Development on research of advanced rare-earth aluminum alloy

The active mechanisms of rare earth element erbium ( Er ) in part of aluminum alloys were investigated. Based on the investigation of the effect of the unitary rare earth elements (Er, La, Y, Ce, Nd, Gd, and Sc) and the transition element zirconium on the aluminum alloys, it is concluded that, with Er alloyed, high purity aluminum and Al Mg alloys are featured with refined grain structure, superior heat stability and even higher hardness or tensile strength with unchanged ductility; but Er is not beneficial to the mechanical property of Al Cu alloy, so is Sc. It may also be concluded, to most of the aluminum alloys, Er can be an effective alloying element, like Sc; and for the lower price of Er, the cost of modifying aluminum alloys by Er will be reduced.

Study on the hydrogen absorption properties of a YGdTbDyHo rare-earth high-entropy alloy

This study investigated the microstructure and hydrogen absorption properties of a rare-earth high-entropy alloy(HEA),YGdTbDyHo.Results indicated that the YGdTbDyHo alloy had a microstructure of equiaxed grains,with the alloy elements distributed homogeneously.Upon hydrogen absorption,the phase structure of the HEA changed from a solid solution with an hexagonal-close-packed(HCP)structure to a high-entropy hydride with an faced-centered-cubic(FCC)structure without any secondary phase precipitated.The alloy demonstrated a maximum hydrogen storage capacity of 2.33 H/M(hydrogen atom/metal atom)at 723 K,with an enthalpy change(ΔH)of-141.09 kJ·mol^(-1)and an entropy change(ΔS)of-119.14 J·mol^(-1)·K^(-1).The kinetic mechanism of hydrogen absorption was hydride nucleation and growth,with an apparent activation energy(E_(a))of 20.90 kJ·mol^(-1).Without any activation,the YGdTbDyHo alloy could absorb hydrogen quickly(180 s at 923 K)with nearly no incubation period observed.The reason for the obtained value of 2.33 H/M was that the hydrogen atoms occupied both tetrahedral and octahedral interstices.These results demonstrate the potential application of HEAs as a high-capacity hydrogen storage material with a large H/M ratio,which can be used in the deuterium storage field.

Fundamental Study of Rare-earth-containing Catalytic Reduction Systems for End-group Functionalization of Telechelic Low-molecular-weight Fluoropolymers

Herein the use of rare-earth compounds in catalytic reduction systems for the end-group functionalization of carboxyl-terminated low-molecularweight fluoropolymers was explored.Leveraging the high catalytic activity and selectivity of rare-earth compounds along with no residual impact on polymer product's performance,highly efficient catalytic reduction systems containing sodium borohydride(NaBH_(4))and rare-earth chloride(RECl_(3))were specifically designed for a telechelic carboxyl-terminated liquid fluoroeslastomer,aiming to facilitate the conversion of chainend carboxyl groups into hydroxyl groups and improvement in end-group reactivity.To achieve this,lanthanum chloride(LaCl_(3)),cerium chloride(CeCl_(3)),and neodymium chloride(NdCl_(3))were used separately to form catalytic reduction systems with NaBH_(4).The effects of solvent dosage,reaction temperature,reaction time length,and reductant dosage on carboxylic conversion were investigated,and the molecular chain structure,molecular weight,and functional group content of the raw materials and the products were analyzed and characterized by means of infrared spectroscopy(FTIR),proton nuclear magnetic resonance(^(1)H-NMR),fluorine-19 nuclear magnetic resonance(^(19)F-NMR),gel permeation chromatography(GPC),and chemical titration.Moreover,the catalytic activity and selectivity of the rare-earth chlorides,as well as the corresponding underlying interactions were discussed.Results indicated that the rare-earth-containing catalytic reduction systems studied in this work could efficiently convert the chain-end carboxyl groups into highly active hydroxyl groups,with a highest conversion up to 87.0%and differing catalytic reduction activities ranked as NaBH_(4)/CeCl_(3)>NaBH_(4)/LaCl_(3)>NaBH_(4)/NdCl_(3).Compared with the conventional lithium aluminum hydride(LiAIH_(4))reduction system,the NaBH_(4)/RECl_(3)systems provide multiple advantages such as mild reaction conditions,high conversion ratio with good selectivity,and environmental innocuity,and are potentially applicable as new reduction-catalysis combinations for the synthesis and functionalization of polymer materials.

