Grain Size Reduction Research Articles

Microstructure control and mechanical properties of ultra-nanocrystalline diamond films

Ultra-nanocrystalline diamond (UNCD) films exhibit excellent mechanical properties because of their unique structure, such as small grain size and high grain boundary ratio. The effect of nitrogen atoms in nitrogen-doped UNCD films on their structure and mechanical properties deserves in-depth study. In this study, we focus on the microstructure control of UNCD films and its effect on the mechanical properties. Ultra-nanocrystalline diamond films were prepared using microwave plasma chemical vapor deposition under varying nitrogen flow rates. It was observed that the hardness and elastic modulus of UNCD films initially increased and then decreased with the increase of nitrogen flow rate. The structure of UNCD films was characterized using transmission electron microscopy and the crystal quality was analyzed through Raman spectroscopy. Nitrogen-interstitial atom defects were identified in the photoluminescence spectra. These defects contribute to shorter interatomic bonds and enhance the covalent bonds in the crystalline structure, resulting in an increase in hardness. The sp2/sp3 ratio and effective nitrogen atom concentration in the UNCD film were analyzed by X-ray photoelectron spectroscopy. The results indicate that an increase in the effective nitrogen atom concentration corresponds with a notable reduction in grain size, which is simultaneously accompanied by a rise in the number of grain boundaries. Meanwhile, the increase of sp2 content in the UNCD leads to the increase of grain boundary width and density, resulting in the increase of hardness and elastic modulus. This work provides theoretical basis and experimental guidance for the development of high performance UNCD films through precisely regulating the microstructure.

Reproducing wrought grain structure in additive IN718 through nanosecond laser induced cavitation

Pulsed laser assisted additive manufacturing has been demonstrated as a promising technology for controlling grain structure in 3D-printing processes. The integration of a nanosecond laser onto a wire arc additive manufacturing tool has enabled the localized printing of Inconel 718 with grain sizes meeting ASTM 9 standards (average measured grain size of 13.7μm) for wrought material within a single bead under solidification conditions that would otherwise produce 340μm columnar grains. The observed grain refinement holds promise, provided scale up is possible, for overcoming the highly anisotropic mechanical properties and microcracking associated with large columnar grains of Inconel 718 that have long stood in the way of leveraging the advantages of direct energy deposition printing techniques of difficult to machine alloys. Experiments on large bead sizes allowed for decoupling surface versus bulk nanosecond laser/liquid metal interaction mechanisms to determine that the source of the observed grain refinement is the collapse of cavitation bubbles originating from acoustic waves generated by momentum transfer into the melt of an ablation plasma. Additionally, experiments that increased the cavitation bubble density within the mushy zone during solidification by tuning the nanosecond laser scan path went beyond the 25 times reduction in grain size to a 70 times factor of refinement with a minimum average grain diameter approaching 4μm.

On the fatigue crack growth behavior of nanocrystalline CrMnFeCoNi

The fatigue crack growth (FCG) behavior of the equimolar CrMnFeCoNi Cantor-alloy in the nanocrystalline grain size regime has been explored with special focus on the influence of specimen orientation and the effect of additional heat-treatments. For the synthesis severe plastic deformation using high-pressure torsion (HPT) was used. The results were critically discussed regarding the impact of grain size on the FCG-behavior and compared to a conventional 316L stainless steel in the nanocrystalline state: The reduction of grain size in the Cantor alloy from the micrometer to the nanometer regime invokes crack growth rates being about one order of magnitude higher paired with significantly lower threshold values. Furthermore, the sensitivity of thresholds and crack growth rates in the Paris regime on the applied load ratio in the NC material state is also profoundly reduced. This can be explained based on a diminishing contribution of crack closure effects, especially roughness induced closure. Even though the chemical composition differs distinctively, the crack growth rates and fatigue threshold values of the nanocrystalline Cantor alloy and the stainless steel are comparable with the latter being slightly lower for the CrMnFeCoNi alloy. Moreover, the extent of anisotropy is more pronounced than for 316L. Heat-treatment leading in the NC-Cantor alloy to an increasing hardness, has also an effect on the FCG-rate and depends on the specimen orientation. In addition, an unusual self-annealing behavior affecting the FCG behavior of the Cantor alloy was found.

