An overview of additively manufactured metal matrix composites:preparation,performance,and challenge

Metal matrix composites(MMCs)are frequently employed in various advanced industries due to their high modulus and strength,favorable wear and corrosion resistance,and other good properties at elevated temperatures.In recent decades,additive manufacturing(AM)technology has garnered attention as a potential way for fabricating MMCs.This article provides a comprehensive review of recent endeavors and progress in AM of MMCs,encompassing available AM technologies,types of reinforcements,feedstock preparation,synthesis principles during the AM process,typical AM-produced MMCs,strengthening mechanisms,challenges,and future interests.Compared to conventionally manufactured MMCs,AM-produced MMCs exhibit more uniformly distributed reinforcements and refined microstructure,resulting in comparable or even better mechanical properties.In addition,AM technology can produce bulk MMCs with significantly low porosity and fabricate geometrically complex MMC components and MMC lattice structures.As reviewed,many AM-produced MMCs,such as Al matrix composites,Ti matrix composites,nickel matrix composites,Fe matrix composites,etc,have been successfully produced.The types and contents of reinforcements strongly influence the properties of AM-produced MMCs,the choice of AM technology,and the applied processing parameters.In these MMCs,four primary strengthening mechanisms have been identified:Hall–Petch strengthening,dislocation strengthening,load transfer strengthening,and Orowan strengthening.AM technologies offer advantages that enhance the properties of MMCs when compared with traditional fabrication methods.Despite the advantages above,further challenges of AM-produced MMCs are still faced,such as new methods and new technologies for investigating AM-produced MMCs,the intrinsic nature of MMCs coupled with AM technologies,and challenges in the AM processes.Therefore,the article concludes by discussing the challenges and future interests of AM of MMCs.

Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21^(st )century

Rising concerns about climate change drive the demand for lightweight components.Magnesium(Mg)alloys are highly valued for their low weight,making them increasingly important in various industries.Researchers focusing on enhancing the characteristics of Mg alloys and developing their Metal Matrix Composites(MMCs)have gained significant attention worldwide over the past decade,driven by the global shift towards lightweight materials.Friction Stir Processing(FSP)has emerged as a promising technique to enhance the properties of Mg alloys and produce Mg-MMCs.Initially,FSP adapted to refine grain size from the micro to the nano level and accelerated the development of MMCs due to its solid-state nature and the synergistic effects of microstructure refinement and reinforcement,improving strength,hardness,ductility,wear resistance,corrosion resistance,and fatigue strength.However,producing defect-free and sound FSPed Mg and Mg-MMCs requires addressing several variables and their interdependencies,which opens up a broad range of practical applications.Despite existing reviews on individual FSP of Mg,its alloys,and MMCs,an attempt has been made to analyze the latest research on these three aspects collectively to enhance the understanding,application,and effectiveness of FSP for Mg and its derivatives.This review article discusses the literature,classifies the importance of Mg alloys,provides a historical background,and explores developments and potential applications of FSPed Mg alloys.It focuses on novel fabrication methods,reinforcement strategies,machine and tool design parameters,material characterization,and integration with other methods for enhanced properties.The influence of process parameters and the emergence of defects are examined,along with specific applications in mono and hybrid composites and their microstructure evolution.The study identifies promising reinforcement materials and highlights research gaps in FSP for Mg alloys and MMCs production.It concludes with significant recommendations for further exploration,reflecting ongoing advancements in this field.

Ballistic performance of titanium-based layered composites made using blended elemental powder metallurgy and hot isostatic pressing

Metal matrix composites tiles based on Ti-6Al-4V(Ti64)alloy,reinforced with 10,20,and 40(vol%)of either TiC or TiB particles were made using press-and-sinter blended elemental powder metallurgy(BEPM)and then bonded together into 3-layer laminated plates using hot isostatic pressing(HIP).The laminates were ballistically tested and demonstrated superior performance.The microstructure and properties of the laminates were analyzed to determine the effect of the BEPM and HIP processing on the ballistic properties of the layered plates.The effect of porosity in sintered composites on further diffusion bonding of the plates during HIP is analyzed to understand the bonding features at the interfaces between different adjacent layers in the laminate.Exceptional ballistic performance of fabricated structures was explained by a significant reduction in the residual porosity of the BEPM products by their additional processing using HIP,which provides an unprecedented increase in the hardness of the layered composites.It is argued that the combination of the used two technologies,BEPM and HIP is principally complimentary for the materials in question with the abilities to solve the essential problems of each used individually.