Pyrimidine derivative as eco-friendly corrosion inhibitor for nickel−aluminum bronze in seawater

A pyrimidine derivative,6-phenyl-2-thiouracil(PT),was synthesized for developing a corrosion inhibitor(CI)applied in the protection of the nickel−aluminum bronze(NAB)in seawater.The anti-corrosion effect of PT was evaluated by the mass loss experiment,electrochemical tests and surface analysis.The results show that PT exhibits excellent inhibition performance and the maximum inhibition efficiency of PT reaches 99.6%.The interaction mechanism was investigated through X-ray photoelectron spectroscopy(XPS)and molecule dynamics simulation based on the density functional theory(DFT).The S-Cu,Al-N and Cu-N bonds are formed by the chemical interactions,leading to the adsorption of PT on the NAB surface.The diffusion of corrosive species is hindered considerably by the protective PT film with composition of(PT-Cu)_(ads)and(PT-Al)_(ads)on the PT/NAB interface.The degree of suppression is increased with the addition of more PT molecules.

Aluminum foam as buffer layer used in soft rock tunnel with large deformation

The squeezing deformation of surrounding rock is an important factor restricting the safe construction and long-term operation of tunnels when a tunnel passes through soft strata with high ground stress.Under such soft rock geological conditions,the large deformation of the surrounding rock can easily lead to the failure of supporting structures,including shotcrete cracks,spalling,and steel arch distortion.To improve the lining support performance during the large deformation of squeezed surrounding rock,this work selects aluminum foam with densities of 0.25 g/cm3,0.42 g/cm3 and 0.61 g/cm3 as the buffer layer material and carries out uniaxial confined compression tests.Through the evaluation and analysis of energy absorption and the comparison of the yield pressure of aluminum foam with those of other cushioning materials and yield pressure support systems,the strength,deformation and energy absorption of aluminum foam with a density of 0.25 g/cm3 meet the yield pressure performance requirements.The numerical model of the buffer layer yielding support system is then established via the finite element analysis software ABAQUS,and the influence of the buffer layer setting on the lining support is analyzed.Compared with the conventional support scheme,the addition of an aluminum foam buffer layer can reduce the stress and deformation of the primary support and secondary lining.The maximum and minimum principal stresses of the primary support are reduced by 13%and 15%,respectively.The maximum and minimum principal stresses of the secondary lining are reduced by 15%and 12%,respectively,and the displacement deformation of the secondary lining position is reduced by 15%.In summary,the application of aluminum foam buffer layer can reduce the stress and deformation of the primary support and secondary lining,improve the stress safety of the support and reduce the deformation of the support.

Leaching behaviors of iron and aluminum elements of ion-absorbed-rare-earth ore with a new impurity depressant

Ion-absorbed rare-earth ore is an important mineral resource which is widely extracted by in-situ leaching process. And such process generates a significant amount of impurities such as aluminum and iron ions in leaching solution simultaneously. The surface characteristics and interactions by infrared spectroscopy and X-ray diffraction were studied to optimize the leaching conditions. It is found that the environment-friendly depressant LG-01 can react with the impurity ions through the formation of a new complex on the surface of leaching residues. Thus, it reduces significantly the concentration of impurity ions in leaching solution and improves the leaching rate of rare-earth ore. Moreover, a leaching rate of 95.6% and an impurity removal rate of 92% have been achieved under the optimized conditions.