High temperature deformation behaviour and recrystallization mechanism of TiC/Ti6Al4V gradient material fabricated by laser directed energy deposition

Metal-ceramic gradient materials are of considerable interest due to their unique capability to integrate the ductility of metals with the mechanical strength and high-temperature resistance of ceramics, thereby reducing the risk of cracking induced by thermal stress. In this article, TiC/Ti6Al4V gradient materials were prepared through the laser directed energy deposition (LDED) process. Subsequently, high-temperature compression tests were performed at various temperatures to investigate the deformation behaviour and recrystallization mechanism of the gradient materials. The Zener-Holomon constitutive equation was then used to calculate the gradient material at 750–900 °C and 0.001–0.1 s−1 to obtain a deformation activation energy of 362.36 KJ·mol−1. The EBSD was used to analyze the microstructural evolution of the gradient material. The results indicate a significant reduction in the average grain size of the specimens after high-temperature compression, and a more random crystal orientation due to the occurrence of dynamic recrystallisation (DRX). The primary softening mechanism of TiC/Ti6Al4V gradient materials is discontinuous dynamic recrystallisation, with TiC primarily affecting the nucleation of discontinuous dynamic recrystallisation (DDRX) and the subsequent grain growth. The nucleation becomes easier with increasing TiC content. However, the TiC hinders the migration of grain boundaries, resulting in a smaller DDRX grain size. After high-temperature compression, the main slip system of the crystal is converted from Pri to Bas. Pyr is difficult to activate due to its high critical resolved shear stress.

Ultrafine Grain 316L Stainless Steel Manufactured by Ball Milling and Spark Plasma Sintering: Consequences on the Corrosion Resistance in Chloride Media

This paper reports experimental results concerning the corrosion of 316L austenitic stainless steels produced by ball milling and spark plasma sintering in NaCl electrolyte. Specimens with grain sizes ranging from 0.3 µm to 3 µm, without crystallographic texture, were obtained and compared with a cast that is 110 µm in grain size and an annealed reference. The potentiodynamic experiments showed that the reduction in grain size leads to a degradation of the electrochemical passivation behavior. This detrimental effect can be overcome by appropriate passivation in a HNO3 concentrated solution before consolidation. The Mott–Schottky measurements showed that the semiconducting properties of the passive layer do not vary significantly on the grain size, especially the donor density, which is responsible for the chemical passivation breakdown by chloride anions. The total electrical resistance of the layer, measured by impedance spectroscopy is always lower than the one of a cast and annealed 316L, but it slightly increases with a reduction in grain size in the ultrafine grain range. This is followed by a slight increase in the thickness of the oxide layer. The effect of chloride ions is very pronounced in terms of passivation breakdown if the powder is not passivated prior to sintering. This leads to the nucleation and growth of subsurface main pits and the formation of secondary satellite pits, especially for the smallest grain sizes. Passivation of the 316L powder before sintering has been found to be an effective way to prevent this phenomenon.

Effect of CO addition on the microstructure and properties of TiN coatings grown by chemical vapor deposition

TiN coatings with 0–8 vol.% CO addition were prepared by chemical vapor deposition at 1000 °C. Pure TiOCN phase was formed with different CO additions, and no apparent local elemental segregation was found. With increasing CO content up to 6 vol.%, the dissolution of O and C increased, accompanied by a decrease in N content and a reduction in grain size. Further increasing the CO content to 8 vol.% did not result in any apparent changes in the amount of O/C dissolution and coating grain size. The intensity of [111] orientation was the highest with 2 vol.% CO addition. The adhesion strength decreased as the CO addition increased, while the hardness first significantly increased with 2 vol.% CO addition, and then remained nearly constant with further increasing CO addition up to 8 vol.%. As the CO content increased to 8 vol.%, the insert continuous cutting life of machining QT500 spheroidal graphite cast iron exhibited a trend similar to that of the hardness.