Recent advances in self-lubricating metal matrix nanocomposites reinforced by carbonous materials:A review

Metal matrix self-lubricating materials lie at the core of cutting-edge aerospace,mechanical,and electrical industries,which demand technological performances that cannot be met by traditional liquid lubricants.Rapid innovation in nanocarbon materials in recent years enabled rapid development of advanced nanocomposites for applications in structural engineering and functional devices.Carbonous materials(e.g.,graphite,graphene and carbon nanotubes),exhibit a wide range of unique electrical,mechanical,and thermal properties,which are also considered ideal lubricating reinforcements for metal matrix nanocomposites(MMCs)with superior mechanical and tribological properties.In this review,we first showcase the distinctive features of the constituents commonly employed in self-lubricating MMCs,encompassing the high-strength metallic matrix and nano-carbonous reinforcement.Then,we present a comprehensive overview of the recent advancements in preparation techniques for these advanced MMCs,followed by an in-depth discussion on their corresponding tribological properties and wear mechanisms.We close this review by outlining key problems to be solved and the future trend of the development in self-lubricating MMCs.

Hot deformation behaviors of 35% SiC_p/2024Al metal matrix composites

The hot deformation behaviors of 35%SiCp/2024 aluminum alloy composites were studied by hot compression tests using Gleeble-1500D thermo-mechanical simulator at temperatures ranging from 350 to 500 °C under strain rates of 0.01-10 s-1. The true stress-true strain curves were obtained in the tests. Constitutive equation and processing map were established. The results show that the flow stress decreases with the increase of deformation temperature at a constant strain rate, and increases with the increase of strain rate at constant temperature, indicating that composite is a positive strain rate sensitive material. The flow stress behavior of composite during hot compression deformation can be represented by a Zener-Hollomon parameter in the hyperbolic sine form. Its activation energy for hot deformation Q is 225.4 kJ/mol. To demonstrate the potential workability, the stable zones and the instability zones in the processing map were identified and verified through micrographs. Considering processing map and microstructure, the hot deformation should be carried out at the temperature of 500 °C and the strain rate of 0.1-1 s-1.

Development of Al-12Si-xTi system active ternary filler metals for Al metal matrix composites

To improve the wettability of Al metal matrix composites（Al-MMCs） by common filler metals,Al-12Si-xTi（x=0.1,0.5,1,3.0;mass fraction,%） system active ternary filler metals were prepared.It was demonstrated that although the added Ti existed within Ti（Al1-xSix）3（0≤x≤0.15） phase,the shear strength and shear fracture surface of the developed Al-12Si-xTi brazes were quite similar to those of traditional Al-12Si braze due to the presence of similar microstructure of Al-Si eutectic microstructure with large volume fraction.So,small Ti addition（～1%） did not make the active brazes brittle and hard compared with the conventional Al-12Si braze.The measured melting range of each Al-12Si-xTi foil was very similar,i.e.,580-590 ℃,because the composition was close to that of eutectic.For wettability improvement,with increasing Ti content,the interfacial gap between the Al2O3 reinforcement and filler metal（R/M） could be eliminated,and the amount of the remainder of the active fillers on the composite substrate decreased after sessile drop test at 610 ℃ for 30 min.So,the wettability improvement became easy to observe repeatedly with increasing Ti content.Additionally,the amount and size of Ti（AlSi）3 phase were sensitive to the Ti content（before brazing） and Si content（after brazing）.

