Role of Iron-Rich Phases and Porosity on the Ductility of Rheocast Al-Mg-Si-Alloys

Treatment of the slurry is important during RheoMetalTM casting. In this work, semi-solid slurries were prepared under different stirring intensities, using two types of stirrers: a naked rod (for regular stirring) and a rod with two blades (for intensified stir). Tensile tests were performed, investigating fracture surfaces, as well as metallographic samples. The results show that intensified stir produces castings with finer primary particles and a more homogeneous microstructure. On the other hand, more faceted Fe-rich phases are found along the α-Al grains boundary as well, due to the dissolution of Fe from the stirrers. Moreover, for intensified stir castings, the porosity found on the fracture surfaces are smaller, while more brittle eutectic phases and second (intermetallic) phases, especially Fe-rich phases, are observed. Consequently, the castings with intensified stir show worse ductility. Finally, a quantitative analysis was made regarding ductility, affected both by porosity and the presence of Fe-rich phases.

Structure and microstructure behavior of iron doped potassium sodium niobate powders

In this paper, the synthesis and characterization of the potassium sodium niobate doped with iron powders have been studied. Solid-state oxide reaction sintering was used. The powders produced in this work exhibit no homogeneous microstructure, which introduced the growth of random cylindrical structures and will can contribute to the increased porosity ceramics. It was observed average particle size of 3μm, besides, also it was observed the formation of agglomerations and an increase in the size of these clusters with the increase in the amount of iron. The calcination temperature was 950 °C. This is slightly higher than other potassium sodium niobate powders systems. In addition to the physical and microstructural properties, structural properties are presented and analyzed for the first-time using Mössbauer spectroscopy as complementary technique in Fe 3+doped potassium sodium niobate powders. This work is important to state solid physics because establishes the influence of iron in the potassium sodium niobate system, and so the future obtaining of multifunctional materials that have piezoelectric and magnetic properties.

Mine Clay Washing Residues as a Source for Alkali-Activated Binders

The aim of this paper is to promote the use of mine clay washing residues for the preparation of alkali activated materials (AAMs). In particular, the influence of the calcination temperature of the clayey by-product on the geopolymerization process was investigated in terms of chemical stability and durability in water. The halloysitic clay, a mining by-product, has been used after calcination and mixed with an alkaline solution to form alkali activated binders. Attention was focused on the influence of the clay’s calcination treatment (450–500–600 °C) on the geopolymers’ microstructure of samples, remaining in the lower limit indicated by the literature for kaolinite or illite calcination. The mixtures of clay and alkali activators (NaOH 8M and Na-silicate) were cured at room temperature for 28 days. The influence of solid to liquid ratio in the mix formulation was also tested in terms of chemical stability measuring the pH and the ionic conductivity of the eluate after 24-h immersion time in water. The results reported values of ionic conductivity higher for samples made with untreated clay or with low temperature of calcination (≥756 mS/m) compared with values of samples made with calcined clay (292 mS/m). This result suggests that without a proper calcination of the as-received clay it was not possible to obtain 25 °C-consolidated AAMs with good chemical stability and dense microstructure. The measures of integrity test, pH, and ionic conductivity in water confirmed that the best sample is made with calcined clay at 600 °C, being similar (53% higher ionic conductivity of the eluate) or equal (integrity test and pH) to values recorded for the metakaolin-based geopolymer considered the reference material. These results were reflected in term of reticulation and morphology of samples through the analysis with scanning electron microscope (SEM) and X-ray diffraction (XRD), which show a dense and homogeneous microstructure predominantly amorphous with minor amounts of quartz, halloysite, and illite crystalline phases. Special attention was dedicated to this by-product to promote its use, given that kaolinite (and metakaolin), as primary mineral product, has a strong impact on the environment. The results obtained led us to consider this halloysite clay very interesting as an aluminosilicate precursor, and extensively deepening its properties and reactivity for the alkaline activation. In fact, the heart of this work is to study the possibility of reusing this by-product of an industrial process to obtain more sustainable high-performance binders.

