Microstructure Evolution and Mechanical Properties of AlCoCrFeNi2.1 Eutectic High-Entropy Alloys Processed by High-Pressure Torsion.

High-entropy alloys (HEAs) have garnered significant attention for their exceptional properties, with eutectic high-entropy alloys (EHEAs) emerging as particularly notable due to their incorporation of eutectic structures comprising soft and hard phases. This study investigated the influence of shear strain on the microstructural refinement and mechanical properties of AlCoCrFeNi2.1 EHEAs, which were subjected to high-pressure torsion (HPT) at room temperature under a pressure of 6 GPa across 0.5 to 3 turns, compared to the initial material. After HPT treatment, significant grain refinement occurred due to strong shear strain, evidenced by the absence of B2 phase peaks in X-ray diffraction (XRD) analysis. Microhardness increased substantially post-HPT, reaching a saturation point at approximately 575 HV after three turns, significantly higher than that of the original sample. Moreover, the ultimate tensile strength of HPT-treated specimens reached around 1900 MPa after three revolutions, compared to approximately 1100 MPa for the as-cast alloy, with a mixed fracture mode maintained. This investigation underscores the efficacy of HPT in enhancing the mechanical properties of AlCoCrFeNi2.1 EHEAs through microstructural refinement induced by shear deformation, offering insights into the design and optimization of advanced HEAs for various engineering applications.

In Situ Synthesis of Liquid Metal Conductive Fibers toward Smart Cloth.

To meet the diverse needs of humans, smart cloth has become a potential research hotspot to replace traditional cloth. However, it is challenging to manufacture a flexible fabric with multiple functions. Here, we introduce a smart cloth based on liquid metal (LM) conductive fibers. Ga2O3 nanoparticles are obtained through ultrasonic pretreatment. Furthermore, a coordination bond is formed between thiol groups on the surface of protein fibers and Ga2O3 through a scraping method, allowing Ga2O3 particles to be grafted onto the surface of protein fibers in situ. Finally, LM conductive fibers are encapsulated using a photocuring adhesive. In addition, a wearable smart cloth integrated with multiple sensors has been developed based on LM conductive fibers. Users can not only monitor their movement trajectory and the surrounding environment in real time but also have their data supervised by family members through a client, achieving remote and continuous monitoring. The development of this wearable smart cloth provides strong support for future wearable, flexible electronic devices.

Tough Gelatin Hydrogel for Tissue Engineering.

Tough hydrogel has attracted considerable interest in various fields, however, due to poor biocompatibility, nondegradation, and pronounced compositional differences from natural tissues, it is difficult to be used for tissue regeneration. Here, a gelatin-based tough hydrogel (GBTH) is proposed to fill this gap. Inspired by human exercise to improve muscle strength, the synergistic effect is utilized to generate highly functional crystalline domains for resisting crack propagation. The GBTH exhibits excellent tensile strength of 6.67 MPa (145-fold that after untreated gelation). Furthermore, it is directly sutured to a ruptured tendon of adult rabbits due to its pronounced toughness and biocompatibility, self-degradability in vivo, and similarity to natural tissue components. Ruptured tendons can compensate for mechanotransduction by GBTH and stimulate tendon differentiation to quickly return to the initial state, that is, within eight weeks. This strategy provides a new avenue for preparation of highly biocompatible tough hydrogel for tissue regeneration.

Influence of bimetal interface confinement on the Hall-petch slope of multiscale Cu/Nb multilayer composites.

Heterostructured materials afford a new way to improve the mechanical properties, which has become vital in both materials science and engineering applications. In the present research, Cu/Nb multilayer composites with layer thicknesses from the micrometer to nanometer were fabricated by accumulative roll bonding and the microstructure and mechanical properties of the Cu/Nb multilayer composites were then investigated. The yield strength and ultimate tensile strength of these composites increase with decreasing layer thickness. Moreover, the relationship between yield strength and (layer thickness)-1/2 approximately accords with the conventional Hall-Petch equation but with a decrease in the Hall-Petch slope when the layer thickness decreases from the micrometer to nanometer scales. The deformation microstructure of these Cu/Nb multilayer composites clearly exhibit dislocations glide in the layers, which reduces the stacking of dislocations at the Cu-Nb interface and thereby weakens the strengthening effect of the interface.

The Effect of Hydrogen on Plastic Anisotropy of Mg and α-Ti/Zr from First-Principles Calculations.

