Mixed Materials Research Articles

Synthesis and characterisation of Al 7075 – Mg AZ31 alloy bimetal produced by friction stir additive manufacturing with Zn interlayer

ABSTRACT The bimetal formation of Al and Mg alloys has various metallurgical difficulties. To overcome these difficulties, Friction Stir Additive Manufacturing has been suggested as a promising technique for the Al and Mg alloy bimetal formation. In the present work, the defect-free bimetal of Al 7075 and Mg AZ31 alloys with Zn interlayer was successfully synthesised for the first time using Friction Stir Additive Manufacturing at a rotational speed of 1300 rpm and welding speed of 20 mm/min. The intermetallic compounds like MgZn and Mg32(Al, Zn)49 have been observed in the Friction Stir Additive Manufacturing through eutectic reaction at the temperatures 325°C and 330°C, respectively. The maximum strength up to 201 MPa and elongation of 5.4% have been achieved due to the proper mechanical mixing and dynamic recrystallization of material in the stir region. The maximum hardness has been observed in stir region. The hardness increases in top plate (Mg) and decreases in bottom plate (Al) as compared to their base material.

The Mechanical and Electrical Properties of the Smart Aggregate Based on the Mixed Cementitious Materials

The Mechanical and Electrical Properties of the Smart Aggregate Based on the Mixed Cementitious Materials

THE INFLUENCE OF DIGITAL COMICS ON STUDENTS’ LEARNING OUTCOMES

This study aims to determine whether or not there is an influence of digital comics on the science learning outcomes of fifth grade elementary school students on single substance and mixed substance material. The research method used was quantitative with true experimental and was designed using a Pretest-Posttest Control Group Design research design. The sample size for the research was 58 students who were divided into 2 groups, namely class V.A, which had 29 students as the experimental class and class V.B, which had 29 students as the control class. levence statistics, hypothesis testing using the t-test stated that both classes showed an rcount7.588 >ttable 1.672and the sig (2-tailed) value shows 0.000 < 0,05of So it can be concluded that Ha is accepted. Based on this research data, it can be proven that there is an influence of digital comics on the science learning outcomes of fifth grade elementary school students in single substance and mixed substance materials.

Separated reactant mix width across diffusion-dominated and hydrodynamically dominated interface mix in inertial confinement fusion implosions

Diffusion-dominated mix in inertial confinement fusion (ICF) is characterized where the majority of the mix occurs in the immediate fuel-shell interface while hydrodynamic-dominated mix pulls shell material from farther away into the central fuel. A thin (150 nm) separated reactants ICF mix platform is highly sensitive to the amount of mix from the first micron of shell-fuel interface. This fine-spatial resolution platform has revealed that material mix in moderate convergence (CR∼12) ICF implosions is dominated by a diffusion mechanism. This technique has now been expanded across a set of OMEGA ICF implosions, observing an increase in mix width and mix amount for cooler, slower, and more compressive implosions. Hydrodynamic simulations require a buoyancy-drag mix model to capture the increasing mix width, suggesting a transition between these two mix mechanisms. Published by the American Physical Society 2024

Enhancing performance through friction welding of dissimilar aluminium 2014 and 7075 hybrid metal-matrix composite: insights into material characterization, crystallographic texture, and mechanical properties

Abstract Welding high-strength, age-hardenable aluminium alloys from the 2XXX and 7XXX series poses challenges when using fusion-based welding processes. Common issues such as hydrogen porosity, hot cracking, stress corrosion cracking, and solidification cracking can lead to a reduction in mechanical properties due to the loss of strengthening precipitates and alloying elements. Consequently, friction stir welding (FSW) has emerged as a promising solid-state welding technique for joining dissimilar aluminium alloys and composites, particularly in aerospace applications where a combination of strength, corrosion resistance, and other desirable properties is required. This study investigates the FSW of dissimilar aluminium alloys, specifically AA2014 and a hybrid metal-matrix composite of AA7075 reinforced with silicon carbide and graphite particles. The microstructural and mechanical properties of the welded joints were characterized, revealing an average grain size of 2.39 μm ± 1.2 in the stir zone (SZ). A high angle grain boundary volume fraction of 47.25% was observed in the SZ, compared to 2.01% in the AA7075 composite and 15.03% in the AA2014 base metal. The presence of shear textures and the distribution of cube, S, and H textures indicate a homogeneous mixing of the base materials and a high shear strain rate during welding. The hardness of the SZ increased by 13%, and the ultimate tensile strength, yield strength, and elongation of the joint were measured at 251 MPa, 183 MPa, and 6.44%, respectively. The flexural strength of the joints improved significantly, with the CW13 sample showing a 67% increase compared to CW1. The dissimilar joint CW13, welded at 12.5 mm min−1, achieved a maximum joint efficiency of 95%.