Multi-directional Forging of Large-Scale Mg-9Gd-3Y-2Zn-0.5Zr Alloy Guided By 3D Processing Maps And Finite Element Analysis

The three-dimensional (3D) processing maps of cast Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr alloy were established based on isothermal compression tests and dynamic material model (DMM). The stable and power efficient forming domains were determined by considering both the instability and power dissipation efficiency maps. Multi-directional forging (MDF) was then simulated by employing finite element (FE) analysis in the Deform-3D software, using the 3D power dissipation efficiency maps as input. The optimal forging parameters were thus obtained for a large-scale ingot with 430 mm in diameter and 440 mm in height, i.e. a forging temperature of 450 ℃ and forging speed of 10 mm/s. Finally, a Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr cake-shaped forged part with 900 mm in diameter and 100 mm in height was produced. After T6-heat treatment, the edge and center of the forged part exhibit homogeneous microstructure and relatively consistent properties, with the tensile strength, yield strength and elongation being about 400 MPa, 320 MPa and 14.0% respectively. Using transmission electron microscopy, the main strengthening phases were revealed to be the dense nano-scale β' phases that are uniformly distributed inside the material.

Study on the Properties of Coated Cutters on Functionally Graded WC-Co/Ni-Zr Substrates with FCC Phase Enriched Surfaces

Currently, the research on mechanical behavior and cutting performance of functionally graded carbides is quite limited, which limits the rapid development of high-performance cemented carbide cutting tools. Based on WC-Co-Zr and WC-Ni-Zr, this study synthesized two kinds of cemented carbide cutters, i.e., the cemented carbide cutters with homogeneous microstructure and functionally graded carbide (FGC) cutters with FCC phase ZrN-enriched surfaces. Furthermore, TiAlN coating has been investigated on these carbide cutters. Mechanical behavior, friction, wear performance, and cutting behavior have been investigated for these coated carbides and their corresponding substrates. It was found that, as compared with coated cutters on WC-Co/Ni-Zr carbide substrates with homogeneous microstructures, the coated cutters on WC-Co/Ni-Zr FGC substrates with FCC phase-enriched surfaces show higher wear resistance and cutting life, and the wear mechanism during cutting is mainly adhesion wear.

Preparation and Evaluation of Cu-Zn-GNSs Nanocomposite Manufactured by Powder Metallurgy

Room-temperature ball milling technique has been successfully employed to fabricate copper-zinc graphene nanocomposite by high-energy ball milling of elemental Cu, Zn, and graphene. Copper powder reinforced with 1-wt.% nanographene sheets were mechanically milled with 5, 10, 15, and 20 wt.% Zn powder. The ball-to-powder weight ratio was selected to be 10:1 with a 400-rpm milling speed. Hexane and methanol were used as a process control agent (PCA) during composite fabrication. The effect of PCA on the composite microstructure was studied. The obtained composites were compacted by a uniaxial press under 700 MPa. The compacted samples were sintered under a controlled atmosphere at 1023 K for 90 min. The microstructure, mechanical, and tribological properties of the prepared Cu-Zn GrNSs nanocomposites were studied. All results indicated that composites using hexane as PCA had a uniform microstructure with higher densities. The densities of sintered samples were decreased gradually by increasing the Zn percent. The obtained composite contained 10 wt.% Zn had a more homogeneous microstructure, low porosity, higher Vickers hardness, and compression strength, while the composite contained 15 wt.% Zn recorded the lowest wear rate. Both the electrical and thermal conductivities were decreased gradually by increasing the Zn content.

The effect of decarburization on the fatigue life of overhead line hardware

Altering the microstructure in order to improve the tensile properties of bow shackles resulted in inconsistency in the fatigue performance. This raises the question whether the inconsistency in fatigue life can be attributed to microstructural changes along the profile of the shackle or to decarburization at the surface. Bow shackles forged from 080M40 (EN8) material were subjected to different heat treatments in order to alter the microstructure. The shackles were subjected to five different fatigue load cases, which represented typical loads experienced at termination points for an overhead power line with a span length of 400 m, with changes in conductor type, configuration, wind, and ice loading. Although the change in microstructure does improve both the tensile and fatigue performance, we found that the depth of the decarburization layer has a greater effect on the high cycle fatigue life of bow shackles than the non-homogeneous microstructure.

