Microstructural Evolution,Tensile Failure,Fatigue Behavior and Wear Properties of Al2O3 Reinforced Al2014 Alloy T6 Heat Treated Metal Composites

The paper focused on an experimental study on the microstructural, mechanical, and wear characteristics of 15 wt.% alumina (Al₂O₃) particulates with an average particle size of 20 µm, reinforced in Al2014 alloy matrix composite as-cast and heat-treated samples. The metal matrix composite (MMC)samples were produced via a novel two-stage stir-casting technique. The fabricated composite samples were subjected to evaluate hardness, tensile strength, fatigue behavior and wear properties for both as cast and T6 heat-treated test samples. The Al2014 alloy and Al2014-15 wt.% Al₂O₃ MMCs were in solution for 1 h at a temperature of 525 °C, quenched instantly in cold water, and then artificially aged for 10 h at a temperature of 175 °C. SEM and X-ray diffraction analyses were used to investigate the microstructure and dispersion of the reinforced Al₂O₃ particles in the composite and the base alloy Al2014. The obtained results indicated that the hardness, tensile and fatigue strength and wear resistance increased when an amount of Al₂O₃ particles was added, compared to the as-cast Al2014 alloy and it was observed that after subjecting the same composite samples to heat treatment, there was further enhancement in the mechanical and wear properties in the Al2014 matrix alloy and Al2014-15 wt.% Al₂O₃ composite samples.     

High-Temperature Oxidation of Fe3Al Intermetallic Alloy Prepared by Additive Manufacturing LENS

The isothermal oxidation of Fe-28Al-5Cr (at%) intermetallic alloy microalloyed with Zr and B (<0.08 at%) in air atmosphere, in the temperature range of 1000 to 1200 °C, was studied. The investigation was carried out on the thin-walled (<1 mm) elements prepared by Laser Engineered Net Shaping (LENS) from alloy powder of a given composition. Characterization of the specimens, after the oxidation, was conducted using X-ray diffraction (XRD) and scanning electron microscopy (SEM, with back-scatter detector (BSE) and energy-dispersive X-ray spectroscopy (EDS) attachments). The investigation has shown, that the oxidized samples were covered with a thin, homogeneous α-Al₂O₃ oxide layers. The intensity of their growth indicates that the material lost its resistance to oxidation at 1200 °C. Structural analysis of the thin-walled components’ has not shown intensification of the oxidation process at the joints of additive layers.     

Microstructural Improvement of Eutectic Al + Mg2Si Phases on Al–Zn–Si–Mg Cast Alloy with TiB2 Particles Additions

In this study, the effects of adding TiB₂ particles to eutectic Al + Mg₂Si phases in aluminum alloys were analyzed. The eutectic Al + Mg₂Si phases were modified effectively when a large amount of TiB₂ was added, and changes in the shape, size, and distribution of the eutectic Al + Mg₂Si phases were confirmed using a polarizing microscope and FE-SEM. The crystal structure of the TiB₂ particles and Mg₂Si phases were analyzed using HR-TEM, and the analysis confirmed that the TiB₂ particles can act as heterogeneous nucleation sites. This paper intends to clarify the principle of phase modification of the eutectic Al + Mg₂Si phases by TiB₂ particles and proposes a new mechanism to improve Mg₂Si phase modification when TiB₂ particles are added.     

Manufacturing of Al2O3/Ni/Ti Composites Enhanced by Intermetallic Phases

In this study, ceramic–metal composites in the Al₂O₃/Ti/Ni system were fabricated using the slip casting method. Two series of composites with 15 vol.% metal content and different solid phase contents were obtained and examined. A proper fabrication process allows obtaining composites enhanced by intermetallic phases. The microstructure of the base powders, slurries, and sintered composites was analyzed by scanning electron microscope. Analysis of the sedimentation tendency of slurries was carried out. The phase composition of the sintered samples was examined by X-ray diffraction analysis. A monotonic compression test was used to investigate the mechanical properties of the composites. A fractography investigation was also carried out. The research conducted revealed that the slip casting method allows the obtaining of composites enhanced by intermetallic phases (TiNi, Ni₃Ti). The results show the correlation between solid-phase content, microstructure, and mechanical properties of the composites.     