Role of submerged friction stir welding in reducing intermetallic growth and enhancing microstructure in dissimilar Al-Ti joints

The integrity of dissimilar Al-Ti welds during conventional friction stir welding (CFSW) is compromised by excessive material mixing, leading to thick intermetallic layers. Underwater friction stir welding (UWFSW) mitigates these effects by inhibiting material mixing due to lower thermal conditions. Scanning electron microscopy revealed substantial Ti particles, appearing as blocks and strips, within the stir zone during CFSW. Static recrystallization, driven by exothermic reactions between Ti blocks and the Al matrix, resulted in over 93% recrystallized grains along stir zone, 10.7% higher than in UWFSW. In contrast, UWFSW resulted in a finer dispersion of Ti particles with reduced density due to lower frictional heat. The average grain size at the Ti interface of CFSW was 1.0 μm, compared to 2.6 μm in UWFSW. The inhomogeneous distribution of Ti particles in CFSW led to uneven dislocation distribution and increased stress concentrations, while finer Ti particles in UWFSW promoted a uniform grain structure, enhancing joint strength to 267 MPa, 13.4% higher than CFSW. Additionally, the γ-fibre and basal fibre texture in UWFSW increased joint ductility. The study highlights UWFSW’s effectiveness in joining dissimilar metals, offering significant advantages for industries such as aerospace and automotive.

Distinguishing and Further Reinforcement for Nanocrystal XRD Peaks Caused by Instrument Broadening in Nanomixed Materials

X-ray diffraction (XRD) is one of the most essential techniques for characterizing various crystals. However, when nanocrystals are present, the diffraction peaks become significantly broadened and reduced in intensity, making phase and microstructure analysis challenging. To obtain more refined microstructural information from nanocrystals, various methods have been developed to enhance diffraction peaks, with step scanning being a commonly used approach. Additionally, increasing instrument broadening (IB) by adjusting slit sizes to enlarge the irradiation area is a convenient yet often overlooked method. In this study, the effects of IB on the diffraction peak intensities of nanocrystals and micron crystals in mixed materials were thoroughly investigated. The results show that the intensities of both nanocrystals and micron crystals increase as IB increases, a behavior similar to that observed when extending the testing time during step scanning. However, the rate of increase in peak heights for nanocrystals is higher than for micron crystals, while the rate of increase in peak width for nanocrystals is lower, which is a significant departure from the effects seen in step scanning. In other words, nanocrystal peaks become sharper and more distinct as IB increases. This phenomenon is explained by the different components of peak width for nanocrystals and micron crystals, based on Lorentz mathematical model analysis. Based on these findings, it is recommended to utilize larger IBs in combination with step scanning to further reinforce nanocrystal peaks in mixed materials.

Machine Learning Driven Fluidity and Rheological Properties Prediction of Fresh Cement-Based Materials

Controlling workability during the design stage of cement-based material mix ratios is a highly time-consuming and labor-intensive task. Applying artificial intelligence (AI) methods to predict and optimize the workability of cement-based materials can significantly enhance the efficiency of mix design. In this study, experimental testing was conducted to create a dataset of 233 samples, including fluidity, dynamic yield stress, and plastic viscosity of cement-based materials. The proportions of cement, fly ash (FA), silica fume (SF), water, superplasticizer (SP), hydroxypropyl methylcellulose (HPMC), and sand were selected as inputs. Machine learning (ML) methods were employed to establish predictive models for these three early workability indicators. To improve prediction capability, optimized hybrid models, such as Particle Swarm Optimization (PSO)-based CatBoost and XGBoost, were adopted. Furthermore, the influence of individual input variables on each workability indicator of the cement-based material was examined using Shapley Additive Explanations (SHAP) and Partial Dependence Plot (PDP) analyses. This study provides a novel reference for achieving rapid and accurate control of cement-based material workability.