High corrosion and wear resistant electroless Ni–P gradient coatings on aviation aluminum alloy parts

A Ni–P alloy gradient coating consisting of multiple electroless Ni–P layers with various phosphorus contents was prepared on the aviation aluminum alloy. Several characterization and electrochemical techniques were used to characterize the different Ni–P coatings’ morphologies, phase structures, elemental compositions, and corrosion protection. The gradient coating showed good adhesion and high corrosion and wear resistance, enabling the application of aluminum alloy in harsh environments. The results showed that the double zinc immersion was vital in obtaining excellent adhesion (81.2 N). The optimal coating was not peeled and shredded even after bending tests with angles higher than 90°and was not corroded visually after 500 h of neutral salt spray test at 35℃. The high corrosion resistance was attributed to the misaligning of these micro defects in the three different nickel alloy layers and the amorphous structure of the high P content in the outer layer. These findings guide the exploration of functional gradient coatings that meet the high application requirement of aluminum alloy parts in complicated and harsh aviation environments.

Review on laser directed energy deposited aluminum alloys

Lightweight aluminum(Al)alloys have been widely used in frontier fields like aerospace and automotive industries,which attracts great interest in additive manufacturing(AM)to process high-value Al parts.As a mainstream AM technique,laser-directed energy deposition(LDED)shows good scalability to meet the requirements for large-format component manufacturing and repair.However,LDED Al alloys are highly challenging due to their inherent poor printability(e.g.low laser absorption,high oxidation sensitivity and cracking tendency).To further promote the development of LDED high-performance Al alloys,this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys.The porosity,cracking,distortion,inclusions,element evaporation and resultant inferior mechanical properties(worse than laser powder bed fusion)are the key challenges in LDED Al alloys.Processing parameter optimizations,in-situ alloy design,reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys.The underlying correlations between processes,alloy innovation,characteristic microstructures,and achievable performances in LDED Al alloys are discussed.The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized.This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys.Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.

Intensifying recovery of metallic aluminum in secondary aluminum dross by alkali roasting−water leaching

An innovative process was proposed to recover metallic aluminum from secondary aluminum dross(SAD)by alkali roasting−water leaching.Thermodynamic calculations and experimental results were used to illustrate the phase transformation and reaction mechanism of the alkali roasting process.The leaching behaviors of roasted residue were also analyzed.Under optimal conditions,the aluminum extraction rate reached 93.08%.In addition,the kinetics of the water leaching of roasted products was studied through shrinking core model,and it was revealed that the leaching process of aluminum was in accord with diffusion control.The apparent activation energy of the leaching process was calculated to be 3.44 kJ/mol.Based on the above study,the underlying mechanism of the alkali roasting−water leaching was clarified.

Electrorefining of aluminum in urea-imidazole chloride-aluminum chloride ionic liquids

The electrochemical behavior of Al(Ⅲ)in urea-1-butyl-3-methylimidazolium chloride-aluminum chloride(urea-BMIC-AlCl_(3))ionic liquids,and the effect of potential and temperature on the characterization of cathode products,current efficiency and energy consumption of aluminum electrorefining have been investigated.Cyclic voltammetry showed that the electrochemical reduction of Al(Ⅲ)was a one-step three-electron-transfer irreversible reaction,and the electrochemical reaction was controlled by diffusion.The diffusion coefficient of Al(Ⅲ)in urea-BMIC-AlCl_(3)ionic liquids at 313 K was 1.94×10^(−7)cm^(2)/s.The 7075 aluminum alloy was used as an anode for electrorefining,and the cathode products were analyzed by XRD,SEM and EDS.The results from XRD analysis indicated that the main phase of the cathode products was aluminum.The results from SEM and EDS characterization revealed that the cathode product obtained by electrorefining−1.2 V(vs.Al)was dense and uniform,and the mass fraction of aluminum decreased from 99.61%to 99.10%as the experimental temperature increased from 313 K to 333 K.In this work,the optimum experimental conditions were−1.2 V(vs.Al)and 313 K.At this time,the cathode current efficiency was 97.80%,while the energy consumption was 3.72 kW·h/kg.