Unveiling microstructure effect on nanoscratch behavior of gold-platinum alloys

The microstructural effect on the mechanical behaviors of gold-platinum alloys during nanoscratch is revealed. By adjusting the microstructures (crystallographic orientation, interface type, grain size, twinning thickness), the hardness, plasticity, removal rate and surface roughness of the alloys are significantly improved. The nanoscratch is performed by molecular dynamics (MD). For the single-crystal (SC) alloys, the [11¯0](111)-oriented SC alloy shows the high hardness, wear resistance and low roughness. The high dislocation density induces the strong work hardening while the horizontal twinning boundaries (HTBs) effectively improve the surface quality by hindering the elastic recovery. For the bi-crystal (BC) alloys, the BC alloy with TB exhibits the excellent plasticity and low roughness. TB can uniformly limit the dislocation slip and promote the dislocation nucleation to strengthen the plasticity and surface quality. For the polycrystal (PC) and nanotwinned-polycrystal (NTPC) alloys, the alloys with small grain size or small twinning thickness show the high removal rate and low roughness. The reduction in grain size or twinning thickness inhibits the dislocation motion and promotes the GB or TB migration to improve the surface quality and atomic removal. These results provide an important theoretical basis for the microstructural design and nanofabrication of gold-platinum alloys with smooth surface and remarkable mechanical property, expanding the application for the bimetallic materials.

Evolution of microstructure, texture and formability of Al–Mg–Si alloys at different hot rolling finish temperatures

The impact of hot rolling finish temperature (HRFT) on the evolution of microstructure, texture, as well as formability—including deep drawability and bendability—of Al–Mg–Si alloy was studied in present work. The obtained results reveal that HRFT has a notable influence on the dynamic softening and dynamic precipitation behaviors during the hot rolling process of the investigated alloy. This leads to the volume fraction and number density of micro-sized Mg2Si particles increase as the increase of HRFT, those of nano-sized particles decrease, and the dislocation density decrease, in the hot-rolled sheets. These microstructural variations persist in the cold-rolled sheets, subsequently affecting the ultimate microstructure, texture, as well as formability of T4P sheets. The deep drawability improves as the HRFT rises, as indicated by the increase in normal anisotropy (r‾) and decrease in planar anisotropy (Δr). This is attributed to the weakening of texture intensity. The bendability, quantified by the minimum hemming factor (Rmin/t), deteriorates as the HRFT rises from 260 °C to 390 °C, attributed to the strengthening of P component along with the weakening of Cube component. Conversely, with the HRFT rises from 390 °C to 420 °C, the bendability improves dramatically due to the significant reduction in the average grain size. A combination of excellent deep drawability and bendability could be obtained by elevating the HRFT to 420 °C, attributed to the combined effect of weakened texture intensity and fine grains.

Influence of Y2O3 Doping on Phase Evolution and Dielectric Characteristics of ZrO2 Ceramics.

Improvements in phase stability and dielectric characteristics can broaden the applications of zirconia in ceramics. Herein, a series of Y2O3-stabilized zirconia (YSZ) ceramics are synthesized using solid-state sintering, followed by an investigation into their phase evolution, grain size, dielectric constant, and breaking field. As the Y2O3 content increases from 0 wt% to 4 wt%, the as-grown YSZ ceramics undergo a distinct phase transformation, transitioning from monoclinic to monoclinic + tetragonal and further to monoclinic + tetragonal + cubic, before finally returning to monoclinic + cubic. Significant changes occur in the internal microstructure and grain size of the ceramics as the phase composition alters, resulting in a reduction in grain size from 3.17 μm to 0.27 μm. Moreover, their dielectric constants exhibit an increasing trend as the Y2O3 content increases, rising from 3.92 to 13.2. Importantly, the dielectric breakdown field of these YSZ ceramics shows a similar variation to the phase evolution, ranging from 0.11 to 0.15 MV/cm. This study sheds light on the phase evolution and dielectric properties of YSZ ceramics, offering an efficient strategy for enhancing their dielectric performances.

