Metals and Materials International最新文献

{"title":"Numerical Study on Melt Flow and Formation Mechanism of Spatter in Selective Laser Melting of Ti-6Al-4 V Alloy","authors":"Chen Liu,&nbsp;Weidong Huang,&nbsp;Yuanta Liu,&nbsp;Fang Wan","doi":"10.1007/s12540-025-01982-z","DOIUrl":"10.1007/s12540-025-01982-z","url":null,"abstract":"<p>During the selective laser melting (SLM) process, the flow of the active molten pool presents various unstable states, which triggers various defects that affect the forming quality of the Ti-6Al-4 V alloy. Through an experimental comparison of Ti-6Al-4 V alloy samples under different laser energy densities in this study, it was found that as the laser energy density increased, the sample density showed a trend of first increasing (E_V = 0.125–0.200 J/mm) and then decreasing (E_V = 0.200–0.550 J/mm). The forming quality of the sample surface showed a continuous decreasing trend. Under the same laser energy density [E_V (<i>P</i> = 165 W, v = 300 mm/s) = E_V (<i>P</i> = 330 W, v = 600 mm/s) = 0.550 J/mm], the surface quality of the sample formed at a low power and speed was significantly improved. To explore the underlying reasons for these phenomena, a reliable three-dimensional model was constructed to simulate the melt flow inside the molten pool during the SLM process. The simulation results showed that as the laser energy density increased, the movement of the fluid inside the molten pool became intense. This led to periodic collapse inside the keyhole, resulting in the formation of bubble defects. A large amount of molten material accumulated behind the molten pool, affecting the surface forming quality of the sample. In addition, the eruption of a large amount of high-temperature metal vapor exacerbated the spatter phenomenon. This research provides a reference basis for further understanding the causes of defect formation during processing and improving the forming quality of later products.</p>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3833 - 3849"},"PeriodicalIF":4.5,"publicationDate":"2026-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176727","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Retraction Note: SECM and EIS Studies of Galvanic Corrosion of Copper/Iron Connected to Automotive Parts in Seawater","authors":"Joseph Raj Xavier","doi":"10.1007/s12540-026-02388-1","DOIUrl":"10.1007/s12540-026-02388-1","url":null,"abstract":"","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 10","pages":"3636 - 3637"},"PeriodicalIF":4.5,"publicationDate":"2026-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148950481","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Hot Workability of a Novel Mg-Nd-Zr-Ca Alloy: Strain-Compensated Constitutive Equation, Processing Map and Instability Analysis","authors":"Yiquan Li,&nbsp;Liwei Lu,&nbsp;Ruicheng Mao,&nbsp;Rui Yang,&nbsp;Shaohui Xiong,&nbsp;Gang Liu,&nbsp;Lei Jing,&nbsp;Lifei Wang,&nbsp;Yujuan Wu","doi":"10.1007/s12540-025-02194-1","DOIUrl":"10.1007/s12540-025-02194-1","url":null,"abstract":"<div><p>The compressive flow stress of a novel Mg-1.8Nd-0.4Zr-0.3Ca alloy was measured using a hot compression testing machine at temperatures between 330 ℃ and 460 °C and strain rates ranging from 0.001 to 1 s⁻¹. The flow stress data were utilized to develop both conventional and strain-compensated constitutive models in conjunction with evaluating the deformation activation energy. Processing maps were further established at various strain levels. The results demonstrate that the established constitutive model effectively predicts flow stress behavior. The deformation activation energy decreases with increasing strain, reaching 170 kJ/mol under peak stress conditions. Results from the dynamic material model reveal that the stable processing window for this alloy ranges from 380 to 460 °C and at strain rates of 0.005 to 0.05 s⁻¹. Microscopic characterizations and analyses revealed the presence of non-basal slip, continuous dynamic recrystallization, &lt; 0001&gt;//CD texture, and dynamic precipitation. Additionally, unstable regions (380 °C, 1 s⁻¹) in the processing map exhibited high-density dislocations, twins, deformation bands, and strong textures, indicating microstructural heterogeneity that may induce local stress concentration and flow instability. The instability modes of Mg-Nd-Zr-Ca alloy under extreme processing parameters provide theoretical guidance for deformation process design and manufacturing parameter determination.