Journal of Materials Engineering and Performance最新文献

{"title":"Design- and Data-Driven Approach with FEA Framework to Enhance the Tensile–Tensile Fatigue Strength of FDM-Fabricated PETG Components","authors":"Vipin Kashyap,&nbsp;Deepak Bhardwaj,&nbsp;Ravinder Gwal,&nbsp;Ravinder Kumar Sahdev,&nbsp;Ashwani Kumar Dhingra,&nbsp;Deepak Chhabra","doi":"10.1007/s11665-026-14046-z","DOIUrl":"10.1007/s11665-026-14046-z","url":null,"abstract":"<div><p>Most of the functional parts in automobiles, aerospace, and healthcare devices undergo fatigue stress. The polyethylene terephthalate glycol (PETG) has stronger interlayer adhesion than polylactic acid (PLA) and less warping than acrylonitrile butadiene styrene (ABS) during FDM printing, thus making it highly suitable material for load-bearing applications under cyclic stresses. In the proposed work, the synergetic effect of significant process parameters, i.e., layer thickness, infill density, infill pattern, and nozzle temperature of fused deposition modeling (FDM) printing, has been investigated to enhance the fatigue strength of PETG parts. A total of 24 different configuration of input parameters was obtained with a central composite design (CCD), and samples were fabricated in accordance with ASTM D638 Type IV geometry. Fatigue tests using ASTM D7719-22 test method were conducted via a Biss Nano servo-hydraulic machine under tension–tension cyclic loading at 1 Hz with four to six replicates per standard ensuring statistical reliability. Finite element analysis (FEA) has been performed to validate stress distribution and correlate the experimental fatigue behavior with numerical stress distribution. Design-driven mathematical model based on response surface methodology (RSM) to find significant parametric effect and a data-driven neural network model based on artificial neural network (ANN) has been designed. Further, ANN with an R² of 0.9986 integrated with genetic algorithm (GA-ANN) enhanced the fatigue strength from 11.34 to 11.635 MPa with optimized process parameters including layer thickness of 0.299 mm, low infill density of 30.02%, moderate nozzle temperature of 244 °C, and the triangular infill pattern.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 28","pages":"28551 - 28567"},"PeriodicalIF":2.6,"publicationDate":"2026-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695198","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of High-Reactivity Energetic Materials on Microstructure and Tribological Properties of Tin Bronze Induction Cladding Layer","authors":"Zhiming Gao,&nbsp;Zhan Wang,&nbsp;Zhongtang Gao,&nbsp;Geng Zhang,&nbsp;Chuangxin Zhang,&nbsp;Chuanwei Zhang","doi":"10.1007/s11665-026-14056-x","DOIUrl":"10.1007/s11665-026-14056-x","url":null,"abstract":"<div><p>As an efficient surface repair technology, induction cladding enables the remediation of hydraulically supported cylinder blocks failed by wear; yet, it suffers from the technical bottlenecks of insufficient molten pool temperature and low coating bonding strength. In this study, 0–5 wt.% of Al/CuO-type highly reactive energetic materials (H-REMs) were incorporated into the cladding system, and coating samples were fabricated via the induction cladding process. The effects of H-REMs on the microstructure, wear resistance, and microhardness of the cladding layers were systematically investigated using XRD, EDS, SEM, and EBSD. H-REMs induced lattice expansion while preserving the main phase composition of the coatings, which consisted of <i>α</i>-Cu, <i>α</i>-(Cu, Sn) solid solution, Pb, and minor Al₂O₃ and SiO₂. The addition of H-REMs effectively regulates the grain size of the cladding layers. The grains exhibit an evolution trend of refinement first and then coarsening with the increase in H-REMs content. At an H-REMs addition of 3 wt.%, the grain size decreased by 46.1% compared with the unreinforced sample, and an excellent metallurgical bond is achieved at the coating–substrate interface. This optimal dosage also delivered superior comprehensive performance with the average microhardness elevated by 18.53% to 153.5 HV_0.5 compared with the H-REMs-free sample. The friction coefficient and wear loss were decreased by 60.1% and 78.4%, respectively, compare to the substrate with an H-REMs content of 3 wt.%. Excessive H-REMs triggered grain coarsening and deteriorated the overall performance of cladding layers. This work provides a novel strategy for fabricating high-performance wear-resistant tin bronze claddings on severely worn engineering components by H-REMs-assisted induction cladding.