LC with 3% MPW fiber.The optimum method for determining maximal load-bearing and comprehending the deformation mechanism is hence the fiber pull-out test. The microstructure study of the LC examined how the pull-out test affected the quality of bonding at fiber-matrix interfaces. The tensile and flexural strength of lightweight concrete are enhanced by MPW fiber's ability to bear significant pulling stress.

Designing calcium-fortified milk for improving stability and calcium bioaccessibility by solid dispersion emulsification

Approximately 70 % of the calcium intake in the adult diet worldwide is derived from dairy products. However, insoluble calcium salts, which are usually added directly during dairy production, have poor suspension stability and are prone to precipitation. The current study aimed to address the constraints of conventional production methods by utilizing solid dispersion emulsification technology to inhibit the aggregation of calcium salts. Calcium-fortified milk samples with different calcium content were prepared and compared with the commercial calcium-fortified milk, and their physicochemical, microstructural, and digestive properties were characterized. The results of this study demonstrated that all the prepared calcium-fortified milk samples exhibited a particle size of approximately 270 nm and a zeta-potential of approximately −40 mV. The calcium-fortified milk, which has been produced using solid dispersed emulsion technology, has been found to have 1.8 times more physical stability than commercial milk. Microstructural studies showed that aggregation of milk with more than 225 mg/100 mL calcium content occurred. During in-vitro digestion, it was found that the increasing calcium loading did not impact protein digestion without the creation of new fragments in the calcium-fortified milk. Calcium bioaccessibility was enhanced by approximately 50 % in comparison with the commercial product. While the release of free fatty acids was found to decrease with increasing calcium content. This study facilitates the development and utilization of calcium-fortified and low-fat foods and provides a new idea for the addition of milk minerals in dairy products.

Evaluation the effect of multi-pass friction stir processing on the wear, mechanical properties, and microstructure of the AA1050/ZrO2 surface nanocomposite

This work presents surface nanocomposites of aluminum alloy AA1050, reinforced with zirconium oxide (ZrO2) nanoparticles developed through multipass friction stir processing (FSP). This article attempts to study the effects of the number of passes on the wear rate, microhardness profile, tensile properties, and macrostructure of surface nanocomposites. The results demonstrate that an improved distribution of ZrO2 nanoparticles is obtained following each FSP pass, and that the number of passes increases with a decrease in stir zone (SZ) grain size. Consequently, it was found that applying FSP passes continuously enhances the materials' microhardness and tensile characteristics. In the microstructure development of the stir zone during the ZrO2 nanoparticle FSP, dynamic recrystallization (DRX) was an essential mechanism. The main reason for this is that surface nanocomposites with homogenous ZrO2 particle dispersion and no discernible particle clustering in the stir zone were shown by microstructural studies conducted through FSP, which significantly reduced the matrix grain size. The AA1050 base metal (BM) has an ultimate tensile strength, yield strength, and hardness of 59.2 MPa, 24 MPa, and 30.1 respectively. The nanocomposite generated by 5 FSP passes exhibits improved yield stress (55 MPa), tensile strength (94.5 MPa), and microhardness (86.5 HV), but its tensile ductility decreased from 34% to 23.8% when compared to the base metal. Tensile strength that is higher is the outcome of fine dimples' ability to pin the dislocation movement during tensile loading. According to fractographic studies, the ductile–brittle mode replaced the dimple-shaped ductile fracture mode.

A novel sustainable AZ31 based Mg matrix composite reinforced with recycled IN718 powder for circular materials economy

The pursuit of sustainable practices in manufacturing has sparked an increased interest in recycling and reusing materials to reduce waste and environmental effect. One interesting technique is incorporating recycled materials to develop advanced composite materials. In this study, we focus on utilizing recycled Inconel IN718 powders as reinforcement particles in AZ31D. Powders of IN718 finer than 37 μm, developed from machining chips through high energy ball milling process, are infused into AZ31 through friction stir processing (FSP), enabling a circular economy practice in advanced material development. The resulting composite material is evaluated for its microstructure and mechanical performance. Microstructural study reveals a uniform distribution of reinforcement particle inside the matrix throughout the processed zone. Strong interfacial bonding between the matrix and reinforcement, and the addition of dispersion strengthening mechanisms helped reducing the tension/compression yield asymmetry problem. The study highlights the use of recycled materials in composites to achieve sustainability in manufacturing.