Hydrodynamic simulation of coastal reservoir in response to flow control: a numerical study of the Saemangeum reservoir

Coastal reservoirs (CRs) are important water resources worldwide, but environmental problems can arise due to limited material mixing caused by the blocked propagation of tidal waves. The Saemangeum Reservoir is a large brackish reservoir in South Korea; owing to its complex fluctuation characteristics, accurate reproduction of its three-dimensional (3D) circulation and material distribution characteristics remains a challenge. Here, we aimed to improve the reproducibility of the Delft3D model through long-term precision monitoring and analyze problems occurring in CRs. The model reproduced the hydraulic flow and stratification phenomena in CRs. The Richardson number ( R i ) was higher than 100, and the Stratification Index ( SI ) was higher than 1 due to the density difference between the surface and bottom layers. The stratification strength of the Saemangeum Reservoir was, therefore, considered high. Moreover, a two-layer circulation occurred due to the strength of the eddy and the horizontal gradient of salinity. When the sluice gate was expanded, the area and number of days where hypoxia occurred decreased. It would also mitigate the retention of materials caused by the eddy and improve circulation. The findings of this study can be used as foundational data for solving and managing hydraulic problems within CRs.

Composting feasibility of organic solid waste ratio of CELSS and associated microbial enhancement effects

Due to the unique environment of the Controlled Ecological Life Support System (CELSS), the type and quantity of organic solid wastes produced during long-term space missions are fixed. However, these mixed materials do not meet the indicators of conventional composting, and the vacuum in CELSS limits bio-degradation due to a shortage of functional microbes. In order to explore the feasibility of the organic solid waste ratio of CELSS and its microbial enhancement effect, composting experiments were setup to compare the actual and optimized material ratios on composting and polluted gaseous emissions, and to investigate the enhancement of microbial inoculation. The results demonstrated that the actual material ratio can be used for composting, whose degradation degree of crude protein, soluble sugar, cellulose, hemicellulose and lignin was better than the optimized treatment. The actual material ratio can also reduce 26.1% of ammonia (NH3) and 66.8% of methane (CH4) emissions. They were attributed to the carbon source in the actual materials, which resulted in higher species abundance, uniformity, and dominance of the microbial community and a stronger overall utilization ability. Moreover, the inoculation of VT microbial agent can further increase the diversity of microorganisms and prolong the duration of high activity, which helps to strengthen the degradation of crude fat, cellulose and lignin, and reduced 50.7% of hydrogen sulfide (H2S) and 33.2% of nitrous oxide (N2O) emissions. Therefore, it is recommended that the aerobic composting technology in CELSS use the proportion of actual organic solid waste to match the material and add VT microbial agent.

Design and optimization of stirrer and mixer design for the correct mixing of pharmaceutical powders through DEM

Mixing of granular materials is an important process for pharmaceutical industries. In this study, a quantifiable calculation method was suggested to determine the final mixing degree of the mixture. Based on that, the effect of the stirrer design, rotational speed, powder density, cohesivity, material ratios, and particle movement in the chamber guided through different designs of deflectors on the final mixing quality is examined. The results show that increasing the stirring speed, generates better mixing quality. However, introducing a varying rotational speed mode improves the mixing degree specially for binary mixtures with high relative densities. The improvement of the mixing with the number of contacting blades is observed. Finally, the introduction of a simple deflector drastically enhances the mixing quality and enables the feeding into the chamber, which is key for continuous operation with cohesive powders, making the process more stable and efficient by using more of the mixing volume.