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32372 - 32387"},"PeriodicalIF":2.6,"publicationDate":"2026-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823016","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of Sintering Temperature on Residual Stress, Microstructure and Mechanical Properties of SiC-ZrB2/SiC-TiCN Laminated Ceramics","authors":"Xinyan Li,&nbsp;Kaishuo Guo,&nbsp;Jiaojiao Gao,&nbsp;Jinpeng Song","doi":"10.1007/s11665-026-14081-w","DOIUrl":"10.1007/s11665-026-14081-w","url":null,"abstract":"<div><p>SiC-ZrB₂/SiC-TiCN laminated ceramics were designed and prepared. The effect of sintering temperature (ST) on residual stress (RS), microstructure, and mechanical properties was investigated. The alternating distribution of residual compressive stress (RCS) and residual tensile stress was in accordance with the alternation of SiC-ZrB₂ layer and SiC-TiCN layer. As the ST increased, relative density, interlaminar fracture toughness, and impact toughness (IT) increased; flexural strength (FS), Vickers hardness, and overall fracture toughness (OFT) first increased and then decreased. The laminated ceramic showed better comprehensive mechanical properties when the ST was 1800 °C: the FS, OFT, and IT were 936.41 ± 10.52, 8.43 ± 0.13 MPa·m^1/2, and 4.47 ± 0.11 J/cm², respectively. The RS induced crack deflection (CD), and the RCS enhanced the resistance strength of the ceramic and inhibited crack propagation. The impact-resistant mechanism was that the RCS inhibited crack initiation. The toughening mechanism primarily included transgranular fracture, intragranular fracture, CD, and crack bridging. This study can provide new strategies and perspectives to enhance the fracture toughness and IT of ceramics.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 32","pages":"32968 - 32979"},"PeriodicalIF":2.6,"publicationDate":"2026-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148871726","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of Carbon Content and Nb/Ti Microalloying on Microstructure and Mechanical Properties of Hot-Rolled Carbide-Free Bainitic Steel","authors":"Haixin Yu,&nbsp;Jiyong Jin,&nbsp;Hongbin Jia,&nbsp;Lin Gui","doi":"10.1007/s11665-026-13999-5","DOIUrl":"10.1007/s11665-026-13999-5","url":null,"abstract":"<div><p>Carbide-free bainitic steels are increasingly employed in high-performance rail systems for their exceptional wear resistance. However, achieving an optimal strength-toughness balance under hot-rolled and air-cooled conditions remains challenging due to the complex multiphase microstructures and coarse bainite formations. This study systematically compares microstructural evolution and mechanical properties of carbide-free bainitic rail steels with low-carbon (0.26 wt%) and high-carbon (0.32 wt%) compositions under Nb and Nb-Ti microalloying. Nb-Ti microalloying facilitates epitaxial NbC nucleation on pre-existing Ti(C,N) precipitates during thermal processing, thereby weakening the dislocation drag effect of solute Nb and reducing the efficacy of prior-austenite grain refinement by 53% compared to steels microalloyed with Nb alone. Conversely, single Nb microalloying synergistically refines prior-austenite grains and bainitic blocks, increasing high-angle grain boundary density and elevating impact toughness by 28%. In high-carbon systems, the strengthening effect from bainitic lath refinement is counteracted by coarsened M/A constituents. The optimal composition (0.26 wt.% C with Nb microalloying) achieves a balanced strength-toughness combination in hot-rolled air-cooled conditions through coordinated control of bainite lath thickness, refined M/A morphology, and enhanced high-angle grain boundary density.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32340 - 32352"},"PeriodicalIF":2.6,"publicationDate":"2026-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823114","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Creep Damage Evolution in 316L Stainless Steel: Correlating Cavitation with Acoustic Emission","authors":"Muhammad Khan,&nbsp;Akash Baski,&nbsp;Chenxi Xu,&nbsp;Javier Obregon,&nbsp;Didem Ozevin,&nbsp;Matthew Daly","doi":"10.1007/s11665-026-14042-3","DOIUrl":"10.1007/s11665-026-14042-3","url":null,"abstract":"<div><p>Tracking creep damage in structural materials is crucial for assessing their long-term integrity under sustained mechanical loads, especially in high-temperature environments. Creep deformation induces a myriad of microscopic defects, including the nucleation and growth of voids and intergranular cracks, which eventually result in catastrophic failure. This study correlates microstructural damage with acoustic emission (AE) sensing to investigate cavitation in 316L stainless steel during high-temperature creep testing. For this purpose, we leverage scanning electron microscopy (SEM) to reveal post-mortem cavity morphology, while AE sensing enables real-time detection of damage events during creep. The results of the SEM analysis show that increasing creep stress raises the void fraction and number density during steady-state creep. These findings are correlated with an increase in the AE event frequency and amplitude. The correspondence between AE parameters (amplitude and event counts) and void formation demonstrates the application of AE as a diagnostic tool for in situ monitoring of cavitation, thereby improving service-life predictions of structural components in long-term high-temperature environments.