Microstructure and Mechanical Properties of W-Al2O3 Alloy Plates Prepared by a Wet Chemical Method and Rolling Process

The uneven distribution and large size of the second phase weakens the effect of dispersion strengthening in ODS-W alloys. In this article, the W-Al₂O₃ composite powders were fabricated using a wet chemical method, resulting in a finer powder and uniformly dispersed Al₂O₃ particles in the tungsten-based alloy. The particle size of the pure tungsten powder is 1.05 μm and the particle size of W-0.2 wt.%Al₂O₃ is 727 nm. Subsequently, the W-Al₂O₃ alloy plates were successfully obtained by induction sintering and rolling processes. Al₂O₃ effectively refined grain size from powder-making to sintering. The micro-hardness of the tungsten alloy plates reached 512 HV_0.2, which is 43.7% higher than that of pure tungsten plates. The nano-hardness reached 14.2 GPa, which is 24.1% higher than that of the pure tungsten plate; the compressive strength reached 2224 MPa, which is 37.2% higher than that of the pure tungsten.     

Preparation and Characterization of Mg–Al–B Alloy (Mg0.5Al0.5B2) Via High-Temperature Sintering

Boron and its alloys have long been explored as potential fuel and increasingly replace pure aluminum powder in high-energy formulations. The ignition and burning properties of boron can be improved by making boron alloys. In this study, an Mg–Al–B alloy was synthesized from magnesium, aluminum and boron powders in a 1:1:4 molar ratio by preheating to 600 °C for 30 min, followed by high-temperature sintering in a tube furnace. The effects of sintering temperature (700–1000 °C) and holding time (0.5–10 h) on the phase composition of mixed powders were studied. After the samples were cooled to room temperature, they were ground into powder. The phase composition, micromorphology and the bonding forms of elements of the synthesized samples were studied using XRD, SEM and XPS. The results show that each element exists in the form of simple substance in the alloy. The influence of the sintering temperature on the synthesis reaction of Mg_0.5Al_0.5B₂ is very important, but holding time has little effect on it. With the increase of sintering temperature, the content of the Mg_0.5Al_0.5B₂ phase gradually increases, and the phase content of residual metal gradually decreases. The phase and morphology analyses show that the optimum sintering temperature is 1000 °C with a minimum holding time of 0.5 h. It is expected to be used in gunpowder, propellant, explosives and pyrotechnics with improved characteristics.     

Influence of Carrier Gas Composition on the Stress of Al2O3 Coatings Prepared by the Aerosol Deposition Method

Al₂O₃ films were prepared by the aerosol deposition method at room temperature using different carrier gas compositions. The layers were deposited on alumina substrates and the film stress of the layer was calculated by measuring the deformation of the substrate. It was shown that the film stress can be halved by using oxygen instead of nitrogen or helium as the carrier gas. The substrates were annealed at different temperature steps to gain information about the temperature dependence of the reduction of the implemented stress. Total relaxation of the stress can already be achieved at 300 °C. The XRD pattern shows crystallite growth and reduction of microstrain while annealing.     

Effect of Vacuum Heat Treatment on the Element Diffusion Behavior and Corrosion Resistance of Al2O3-3wt.%TiO2 Coating of Q235 Steel

In this study, we address the effect of vacuum heat treatment on the morphology of Al₂O₃-3wt.%TiO₂ coating, element diffusion behavior, coating hardness, and corrosion resistance. The pores, cracks, and non-liquefied particles on the as-heat treated coating surface of the vacuum-heat-treated coating were observed and compared with the as-sprayed coating using a scanning electron microscope. The diffusion behavior of the elements in the coating was demonstrated by using a line scanning of a cross-section of the coating. Hardness and corrosion-resistance test results were used to judge the effect of a vacuum heat treatment on the coating. The research results show that compared with atmospheric heat treatment, the vacuum heat treatment had less effect on the pores, cracks, and non-liquefied particles on the surface of the coating. However, in the absence of new oxide formation, the pores and cracks in the cross-section of the coating were significantly improved by the vacuum heat treatment. The surface hardness and corrosion resistance of the coating were significantly improved. The crack defects were eliminated, and the uniformity of TiO₂ distribution was improved, which are the main factors that improved the coating performance after vacuum heat treatment. The combination of the coating and the substrate is strengthened, and an Al₂O₃ and TiO₂ interdiffusion zone is formed when the coating undergoes vacuum heat treatment, which is the main mechanism improving the performance of the AT3 coating.     