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3814 - 3832"},"PeriodicalIF":4.5,"publicationDate":"2026-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176681","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards High-Rate Additive Friction Stir Deposition of Al 7075: Tribological, Microstructural, and Mechanical Properties","authors":"Ehsan Bagheri,&nbsp;Lijesh Koottaparambil,&nbsp;Noushin Adibi,&nbsp;Huan Ding,&nbsp;Saeid Zavari,&nbsp;Michael Khonsari,&nbsp;Shengmin Guo","doi":"10.1007/s12540-025-02195-0","DOIUrl":"10.1007/s12540-025-02195-0","url":null,"abstract":"<div><p>Increasing the deposition rate in additive manufacturing (AM) techniques is critical to enhance production efficiency and reduce costs. In this context, additive friction stir deposition (AFSD) offers great potential for high-rate fabrication of metallic parts. It is essential to further develop this technique to expand the range of processable materials at high deposition rates. In this study, Al 7075-T651 parts were deposited by AFSD at a rate approximately 2.6 times higher than those reported in previous studies. The AFSD output parameters and the deposited part’s properties including mechanical properties and microstructure were evaluated and compared with literature. The results indicated increases in average force and torque by 70.9% and 36.7% respectively during the high-rate AFSD deposition process, along with 12% and 22.4% improvements in the average hardness and tensile strength, respectively for the AFSD part. The property changes were attributed to the reduced heat input during the process, finer grain microstructure, and a higher density of dislocations. Additionally, tribological properties of the high-rate as-deposited Al 7075 part were assessed and compared to the feedstock material. The results revealed improved wear resistance in the deposited part, particularly in the bottom layers, in most cases, which was primarily attributed to their higher toughness.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3921 - 3934"},"PeriodicalIF":4.5,"publicationDate":"2026-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing Impact Resistance and Structural Stability of Thermal Battery Cases Using Epoxy Molding: FEM Simulation and Experimental Validation","authors":"Yeon Taek Choi,&nbsp;Jihye Kwon,&nbsp;Minu Kim,&nbsp;Hyungu Kang,&nbsp;Seung-Ho Kang,&nbsp;Heesook Roh,&nbsp;Sunghak Lee,&nbsp;Hyoung Seop Kim","doi":"10.1007/s12540-025-02198-x","DOIUrl":"10.1007/s12540-025-02198-x","url":null,"abstract":"<div><p>Thermal batteries serve as critical power supply systems for military applications, including missiles and aerospace platforms, where stable operation is required under severe impact, high-temperature, and high-pressure conditions. This study introduces epoxy molding as a reinforcement strategy for the header lid of a thermal battery case, aiming to enhance its impact resistance. The effectiveness of this approach is systematically evaluated using finite element method (FEM) simulations and gas gun impact experiments. The epoxy molding demonstrated superior energy absorption and dissipation capabilities, substantially reducing the maximum depression depth at the center of the header lid. FEM simulations predicted that the addition of a 70 mm-diameter, 20 mm-high epoxy molding layer decreased the maximum depression depth to 0.78 mm, compared to 2.73 mm in the unreinforced case, corresponding to a reduction of over 70%. These predictions were validated by high correlation with experimental results obtained from gas gun impact tests. Additionally, the low thermal conductivity of epoxy minimizes heat dissipation, preserving the battery’s thermal efficiency, while its lightweight nature ensures negligible weight penalty, thereby maintaining the structural integrity of the battery system. These findings confirm that epoxy molding is a promising engineering solution for enhancing impact resistance, deformation suppression, mechanical durability, and operational reliability of thermal battery header lids.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3658 - 3671"},"PeriodicalIF":4.5,"publicationDate":"2026-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12540-025-02198-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176682","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Saccharin-Controlled Electrodeposition of Ultra-Thin Fe–Ni Foils for Low CTE","authors":"Jin-Bum Kim,&nbsp;Seon-Min Kim,&nbsp;In Gyeong Kim,&nbsp;Yong Bum Park,&nbsp;Se-Eun Shin","doi":"10.1007/s12540-025-02185-2","DOIUrl":"10.1007/s12540-025-02185-2","url":null,"abstract":"<div><p>The fine metal mask (FMM) used in OLED display manufacturing is a thin metallic sheet with precision holes that enable the deposition of diode materials exclusively onto sub-pixel areas. To prevent deformation and misalignment of the holes caused by heat generated during