Optimizing high-temperature energy storage in tungsten bronze-structured ceramics via high-entropy strategy and bandgap engineering

As a vital material utilized in energy storage capacitors, dielectric ceramics have widespread applications in high-power pulse devices. However, the development of dielectric ceramics with both high energy density and efficiency at high temperatures poses a significant challenge. In this study, we employ high-entropy strategy and band gap engineering to enhance the energy storage performance in tetragonal tungsten bronze-structured dielectric ceramics. The high-entropy strategy fosters cation disorder and disrupts long-range ordering, consequently regulating relaxation behavior. Simultaneously, the reduction in grain size, elevation of conductivity activation energy, and increase in band gap collectively bolster the breakdown electric strength. This cascade effect results in outstanding energy storage performance, ultimately achieving a recoverable energy density of 8.9 J cm−3 and an efficiency of 93% in Ba0.4Sr0.3Ca0.3Nb1.7Ta0.3O6 ceramics, which also exhibit superior temperature stability across a broad temperature range up to 180 °C and excellent cycling reliability up to 105. This research presents an effective method for designing tetragonal tungsten bronze dielectric ceramics with ultra-high comprehensive energy storage performance.

Study on the high resistivity and resonant frequency characteristics of Eu-doped NiZnCo ferrites

To fulfill the urgent demand for materials suitable for contemporary high-frequency applications, Eu-substituted Ni0.55Zn0.35Co0.1EuxFe2-xO4 (NZCEF, 0 ≤ x ≤ 0.10) composite ferrites were successfully synthesized by a solid-state reaction method, demonstrating characteristics apt for high-frequency functionalities. Detailed examination via SEM and EDS confirmed the compositional purity of these ferrites. Microstructural analysis indicates that the incorporation of europium results in a reduction of the average grain size in NZCEF composites, enhancing the material's densification. Measurements of resistivity and dielectric properties reveal that Eu doping affects the concentration of Fe2+ and Fe3+ ions as well as lattice defects within the ferrite, thereby leading to higher dielectric constants and resistivity (ρ, 6.51 × 108 Ω m). Magnetic analysis confirms that the substitution with Eu ions significantly increases both the coercivity and the ferromagnetic resonance frequency (fr), from 25.7 Oe and 445 MHz to 45.73 Oe and 1.22 GHz, respectively. This improvement is attributed to changes in grain size and domain wall motion. Consequently, Eu3+-substituted NZCEF ferrites exhibit superior electromagnetic properties, making them ideal candidates for advanced high-frequency material applications.

Analysing the Impact of Severe Shot Peening on the Fatigue Strength of Wire Arc Additively Manufactured Carbon Steel

The study investigates the impact of severe shot peening on the fatigue strength of wire arc additively manufactured carbon steel. Initial characterization revealed a material with prominent equiaxed grains and large grain sizes. However, the application of SSP induced a considerable reduction in grain size, particularly on the surface, consequently enhancing the surface's strength and hardness, yet leading to an inhomogeneous structure within the WAAM CS SSP part. Hardness measurements demonstrated a substantial impact on surface hardness, reaching a depth of approximately 0.4 mm, with a 64% increase observed due to SSP, elevating it from an average of 165 HV to a maximum of 270 HV near the surface. Tensile tests on WAAM CS and WAAM CS SSP displayed notable improvements in mechanical properties following SSP treatment. Yield strength increased by approximately 5%, and ultimate tensile strength rose by 2.5%, resulting in a peak tensile strength of 513 MPa. However, this enhancement was accompanied by reduced ductility, evidenced by decreased elongation from 44% in WAAM CS to 35% in WAAM CS SSP. Bending fatigue tests highlighted a significant enhancement in fatigue resistance due to SSP treatment. The fatigue limit increased by 21% from 190 MPa for WAAM CS to 230 MPa for WAAM CS SSP, indicating improved resistance in both low-cycle and high-cycle fatigue regimes. This enhancement in fatigue resistance is attributed to the heightened mechanical strength post-SSP treatment, suggesting a trade-off between increased strength and reduced ductility. The results demonstrate that SSP significantly enhances surface attributes, strength, and fatigue resistance of WAAM CS. This advancement bears implications for engineering applications where enhanced mechanical properties and fatigue resistance are vital, despite the induced trade-offs in material characteristics.