Mg and α-Ti/Zr exhibit high plastic anisotropy. In this study, the ideal shear strength across the basal, prismatic, pyramidal I, and pyramidal II slip systems in Mg and α-Ti/Zr with and without hydrogen was computed. The findings indicate that hydrogen reduces the ideal shear strength of Mg across the basal and pyramidal II slip systems, as well as of α-Ti/Zr across all four systems. Moreover, the activation anisotropy of these slip systems was analyzed based on the dimensionless ideal shear strength. The results suggest that hydrogen increases the activation anisotropy of these slip systems in Mg, while decreasing it in α-Ti/Zr. Furthermore, the activation possibility of these slip systems in polycrystalline Mg and α-Ti/Zr subjected to uniaxial tension was analyzed by utilizing the ideal shear strength and Schmidt's law. The results reveal that hydrogen increases the plastic anisotropy of Mg/α-Zr alloy while decreasing that of α-Ti alloy.

Effect of Pulsed Current-Assisted Tension on the Mechanical Behavior and Local Strain of Nickel-Based Superalloy Sheet.

Electrically assisted (EA) forming is a plastic forming technique under the coupling action of multiple energy fields, such as force field, temperature field, and electric field. It is suitable for the forming of difficult-to-deform materials such as nickel-based superalloys. In this paper, uniaxial tensile tests on nickel-based superalloy sheets were carried out using the pulsed current assisted with different parameters. The experimental results show that the flow stress of the material decreased with the increase in the current density under a high-frequency pulsed current, and the Joule heating effect explains the flow stress drop. In the pulsed current application process, the different types of Portevin-Le Chatelier phenomena appeared with the increase in the current density. The decrease in elongation assisted by the pulsed current was explained by analyzing the inhomogeneity of the maximum Joule heating temperature distribution. In addition, the digital image correlation (DIC) analysis was used to analyze the local strain behavior of the pulsed current-assisted tensile process. Under the application of a high-frequency pulse current, the specimen exerted an inhomogeneous temperature increase and local hot pressing stress, which resulted in the inhomogeneous distribution of the local strain.

Development of pulsed magnetic field assisted supersonic plasma spraying.

This study designs a pulsed magnetic field assisted supersonic plasma spraying (PM-SPS) device. The instrument is divided into magnetic field generation and spraying modules, and they are connected by a dual control system and professional fixture. The PM-SPS system is simple to operate and has no contact with the spraying process. In addition, it can achieve high field intensity and stable pulse frequency in a short time. It has a strengthening effect on the whole coating forming process. The porosity, roughness, hardness, and tribological properties of the coatings prepared using the PM-SPS system were improved. The reported experiments and results can be generalized to other coating applications, which require high quality surfaces.

Effects of Forging and Heat Treatment on Martensite Lath, Recrystallization and Mechanical Properties Evolution of 18Ni(250) Maraging Steel.

The manufacturing process of maraging steel parts include forging, heat treatment and other technological links, and the strengthening mechanism at different stages is different, which has an important impact on the process design of forgings. To investigate the strengthening behavior of maraging steel, forging experiments with different deformation amounts and heat treatment conditions were carried out, and the microstructural and mechanical properties evolution of 18Ni(250) steel was analyzed. The experimental results show that the size of the martensite lath is affected by multiple factors such as the influence of grain size, recrystallization and martensite substructure fraction. The strengthening mechanism of maraging steel during forging and heat treatment is different. Forging combined with heat treatment can refine grains, and the internal defects of the original material can be better eliminated. The thermal deformation can better play the role of grain refinement compared with cyclic phase transformation, which can improve the plasticity of 18Ni(250) maraging steel.

The Effects of Geometry Size and Initial Microstructure on Deformation Behavior of Electrically-Assisted Micro-Compression in Ti-6Al-4V Alloy.

In this study, electrically-assisted micro-compression (EAMC) tests were conducted for cylindrical specimens of Ti-6Al-4V alloy with four geometric sizes and three initial microstructures. The result showed that the specimen temperature nonlinearly increased with the square of current density. The quasi-static heat equilibrium equation was established to quantify the effects of the scale factor on the Joule heat temperature. Moreover, it was demonstrated that the Joule temperature scale effect had a greater effect on the flow stress than the sample size effect for specimens of different dimensions. It was noted that the 0.5 mm diameter sample displayed abnormal deformation behavior, which was related to surface oxidation leading a brittle surface layer. By comparison of the microstructures, it was found that the αâ†’ß phase transformation occured below the ß transus temperature, which was attributed to the local Joule heat effect and the scattering of drift electrons during EAMC. Furthermore, the flow curves showed a strong dependence of the strength and ductility on the initial microstructure. The widmannstatten microstructure exhibited higher strength, smaller hardening rate and more easy flow localization compared with basket-weave microstructures, which was attributed to the low ß phase content and narrow interlamellar spacing of α lamellae grains in the widmannstatten microstructure.