Durability and Compressive Strength of Composite Polyolefin Fiber-Reinforced Recycled Aggregate Concrete: An Experimental Study

This study investigates of using recycled concrete aggregates along with the reinforcement of polyolefin fibers to augment both the compressive strength and durability of concrete, in alignment with the principles of sustainable development. This study experimentally investigated the compressive strengths and durability of composite polyolefin fiber-reinforced recycled aggregate concrete (PFRRAC) exposed to chloride and acidic environments. For this purpose, 150 cubic samples of 100 × 100 × 100 concrete with various combinations of recycled aggregates and polyolefin fibers were made and subjected to axial compressive loading. The results show that the addition of fibers significantly enhances the compressive strength of concrete, with an increase of up to 34.36% at 5% fiber content. However, increasing the proportion of recycled aggregates reduces the compressive strength, with reductions ranging from 21.12% to 43.85% as the recycled aggregate content rises to 70%. Moreover, the combination of fibers and recycled aggregates demonstrates potential for improving the sustainability and durability of concrete under challenging environmental conditions, particularly in chloride and acidic environments. In acidic environments, the inclusion of fibers significantly enhances the resistance to strength reduction. Furthermore, the study uncovers that a higher concentration of recycled aggregates exacerbates the reduction in strength in chloride-rich settings, emphasizing the imperative nature of meticulous mix design and material selection. The findings for the integration of even minor quantities of polyolefin fibers to amplify the performance and sustainability of concrete mixtures, especially when utilizing recycled aggregates, thus promoting eco-friendly construction practices.

Fluoride- and OSDA-free synthesis of ZSM-5 with controllable b-axis orientation: Insights into the role of medium alkalinity and seed induction

MFI-topology nanosheets with a b-axis-oriented structure are valuable catalysts in diffusion-controlled acid-catalyzed reactions. Therefore, b-axis-oriented ZSM-5 nanosheets were synthesized herein in a fluoride-free solution without using special additives and complex methods. The initial gel pH of mixed raw materials was adjusted to approximately 5–7 (weak acidity) to direct nanosheet structure formation. The target ZSM-5 zeolite with a b-axis-oriented structure was achieved through the synergistic effect between the involved gel pH and seed solution. The seed solution directed the formation of an MFI structure, and the low alkalinity of the gel limited crystal growth in the b plane, thereby affording b-axis-oriented thin sheets. The ratio of the lengths of the c and b axes of the obtained ZSM-5 could be effectively tuned by adjusting the pH of the initial gel. Compared with the nanosized hexagonal ZSM-5 sample synthesized in a strong-basic system, the as-synthesized b-axis-oriented ZSM-5 exhibited a lower coking rate and higher propylene yield during the considered 1-hexene cracking reaction.

Promising transition metal molybdate (TMM) single phase microstructures for asymmetric supercapacitor and photocatalytic applications

The increasing impact of worldwide energy challenges has sparked significant interest in developing multifunctional nanomaterials for energy and environmental applications. Among semiconductor photocatalysts, stable mixed metal molybdate materials have garnered much interest regarding energy storage and photocatalytic dye degradation. In this context, we have synthesized three different single-phase metal molybdates (NiMoO4, MnMoO4, and Fe2(MoO4)3) using the gel matrix method. XRD and Raman were executed to confirm phase formation of the acquired materials. Difference in surface morphology of synthesized transition metal molybdate powders was examined using SEM analysis. The energy-storing properties of synthesized transition metal molybdate powders were analyzed and compared using three and two electrode method. At a 1 Ag-1 current density, the as-synthesized NiMoO4, MnMoO4, and Fe2(MoO4)3 nanostructures exhibit specific capacitances of about 424.6, 325.5 and 157.8 Fg-1, respectively. Furthermore, the fabricated ASC device with NiMoO4 shows 41.6 Whkg-1 and 750 Wkg-1 as maximum energy and power density at 1 Ag-1, respectively. Meanwhile, photocatalytic methylene blue degradation was carried out using the as-synthesized materials as photocatalysts. The Fe2(MoO4)3 effectively decolourizes the dye with a maximum efficiency of 82.7 %, when compared to other two metal molybdate powders. Thus, the results show that the synthesized metal molybdates such as NiMoO4, and Fe2(MoO4)3 can act as potent electrode materials and efficient photocatalysts for energy storage and dye degradation applications when compared to MnMoO4.

Esh-Shaheinab: The archetype of the Sudanese Neolithic, its premises and sequels.