the RGB organic material deposition process, Invar sheets with a coefficient of thermal expansion (CTE) close to zero are employed. Currently, FMMs are fabricated by rolling to about 20 μm, but this top-down process cannot achieve thinner foils. Therefore, to realize next-generation UHD displays requiring FMMs below 10 μm, a bottom-up electrodeposition method is needed. Achieving both dimensional stability and a low CTE comparable to commercial Invar alloys in electrodeposited ultra-thin Invar sheets requires prolonged high-temperature heat treatment above 600 °C using thermomechanical processing. If the electrodeposited Invar alloy can achieve a homogeneous nanocrystalline microstructure in the as-deposited state, the required heat-treatment temperature and duration can be reduced, improving overall process efficiency. In this study, we investigated the effect of controlling saccharin, a key additive in the Fe–Ni electrolyte, on the microstructural evolution of ultra-thin electrodeposited Invar sheets. By regulating surface stress during electrodeposition, Fe and Ni ion diffusion was promoted, and the relationship between microstructural uniformity and CTE was systematically analyzed.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3776 - 3785"},"PeriodicalIF":4.5,"publicationDate":"2026-06-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176414","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Unraveling the Hot Deformation Mechanisms and Dynamic Recrystallization Behavior of FeCoCrNiMn High-Entropy Alloy","authors":"Luhai Liao,&nbsp;Shengjie Zhou,&nbsp;Fengguang Li,&nbsp;Shang Dai,&nbsp;Muhammad Abubaker Khan","doi":"10.1007/s12540-025-02182-5","DOIUrl":"10.1007/s12540-025-02182-5","url":null,"abstract":"<div><p>The hot deformation behavior and dynamic recrystallization (DRX) mechanisms of an equiatomic FeCoCrNiMn high-entropy alloy (HEA) were thoroughly investigated via uniaxial hot compression tests conducted at temperatures ranging from 900 ℃ to 1200 °C and strain rates from 0.01 to 10 s⁻¹. The flow stress behavior was accurately described by a constitutive model based on the Zener-Hollomon parameter, yielding an activation energy of 408 kJ/mol. Processing maps derived from the dynamic materials model (DMM) identified safe deformation domains (1000 ℃–1100 °C/0.01–0.1 s⁻¹ and 1200 °C/0.1 s⁻¹) and instability regions characterized by low DRX fractions and strain localization. Microstructural analyses via EBSD and TEM revealed that discontinuous dynamic recrystallization (DDRX) dominated under most conditions, facilitated by twinning and necklace structure formation, while continuous dynamic recrystallization prevailed at high temperatures and low strain rates. A high density of annealing twin boundaries was observed, particularly under high-strain-rate conditions, which played a critical role in promoting DDRX nucleation. This work provides valuable insights into the DRX mechanisms and hot workability of FeCoCrNiMn HEA, serving as a guide for optimizing thermo-mechanical processing parameters to achieve superior mechanical properties and microstructural control.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3902 - 3920"},"PeriodicalIF":4.5,"publicationDate":"2026-06-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176416","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure, Mechanical Behavior and Magnetic Response of Friction Stir-Processed Quenched and Tempered Ultra-High Strength AISI 4340 Steels","authors":"Pradeep Kumar,&nbsp;Piyush Rai,&nbsp;Rajnish Mishra,&nbsp;Meghanshu Vashista,&nbsp;Mohd Zaheer Khan Yusufzai","doi":"10.1007/s12540-025-02193-2","DOIUrl":"10.1007/s12540-025-02193-2","url":null,"abstract":"<p>Friction stir processing (FSP) was employed to modify the surface and subsurface characteristics of quenched and tempered ultra-high strength AISI 4340 steels. Comprehensive evaluations of microstructure, micromagnetic response, mechanical and tribological properties were conducted before and after processing. Microstructural examination revealed the transformation of the tempered martensitic matrix into a highly refined martensite with the presence of lower bainite and nano-sized carbides structures within the stir zone, with average grain size reduced from 36.5 µm to 1.7 µm due to severe plastic deformation and dynamic recrystallization. Barkhausen Noise (BN) and Hysteresis Loop (HL) analysis confirmed these microstructural refinements through suppressed BN activity, increased coercivity (77.8 to 107.4 Oe), and enhanced remanence (977 to 2345 G), indicative of a magnetically harder martensitic state. Mechanical evaluation demonstrated a marked increase in microhardness, rising from ~ 350 