Atomic Layer Deposition of Ultrathin La2O3/Al2O3 Nanolaminates on MoS2 with Ultraviolet Ozone Treatment

Due to the chemically inert surface of MoS₂, uniform deposition of ultrathin high-κ dielectric using atomic layer deposition (ALD) is difficult. However, this is crucial for the fabrication of field-effect transistors (FETs). In this work, the atomic layer deposition growth of sub-5 nm La₂O₃/Al₂O₃ nanolaminates on MoS₂ using different oxidants (H₂O and O₃) was investigated. To improve the deposition, the effects of ultraviolet ozone treatment on MoS₂ surface are also evaluated. It is found that the physical properties and electrical characteristics of La₂O₃/Al₂O₃ nanolaminates change greatly for different oxidants and treatment processes. These changes are found to be associated with the residual of metal carbide caused by the insufficient interface reactions. Ultraviolet ozone pretreatment can substantially improve the initial growth of sub-5 nm H₂O-based or O₃-based La₂O₃/Al₂O₃ nanolaminates, resulting in a reduction of residual metal carbide. All results indicate that O₃-based La₂O₃/Al₂O₃ nanolaminates on MoS₂ with ultraviolet ozone treatment yielded good electrical performance with low leakage current and no leakage dot, revealing a straightforward approach for realizing sub-5 nm uniform La₂O₃/Al₂O₃ nanolaminates on MoS₂.     

Effect of Current Density on the Microstructure and Mechanical Properties of 3YSZ/Al2O3 Composites by Flash Sintering

The 3YSZ/40 wt% Al₂O₃ composites were prepared by flash sintering at a low furnace temperature (700 °C). The effects of the current density on the relative density and Vickers hardness of the composites were systematically investigated. The results showed that the relative densities and Vickers hardness of the samples increased gradually with the increasing of the current densities, and the relative density was as high as 94.2%. The Vickers hardness of 11.3 GPa was obtained under a current density of 102 mA/mm². Joule heating and defects generation are suggested to be the main causes of rapid densification in flash sintering. The microstructure of the molten zone showed the formation of eutectic structures in the composite, suggesting that grain boundary overheating may have contributed to the formation of the molten zone.     

Microstructure and Phase Evolution of Ti-Al-C-Nb Composites Prepared by In Situ Selective Laser Forming

In the present work, a novel Ti-Al-C-Nb composite was prepared using in situ selective laser forming (ISLF). The formation mechanism of the Ti-Al-C-Nb bulks, which were synthesized using elemental titanium, aluminum, and carbon (graphite) powders via ISLF techniques, was investigated. The results showed that the Ti₃Al and TiC phases were the dominant synthesis products during the chemical reactions, and these occurred during the ISLF process. The size of the fine nanoscale crystal TiC grains could reach 157 nm at an energy level of 60 J/mm³. The porous structure of the ISLF specimens was disclosed, and an open porosity of 20–44% was determined via the scanning speed and the laser power. Both the high dynamic viscosity and the reactions of the raw powders led to the generation of a considerable number of pores, whereas the specimen processed using 45 W and 100 mm/s possessed the lowest degree of open porosity.     

Effect of Al2TiO5 Content and Sintering Temperature on the Microstructure and Residual Stress of Al2O3–Al2TiO5 Ceramic Composites