MACHINING OF METAL MATRIX COMPOSITES

Two types of aluminium-based composites reinforced respectively with 20 vol short fibre alumina and with a hybrid of 15 vol SiC particle and 5 vol short alumina fibre are machined with different tool materials:cemented carbide,ceramic,cubic boron nitride(CBN)and polycrystalline diamond(PCD).The analysis on tool wear shows that the various tool materials exhibite different tool wear behaviours,and the tool wear mechanisma are discussed.Apparently,PCD tools do not necessarily guarantee dimensional stability but they can provide the most economic means for machining all sorts of composites.Consequently,a suitable tool material is suggested for machining each metal matrix composite(MMC) from the standpoints of tool wear and machined surface finish.

12.6μm-Thick Asymmetric Composite Electrolyte with Superior Interfacial Stability for Solid-State Lithium-Metal Batteries

Solid-state lithium metal batteries(SSLMBs)show great promise in terms of high-energy-density and high-safety performance.However,there is an urgent need to address the compatibility of electrolytes with high-voltage cathodes/Li anodes,and to minimize the electrolyte thickness to achieve highenergy-density of SSLMBs.Herein,we develop an ultrathin(12.6μm)asymmetric composite solid-state electrolyte with ultralight areal density(1.69 mg cm^(−2))for SSLMBs.The electrolyte combining a garnet(LLZO)layer and a metal organic framework(MOF)layer,which are fabricated on both sides of the polyethylene(PE)separator separately by tape casting.The PE separator endows the electrolyte with flexibility and excellent mechanical properties.The LLZO layer on the cathode side ensures high chemical stability at high voltage.The MOF layer on the anode side achieves a stable electric field and uniform Li flux,thus promoting uniform Li^(+)deposition.Thanks to the well-designed structure,the Li symmetric battery exhibits an ultralong cycle life(5000 h),and high-voltage SSLMBs achieve stable cycle performance.The assembled pouch cells provided a gravimetric/volume energy density of 344.0 Wh kg^(−1)/773.1 Wh L^(−1).This simple operation allows for large-scale preparation,and the design concept of ultrathin asymmetric structure also reveals the future development direction of SSLMBs.

Laser‑Induced and MOF‑Derived Metal Oxide/Carbon Composite for Synergistically Improved Ethanol Sensing at Room temperature

Advancements in sensor technology have significantly enhanced atmospheric monitoring.Notably,metal oxide and carbon(MO_(x)/C)hybrids have gained attention for their exceptional sensitivity and room-temperature sensing performance.However,previous methods of synthesizing MO_(x)/C composites suffer from problems,including inhomogeneity,aggregation,and challenges in micropatterning.Herein,we introduce a refined method that employs a metal–organic framework(MOF)as a precursor combined with direct laser writing.The inherent structure of MOFs ensures a uniform distribution of metal ions and organic linkers,yielding homogeneous MO_(x)/C structures.The laser processing facilitates precise micropatterning(<2μm,comparable to typical photolithography)of the MO_(x)/C crystals.The optimized MOF-derived MO_(x)/C sensor rapidly detected ethanol gas even at room temperature(105 and 18 s for response and recovery,respectively),with a broad range of sensing performance from 170 to 3,400 ppm and a high response value of up to 3,500%.Additionally,this sensor exhibited enhanced stability and thermal resilience compared to previous MOF-based counterparts.This research opens up promising avenues for practical applications in MOF-derived sensing devices.

Recent advances of metal vacancies in energy and environmental catalysis:Synthesis,characterization,and roles

With the ongoing depletion of fossil fuels,energy and environmental issues have become increasingly critical,necessitating the search for effective solutions.Catalysis,being one of the hallmarks of modern industry,offers a promising avenue for researchers.However,the question of how to significantly enhance the performance of catalysts has gradually drawn the attention of scholars.Defect engineering,a commonly employed and effective approach to improve catalyst activity,has become a significant research focus in the catalysis field in recent years.Nonmetal vacancies have received extensive attention due to their simple form.Consequently,exploration of metal vacancies has remained stagnant for a considerable period,resulting in a scarcity of comprehensive reviews on this topic.Therefore,based on the latest research findings,this paper summarizes and consolidates the construction strategies for metal vacancies,characterization techniques,and their roles in typical energy and environmental catalytic reactions.Additionally,it outlines potential challenges in the future,aiming to provide valuable references for researchers interested in investigating metal vacancies.

