{"title":"Friction stir welding-based technologies: A comprehensive review from the sustainable manufacturing perspectives","authors":"Mohamed I.A. Habba , Mohamed M.Z. Ahmed","doi":"10.1016/j.jmrt.2025.07.184","DOIUrl":"10.1016/j.jmrt.2025.07.184","url":null,"abstract":"<div><div>Process impact, energy efficiency, and resource conservation are critical in sustainable manufacturing (SM). Friction Stir Welding (FSW) based technologies offer a solid-state joining and processing approach that significantly reduces energy input, material waste, and environmental impact compared with conventional fusion welding methods, making them at the forefront of sustainable manufacturing. By enabling high-integrity joints without the use of consumables, shielding gases, or post-processing treatments, FSWBTs exemplify how advanced manufacturing technologies can directly support the global transition toward cleaner, safer, and more resource-efficient production systems. This review examines FSWBTs in terms of manufacturing sustainability by analyzing their operational principles, industrial implementations, and sustainability contributions. The FSWBTs family, including Friction Stir Welding (FSW), Friction Stir Processing (FSP), and Friction Stir Additive Manufacturing (FSAM), operates in the solid state at sub-melting temperatures, using non-consumable rotational tooling that generates thermal energy and plastic deformation for bonding and material processing. This analysis examines the environmental advantages of FSWBTs, including reduced emissions, elimination of consumables, and enhanced product lifecycle performance. This review assesses the energetic benefits of FSWBTs, focusing on reduced energy requirements, improved process efficiencies, and enhanced productivity. The material conservation aspects and recyclability of FSWBTs were examined, with an emphasis on optimizing material utilization and directly reusing metal waste. This review examines FSWBTs applications in sustainability-focused industries, including electric mobility and renewable energy generation. Methods for sustainability optimization in FSWBTs implementation include tool geometry refinement, process parameter optimization, strategy-assisted FSWBTs, and integration with Industry 4.0. Additionally, developments in the FSWBTs field, which highlight its potential to advance sustainable manufacturing, have been addressed. This analysis highlights the crucial role of FSWBTs as enablers of sustainable manufacturing.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 1-29"},"PeriodicalIF":6.2,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703433","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"An amorphous-crystallization strategy towards high-quality graphene for constructing highly conductive Cu matrix composites","authors":"Guoqing Li, Wei Pan, Mengting Shi, Jingmei Tao, Xiaofeng Chen, Yichun Liu, Caiju Li, Jianhong Yi","doi":"10.1016/j.jmrt.2025.07.200","DOIUrl":"10.1016/j.jmrt.2025.07.200","url":null,"abstract":"<div><div>High-quality graphene (HQG)-Cu composites demonstrate remarkable properties; however, there remains a scarcity of preparation methods that are both simple and efficient for large-scale industrial application. Herein, amorphous graphene-like carbon (AGLC) synthesized on Cu powders using affordable solid carbon sources (SCS) was successfully converted into HQG inside the unconsolidated Cu skeletons by simple cold pressing combined with high-temperature hydrogen annealing technology. The HQG-Cu composites densified by spark plasma sintering exhibit repeatable high electrical and thermal conductivity (∼433 Wm<sup>−1</sup>K<sup>−1</sup>). Importantly, it demonstrates a remarkable enhancement of ∼23 % in thermal conductivity efficiency (per volume fraction of graphene). Compared with the original AGLC-Cu composites, the electrical conductivity of HQG-Cu composite has increased substantially, rising from 91.5 to 100.6 %IACS. Furthermore, such new design avoids the conflict between the high-temperature growth of HQG (above 1000 <span><math><mrow><mo>°C</mo></mrow></math></span>) and the welding of Cu powders (about 1000 <span><math><mrow><mo>°C</mo></mrow></math></span>). The conversion mechanism from SCS to HQG involving the competition between Cu catalysis and hydrogen etching is clearly revealed. Our research demonstrates the potential of SCS-converted HQG-Cu composites for industrial application, providing a promising avenue for further development of graphene-Cu composites.