A series of Al₂O₃–Al₂TiO₅ ceramic composites with different Al₂TiO₅ contents (10 and 40 vol.%) fabricated at different sintering temperatures (1450 and 1550 °C) was studied in the present work. The microstructure, crystallite structure, and through-thickness residual stress of these composites were investigated by scanning electron microscopy, X-ray diffraction, time-of-flight neutron diffraction, and Rietveld analysis. Lattice parameter variations and individual peak shifts were analyzed to calculate the mean phase stresses in the Al₂O₃ matrix and Al₂TiO₅ particulates as well as the peak-specific residual stresses for different hkl reflections of each phase. The results showed that the microstructure of the composites was affected by the Al₂TiO₅ content and sintering temperature. Moreover, as the Al₂TiO₅ grain size increased, microcracking occurred, resulting in decreased flexure strength. The sintering temperatures at 1450 and 1550 °C ensured the complete formation of Al₂TiO₅ during the reaction sintering and the subsequent cooling of Al₂O₃–Al₂TiO₅ composites. Some decomposition of AT occurred at the sintering temperature of 1550 °C. The mean phase residual stresses in Al₂TiO₅ particulates are tensile, and those in the Al₂O₃ matrix are compressive, with virtually flat through-thickness residual stress profiles in bulk samples. Owing to the thermal expansion anisotropy in the individual phase, the sign and magnitude of peak-specific residual stress values highly depend on individual hkl reflection. Both mean phase and peak-specific residual stresses were found to be dependent on the Al₂TiO₅ content and sintering temperature of Al₂O₃–Al₂TiO₅ composites, since the different developed microstructures can produce stress-relief microcracks. The present work is beneficial for developing Al₂O₃–Al₂TiO₅ composites with controlled microstructure and residual stress, which are crucial for achieving the desired thermal and mechanical properties.     

Effect of CeO2 Content on Microstructure and Properties of SiCp/Al-Si Composites Prepared by Powder Metallurgy

The effect of CeO₂ content on the microstructure and properties of SiCp/Al-Si composites prepared by powder metallurgy was studied, and the mechanism of CeO₂ in composites was deeply analyzed. The results show that the addition of the appropriate amount of CeO₂ can refine the Si particles and improve the tensile properties of the SiCp/Al-Si composites. As the CeO₂ content increases from 0 to 0.4 vol%, the particle size of the Si phase shows a tendency to decrease first and then increase, while the tensile strength, yield strength, and elongation of the composites show a trend of first increasing and then decreasing. When the CeO₂ content is 0.2 vol%, the refining effect of CeO₂ and the tensile properties of composites are the best. The fracture mode of SiCp/Al-Si composites with a rare earth addition is a mixed fracture. There are three main mechanisms for CeO₂ in SiCp/Al-Si composites. One is when CeO₂ serves as the nucleation substrate of Si phase to refine Si particles. The second is when CeO₂ reacts with the alloying elements in the aluminum matrix to form a new phase, CeCu₂Si₂, which can not only play a role of dispersion strengthening, but also improve the bonding strength between Al matrix and Si particles. The third is the pinning effect of CeO₂ and CeCu₂Si₂ particles on grain boundaries or phase boundaries to refine aluminum grains.     

Comparing the Corrosion Resistance of 5083 Al and Al2O33D/5083 Al Composite in a Chloride Environment

In this study, an Al₂O₃3D/5083 Al composite was fabricated by infiltrating a molten 5083 Al alloy into a three-dimensional alumina reticulated porosity ceramics skeleton preform (Al₂O₃3D) using a pressureless infiltration method. The corrosion resistance of 5083 Al alloy and Al₂O₃3D/5083 Al in NaCl solution were compared via electrochemical impedance spectroscopy (EIS), dynamic polarization potential (PDP), and neutral salt spray (NSS) tests. The microstructure of the two materials were investigated by 3D X-ray microscope and scanning electron microscopy aiming at understanding the corrosion mechanisms. Results show that an Al₂O₃3D/5083 Al composite consists of interpenetrating structure of 3D-continuous matrices of continuous networks 5083 Al alloy and Al₂O₃3D phase. A large area of strong interfaces of 5083 Al and Al₂O₃3D exist in the Al₂O₃3D/5083 Al composite. The corrosion development process can be divided into the initial period, the development period, and the stability period. Al₂O₃3D used as reinforcement in Al₂O₃3D/5083 Al composite improves the corrosion resistance of Al₂O₃3D/5083 Al composite via electrochemistry tests. Thus, the corrosion resistance of Al₂O₃3D/5083 Al is higher than that of 5083 Al alloy. The NSS test results indicate that the corrosion resistance of Al₂O₃3D/5083 Al was lower than that of 5083 Al alloy during the initial period, higher than that of 5083 Al alloy during the development period, and there was no obvious difference in corrosion resistance during the stability period. It is considered that the elements in 5083 Al alloy infiltrated into the Al₂O₃3D/5083 Al composite are segregated, and the uniform distribution of the segregated elements leads to galvanic corrosion during the corrosion initial period. The perfect combination of interfaces of Al₂O₃3D and the 5083 Al alloy matrix promotes excellent corrosion resistance during the stability period.     