Effect of Multi-Pass Power Spinning on Microstructure Homogenization and Mechanical-Property Strengthening of Ti2AlNb-Based Alloy Using Welded Tube Blank.

Long seamless tubes of Ti2AlNb-based alloys are difficult to manufacture through conventional forming methods. In this study, a multi-pass power spinning process was first utilized to fabricate thin-walled tube of Ti-22Al-24Nb-0.5Mo alloy using welded thick tube blank, assisted by on-line electro-magnetic induction heating to maintain high spinning temperature during the whole spinning process. After six-pass hot power spinning at 950 ± 30 °C, the microhardness difference of BM (base metal), HAZ (heat affect zone) and FZ (fusion zone) became much smaller, and the microhardness fluctuation ΔHV dropped to 32 from 122 of the as-welded joint due to the phase composition and microstructure homogenization. The grain size of B2 phase was refined to 0.4/0.6 µm from 2.7/10.8 µm of the as-received BM/FZ, respectively. Meanwhile, the B2 phase <111>B2//ND texture of the as-received rolled sheet weakened during multi-pass spinning due to recrystallization, which co-existed with <001>B2//ND texture in final pass. The ultimate tensile strength in axial/tangential direction was increased to 1245/1299 MPa from 1206/1010 MPa of the as-received rolled sheet, respectively, mainly due to the effect of fine grain strengthening. This study provides an effective way to manufacture high-performance tubular workpieces with low cost and high efficiency.

Research on the Secondary Forgeability of High Volume Fraction Whisker Reinforced Aluminum Matrix Composites of Original Squeeze Casting.

The poor formability of high volume fraction whisker reinforced aluminum matrix composites of original squeeze casting is an important factor restricting its further development and application. Currently, there are no reports on the secondary forgeability of aluminum matrix composites of original squeeze casting, although some papers on its first forgeability are published. The secondary forgeability is very important for most metals. This study aims to investigate the secondary forgeability of aluminum matrix composites. In this study, the secondary upsetting experiments of 20 vol% SiCw + Al18B4O33w/2024Al composites, treated by the original squeeze casting and extrusion, were carried out. The first upsetting deformation is close to the forming limit, the secondary upsetting deformation under the same deformation conditions was carried out to investigate the secondary forgeability. The experimental results show that, unlike aluminum alloys, the 20 vol% SiCw + Al18B4O33w/2024Al composites at the original squeeze casting and extrusion states have no secondary forgeability due to the whisker rotating and breaking during the secondary upsetting. The high volume fraction whisker reinforced aluminum matrix composites of original squeeze casting cannot be formed by the multiple-forging method since the cavities and cracks caused by whisker fracture continue to expand during secondary processing, which leads to further extension of macroscopic cracks.

Deformation Behavior and Microstructural Evolution of T-Shape Upsetting Test in Ultrafine-Grained Pure Copper.

Ultrafine-grained (UFG) materials can effectively solve the problem of size effects and improve the mechanical properties due to its ultra-high strength. This paper is dedicated to analyzing the deformation behavior and microstructural evolution of UFG pure copper based on T-shape upsetting test. Experimental results demonstrate that: the edge radius and V-groove angle have significant effects on the rib height and aspect ratio λ during T-shape upsetting; while the surface roughness has little effect on the forming load in the first stage, but in the second stage the influence becomes significant. The dynamic recrystallization temperature of UFG pure copper is between 200 °C and 250 °C.

Bending Fatigue Behaviour and Fatigue Endurance Limit Prediction of 20Cr2Ni4A Gear Steel after the Ultrasonic Surface Rolling Process.