Esh-Shaheinab is a landmark in the African Neolithic. This site gave the name Shaheinab Neolithic to the Neolithic period in central Sudan, becoming its archetype. Excavated in the late 1940s by A.J. Arkell, it bears witness to the processes of domestic animal introduction from the Middle East into North and East Africa. Its excavation also uncovered the remains of an earlier Mesolithic or Early Khartoum (ca. ninth-sixth millennia BC) and a Late Neolithic occupation (ca. fourth millennium BC), providing essential insights into the Neolithic's premises and sequels. Although the influence of Esh-Shaheinab has been recognized for more than seventy years, our knowledge of its material culture has remained as it was then. In 2001, one of the present authors (EAAG) had permission to restudy the ceramic collection at the National Museum in Khartoum and subsequently export samples for laboratory analyses. Here, for the first time, we provide a multi-scale analysis of the Esh-Shaheinab ceramic material from the Early Khartoum to the Late Neolithic periods by integrating the chaîne opératoire approach into the local landscape. By combining the results of macroscopic and microscopic analyses, we performed petrographic investigations on the composition and manufacturing technology of the ceramic pastes using polarized optical microscopy (POM) and scanning electron microscopy (SEM-EDS). Organic residue analysis (ORA) was also carried out, to provide information on diet, vessel use, and subsistence practices. The results of our combined analyses showed that the inhabitants of Esh-Shaheinab developed an adaptation specific to the ecological niche they inhabited. They lived in the western valley of the Nile, which was narrower and offered different environmental conditions than the eastern bank. This resulted in partial continuity in manufacturing traditions and ceramic recipes, including more mixed wadi materials and a strong emphasis on wild meat consumption as the narrower alluvial plain restricted animal herding.

Pulsar-wind nebulae meeting the circumstellar media of their progenitors

A significative fraction of high-mass stars sail away through the interstellar medium of the galaxies. Once they evolved and died via a core-collapse supernova, a magnetised, rotating neutron star (a pulsar) is usually left over. The immediate surroundings of the pulsar is the pulsar wind, which forms a nebula whose morphology is shaped by the supernova ejecta and channelled into the circumstellar medium of the progenitor star in the pre-supernova time. Irregular pulsar-wind nebulae display a large variety of radio appearances, screened by their interacting supernova blast wave, or harbour asymmetric up–down emission. Here, we present a series of 2.5-dimensional (2 dimensions for the scalar quantities plus a toroidal component for the vectors) black non-relativistic magneto-hydrodynamical simulations exploring the evolution of the pulsar-wind nebulae generated by a red supergiant and a Wolf-Rayet massive supernova progenitor, moving with Mach number $M=1$ and $M=2$ into the warm phase of the Galactic plane. black In such a simplified approach, the progenitor's direction of motion, the local ambient medium magnetic field, and the progenitor and pulsar axis of rotation, are all aligned; this restricted our study to peculiar pulsar-wind nebula of high-equatorial-energy flux. We find that the reverberation of the termination shock of the pulsar-wind nebulae, when sufficiently embedded into its dead stellar surroundings and interacting with the supernova ejecta, is asymmetric and differs greatly as a function of the past circumstellar evolution of its progenitor, which reflects into their projected radio synchrotron emission. This mechanism is particularly at work in the context of remnants involving slowly moving or very massive stars. We find that the mixing of material in plerionic core-collapse supernova remnants is strongly affected by the asymmetric reverberation in their pulsar-wind nebulae.

Mechanical performance of dissimilar Al6082 aluminum and AZ91 magnesium alloy joints produced by friction stir welding

Abstract The current research work aims to produce a defect free joint of Al6082 aluminum and AZ91 magnesium alloy sheets by friction stir welding (FSW) at various tool rotational and travel speeds with an objective to obtain the best combination of welding parameters to produce quality joint. The weld joint that was produced at the combination of 1400 rpm tool rotational speed and 30 mm min−1 feed exhibited defect free stir zone. Microstructural studies carried out in the weld joint demonstrated mechanical mixing of base materials from both the alloys in the stir zone. The mixing of Al6082 and AZ91 alloys was clearly appeared in the weld zone. It can be observed that the x-ray diffraction studies clearly demonstrated the development of intermetallics in the weld region. Higher hardness was observed for the joints that can be ascertained to the presence of more mixed regions in the stir zone that contains hard and brittle intermetallics. From the tensile test data, lower strength (175.71 ± 4.24 MPa) was observed for the weld joint compared with Al6082 (242. 6 ± 11.4 MPa) and AZ91 (205.27 ± 6.39 MPa) base materials. Furthermore, the ductility of the weld joint was measured as marginally higher than the AZ91 Mg alloy and lower than the Al6082 alloy. It can be concluded that the defect free weld joints of Al6082-AZ91 alloys can be successfully produced by FSW for structural applications targeted for dry environment.