Phase Formation,Mechanical Strength,and Bioactive Properties of Lithium Disilicate Glass–Ceramics with Different Al2O3 Contents

Owing to its excellent mechanical properties and aesthetic tooth-like appearance, lithium disilicate glass–ceramic is more attractive as a crown for dental restorations. In this study, lithium disilicate glass–ceramics were prepared from SiO₂–Li₂O–K₂O–P₂O₅–CeO₂ glass systems with various Al₂O₃ contents. The mixed glass was then heat-treated at 600 °C and 800 °C for 2 h to form glass–ceramic samples. Phase formation, microstructure, mechanical properties and bioactivity were investigated. The phase formation analysis confirmed the presence of Li₂Si₂O₅ in all the samples. The glass–ceramic sample with an Al₂O₃ content of 1 wt% showed rod-like Li₂Si₂O₅ crystals that could contribute to the delay in crack propagation and demonstrated the highest mechanical properties. Surface treatment with hydrofluoric acid followed by a silane-coupling agent provided the highest micro-shear bond strength for all ceramic conditions, with no significant difference between ceramic samples. The biocompatibility tests of the material showed that Al₂O₃-added lithium disilicate glass–ceramic sample was bioactive, thus activating protein production and stimulating the alkaline phosphatase (ALP) activity of osteoblast-like cells.     

Ceramic Matrix Composites Obtained by the Reactive Sintering of Boron Carbide with Intermetallic Compounds from the Ti-Si System

In this study, we investigated the effect of adding two different intermetallics, Ti₅Si₃ and TiSi₂, for the preparation of TiB₂-SiC-B₄C composites. As part of the research, stoichiometric composites consisting only of two phases TiB₂ and SiC were obtained. The TiB₂-SiC-B₄C composites were prepared via pressureless sintering. The presence of the phases in the sintered composites was confirmed using X-ray diffraction and scanning electron microscopy. The SEM-EDS examination revealed that the TiB₂ and SiC phases were formed during the composite process synthesis and were distributed homogeneously in the B₄C matrix. The obtained results allowed us to usually exceed 2000 °C and the use of specialized equipment for firing, that is, vacuum or protective atmosphere furnaces as well as control and measurement equipment. Such an approach generates high costs that are decisive for the economics of the technological processes. In the case of our compositions, it is possible to lower the temperature to 1650 °C. The TiB₂-SiC-B₄C composites were classified as UHTCs.     

Fabrication and Mechanical Properties of Cr2AlC MAX Phase Coatings on TiBw/Ti6Al4V Composite Prepared by HiPIMS

The high-power impulse magnetron sputtering (HiPIMS) technique is widely used owing to the high degree of ionization and the ability to synthesize high-quality coatings with a dense structure and smooth morphology. However, limited efforts have been made in the deposition of MAX phase coatings through HiPIMS compared with direct current magnetron sputtering (DCMS), and tailoring of the coatings’ properties by process parameters such as pulse width and frequency is lacking. In this study, the Cr₂AlC MAX phase coatings are deposited through HiPIMS on network structured TiBw/Ti6Al4V composite. A comparative study was made to investigate the effect of average power by varying frequency (1.2–1.6 kHz) and pulse width (20–60 μs) on the deposition rate, microstructure, crystal orientation, and current waveforms of Cr₂AlC MAX phase coatings. X-ray diffraction (XRD), scanning electron microscopy (SEM), and atomic force microscopy (AFM) were used to characterize the deposited coatings. The influence of pulse width was more profound than the frequency in increasing the average power of HiPIMS. The XRD results showed that ex situ annealing converted amorphous Cr-Al-C coatings into polycrystalline Cr₂AlC MAX phase. It was noticed that the deposition rate, gas temperature, and roughness of Cr₂AlC coatings depend on the average power, and the deposition rate increased from 16.5 to 56.3 nm/min. Moreover, the Cr₂AlC MAX phase coatings produced by HiPIMS exhibits the improved hardness and modulus of 19.7 GPa and 286 GPa, with excellent fracture toughness and wear resistance because of dense and column-free morphology as the main characteristic.     