Ultra-large aluminum shape casting:Opportunities and challenges

Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural components subject to both quasi-static,dynamic and cyclic loading,the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing.This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits.Factors affecting quality,microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms,multi-physics phenomena,and potentially large uncertainties that significantly influence the casting quality and performance.Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented.Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.

Synthesis of Organic-Inorganic Hybrid Aluminum Hypophosphite Microspheres Flame Retardant and Its Flame Retardant Research on Thermoplastic Polyurethane

Aluminum hypophosphite microspheres(AHP) were synthesized by hydrothermal method using NaH2PO2·H2O and AlCl3·6H2O as raw materials, and then the AHP microspheres were polymerized by surface polymerization of micro-nanospheres with cyclic cross-linked poly(cyclotriphosphazene-co-4,4'-sulfonyldiphenol)(PZS). A new organic-inorganic poly(phosphonitrile)-modified aluminum hypophosphite microspheres(PZS-AHP) were synthesized by encapsulation and applied to flame retardant thermoplastic polyurethane(TPU). The microstructure and chemical composition of the PZS-AHP microsphere were characterized by scanning electron microscopy, transmission electron microscopy, Fourier transform infrared spectroscopy and X-ray spectroscopy. The thermal stability of PZS-AHP microsphere was explored with thermogravimetric analysis. Thermogravimetric data indicate that the PZS-AHP microspheres have excellent thermal stability. The thermal and flame-retarding properties of the TPU composites were evaluated by thermogravimetric(TG), limited oxygen index tests(LOI), and cone calorimeter test(CCT). The TPU composite achieved vertical burning(UL-94) V-0 grade and LOI value reached 29.2% when 10 wt% PZS-AHP was incorporated. Compared with those of pure TPU, the peak heat release rate(pHRR) and total heat release(THR) of TPU/10%PZS-AHP decreased by 82.2% and 42.5%, respectively. The results of CCT indicated that PZS-AHP microsphere could improve the flame retardancy of TPU composites.

Improvement of Microstructure and Mechanical Properties of Rapid Cooling Friction Stir-welded A1050 Pure Aluminum

Two-mm thick A1050 pure aluminum plates were successfully joined by conventional and rapid cooling friction stir welding(FSW), respectively. The microstructure and mechanical properties of the welded joints were investigated by electron backscatter diffraction characterization, Vickers hardness measurements, and tensile testing. The results showed that liquid CO_(2) coolant significantly reduced the peak temperature and increased the cooling rate, so the rapidly cooled FSW joint exhibited fine grains with a large number of dislocations. The grain refinement mechanism of the FSW A1050 pure aluminum joint was primarily attributed to the combined effects of continuous dynamic recrystallization, grain subdivision, and geometric dynamic recrystallization. Compared with conventional FSW, the yield strength, ultimate tensile strength, and fracture elongation of rapidly cooled FSW joint were significantly enhanced, and the welding efficiency was increased from 80% to 93%. The enhanced mechanical properties and improved synergy of strength and ductility were obtained due to the increased dislocation density and remarkable grain refinement. The wear of the tool can produce several WC particles retained in the joint, and the contribution of second phase strengthening to the enhanced strength should not be ignored.

Structure and dynamical properties during solidification of liquid aluminum induced by cooling and compression

The structural transformation from a liquid into a crystalline solid is an important subject in condensed matter physics and materials science. In the present study, first-principles molecular dynamics calculations are performed to investigate the structure and properties of aluminum during the solidification which is induced by cooling and compression. In the cooling process and compression process, it is found that the icosahedral short-range order is initially enhanced and then begin to decay, the face-centered cubic short-range order eventually becomes dominant before it transforms into a crystalline solid.

Impact of cooling rate on exfoliation corrosion resistance of a Li-containing 7xxx aluminum alloy

The impact of cooling rate after solution heat treatment on exfoliation corrosion resistance of a Li-containing 7xxx aluminum alloy was investigated by accelerated immersion and electrochemical impedance spectroscopy test,optical microscope,electron backscatter diffraction and scanning transmission electron microscope.With the decrease of cooling rate from 1700℃/s to 4℃/s,exfoliation corrosion resistance of the aged specimens decreases with rating changing from EA to EC and the maximum corrosion depth increasing from about 169.4μm to 632.1μm.Exfoliation corrosion tends to develop along grain boundaries in the specimens with cooling rates higher than about 31℃/s and along both grain boundaries and sub-grain boundaries in the specimens with lower cooling rates.The reason has been discussed based on the changes of the microstructure and microchemistry at grain boundaries and sub-grain boundaries due to slow cooling.