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 184-190"},"PeriodicalIF":6.2,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144713009","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Process optimization of gravity sand casting process for thin-walled castings of Al–7Si-0.5 Mg alloy using a coupled simulation-experiment method","authors":"Zhijie Guo, Dong-Rong Liu, Hongyu Bao, Zhenpeng Pu, Yicheng Feng, Erjun Guo","doi":"10.1016/j.jmrt.2025.07.199","DOIUrl":"10.1016/j.jmrt.2025.07.199","url":null,"abstract":"<div><div>Optimizing casting parameters serves as a crucial method for reducing porosity and misrun defects during solidification of thin-walled castings. A heat-momentum-transfer coupled model is hired to simulate the solidification and fluid dynamics in thin-walled castings (ProCAST). Locations in a casting with Niyama values below 2 (°C <span><math><mrow><mo>·</mo></mrow></math></span> s)<sup>0.5</sup>cm<sup>−1</sup> are regarded as having higher tendency of forming shrinkage porosity. Numerical simulations are employed in conjunction with experimental characterizations to systematically investigate the effects of pouring temperature, sand-mold preheating temperature, and filling time on the porosity distribution and filling length of Al–7Si-0.5 Mg alloy. The simulated results indicate that the pouring temperature has the most significant impacts on the fluidity and porosity formation in the thin-walled castings. High pouring temperature accelerates the gas absorption and causes the formation of coarse microstructure, finally resulting in the occurrence of gas pore and shrinkage porosity. Increasing the sand-mold preheating temperature reduces the chilling effect of mold and enhances the fluidity, however, slightly increases the porosity. Quick pouring minimizes the heat loss and increases the fluidity. The optimal processing parameters are pouring temperature of 720 °C, sand-mold preheating temperature of 110 °C, and the filling time of 2.5 s. Two mechanisms stand out with respect to the porosity formation. The refined equiaxed dendrites form skeleton along the filling path that stops the further feeding from the surrounding liquid, which results in the shrinkage porosity. In the case of higher pouring temperature, the formation of gas pores is also related to the gas absorption during pouring and the gas entrapment during solidification.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 432-450"},"PeriodicalIF":6.6,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144720749","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yue Wu , Renhao Wu , Haiming Zhang , Tao Wang , Qingxue Huang , Hyoung Seop Kim
{"title":"Understanding the performance improvement mechanism of Ti/steel clad plates fabricated by double-layered hot rolling","authors":"Yue Wu , Renhao Wu , Haiming Zhang , Tao Wang , Qingxue Huang , Hyoung Seop Kim","doi":"10.1016/j.jmrt.2025.07.203","DOIUrl":"10.1016/j.jmrt.2025.07.203","url":null,"abstract":"<div><div>Developing high-performance Ti/steel clad plates is crucial for applications demanding superior mechanical properties and cost efficiency. In this study, we fabricated Ti/steel clad plates via hot rolling using symmetrical assembly (SA) and double-layer assembly (DA) methods. Through comprehensive microstructure characterizations and finite element method (FEM) analysis, we elucidated the influence of assembly configurations on microstructural evolution and mechanical properties. The results show that the DA method achieved higher bonding strength with a single rolling pass than the SA method with two passes, indicating a more efficient bonding process. In the SA method, the symmetric geometry concentrated the overall deformation of the clad plates on the Ti side during rolling, leading to interfacial sliding and accelerating the thinning of the Ti side thickness. This degraded the interfacial bonding strength and triggered geometric dynamic recrystallization (GDRX) on the Ti side. In contrast, the asymmetric DA geometry promoted shear deformation in the steel side, ensuring comparable thickness reduction in both Ti and steel, thereby enhancing the interface bonding strength and deformation coordination between the components. Additionally, direct Ti-roller contact in DA not only improved the surface finish but also reduced the difference in deformation resistance between Ti and steel plates through heat transfer. The continuous dynamic recrystallization (CDRX) in the Ti side of the DA samples, produced finer grains and higher geometric necessary dislocation (GND) density. The combined effects of higher work hardening in the matrix and robust interfacial bonding contribute to the enhanced tensile properties observed in DA clad plates. Our findings underscore the potential of the DA approach, coupled with hot rolling, to produce Ti/steel clad plates with exceptional mechanical properties, providing valuable insights for optimizing bimetallic composite manufacturing processes.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 823-839"},"PeriodicalIF":6.6,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144748644","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wei Guo , Xinlei Ding , Jingru Xin , Long Gao , Jiangtao Xiong , Jinglong Li