High strength and elongation of Mg-Gd-Nd-Zr alloy obtained by synergistic action of high-speed extrusion and short-time aging treatment

Magnesium–gadolinium (Mg–Gd)-based alloys have excellent high-temperature properties and the addition of two heterogeneous rare earth (RE) elements may promote the formation of secondary phase for better-strengthened properties. Herein, novel Mg-7Gd-2Nd-0.5Zr (wt%) alloys were prepared by synergistic reaction induced by high-speed extrusion (EX) and short-time aging treatment (AT). The microstructures, textures, and mechanical properties of the resulting alloys were then comprehensively studied by various analytical methods. The result reveals that the as-cast Mg-7Gd-2Nd-0.5Zr (wt%) alloy is composed of α-Mg matrix and Mg5(Gd,Nd) phase with bony and continuous networks at grain boundaries. The microstructure presents coarse deformed grains and fine recrystallized grains after high-speed EX, and formation of typical (0001)∥ ED extruded fiber texture and [1¯21¯1] RE texture is observed. The EX22 sample exhibits more Mg5(Gd,Nd) precipitated phases, fuller DRXed grains, and shorter peak aging times than the EX9 sample. After the AT at 250 °C, the proportion of deformed grains decreases due to static recrystallization, which leads to a reduction in the average grain size and weakening of the texture intensity. Therefore, combined effect of all strengthening mechanisms aids in achieving balance of high-strength and high-elongation for Mg-7Gd-2Nd-0.5Zr (wt%) alloy. The values of yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) of EX22-A sample at room temperature are found to be 292.5 MPa, 350.6 MPa, and 24.3%, respectively. Overall, this study provides relevant experimental basis and theoretical guidance for the development of high-strength Mg-RE alloys, which are useful for future consideration.

Improving the wear resistance of Ti–6Al–4V alloy through electro-pulsing combined with laser shock peening

In this study, the effects of surface treatment namely electro-pulsing followed by laser shock peening (EP-LSP) on wear resistance properties of Ti–6Al–4V alloy are investigated. It was compared with samples treated solely with laser shock peening (LSP) and electro-pulsing treatment (EP) to investigate the effects of different processes on the friction and wear properties of Ti–6Al–4V alloy. In addition, the friction coefficient, wear rate, wear morphology were also investigated. Finally, the wear mechanism was described in detail. The results demonstrated a significant reduction in grain size for the samples after EP-1-LSP treatments. Furthermore, compared with the as-received samples, the maximum hardness of EP-1, LSP and EP-1-LSP treated samples increased by 6.5%, 5.9%, and 19.6%, respectively, and the compressive residual stress on the surface increased by 2.4%, 15.0%, and 37.2%, respectively. Under the same friction conditions, the depth of wear scar of the samples after EP-1, LSP, and EP-1-LSP treatments decreased by 7.2%, 10.6%, and 18.5% than that of the as-received sample. The as-received samples mainly exhibited severe oxidative and adhesive wear, and the LSP and EP-1 treated samples showed slight adhesive and oxidative wear. The EP-1-LSP treated samples predominantly showed signs of abrasive wear.

Enhanced strength-plasticity synergy of 304 stainless steel by introducing gradient nanograined single austenite phase structure via USRP and induction annealing

The drawback of low strength of 304 stainless steel could be overcome by fabricating gradient nanostructures (GNS). However, deformation-induced martensite results in magnetic generation and plasticity degradation. In this work, a single austenitic GNS 304 stainless steel is fabricated by first creating a dual-phase GNS through the ultrasonic surface rolling process (USRP), followed by rapid induction heating. The yield strength of the single austenite GNS (520 MPa) is 1.68 times higher than that of the homogeneous coarse-grained structure (310 MP) without sacrificing plasticity (elongation of 65 %). Quantitative calculations indicate that fine grain, dislocation, twinning, and back-stress strengthening contribute to the strength increment by 30 %, 17.5 %, 23.4 %, and 29.1 %, respectively. Coarse-grained regions deform mainly through FCC-HCP-BCC martensitic transformation, whereas the subsurface layer forms stacking faults and twins due to increased stacking fault energy caused by the reduction in grain size. At the topmost layer, the stress required to activate dislocations is lower than that for twinning. Under high-stress conditions, martensite forms along the nanograin boundaries via a phase transition from FCC to BCC. Consequently, the excellent plasticity of the single austenite GNS stems from the synergistic effects of high back-stress hardening, TRIP and TWIP effect.