Zinc finger protein ZFP36 and pyruvate dehydrogenase kinase PDK1 function in ABA-mediated aluminum tolerance in rice

Aluminum(Al)toxicity poses a significant constraint on field crop yields in acid soils.Zinc finger protein36(ZFP36)is well-documented for its pivotal role in enhancing tolerance to both drought and oxidative stress in rice.This study unveils a novel function of ZFP36 modulated by abscisic acid(ABA)-dependent mechanisms,specifically aimed at alleviating Al toxicity in rice.Under Al stress,the expression of ZFP36significantly increased through an ABA-dependent pathway.Knocking down ZFP36 heightened Al sensitivity,while overexpressing ZFP36 conferred increased resistance to Al stress.Additionally,our investigations revealed a physical interaction between ZFP36 and pyruvate dehydrogenase kinase 1 in rice(OsPDK1).Biochemical assays further elucidated that OsPDK1 phosphorylates ZFP36 at the amino acid site 73–161.Subsequent experiments demonstrated that ZFP36 positively regulates the expression of ascorbate peroxidases(OsAPX1)and OsALS1 by binding to specific elements in their upstream segments in rice.Through genetic and phenotypic analyses,we unveiled that OsPDK1 influences ABA-triggered antioxidant defense to alleviate Al toxicity by interacting with ZFP36.In summary,our study underscores that pyruvate dehydrogenase kinase 1(OsPDK1)phosphorylates ZFP36 to modulate the activities of antioxidant enzymes via an ABA-dependent pathway,influencing tolerance of rice to soil Al toxicity.

AP assembled on ultrafine aluminum particle and its application to NEPE propellant

Coating modification is an important way to enhance the reactivity of aluminum powder.In this paper,ammonium perchlorate and aluminum powder were assembled into energetic microunits by liquid deposition method.Spherical particles with AP as shell and ultrafine aluminum powder as the core(Al@AP)were gained.The micromorphology results show that the coated particles are about 5μm,and the coating layer is evenly distributed on the outer surface of aluminum powder,indicating a complete coating.The energetic microunits were implanted into the nitrate ester plasticizing adhesive system(NEPE)as solid phase fillers.The effect of filler on the rheological properties,safety,mechanical properties,thermal reaction and energy properties of the system was analyzed by comparing with the raw aluminum filler.The test results show that the rheological properties,mechanical properties and pressure index of NEPE containing system Al@AP meets the requirements of solid propellant charging.Compared with Al based propellant,the mechanical sensitivity and thermal sensitivity are decreased,the safety is better,and the explosion heat of the propellant is increased by 7.8%.The engine test shows that the specific impulse is increased by 1.2 s.Al@AP can improve the energy output and safety of NEPE propellant,and has potential application prospects in high-energy propellants.

Simulation of Dynamic Recrystallization in 7075 Aluminum Alloy Using Cellular Automaton

The evolution of microstructure during hot deformation is key to achieving good mechanical properties in aluminum alloys.We have developed a cellular automaton(CA) based model to simulate the microstructural evolution in 7075 aluminum alloy during hot deformation.Isothermal compression tests were conducted to obtain material parameters for 7075 aluminum alloy,leading to the establishment of models for dislocation density,nucleation of recrystallized grains,and grain growth.Integrating these aspects with grain topological deformation,our CA model effectively predicts flow stress,dynamic recrystallization(DRX) volume fraction,and average grain size under diverse deformation conditions.A systematic comparison was made between electron back scattered diffraction(EBSD) maps and CA model simulated under different deformation temperatures(573 to 723 K),strain rates(0.001 to 1 s^(-1)),and strain amounts(30% to 70%).These analyses indicate that large strain,high temperature,and low strain rate facilitate dynamic recrystallization and grain refinement.The results from the CA model show good accuracy and predictive capability,with experimental error within 10%.