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32446 - 32452"},"PeriodicalIF":2.6,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823112","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Coupling Microstructural Embrittlement with Numerical Damage Prediction in Hot Roll Forming of Stainless/Carbon Steel Clad Plates","authors":"Xuejin Li","doi":"10.1007/s11665-026-14057-w","DOIUrl":"10.1007/s11665-026-14057-w","url":null,"abstract":"<div><p>The interfacial integrity of Q235B/304 clad plates during hot roll forming is critical for structural performance. This study investigates the damage mechanism within the 600-900 °C range, coupling T-peel tests with finite element analysis (FEA). T-peel experiments identified 600 °C as the lower threshold for valid characterization, below which cladding fracture occurs. FEA of the 70-degree forming process, utilizing a cohesive zone model (CZM), predicted a counterintuitive increase in stiffness degradation (SDEG) from 0.713 at 600 °C to a critical 0.891 at 900 °C. Microstructural analysis revealed that this degradation stems from thermal embrittlement rather than geometric strain. At 900 °C, the non-equilibrium diffusion of carbon from the substrate leads to a massive co-segregation of C and Cr at the interface, forming a brittle Cr-rich carbide network. These coarse precipitates induce incompatible deformation and micro-void nucleation under forming loads. The results demonstrate that the benefits of thermal softening are overridden by carbide-induced embrittlement at elevated temperatures. Consequently, a strictly controlled forming window of 600-700 °C is proposed to balance ductility and interfacial suppression of brittle phases.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32028 - 32038"},"PeriodicalIF":2.6,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823107","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Gray Relational Optimization of Dry Electrical Discharge Coating Parameters for Copper-Graphene Coating on Al6061 Alloy in Argon Atmosphere","authors":"Panna Goswami,&nbsp;Sujoy Chakraborty,&nbsp;Vidyut Dey,&nbsp;Debashis Podder","doi":"10.1007/s11665-026-14015-6","DOIUrl":"10.1007/s11665-026-14015-6","url":null,"abstract":"<div><p>This study investigates the dry electro-discharge coating (DEDC) process on Al6061 alloy using a copper-graphene green compact electrode in an argon dielectric medium. The process parameters considered include discharge current (Ip) ranging from 4 to 10 A, pulse-on time (Ton) ranging from 50 to 200 µs, and compaction load for electrode fabrication ranging from 5 to 20 ton, composition Cu:Gr. Gray relational analysis (GRA) was employed to optimize the process parameters, aiming to enhance MDR, minimize tool wear rate (TWR), and achieve improved surface roughness (SR) and microhardness (HV). The results indicate that discharge current has the most substantial influence on MDR and SR, while compaction load predominantly affects TWR. The optimal process parameters identified through gray relational analysis (GRA) are a discharge current of 8 A, a pulse-on time of 150 µs, and a compaction load 20 ton. Under these conditions, MDR improved by 12.5%, TWR was reduced by 15.3%, and SR decreased by 18.9% compared to the initial settings. This work contributes to advancing the way for industrial applications requiring enhanced surface properties.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"31813 - 31828"},"PeriodicalIF":2.6,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823160","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Role of Microstructure Evolution on Hardness, Machinability, and Corrosion Resistance of a Recycled IN738 Superalloy","authors":"Shimaa El-Hadad,&nbsp;Ahmed H. Awad,&nbsp;Bin Shi,&nbsp;Nader El-Bagoury,&nbsp;Hamid Ghorbani,&nbsp;Helmi Attia","doi":"10.1007/s11665-026-13980-2","DOIUrl":"10.1007/s11665-026-13980-2","url":null,"abstract":"<div><p>The effect of the microstructure of recycled IN738 (RIN738) on the hardness, machinability, and corrosion resistance was investigated. Three conditions were employed: one in the as-cast state, and two subjected to heat treatment involving a double solution treatment (DST) and aging. The solution treatment consisted of heating to 1180 °C for 120 min, followed by cooling, and then reheating to 1220 °C for 90 min, followed by aging. After treatments, samples that were cooled in air were named as AAC, while the ones quenched in water were labeled AWQ. The microstructure was analyzed using scanning electron microscopy combined with energy-dispersive x-ray (SEM &amp; EDX) and x-ray diffraction (XRD). Machining tests were performed using a conventional drill. The surface roughness, tool wear, and sub-machined surface features were investigated. The corrosion resistance at 40 °C in 10% NaCl solution was also evaluated. It was observed that DST lowered the segregation and homogenized the microstructure. After aging, the AAC sample exhibited coarser <i>γ</i>′ precipitates compared to the AWQ. The hardness of the as-cast and AAC samples was around 399 HV, whereas that of the AWQ sample increased to 465 HV. The changes in the microstructure and hardness following the heat treatment consequently influenced the machinability. The machining results showed that the thrust force increased from 1454 to 1555 N for the as-cast and the AAC samples, respectively, to 1581 N for the AWQ, which is in accordance with the hardness values. The AAC sample recorded the lowest average surface roughness of 0.77 and a minimum average tool wear of 33.8 µm, while the AWQ showed the highest roughness of 1.1 and a tool wear of 43.2 µm. Clear tool wear was observed for the as-cast samples, averaging 63.6 µm, which can be attributed to the inhomogeneity of the microstructure, where segregation and agglomeration of carbides can heavily affect the drilling tool. Regarding the corrosion behavior of the investigated samples, the AAC sample exhibited the best corrosion resistance among the samples, with a corrosion rate of 1.795 × 10⁻³ mm/year and a polarization resistance of 3061 kΩ cm². The findings demonstrate that the heat treatment using DST and air cooling, followed by aging, provides the optimal balance among machinability, surface integrity, and corrosion performance of RIN738.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 30","pages":"31033 - 31047"},"PeriodicalIF":2.6,"publicationDate":"2026-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148781871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of Heat Treatment on the Mechanical Properties of High-Frequency Welded Pipe Flaring","authors":"Peng Wang,&nbsp;Xudong Wang,&nbsp;Ziping Liu,&nbsp;Jiakuan Ren,&nbsp;Qi Ji,&nbsp;Jian Long","doi":"10.1007/s11665-026-14033-4","DOIUrl":"10.1007/s11665-026-14033-4","url":null,"abstract":"<div><p>High-frequency-welded oil well pipes are widely used in the petrochemical industry as casings and transmission pipelines. This study investigated the microstructure and mechanical properties of high-frequency-welded straight-seam pipes before and after heat treatment. The base material and the weld in the as-welded joints showed significant microstructural differences. The base material consisted mainly of coarse polygonal ferrite with martensite–austenite constituents distributed along the grain boundaries. By contrast, the weld consisted of elongated martensite. After heat treatment, the microstructural differences between the base material and the weld metal were reduced, and martensite was abundant in both regions. Heat treatment altered the joint microstructure, enhancing mechanical properties. Flaring tests—using custom fixtures—evaluated both joint types. The maximum destructive loads were 50.6 kN (as-welded) and 142.9 kN (heat-treated), confirming a substantial increase after heat treatment. The research findings are expected to advance the adoption of high-frequency welded pipes in oil well tubing applications.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32199 - 32206"},"PeriodicalIF":2.6,"publicationDate":"2026-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823150","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on the Corrosion Resistance Behavior of Longitudinal and Cross Sections of Cylindrical Mesh Structures Composed of 2.5 vol.% TiBw/TA15 Composite Materials","authors":"Qingkai Meng,&nbsp;Wei Wang,&nbsp;Xinxing Li,&nbsp;Yangju Feng","doi":"10.1007/s11665-026-14024-5","DOIUrl":"10.1007/s11665-026-14024-5","url":null,"abstract":"<div><p>To further investigate the corrosion resistance of titanium-based composites and broaden their applications in marine environments, this study successfully fabricated 2.5 vol.% TiBw/TA15 composites featuring a columnar network distribution of reinforcements using vacuum hot pressing sintering combined with hot extrusion. Microstructural variations across different cross-sections and corrosion behavior in a simulated marine environment (3.5 wt.% NaCl) were examined. The results show that the reinforcements are arranged in a network within the transverse cross-section but align in parallel within the longitudinal one, where they also exhibit superior corrosion resistance. This difference arises because, during hot extrusion, the composite undergoes compressive stress perpendicular to the transverse section, resulting in finer grains and reinforcements in that section. In contrast, the longitudinal section experiences compressive stress along the same direction, leading to coarser grains and reinforcements. Consequently, for the same area, the longitudinal cross-section has a lower grain boundary density and stronger coupling effects, facilitating the faster formation of a more stable passive film, which enhances its corrosion resistance.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 31","pages":"32436 - 32445"},"PeriodicalIF":2.6,"publicationDate":"2026-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148823168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}