Controlling the columnar-to-equiaxed transition and crack propagation behavior of laser welded Al–Li alloy reinforced with TiC nanoparticles

The predominant method for improving the mechanical characteristics of aluminum-lithium (Al–Li) alloys during laser welding is by regulating the transition from columnar crystals to equiaxed crystals. The transition is facilitated through the incorporation of TiC particles, which play a crucial role in augmenting the strength and toughness of the aluminum alloy. The inclusion of TiC particles offers a new opportunity to enhance the utilization of Al–Li alloys in laser welding procedures. The main aim of this study is to control the transition from columnar to equiaxed crystal structures by creating a TiC nanoparticle-reinforced aluminum alloy filler wire. This is intended to improve the properties of laser-welded joints. The study investigates the impact of different TiC particle contents on the microstructural characteristics. The presence of TiC particles is noted to enhance the transformation of columnar crystals into equiaxed crystals in the welded joints, resulting in a refined microstructure. The augmentation of particle content results in a notable reduction in the average grain size, decreasing from 78.25 μm to 37.15 μm. This alteration shifts the directional growth preference from specific crystallographic axes to a stochastic trajectory. Significantly, when the particle content reaches 0.6 wt%, remarkable enhancements in both tensile strength and elongation are evident, resulting in an ultimate tensile strength of 318 MPa and an elongation of 4.8 %. The dispersed configuration of TiC particles plays a pivotal role in hindering the movement of dislocations, consequently increasing the energy necessary for this mechanism. Moreover, the existence of these particles at grain boundaries impedes the propagation of cracks by altering the direction of the crack path, absorbing additional energy, and consequently improving toughness. An evident pattern emerges when examining higher particle concentrations, indicating that a decrease in ultimate tensile strength is concomitant with an increase in elongation.

AlxHfTaTi (0≤x≤0.5) refractory medium entropy alloys with excellent room-temperature tensile properties

Refractory high entropy alloys are strong candidates for high-temperature structural materials, because of their high strength, excellent thermal stability and exceptional softening resistance under high-temperature. However, majority of the existing refractory high entropy alloys are seriously limited in widespread application, due to their severe brittleness at room temperature. In this study, we proposed a novel AlxHfTaTi body-centered cubic (BCC) refractory medium entropy alloy with remarkable strength-ductility combination at room temperature. Adjusting the atomic ratio of Al (from 0 to 0.5 at.%), we investigated the effect of Al on the structure-property characteristics of the alloy under as-cast as well as cold-rolled and annealed conditions. Compared with the as-cast samples, the rolled and annealed samples exhibit more excellent tensile properties due to the remarkable reduction of grain size resulted from recrystallization. The Al0.3HfTaTi sample annealed for 5 min exhibits outstanding comprehensive properties at room temperature, with a yield strength higher than 1000 MPa and a fracture elongation of up to 24 ± 1 %, respectively. Quasi in-situ EBSD analysis results reveal that, during tensile deformation, the grain size has a significant effect on the grain rotation and dislocation gliding. Small grains are more likely to initiate multiple slip bands, promoting the synergistic effect of grain rotation and dislocation gliding, thereby improving the ductility of the alloy. Our findings can provide new ideas for the development of refractory high entropy alloys with outstanding room-temperature tensile properties.

Unveiling the role of ZrO2 doping in Sr2SmTi2Nb3O15 ceramics: From structural study to dielectric enhancement

Solid-state processing was used to synthesize tungsten bronze type (TTB) solid solutions, specifically Sr2Sm(Ti1-xZrx)2Nb3O15 with x values of 0, 0.2, 0.3, and 0.4. The study examined the crystalline structure, optical properties, morphology, and electrical and dielectric characteristics of these compounds. X-ray diffraction revealed a tetragonal structure (space group P4bm). Scanning electron microscopy showed significant sample densification with grain sizes decreasing from 6.19 μm to 2.78 μm. Dielectric measurements indicated that the dielectric constant varied from 150 for x = 0 to 567.24 for x = 0.2, then decreased to 380.88 for x = 0.4, with the x = 0.3 compound having the lowest dielectric loss. The Curie temperature (Tc) decreased from 332 °C to 248.5 °C with increasing Zr content, corresponding with a reduction in grain size. The energy gap (Eg) narrowed from 2.914 eV to 2.714 eV as Zr content increased. AC conductivity increased with temperature and frequency. Electrical conductivity followed Jonscher's power law, with activation energies decreasing from 1.54 eV to 0.87 eV, explained by the small polaron tunneling (NSPT) model.