Recent progress in constructing fluorinated solid-electrolyte interphases for stable lithium metal anodes

Lithium metal batteries(LMBs)are emerging as a promising energy storage solution owing to their high energy density and specific capacity.However,the non-uniform plating of lithium and the potential rupture of the solid-electrolyte interphase(SEI)during extended cycling use may result in dendrite growth,which can penetrate the separator and pose significant short-circuit risks.Forming a stable SEI is essential for the long-term operation of the batteries.Fluorine-rich SEI has garnered significant attention for its ability to effectively passivate electrodes,regulate lithium deposition,and inhibit electrolyte corrosion.Understanding the structural components and preparation methods of existing fluorinated SEI is crucial for optimizing lithium metal anode performance.This paper reviews the research on optimizing LiF passivation interfaces to protect lithium metal anodes.It focuses on four types of compositions in fluorinated SEI that work synergistically to enhance SEI performance.For instance,combining compounds with LiF can further enhance the mechanical strength and ionic conductivity of the SEI.Integrating metals with LiF significantly improves electrochemical performance at the SEI/anode interface,with a necessary focus on reducing electron tunneling risks.Additionally,incorporating polymers with LiF offers balanced improvements in interfacial toughness and ionic conductivity,though maintaining structural stability over long cycles remains a critical area for future research.Although alloys combined with LiF increase surface energy and lithium affinity,challenges such as dendrite growth and volume expansion persist.In summary,this paper emphasizes the crucial role of interfacial structures in LMBs and offers comprehensive guidance for future design and development efforts in battery technology.

Research status and prospects of the fractal analysis of metal material surfaces and interfaces

As a mathematical analysis method,fractal analysis can be used to quantitatively describe irregular shapes with self-similar or self-affine properties.Fractal analysis has been used to characterize the shapes of metal materials at various scales and dimensions.Conventional methods make it difficult to quantitatively describe the relationship between the regular characteristics and properties of metal material surfaces and interfaces.However,fractal analysis can be used to quantitatively describe the shape characteristics of metal materials and to establish the quantitative relationships between the shape characteristics and various properties of metal materials.From the perspective of two-dimensional planes and three-dimensional curved surfaces,this paper reviews the current research status of the fractal analysis of metal precipitate interfaces,metal grain boundary interfaces,metal-deposited film surfaces,metal fracture surfaces,metal machined surfaces,and metal wear surfaces.The relationship between the fractal dimensions and properties of metal material surfaces and interfaces is summarized.Starting from three perspectives of fractal analysis,namely,research scope,image acquisition methods,and calculation methods,this paper identifies the direction of research on fractal analysis of metal material surfaces and interfaces that need to be developed.It is believed that revealing the deep influence mechanism between the fractal dimensions and properties of metal material surfaces and interfaces will be the key research direction of the fractal analysis of metal materials in the future.

Deep eutectic solvents for separation and purification applications in critical metal metallurgy:Recent advances and perspectives

Solvent extraction,a separation and purification technology,is crucial in critical metal metallurgy.Organic solvents commonly used in solvent extraction exhibit disadvantages,such as high volatility,high toxicity,and flammability,causing a spectrum of hazards to human health and environmental safety.Neoteric solvents have been recognized as potential alternatives to these harmful organic solvents.In the past two decades,several neoteric solvents have been proposed,including ionic liquids(ILs)and deep eutectic solvents(DESs).DESs have gradually become the focus of green solvents owing to several advantages,namely,low toxicity,degradability,and low cost.In this critical review,their classification,formation mechanisms,preparation methods,characterization technologies,and special physicochemical properties based on the most recent advancements in research have been systematically described.Subsequently,the major separation and purification applications of DESs in critical metal metallurgy were comprehensively summarized.Finally,future opportunities and challenges of DESs were explored in the current research area.In conclusion,this review provides valuable insights for improving our overall understanding of DESs,and it holds important potential for expanding separation and purification applications in critical metal metallurgy.