Exploring the Impact of Ni Doping in Tuning the Bandgap, Electronic, Optoelectronic and Photocatalytic Properties of ZnFe2O4

AbstractThe exploration of semiconductor nanostructures utilizing mixed metal materials is an emerging area of study across fields including field‐effect transistors, chemical sensors, photodetectors, photocatalysts, and many more. In this study, Schottky diodes based on ZnFe2O4 (ZFO) were constructed with an aim to tune their electronic and optoelectronic characteristics. Here, Ni doping facilitated the tuning of electronic properties, leading to a significant increase in the rectification ratio from 238 to 1172, along with a reduction in the potential barrier height from 0.67 V to 0.65 V. This is attributed to Ni's role as a charge carrier in ZFO, enhancing carrier concentration, confirmed by Mott‐Schottky analysis. The 5 mol % Ni‐doped ZFO also exhibited remarkable light sensitivity, with its rectification ratio surging to 1795 under illumination, four times that of the undoped version. Additionally, its photo‐sensitivity soared to 42.46 %, nearly quadrupling the undoped device's performance, and its power gain impressively climbed to 38.4 %, which is over twelvefold the undoped sample's output. Furthermore, the diode responds strongly to optical illumination, making this structure suitable for use as a photodiode or photosensor. Apart from that by employing a doping strategy, we achieved 64.61 % degradation of methylene blue dye under visible light in 120 minutes, compared to 36.85 % for the undoped sample. These indicate that hydrothermally synthesized Ni‐doped ZFO is promising for visible light‐driven multifunctional applications.

Real-time data sensing and digital twin model development for pavement material mixing: enhancing workability and optimisation

ABSTRACT An essential aspect of pavement construction sustainability is its low-energy consumption and emissions. The study of pavement materials workability tests holds significant importance in terms of achieving well-mixed conditions with low-energy consumption. The complex components of the material and the uncertain kinematic behaviours of aggregates during mixing make this process challenging. And, few studies of the signal response of pavement materials have been found in the field of civil engineering. For this purpose, an accurate evaluation and monitoring approach for mixing are needed. In this paper, a wireless real-time sensing method is used to monitor the dynamic behaviour of aggregates during mixing. A 3D digital twin model, combining data-sensing techniques and numerical simulation, has been proposed for rapid identification of the mixing material. This model has been validated via a data-fusion algorithm. The application of this model makes a contribution to the data-intensive analysing jobs and decision-making tasks in pavement construction engineering.

Multi-material bronze-steel plain bearings produced by laser-directed energy deposition

PurposeThis study aims to manufacture bimetallic bearings by achieving a sound deposition of bronze. Indeed, systems with rotating components use parts that reduce friction by allowing them to rotate freely. This is typically achieved with either rolling bearings or plain bearings. The last ones are usually made of self-lubricating materials, which may not excel in mechanical properties. An interesting alternative lies in bimetallic brass bearings, like bronze-steel combinations. However, they are limited in terms of available shapes and sizes due to challenges associated with the conventional manufacturing process.Design/methodology/approachThis study addresses the problems of mechanical weakness and production limitations of conventional brass bearings by introducing the use of Hybrid Manufacturing techniques: Laser Directed Energy Deposition technology in combination with five-axis milling. Specifically, Cu89Sn11 was deposited on a C45 substrate by varying the number of layers, and based on the results obtained, two kinds of bimetallic bearings were produced.FindingsThe results of the one, two and five-layers samples indicate a sound deposition of Cu89Sn11, without defects such as detachments, cracks or porosities. The microhardness profile shows a decreasing trend from the substrate to the deposition zones. Bending and adhesion tests confirmed the excellent material bonding. Five-layers of Bronze were deposited on a C45 substrate to fabricate hemispherical and flat-face bearings.Originality/valueThis study validates the feasibility of expanding the new class of 3D-printed high-performance materials, highlighting the advantages of additive manufacturing technologies, such as the design and material mixing freedom, by manufacturing two kinds of bimetallic bearings.