Extrusion and Injection Molding of Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx): Influence of Processing Conditions on Mechanical Properties and Microstructure

Biobased and biodegradable polyhydroxyalkanoates (PHAs) have great potential as sustainable packaging materials. However, improvements in their processing and mechanical properties are necessary. In this work, the influence of melt processing conditions on the mechanical properties and microstructure of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) is examined using a full factorial design of experiments (DoE) approach. We have found that strict control over processing temperature, mold temperature, screw speed, and cooling time leads to highly increased elongation at break values, mainly under influence of higher mold temperatures at 80 °C. Increased elongation of the moldings is attributed to relaxation and decreased orientation of the polymer chains together with a homogeneous microstructure at slower cooling rates. Based on the statistically substantiated models to determine the optimal processing conditions and their effects on microstructure variation and mechanical properties of PHBHHx samples, we conclude that optimizing the processing of this biopolymer can improve the applicability of the material and extend its scope in the realm of flexible packaging applications.

The Effect of PVA Binder Solvent Composition on the Microstructure and Electrical Properties of 0.98BaTiO3-0.02(Ba0.5Ca0.5)SiO3 Doped with Dy2O3

In this study, the effect of the polyvinyl alcohol (PVA) binder solvent composition on the electrical properties of sintered 0.98BaTiO3-0.02(Ba0.5Ca0.5)SiO3 ceramics doped with x wt.% Dy2O3 (0.0 ≤ x ≤ 0.3) was investigated. In the absence of the PVA binder, the specimens sintered at 1260 and 1320 °C for 1 h in a reducing atmosphere showed a single BaTiO3 phase with the perovskite structure. The relative densities of the specimens were higher than 90%, and the grain morphologies were uniform for all the solvent compositions. At 1 kHz, the dielectric constant of the specimens depended not only on their crystal structural characteristics, but also on their microstructural characteristics. The microstructural characteristics of the specimens with the PVA binder were affected by the ethyl alcohol:water ratio of the 10 wt.% PVA-111 solution. A homogeneous microstructure was observed for the 0.1 wt.% Dy2O3-doped specimens sintered at 1320 °C for 1 h when the ethyl alcohol/water ratio of the binder solution was 40/60. These specimens showed the maximum dielectric constant (εr = 2723.3) and an insulation resistance of 270 GΩ. The relationships between the microstructural characteristics and dissipation factor (tanδ) of the specimens were also investigated.

Characteristics of Dough Rheology and the Structural, Mechanical, and Sensory Properties of Sponge Cakes with Sweeteners

Changes in the rheological properties of dough, as well as the microstructural, mechanical, and sensory properties of sponge cakes, as a function of the substitution of sucrose in a formulation with maltitol, erythritol, and trehalose are described. Moreover, the relationship between the examined properties was investigated. The replacement of sucrose with maltitol or trehalose did not affect the consistency index, whereas erythritol caused a decrease in its value. X-ray tomography was used to obtain the 2D and 3D microstructures of sponge cakes. All studied sweeteners caused the sponge cakes to have a typical porous structure. Erythritol and maltitol resulted in about 50% of the pores being smaller than 0.019 mm2 and 50% of the pores being larger than 0.032 mm2. Trehalose resulted in a homogeneous microstructure, 98% of whose pores were similar in size (0.019 to 0.032 mm2). The sponge cakes with polyols had a higher structure index than did the trehalose and sucrose samples. There were also significant differences in color parameters (lightness and chromaticity). The crust of the sponge cake with sweeteners was lighter and had a less saturated color than the crust of the sponge cake with sucrose. The sponge cake with maltitol was the most similar to the sponge cake with sucrose, mainly due to the mechanical and sensory properties. Trehalose led to the samples having high adhesiveness, which may limit its application as a sucrose substitute in sponge cake. Sensory properties were strongly correlated to cohesiveness, adhesiveness, and springiness and did not correlate to the 2D and 3D microstructures. It was found that 100% replacement of sucrose allows for a porous structure to be obtained. These results confirm that it is not the structure, but most of all the flavor, that determines the sensory perception of the sponge cakes.