To study the effect of the surface properties on the bending fatigue performance of heavy-duty gear steel, the authors of this paper used the ultrasonic surface rolling process (USRP) to strengthen 20Cr2Ni4A carburized gear steel. USRP is a novel technique in which the ultrasonic technology is incorporated into the concept of conventional deep rolling. In this study, we illustrated how the surface properties and cross-section mechanical property influence the three-point bending fatigue life of the samples before and after USRP treatment. At the same time, the predicted failure probability-stress-number of cycles (P-S-N) curve was drawn, and the fatigue fracture was analysed. The results show that the fatigue limit increased from 651.36 MPa to 918.88 MPa after USRP treatment. The fatigue source is mainly from the sample interior or surface scratches, and the fatigue performance is positively correlated with the results of the material surface roughness, surface residual stress and surface hardness. At the same time, combined with the change in the phase structure, dislocation structure, residual stress and hardness of the cross section of the material, it is found that the USRP process turns the steel into a gradient material with five layers. Finally, the coupling mechanism between the ultrasonic surface strengthening deformation layer and the carburized layer of 20Cr2Ni4A carburized gear steel is presented, and the grain structure distribution diagram of the section of the 20Cr2Ni4A model after surface strengthening treatment was simulated. The mechanism that influenced the fatigue performance after USRP treatment is explained from the perspectives of the surface and cross section of the samples.

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures.

With the rapid development of micro-electromechanical systems (MEMS), micro/nanoscale fabrication of 3D metallic structures with complex structures and multifunctions is becoming more and more important due to the recent trend of product miniaturization. As a promising micromanufacturing approach based on plastic deformation, micro/nanoforming shows the attractive advantages of high productivity, low cost, near-net-shape, and excellent mechanical properties, compared with other non-silicon-based micromanufacturing technologies. However, micro/nanoforming is far less established due to the so-called size effects in terms of materials models, process laws, tooling design, etc. The understanding of basic issues on micro/nanoforming is not yet mature, and it is currently a topic of rigorous investigation. Here, a systematic review on the micro/nanoforming processes of 3D structures with multifunctional properties is presented, wherein also a critical examination of the interplay between relevant length scales and size effects affecting the structural integrity of micro/mesoscale metallic systems is also provided. Finally, the challenges of micro/nanoscale fabrication are proposed, including the development trends of new micro/nanoforming processes, multiple field coupling effects, and theoretical modeling at the trans-scale.

Investigation of Electrically-Assisted Rolling Process of Corrugated Surface Microstructure with T2 Copper Foil.

Electrically-assisted (EA) forming is a low-cost and high-efficiency method to enhance the formability of materials. In the study, EAF tensile tests are carried out to study the properties of T2 copper foil in an annealed state, and the effect of the electric current on the forming quality of corrugated foils is further studied in the EA rolling forming process. The result shows that the current reduces the flow stress and the fracture strain, which is different from the result of rolled samples. The joule heating effect on mechanical properties is significant in EA tension, and the softening effect of the surface layer can be observed at tensile strength, due to the grain size effect. Moreover, the current can weaken the grain size effect. In the rolling forming process, the influence of different electrical parameters on the forming height is remarkable, especially for the rolled T2 copper. The appropriate electrical parameters can improve the forming height, while keeping a small thickness thinning. Nevertheless, the high current density will lead to local rupture. This study proves that the current can improve the forming quality of the corrugated foils and is a promising surface texture forming process.

Bending Fatigue Behaviors Analysis and Fatigue Life Prediction of 20Cr2Ni4 Gear Steel with Different Stress Concentrations near Non-metallic Inclusions.

To investigate the relationship between inclusions and bending fatigue behaviors in 20Cr2Ni4 steel under different stress concentrations. This paper designs a new experimental method to prefabricate different size stress concentrations near the inclusions, and then conducts a new type of bending fatigue test to study the inclusions and their surrounding stress distributions in 20Cr2Ni4 steel. A microhardness tester was combined with laser etching equipment to realize the prefabrication of different stress concentrations at arbitrary positions around any inclusion on the gear steel surface. This method provides an experimental basis for the quantitative analysis of the relationship between stress distribution and fatigue life around the inclusions of heavy-duty gear steels. We also predict the bending fatigue lives of heavy-duty gear steels with different types of inclusions, stress states, and spatial distributions. Then, based on the prefabricated notch parameters and the state of inclusions in the steel, a mathematical model of quantitative analysis is proposed, which can accurately predict the fatigue limit of heavy-duty gear steel. The research results can be applied to the actual use of heavy-duty gears and to the accurate life estimation based on the state of gear stress, thereby providing a quantitative reference model for subsequent gear steel production and gear part processing.

The Fabrication of Micro-Array Channels with the Ultrafine-Grained LZ91 Mg-Li Alloy by Micro-Embossing.