HV in the base material to ~ 770 HV in the FSPed stir zone. Ultimate tensile strength (UTS) improved from 1256 to 1294 MPa, accompanied by an increase in elongation from 18.4% to 20.4%. These enhancements highlight the role of homogenized ultrafine grains in achieving superior strength-ductility synergy. Despite this nearly twofold increase in hardness, wear testing under dry sliding conditions revealed a higher wear volume (0.968 mm³ in FSPed vs. 0.688 mm³ in base material) and specific wear rate in the FSPed material (53.79 × 10⁻⁶ mm³/N m) compared to the base material (38.22 × 10⁻⁶ mm³/N m). This is attributed to the brittle fragmentation of the refined martensitic laths and reduced elastic modulus (244.6 ± 4.2 GPa), which facilitated micro-cracking and delamination. Overall, FSP enhanced microstructural refinement, magnetic hardening, and strength–ductility balance, but at the cost of reduced wear resistance, underscoring a critical trade-off in tailoring surface-engineered UHSS components.</p>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3873 - 3901"},"PeriodicalIF":4.5,"publicationDate":"2026-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176605","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modulating the Phases Precipitation to Enhance Strength-Ductility in a High-Cr Ni-Based Polycrystalline Superalloy","authors":"Han Wang,&nbsp;Naicheng Sheng,&nbsp;Shijie Sun,&nbsp;Chen Wang,&nbsp;Shigang Fan,&nbsp;Zhaokuang Chu,&nbsp;Guichen Hou,&nbsp;Jinguo Li,&nbsp;Yizhou Zhou","doi":"10.1007/s12540-025-02180-7","DOIUrl":"10.1007/s12540-025-02180-7","url":null,"abstract":"<div><p>In this work, the synergistic enhancement of strength and ductility in a high-Cr Ni-based polycrystalline superalloy was achieved through modulating the precipitation behavior. The optimized alloy with more irregular shape and higher linear density of M₂₃C₆ carbide along grain boundaries, higher absolute value of γ/γ’ lattice misfit and higher area fraction of γ’ phase exhibited the best strength and elongation. Firstly, M₂₃C₆ carbide along grain boundaries in the optimized alloy, which had more irregular morphology and higher linear density, can efficiently separate micro-voids, leading to the enhancement of pinning effect and improved elongation. Secondly, the stacking fault energy of γ’ phase in the optimized alloy increased, which made greater resistance of γ’ phase to deform. Additionally, the area fraction of γ’ phase and absolute value of γ/γ’ lattice misfit in the optimized alloy were both higher, resulting in a stronger strengthening effect. Therefore, the synergistic enhancement of the strength and ductility of the superalloy was achieved by regulating the precipitation behavior of the precipitates.</p><h3>Graphical abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3701 - 3713"},"PeriodicalIF":4.5,"publicationDate":"2026-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Evolution of Microstructure, Texture, and Room Temperature Mechanical Properties of Hot-Extruded Mg-4Gd-xZn Alloys with Homogenization Followed by Furnace Cooling Treatment","authors":"Zhiyong Kan,&nbsp;Guangyu Yang,&nbsp;Chunhui Wang,&nbsp;Wanqi Jie","doi":"10.1007/s12540-025-02183-4","DOIUrl":"10.1007/s12540-025-02183-4","url":null,"abstract":"<div><p>Microstructure, texture and room temperature mechanical properties of hot-extruded Mg-4Gd-<i>x</i>Zn (0, 1, 2 wt%) alloys were comparatively investigated. The results showed that hot-extruded Mg-4Gd-<i>x</i>Zn alloys was mainly consist of α-Mg matrix and second phases streamlined along extrusion direction. Besides, some LPSO/SFs and W phases were found in grain interiors of hot-extruded Mg-4Gd-(1, 2) Zn alloys. With the increase of Zn content, the average grain size was firstly refined from 18.5 to 7.5 μm and then increased to 9.3 μm. The proportion of rare earth texture component of hot-extruded Mg-4Gd alloy was decreased after Zn addition, with the lowest proportion observed in the hot-extruded Mg-4Gd-1Zn alloy. It was found that hot-extruded Mg-4Gd-1Zn alloy exhibited the best room temperature mechanical properties, with yield strength, ultimate tensile strength and elongation of 150 MPa, 244 MPa and 29.3%, respectively. Compared with the hot-extruded Mg-4Gd alloy, its yield strength was improved by 58 MPa, with grain boundary and texture strengthening providing the strength increment of over 60%.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":703,"journal":{"name":"Metals and Materials International","volume":"32 11","pages":"3687 - 3700"},"PeriodicalIF":4.5,"publicationDate":"2026-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149176344","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}