{"title":"Synergistic effects of the pure Ni interlayer on microstructural evolution and mechanical properties of diffusion-bonded GH5188 superalloy","authors":"Wei Guo , Xinlei Ding , Jingru Xin , Long Gao , Jiangtao Xiong , Jinglong Li","doi":"10.1016/j.jmrt.2025.07.197","DOIUrl":"10.1016/j.jmrt.2025.07.197","url":null,"abstract":"<div><div>This study systematically compares interfacial evolution and mechanical performance in GH5188 cobalt-based superalloy joints produced through direct diffusion bonding and nickel-interlayered diffusion bonding. Under the constant bonding pressure (6 MPa) and holding time (60 min), direct-bonded joints transition from macro-cracking (1130 °C) to micro-porosity (1190 °C), achieving 95 % interface integrity and 607 MPa shear strength at 1190 °C with brittle fracture morphology. Compared with the direct diffusion bonding of GH5188, the joint can be optimized to a certain extent by introducing a 10 μm thick Ni foil interlayer. Comparing the two bonding methods, it can be found that Ni foil can effectively eliminate the interface defects, dissolve the carbides, and avoid the deterioration of the mechanical properties of the joints. At the same time, by adjusting the bonding process parameters, the interface defects can be completely eliminated and the effective bonding of the interface can be achieved. Optimized Ni-interlayered joints demonstrate 6.7 % strength enhancement (648 MPa) with ductile fracture characteristics at 1190 °C. The results indicate that the nickel interlayer effectively improves joint performance through three ways: enhanced elemental interdiffusion, suppression of carbide precipitation, and restriction of grain boundary migration. This work establishes a reliable pathway for manufacturing high-integrity joints in cobalt-based superalloys under elevated temperature conditions.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 262-275"},"PeriodicalIF":6.6,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144720752","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yifan Yan , Yilin Qiu , Xi Zhang , Bao Wang , Rui Li , Haoran Wu , Zheng Wei , Weiyang Long , Guoshang Zhang , Zhiyuan Zhu , Pengfei Yue , Kexing Song
{"title":"Tailoring the strength-conductivity combination in Cu matrix composites via in-situ TiB2 synthesis","authors":"Yifan Yan , Yilin Qiu , Xi Zhang , Bao Wang , Rui Li , Haoran Wu , Zheng Wei , Weiyang Long , Guoshang Zhang , Zhiyuan Zhu , Pengfei Yue , Kexing Song","doi":"10.1016/j.jmrt.2025.07.192","DOIUrl":"10.1016/j.jmrt.2025.07.192","url":null,"abstract":"<div><div>Optimal interfacial bonding coupled with outstanding strengthening efficiency of reinforcement remains the cornerstone for developing high-performance Cu matrix composites. This study focuses on modulating both interface characteristics and microstructural architecture through in-situ processing, aiming to achieve a strength-conductivity balance in Cu matrix composites. Fabricated via direct current resistance sintering, the in situ TiB<sub>2</sub>/Cu composites exhibit increasing yield strength from 174 MPa to 388 MPa with increasing TiB<sub>2</sub> content, achieving a 155.9 %–470.6 % enhancement over pure Cu while maintaining room-temperature thermal conductivity exceeding 200 W/m·K. Notably, these in-situ composites achieve superior strength-conductivity synergy compared to both conventional Cu matrix composites and Cu alloys reported in existing literature. This is attributed to the in-situ process regulation achieving: semi-coherent interfacial bonding, grain refinement (98 % refinement), dislocation strengthening (32.6-fold multiplication in dislocation density), and effective load transfer. Complementary mesomechanical simulations demonstrate that composite damage primarily originates from stress-strain concentration within the interparticle matrix regions, with matrix ductile fracture dominating the failure mode, and no significant interfacial debonding observed. These findings establish a theoretical framework for designing Cu matrix composites with exceptional strength-conductivity properties.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 62-74"},"PeriodicalIF":6.2,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144704884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abba A. Abubakar , Khaled S. Al-Athel , Nestor Ankah , S. Sohail Akhtar , Abul Fazal M. Arif
{"title":"Numerical evaluation of Ni–Al2O3 particles deposition during cold spraying","authors":"Abba A. Abubakar , Khaled S. Al-Athel , Nestor Ankah , S. Sohail Akhtar , Abul Fazal M. Arif","doi":"10.1016/j.jmrt.2025.07.172","DOIUrl":"10.1016/j.jmrt.2025.07.172","url":null,"abstract":"<div><div>This study investigates the cold spray deposition behavior of a Ni–Al<sub>2</sub>O<sub>3</sub> particle blend onto SS304 stainless steel substrates using a hybrid numerical approach that combines smooth particle hydrodynamics and Lagrangian finite element. The model is used to evaluate the complex thermo-mechanical interactions that occur during the impact of Ni and Al<sub>2</sub>O<sub>3</sub> particles. The simulations were conducted for a varying range of particle sizes (20–60 μm), morphologies (spherical, rod-like, flake-like, dodecahedron, coated, and hollow), impact velocities (250–100 m/s), and temperatures (300–600K), including both mono- and multi-particle scenarios with concentric, eccentric or mixed impact configurations. Optimum process parameters were used to coat SS304 substrates with a Ni-Al<sub>2</sub>O<sub>3</sub> composite layer. The numerical simulation results were validated against the ALE scheme and experimental works. The results indicate strong correlations