Molecule‑Level Multiscale Design of Nonflammable Gel Polymer Electrolyte to Build Stable SEI/CEI for Lithium Metal Battery

The risk of flammability is an unavoidable issue for gel polymer electrolytes(GPEs).Usually,flameretardant solvents are necessary to be used,but most of them would react with anode/cathode easily and cause serious interfacial instability,which is a big challenge for design and application of nonflammable GPEs.Here,a nonflammable GPE(SGPE)is developed by in situ polymerizing trifluoroethyl methacrylate(TFMA)monomers with flame-retardant triethyl phosphate(TEP)solvents and LiTFSI–LiDFOB dual lithium salts.TEP is strongly anchored to PTFMA matrix via polarity interaction between-P=O and-CH_(2)CF_(3).It reduces free TEP molecules,which obviously mitigates interfacial reactions,and enhances flame-retardant performance of TEP surprisingly.Anchored TEP molecules are also inhibited in solvation of Li^(+),leading to anion-dominated solvation sheath,which creates inorganic-rich solid electrolyte interface/cathode electrolyte interface layers.Such coordination structure changes Li^(+)transport from sluggish vehicular to fast structural transport,raising ionic conductivity to 1.03 mS cm^(-1) and transfer number to 0.41 at 30℃.The Li|SGPE|Li cell presents highly reversible Li stripping/plating performance for over 1000 h at 0.1 mA cm^(−2),and 4.2 V LiCoO_(2)|SGPE|Li battery delivers high average specific capacity>120 mAh g^(−1) over 200 cycles.This study paves a new way to make nonflammable GPE that is compatible with Li metal anode.

Porous Organic Cage‑Based Quasi‑Solid‑State Electrolyte with Cavity‑Induced Anion‑Trapping Effect for Long‑Life Lithium Metal Batteries

Porous organic cages(POCs)with permanent porosity and excellent host–guest property hold great potentials in regulating ion transport behavior,yet their feasibility as solid-state electrolytes has never been testified in a practical battery.Herein,we design and fabricate a quasi-solid-state electrolyte(QSSE)based on a POC to enable the stable operation of Li-metal batteries(LMBs).Benefiting from the ordered channels and cavity-induced anion-trapping effect of POC,the resulting POC-based QSSE exhibits a high Li+transference number of 0.67 and a high ionic conductivity of 1.25×10^(−4) S cm^(−1) with a low activation energy of 0.17 eV.These allow for homogeneous Li deposition and highly reversible Li plating/stripping for over 2000 h.As a proof of concept,the LMB assembled with POC-based QSSE demonstrates extremely stable cycling performance with 85%capacity retention after 1000 cycles.Therefore,our work demonstrates the practical applicability of POC as SSEs for LMBs and could be extended to other energy-storage systems,such as Na and K batteries.

Synergistic mechanism of metal ions and sodium N-oleoylsarcosinate on flotation separation of lepidolite from feldspar

The combined reagents of sodium N-oleoylsarcosinate(SNOS)with metal ions(Ca(Ⅱ),Mg(Ⅱ),Cu(Ⅱ),and Pb(Ⅱ))was employed to facilitate the separation of lepidolite from feldspar.The synergistic interaction mechanism of this combined reagent was systematically investigated via contact angle measurements,AFM,FTIR,species distribution calculations,and DFT calculations.The results suggested that Ca(Ⅱ)exhibited the best selectivity for activating lepidolite flotation.SNOS was chemically adsorbed on the Ca(Ⅱ)-activated lepidolite surface with an adsorption energy of−1248.91 kJ/mol while a lower adsorption energy of−598.84 kJ/mol of SNOS on Ca(Ⅱ)-activated feldspar was calculated.Therefore,this combination of SNOS and Ca(Ⅱ)is a promising reagent scheme for the efficient recovery of lithium from aluminosilicate ore.