Reversible aqueous aluminum metal batteries enabled by a water-in-salt electrolyte

Aluminum(Al),the most abundant metallic element on the earth crust,has been reckoned as a promising battery material for its the highest theoretical volume capacity(8046 mAh cm^(-3)).Being rechargeable in ionic liquid electrolytes,however,the Al anode and battery case suffer from corrosion.On the other hand,Al is irreversible in aqueous electrolyte with severe hydrogen evolution reaction.Here,we demonstrate a water-in-salt aluminum ion electrolyte(WISE)based on Al and lithium salts to tackle the above challenges.In the WISE system,water molecules can be confined within the Li^(+)solvation structures.This diminished Al^(3+)-H_(2)O interaction essentially eliminates the hydrolysis effect,effectively protecting Al anode from corrosion.Therefore,long-term Al plating/stripping can be realized.Furthermore,two types of high-performance full batteries have been demonstrated using copper hexacyanoferrate(CuHCF,a Prussian Blue Analogues)and LiNi_(0.8)Co_(0.1)Mn_(0.1)O_(2)(NCM)as cathodes.The reversibility of Al anode laid the foundation for low cost rechargeable batteries suffering for large-scale energy storage.Broader context:Al batteries are expected to become a safe and sustainable alternative to lithium batteries.For decades,chase for a feasible Al secondary battery has not been successful.The key challenge is to find suitable cathode and electrolyte materials,together with which Al anode battery can function reversibly.Currently,fatal drawbacks have impeded the practical application of Al metal batteries(AMBs),such as sustained corrosion of Al anode and battery case in ionic liquid electrolytes,irreversibility issues as well as severe hydrogen evolution reaction during cycling in aqueous electrolyte.Therefore,electrolyte and their electrochemical kinetics play a vital role in the performance and environmental operating limitations of high-energy Al metal batteries.In this work,we demonstrate a nearly neutral Al ion water-in-salt electrolyte(WISE)to tackle the above challenges.The WISE shows excellent stability in the open atmosphere.The distinct solvation-sheath structure of Al^(3+)in the WISE system would protect Al metal anodes from corrosion and eliminate hydrogen evolution reaction effectively,further promoting the reversibility of Al metal anodes with dendrite-free morphology.Moreover,such a WISE exhibits superior compatibility with LiNi_(0.3)Co_(0.3)Mn_(0.3)O_(2)(NCM)and copper hexacyanoferrate(CuHCF)cathodes and long-term stabilities with high coulombic efficiency(CE)can be attained for full batteries with the WISE.The approach in this study can furnish an opportunity to develop reversible AMBs and lay the foundation for other potential multivalent-metalbased secondary batteries suffering from interface passivation and poor reversibility,which suggest the promise of multivalent metal batteries and their applications in large-scale energy storage.

Effect of combination of ultraviolet radiation and biocide on fungal-induced corrosion of high-strength 7075 aluminum alloy

The effect of ultraviolet(UV)radiation and biocide benzalkonium chloride(BKC)on fungal-induced corrosion of AA7075 induced by Aspergillus terreus(A.terreus)was deeply studied using analysis of biological activity,surface analysis,and electrochemical measurements.Results demonstrated that the planktonic and sessile spore concentrations decline by more than two orders of magnitude when UV radiation and BKC are combinedly used compared with the control.UV radiation can inhibit the biological activity of A.terreus and influence the stability of passive film of AA7075.Except for direct disinfection,the physical adsorption of BKC on the specimen can effectively inhibit the attachment of A.terreus.The combination of UV radiation and BKC can much more effectively inhibit the corrosion of AA,especially pitting corrosion,due to their synergistic effect.The combined application of UV radiation and BKC can be a good method to effectively inhibit fungal-induced corrosion.