Effect of Ti3SiC2 and Ti3AlC2 Particles on Microstructure and Wear Resistance of Microarc Oxidation Layers on TC4 Alloy

Microarc oxidation (MAO) layers were prepared using 8g/L Na₂SiO₃ + 6g/L (NaPO₃)₆ + 4g/L Na₂WO₄ electrolyte with the addition of 2g/L Ti₃SiC₂/Ti₃AlC₂ particles under constant-current mode. The roughness, porosity, composition, surface/cross-sectional morphology, and frictional behavior of the prepared MAO layers were characterized by 3D real-color electron microscopy, scanning electron microscopy, X-ray energy spectrometry, X-ray diffractometry, and with a tribo-tester. The results showed that the addition of Ti₃SiC₂ and Ti₃AlC₂ to the electrolyte reduced the porosity of the prepared layers by 9% compared with that of the MAO layer without added particles. The addition of Ti₃SiC₂/Ti₃AlC₂ also reduced the friction coefficient and wear rate of the prepared layers by 35% compared with that of the MAO layer without added particles. It was found that the addition of Ti₃AlC₂ particles to the electrolyte resulted in the lowest porosity and the lowest wear volume.     

Effect of Al2Ca Addition and Heat Treatment on the Microstructure Modification and Tensile Properties of Hypo-Eutectic Al–Mg–Si Alloys

The current study investigated the microstructure modification in Al–6Mg–5Si–0.15Ti alloy (in mass %) through the minor addition of Ca using Mg + Al₂Ca master alloy and heat treatment to see their impact on mechanical properties. The microstructure of unmodified alloy (without Ca) consisted of primary Al, primary Mg₂Si, binary eutectic Al–Mg₂Si, ternary eutectic Al–Mg₂Si–Si, and iron-bearing phases. The addition of 0.05 wt% Ca resulted in significant microstructure refinement. In addition to refinement, lamellar to fibrous-type modification of binary eutectic Al–Mg₂Si phases was also achieved in Ca-added (modified) alloy. This modification was related to increasing Ca-based intermetallics/compounds in the modified alloy that acted as nucleation sites for binary eutectic Al–Mg₂Si phases. The dendritic refinement with Ca addition was related to the fact that it improves the efficacy of Ti-based particles (TiAl₃ and TiB₂) in the melt to act as nucleation sites. In contrast, the occupation of oxide bifilms by Ca-based phases is expected to force the iron-bearing phases (as iron-bearing phases nucleate at oxide films) to solidify at lower temperatures, thus reducing their size. The as-cast microstructure of these alloys was further modified by subjecting them to solution treatment at 540 °C for 6 h, which broke the eutectic structure and redistributed Mg₂Si and Si phases in Al-matrix. Subsequent aging treatment caused a dramatic increase in the tensile strength of these alloys, and tensile strength of 291 MPa (with El% of 0.45%) and 327 MPa (with El% of 0.76%) was achieved for the unmodified alloy and modified alloy, respectively. Higher tensile strength and elongation of the modified alloy than unmodified alloy was attributed to refined dendritic structure and modified second phases.     

Microstructure Evolution and Properties of an In-Situ Nano-Gd2O3/Cu Composite by Powder Metallurgy

Gadolinia (Gd₂O₃) is potentially attractive as a dispersive phase for copper matrix composites due to its excellent thermodynamic stability. In this paper, a series of 1.5 vol% nano-Gd₂O₃/Cu composites were prepared via an internal oxidation method followed by powder metallurgy in the temperature range of 1123–1223 K with a holding time of 5–60 min. The effects of processing parameters on the microstructure and properties of the composites were analyzed. The results showed that the tensile strength and conductivity of the nano-Gd₂O₃/Cu composite have a strong link with the microporosity and grain size, while the microstructure of the composite was determined by the sintering temperature and holding time. The optimal sintering temperature and holding time for the composite were 1173 K and 30 min, respectively, under which a maximum ultimate tensile strength of 317 MPa was obtained, and the conductivity was 96.8% IACS. Transmission electron microscopy observations indicated that nano-Gd₂O₃ particles with a mean size of 76 nm formed a semi-coherent interface with the copper matrix. In the nano-Gd₂O₃/Cu composite, grain-boundary strengthening, Orowan strengthening, thermal mismatch strengthening, and load transfer strengthening mechanisms occurred simultaneously.