Surface Metallization of Glass Fiber(GF)/Polyetheretherketone(PEEK) Composite with Cu Coatings Deposited by Magnetron Sputtering and Electroplating

Surface metallization of glass fiber(GF)/polyetheretherketone(PEEK)[GF/PEEK] is conducted by coating copper using electroplating and magnetron sputtering and the properties are determined by X-ray diffraction(XRD), scanning electron microscopy(SEM), and electron backscatter diffraction(EBSD).The coating bonding strength is assessed by pull-out tests and scribing in accordance with GB/T 9286-1998.The results show that the Cu coating with a thickness of 30 μm deposited on GF/PEEK by magnetron sputtering has lower roughness, finer grain size, higher crystallinity, as well as better macroscopic compressive stress,bonding strength, and electrical conductivity than the Cu coating deposited by electroplating.

Microstructure characteristics and corrosion behavior of metal inert gas welded dissimilar joints of 6005A modified by Sc and 5083 alloys

The corrosion behavior and microstructure characteristics of metal inert gas(MIG)welded dissimilar joints of the 6005A alloy modified with Sc(designated as 6005A+Sc)and the 5083 alloy were investigated using corrosion tests and microscopy techniques.Results show that the dissimilar joints exhibit strong stress corrosion cracking(SCC)resistance,maintaining substantial strength during slow strain rate tensile tests.Notably,the heat-affected zone(HAZ)and base metal(BM)on the 6005A+Sc side show superior performance in terms of inter-granular corrosion(IGC)and exfoliation corrosion(EXCO)compared to the corresponding zones on the 5083 side.The lower corrosion resistance of the 5083-BM and the 5083-HAZ can be attributed to the presence of numerous Al_(2)Mg_(3)phases and micro-scaled Al_(6)(Mn,Fe)intermetallics,mainly distributed along the rolling direction.Conversely,the enhanced corrosion resistance of the 6005A+Sc-BM and the 6005A+Sc-HAZ can be attributed to the discontinuously distributed grain boundary precipitates(β-Mg_(2)Si),the smaller grain size,and the reduced corrosive current density.

Functional inorganic additives in composite solid-state electrolytes for flexible lithium metal batteries

Flexible lithium metal batteries with high capacity and power density have been regarded as the core power resources of wearable electronics.However,the main challenge lies in the limited electrochemical performance of solid-state polymer electrolytes,which hinders further practical applications.Incorporating functional inorganic additives is an effective approach to improve the performance,including increasing ionic conductivity,achieving dendrite inhibiting capability,and improving safety and stability.Herein,this review summarizes the latest developments of functional inorganic additives in composite solid-state electrolytes for flexible metal batteries with special emphasis on their mechanisms,strategies,and cutting-edge applications,in particular,the relationship between them is discussed in detail.Finally,the perspective on future research directions and the key challenges on this topic are outlooked.

A Single-Layer Piezoelectric Composite Separator for Durable Operation of Li Metal Anode at High Rates

Piezoelectric ceramic and polymeric separators have been proposed to effectively regulate Li deposition and suppress dendrite growth,but such separators still fail to satisfactorily support durable operation of lithium metal batteries owing to the fragile ceramic layer or low-piezoelectricity polymer as employed.Herein,by combining PVDF-HFP and ferroelectric BaTiO_(3),we develop a homogeneous,single-layer composite separator with strong piezoelectric effects to inhibit dendrite growth while maintaining high mechanical strength.As squeezed by local protrusion,the polarized PVDF-HFP/BaTiO_(3)composite separator generates a local voltage to suppress the local-intensified electric field and further deconcentrate regional lithium-ion flux to retard lithium deposition on the protrusion,hence enabling a smoother and more compact lithium deposition morphology than the unpoled composite separator and the pure PVDF-HFP separator,especially at high rates.Remarkably,the homogeneous incorporation of BaTiO_(3)highly improves the piezoelectric performances of the separator with residual polarization of 0.086 pC cm^(-2)after polarization treatment,four times that of the pure PVDF-HFP separator,and simultaneously increases the transference number of lithium-ion from 0.45 to 0.57.Beneficial from the prominent piezoelectric mechanism,the polarized PVDF-HFP/BaTiO_(3)composite separator enables stable cyclic performances of Li||LiFePO_(4)cells for 400 cycles at 2 C(1 C=170 mA g^(-1))with a capacity retention above 99%,and for 600 cycles at 5 C with a capacity retention over 85%.