The fabrication of the micro-channel array through micro-embossing on an ultrafine-grained (UFG) LZ91 Mg-Li alloy was investigated in this paper. Micro-embossing tests indicated that the depth of the channels increase with increasing temperatures. Micro-array channels with widths ranging from 50 µm to 200 µm were performed with an applied force of 2 kN at 423 K, following by a dwell time of 60 s on the UFG LZ91 Mg-Li alloy. The surface topography indicates that embossed micro-channels for UFG LZ91 Mg-Li with all widths are clearly printed well with good geometrical transferability and no obvious defects. The comparison filling behavior of UFG and the CG LZ91 Mg-Li alloy reveals that grain sizes mainly affect the filling quality of micro-embossing. The results indicate a potential application of the UFG Mg-Li alloy in the mass fabrication of micro-electro-mechanical system (MEMS) components.

Microstructural Evolution and Mechanical Properties in Superlight Mg-Li Alloy Processed by High-Pressure Torsion.

Microstructural evolution and mechanical properties of LZ91 Mg-Li alloy processed by high-pressure torsion (HPT) at an ambient temperature were researched in this paper. The microstructure analysis demonstrated that significant grain refinement was achieved after HPT processing with an average grain size reducing from 30 μm (the as-received condition) to approximately 230 nm through 10 turns. X-ray diffraction analysis revealed LZ91 alloy was consisted of α phase (hexagonal close-packed structure, hcp) and β phase (body-centered cubic structure, bcc) before and after HPT processing. The mean value of microhardness increased with the increasing number of HPT turns. This significantly increased hardness of specimens can be explained by Hall-Petch strengthening. Simultaneously, the distribution of microhardness along the specimens was different from other materials after HPT processing due to the different mechanical properties of two different phases. The mechanical properties of LZ91 alloy processed by HPT were assessed by the micro-tensile testing at 298, 373, 423, and 473 K. The results demonstrate that the ultra-fine grain LZ91 Mg-Li alloy exhibits excellent mechanical properties: tensile elongation is approximately 400% at 473 K with an initial strain rate of 1 × 10−2 s−1.

Microcrack healing in non-ferrous metal tubes through eddy current pulse treatment.

This study proposed a novel method to heal microcrack within Mg alloy tubes using high density eddy current pulse treatment (ECPT). Through electromagnetic induction inside a copper coil connected with a high density pulse power source supply, the high density (greater than 5 × 109 A/m2) and short duration eddy current was generated in tube specimens of Mg alloy. The results show that the microcracks in tube specimens was healed evidently and the mechanical properties of the tubes subjected to ECPT were improved simultaneously. The crack healing during ECPT was ascribed to not only the thermal stress around the microcrack tips and the softening or melting of metals in the vicinity of microcrack tips, but also the squeezing action acted by the Lorentz force. In the inward-discharging scheme, both the compressive radial stress and tangential stress induced by the Lorentz force contributed to more sufficient crack healing and thus better mechanical properties of tube specimens after the ECPT experiment, compared to the outward-discharging scheme. The ECPT can heal microcracks automatically without directly contacting tubular specimens and is not limited by the length of tubular workpieces, exhibiting great potential for crack healing in non-ferrous alloy tubes.

Current-Induced Ductility Enhancement of a Magnesium Alloy AZ31 in Uniaxial Micro-Tension Below 373 K.

The size effects in metal forming have been found to be crucial in micro-scale plastic deformation or micro-forming processes, which lead to attenuation of the material's formability due to the increasing heterogeneity of the plastic flow. The use of an electric field during micro-scale plastic deformation has shown to relieve size effects, enhance the material's formability, modify the microstructure, etc. Consequently, these electric-assisted (EA) micro-forming processes seem to bring many potential benefits that need to be investigated. Accordingly, here we investigated the influence of an electric field on the size effects to describe the fracture behavior in uniaxial micro-tension tests of an AZ31 alloy with various grain sizes. In order to decouple the thermal-mechanical and microstructure changes, room temperature (RT), oven-heated (OH), air-cooled (AC), and EA uniaxial micro-tension tests were conducted. The size effects contribution on the fracture stress and strain showed a similar trend in all the testing configurations. However, the smallest fracture stresses and the largest fracture strains were denoted in the EA configuration. EBSD examination shows that current-induced dynamic recrystallization (DRX) and texture evolution could be negligible under the studied conditions. The kernel average misorientation (KAM) maps give the larger plastic deformation in the EA specimens due to the reduction of plastic micro-heterogeneity. Finally, the fracture morphology indicates that the current-induced ductility enhancement may be attributed to the arrest of micro-crack propagation and the inhibition of void initiation, growth, and coalescence caused by lattice melting and expansion.