between deposition parameters and particle deformation characteristics. The flattening ratio of Ni particles increases with increasing impact temperatures, velocities (≤750 m/s), and decreasing diameters, but decline at velocities >750 m/s due to significant embedment into the substrate. High-aspect-ratio particles penetrate deeper into substrate, while coated or hollow ones spread more laterally. Al<sub>2</sub>O<sub>3</sub> particles undergoes partial fracturing and exhibit higher penetration depth. Concentric multi-particle impacts yielded Ni flattening ratios up to 0.78, whereas eccentric impacts ranged from 0.4 to 0.43. Experimental results demonstrated limited Al<sub>2</sub>O<sub>3</sub> retention due to rebounding and wider variation in embedded particles size due to Al<sub>2</sub>O<sub>3</sub> fracturing. However, its presence improved densification, work hardening, and bonding of Ni coating material, resulting in a hard and dense coating layer with better scratch resistance. These findings offer critical insights for optimizing cold spray feedstock and deposition parameters for advanced composite coatings.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 226-241"},"PeriodicalIF":6.6,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144720836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"High-temperature tribological performance of Co45Fe20Cr15W15Si5 complex concentrated alloy: Evolution of multiscale microstructure and friction-induced in-situ oxide layer","authors":"Junjie Jiang , Benbin Xin , Aijun Zhang , Jiesheng Han , Qiangliang Yu , Junhu Meng","doi":"10.1016/j.jmrt.2025.07.136","DOIUrl":"10.1016/j.jmrt.2025.07.136","url":null,"abstract":"<div><div>Designing wear-resistant alloys for extreme high-temperature tribological conditions remains challenging due to the conflicting requirements between oxidation resistance and mechanical stability. The high temperature wear behavior of these materials is significantly affected by microstructure transformation and friction-induced oxide layer evolution. Herein, a Co<sub>45</sub>Fe<sub>20</sub>Cr<sub>15</sub>W<sub>15</sub>Si<sub>5</sub> complex concentrated alloy (CCA) which composed by FCC and multi-scale silicides was developed by vacuum arc melting. This alloy exhibits good high temperature wear resistance (the wear rate <4.5 × 10<sup>−7</sup> mm<sup>3</sup> N<sup>−1</sup> m<sup>−1</sup>), which is mainly due to the multiscale structure and friction-induced in-situ oxide layer. Multiscale silicides can effectively enable the alloy to resist abrasive wear and better relieve stress. The friction-induced in-situ layered oxide layer leads to a soft-hard combined dual-layer oxide structure, which can prevent further oxidation while providing good lubricity.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 710-717"},"PeriodicalIF":6.6,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144748259","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Hybrid manufacturing and mechanics of copper-based architected materials and copper–aluminum interpenetrating phase composites","authors":"Abdulrahman Jaber , Agyapal Singh , Dimitrios C. Rodopoulos , Nikolaos Karathanasopoulos","doi":"10.1016/j.jmrt.2025.07.180","DOIUrl":"10.1016/j.jmrt.2025.07.180","url":null,"abstract":"<div><div>The work investigates the thermomechanical performance of copper-based architected metamaterials and Copper–Aluminum Interpenetrating Phase Composites (IPCs) engineered through hybrid casting manufacturing methods. Triply periodic minimal surface (TPMS) Gyroid and IWP sheet- and solid-based metamaterials are fabricated and analyzed for their mechanical performance and thermal conductivity. In particular, architected CuCrZr alloy lattices with feature sizes as low as ∼320 μm, smooth surface finishes, and high-fidelity inner architected topologies are engineered. It is observed that sheet-based, single-phase architectures allow for substantially enhanced stiffness, specific strength, and effective heat conductivity attributes, compared to equal-weight, solid TPMS designs. Moreover, IWP-based, CuCrZr–AlSi10Mg IPCs with superior load-bearing capacities are engineered (up to ∼420 MPa), along with Gyroid-based IPCs, furnishing exceptional energy absorption attributes (toughness ∼105 MJ/m<sup>3</sup>). Their high specific energy absorption (up to ∼23 kJ/kg) is combined with extraordinary effective thermal conductivity values (∼280 W/m·K), attributes highly desirable in applications requiring combinations of high strength and efficient heat dissipation. The findings highlight the effectiveness of hybrid manufacturing techniques in the engineering of architected materials and IPCs, laying the foundation for the development of a novel class of multifunctional, architected advanced materials, with thermomechanical attributes beyond the performance range of available designs.</div></div>","PeriodicalId":54332,"journal":{"name":"Journal of Materials Research and Technology-Jmr&t","volume":"38 ","pages":"Pages 674-691"},"PeriodicalIF":6.6,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144748565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}