Diffraction and microstructure study of miscible interfaces in metallic multilayers

The structural characterization of two-metal phase systems at nanometer scale which present partial or total mixing, is extremely challenging. In the present work, a model to reproduce the x-ray diffraction patterns of multilayers composed by two miscible metals, Mo and W, is presented. Two different deposition conditions were used to obtain different stress states (compressive and tensile). From the proposed model, the contribution of each metal phase was discerned, the intra layer disorder and the level of mixing at the interface were quantified. The comparison between structures deposited sequentially, with others obtained by co-evaporation is also carried out to better understand the details of the interdiffusion and to separate them from the effects of roughness and elastic adaptation stresses. Microstructure characterization by scanning and transmission electron microscopy was compared and discussed with the diffraction analysis.

TiC-Reinforced Austenitic Stainless Steel Laser Cladding Layer on 27SiMn Steel Surface: A Comparative Study of Microstructure, Corrosion, Hardness, and Wear Performance

TiC-Reinforced Austenitic Stainless Steel Laser Cladding Layer on 27SiMn Steel Surface: A Comparative Study of Microstructure, Corrosion, Hardness, and Wear Performance

High-temperature oxidation behaviour of additively manufactured and wrought HAYNES 282

Direct Metal Laser Sintered Haynes 282 specimens as well as wrought ones were subjected to high-temperature exposure at 1000 °C for 100h in air to compare their oxidation behaviour. The specimens were removed from the furnace after 1h, 5h, 25h, 50h and 100h to reveal and study oxidation mechanisms through morphological and cross-sectional examination by using scanning electron microscopy with energy dispersive spectroscopy attachment and X-ray diffraction. Microstructural studies revealed that the oxidation kinetics, determined by changes in thickness scale and depth of aluminium diffusion zone, were mainly driven by the formation of Cr2O3 for the wrought material, and TiO2 for DMLS one. The wrought material was characterized by the oxidation rate equal to 0.96 and followed the logarithmic law. On the other hand, DMLS-manufactured Haynes 282 exhibited oxidation rate of 0.90 and follows the linear law for the thickness scale considerations. However, when the depth of aluminium diffusion was investigated, it had an oxidation rate of 0.87 and followed cubic law.

Effect of surface area on the wear properties of Al-based automotive alloy and the role of Si at eutectic level

The efficiency of an engine material is closely correlated with its surface area. In order to investigate wear properties, effect of surface contact area as well as silicon addition at the eutectic level of Al-Cu-Mg alloy has been studied. This test is performed under room atmosphere and dry sliding conditions using a standard pin-on-disk apparatus. Weight reduction method is adopted to measure the wear rate in microns to get more accurate results. A load varying from of 5 to 50 N and a constant sliding speed of 0.77 ms−1 are maintained throughout the test. The test results show that a lower contact surface area has a negative impact on the wear properties having higher wear rate, while the coefficient of friction of the alloy and Si addition into the alloy improve the properties to some extent. Reduction of the contact surface area increases the unit pressure and decreased material volume causes softening of the alloy matrix, resulting in a higher wear rate and coefficient of friction. The Si addition offers such an improvement mostly for an increase in strength via the Si-rich intermetallic formation. A microstructural study confirms a lower abrasive wear with a minor plastic deformation on the worn surfaces of Si added alloy and wear with higher contact surface. The Si-added alloys contain the fine and strong Si-rich intermetallic, which are responsible for such a smooth worn surface.