Effects of Al2O3 micro/nanoparticles on the microstructure and corrosion behavior of W–Ni–Fe matrix through spark plasma sintering process

The purpose of this research is to examine the effect of Al2O3 micro/nanoparticles on the properties of the W–Ni–Fe matrix. The study involved analyzing the microstructure, hardness, density, and corrosion behavior of the W-4.9Ni-2.1Fe matrix with varying percentages of Al2O3 micro/nanoparticles (0.5, 1, and 1.5 wt%) that were sintered using the spark plasma method. The corrosion properties of different composites were studied using electrochemical impedance spectroscopy, Tafel polarization, and weight loss measurements. Furthermore, microstructural evaluations were carried out on samples before and after corrosion tests using optical and field emission scanning electron microscopy. The results indicated that a 1% increase in the percentage of Al2O3 nanoparticles led to approximately a 16% increase in the matrix hardness. This increase was attributed to the reduction in grain size and the distribution of pores in the nanocomposites. Tafel polarization measurements also showed that adding 1% Al2O3 nanoparticles resulted in an 83% improvement in the corrosion resistance of the W–Ni–Fe matrix in a 3.5 wt% NaCl solution. The improved corrosion resistance of the fabricated nanocomposites was attributed to the uniform distribution of Al2O3 nanoparticles in the matrix and reduction in the cathodic region. However, it was found that the formation of galvanic microcells was a critical cause of corrosion in micro-composites, leading to a reduction in corrosion resistance compared to the W–Ni–Fe matrix. Raman spectroscopy patterns indicated that Fe3O4, Fe(OH)2, NiO, and Ni(OH)2 were the main corrosion products.

Cryogenic and conventional milling of AZ91 magnesium alloy

Use of magnesium is the need of the hour due to its low density as well as its high strength-to-weight and stiffness-to-weight ratio etc. This study focuses on the effectiveness of liquid nitrogen (LN2) assisted cryogenic machining on the surface integrity (SI) characteristics of AZ91 magnesium alloy. Face milling using uncoated carbide inserts have been performed under liquid nitrogen (LN2) assisted cryogenic condition and compared with conventional (dry) milling. Experiments are performed using machining parameters in terms of cutting speeds of 325, 475, 625 m/min, feed rates of 0.05, 0.1, 0.15 mm/teeth and depth of cuts of 0.5, 1, 1.5 mm respectively. Most significant surface integrity characteristics such as surface roughness, microhardness, microstructure, and residual stresses have been investigated. Behaviour of SI characteristics with respect to milling parameters have been identified using statistical technique such as ANOVA and signal-to-noise (S/N) ratio plots. Additionally, the multi criteria decision making (MCDM) techniques such as additive ratio assessment method (ARAS) and complex proportional assessment (COPRAS) have been utilized to identify the optimal conditions for milling AZ91 magnesium alloy under both dry and cryogenic conditions. Use of LN2 during machining, resulted in reduction in machining temperature by upto 29% with a temperature drop from 251.2 °C under dry condition to 178.5 °C in cryogenic condition. Results showed the advantage of performing cryogenic milling in improving the surface integrity to a significant extent. Cryogenic machining considerably minimized the roughness by upto 28% and maximised the microhardness by upto 23%, when compared to dry machining. Cutting speed has caused significant impact on surface roughness (95.33% – dry, 92.92% – cryogenic) and surface microhardness (80.33% – dry, 82.15% – cryogenic). Due to the reduction in machining temperature, cryogenic condition resulted in compressive residual stresses (maximum σ║ = -113 MPa) on the alloy surface. Results indicate no harm to alloy microstructure in both conditions, with no alterations to grain integrity and minimal reduction in the average grain sizes in the near machined area, when compared to before machined (base material) surface. The MCDM approach namely ARAS and COPRAS resulted in identical results, with the optimal condition being cutting speed of 625 m/min, a feed rate of 0.05 mm/teeth, and a depth of cut of 0.5 mm for both dry and cryogenic environments.