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.

Development of 3D bicontinuous metal-intermetallic composites through subsequent alloying process after liquid metal dealloying

This study presents a novel process for the fabrication of metal-intermetallic composites with a 3D bicontinuous structure, achieved through a combination of liquid metal dealloying(LMD) and subsequent alloying. Initially, porous Ti structures are produced using the LMD process, followed by immersion in a molten Mg-3Al(wt%) metal. Due to the higher thermodynamic miscibility of Al with Ti compared to Mg, the concentration of Al in the Ti matrix increases as the immersion time increases. This results in a sequential phase transition within the Ti matrix: α-Ti → Ti_(3)Al → Ti Al. The phase transition considerably affects the hardness and strength of the composite material,with the Mg-Ti_(3)Al-Ti Al composite exhibiting a maximum hardness nearly twice as high as that of the conventional Mg-Ti composite. This innovative process holds potential for the development of various bicontinuous metal-intermetallic composites.

Mechanical behavior of entangled metallic wire materials-polyurethane interpenetrating composites

Composite materials exhibit the impressive mechanical properties of high damping and stiffness,which cannot be attained by employing conventional single materials.Along these lines,a novel material architecture is presented in this work in order to fabricate composites with enhanced mechanical characteristics.More specifically,entangled metallic wire materials were used as the active matrix,whereas polyurethane was employed as the reinforcement elements.As a result,an entangled metallic wire material-polyurethane composite with high damping and stiffness was prepared by enforcing the vacuum infiltration method.On top of that,the mechanical properties(loss factor,energy consumption,and average stiffness)of the proposed composite materials were characterized by performing dynamic tests,and its fatigue characteristics were verified by the micro-interface bonding,as well as the macro-damage factor.The impact of the density,preloading spacing,loading amplitude,and exciting frequency on the mechanical properties of the composites were also thoroughly analyzed.The extracted results indicate that the mechanical properties of the composites were significantly enhanced than those of the pure materials due to the introduction of interface friction.Moreover,the average stiffness of the composites was about 10 times the respective value of the entangled metallic wire material.Interestingly,a rise in the loading period leads to some failure between the composite interfaces,which reduces the stiffness property but enhances the damping dissipation properties.Finally,a comprehensive dynamic mechanical model of the composites was established,while it was experimentally verified.The proposed composites possess higher damping features,i.e.,stiffness characteristics,and maintain better fatigue characteristics,which can broaden the application range of the composites.In addition,we provide a theoretical and experimental framework for the research and applications in the field of metal matrix composites.

An effective strategy of constructing multi-metallic oxides of ZnO/ CoNiO_(2)/CoO/C microflowers for improved supercapacitive performance

In this work,a new ZnO/CoNiO_(2)/CoO/C metal oxides composite is prepared by cost-effective hydrothermal method coupled with annealing process under N_(2) atmosphere.Notably,the oxidation-defect annealing environment is conducive to both morphology and component of the composite,which flower-like ZnO/CoNiO_(2)/CoO/C is obtained.Benefited from good chemical stability of ZnO,high energy capacity of CoNiO_(2) and CoO and good conductivity of C,the as-prepared sample shows promising electrochemical behavior,including the specific capacity of 1435 C·g^(-1) at 1 A·g^(-1),capacity retention of 87.3%at 20 A·g^(-1),and cycling stability of 90.5%for 3000 cycles at 5 A·g^(-1),respectively.Furthermore,the prepared ZnO/CoNiO_(2)/CoO/C/NF//AC aqueous hybrid supercapacitors device delivers the best specific energy of 55.9 W·h·kg^(-1) at 850 W·kg^(-1).The results reflect that the as-prepared ZnO/CoNiO_(2)/CoO/C microflowers are considered as high performance electrode materials for supercapacitor,and the strategy mentioned in this paper is benefit to prepare mixed metal oxides composite for energy conversion and storage.

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.

Effect of heat treatment on the microstructure,mechanical properties and fracture behaviors of ultra-high-strength SiC/Al-Zn-Mg-Cu composites

A high-zinc composite,12vol%SiC/Al-13.3 Zn-3.27 Mg-1.07Cu(wt%),with an ultra-high-strength of 781 MPa was success-fully fabricated through a powder metallurgy method,followed by an extrusion process.The effects of solid-solution and aging heat treat-ments on the microstructure and mechanical properties of the composite were extensively investigated.Compared with a single-stage sol-id-solution treatment,a two-stage solid-solution treatment(470℃/1 h+480℃/1 h)exhibited a more effective solid-solution strengthen-ing owing to the higher degree of solid-solution and a more uniform microstructure.According to the aging hardness curves of the com-posite,the optimized aging parameter(100℃/22 h)was determined.Reducing the aging temperature and time resulted in finer and more uniform nanoscale precipitates but only yielded a marginal increase in tensile strength.The fractography analysis revealed that intergranu-lar cracking and interface debonding were the main fracture mechanisms in the ultra-high-strength SiC/Al-Zn-Mg-Cu composites.Weak regions,such as the SiC/Al interface containing numerous compounds and the precipitate-free zones at the high-angle grain boundaries,were identified as significant factors limiting the strength enhancement of the composite.Interfacial compounds,including MgO,MgZn2,and Cu5Zn8,reduced the interfacial bonding strength,leading to interfacial debonding.

Design,preparation,microstructure and mechanical property of the lightweight radiation-shielding Mg-Ta-Al composites basing differential temperature hot rolling

A novel lightweight,radiation-shielding Mg-Ta-Al layered metal-matrix composite(LMC)was successful designed by doping the extremely refractory metal(Ta)into Mg sheets.These Mg-based LMCs sheets shows excellent radiation-dose shield effect,about 145 krad·a^(−1),which is about 17 times of traditional Mg alloy,while its surface density is only about 0.9 g·cm^(−2),reducing by 60%than that of pure Ta.The quantitate relationship between radiation-dose and the materials’thickness was also confirmed to the logistic function when the surface density is in the range of 0.6-1.5 g·cm^(−2).Meantime,the rolling parameters,interface microstructure and mechanical properties in both as-rolled and annealing treated samples were evaluated.The sheets possess a special dissimilar atoms diffusion transitional zone containing an obvious inter-diffusion Mg-Al interface and the unique micro-corrugated Ta-Al interface,as well as a thin Al film with a thickness of about 10μm.The special zone could reduce the stress concentration and enhance the strength of Mg-Ta-Al LMCs.The interface bonding strength reaches up to 54-76 MPa.The ultimate tensile strength(UTS)and yield strength(TYS)of the Mg-Ta-Al sheet were high to 413 MPa and 263 MPa,respectively,along with an elongation of 5.8%.The molecular dynamics(MD)analysis results show that the two interfaces exhibit different formation mechanism,the Mg-Al interface primarily depended on Mg/Al atoms diffusion basing point defects movement,while the Ta-Al interface with a micro-interlock pining shape formed by close-packed planes slipping during high temperature strain-induced deformation process.

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.

Development and Characterization of Aluminium-Based Metal Matrix Composites

Aluminum based metal matrix composites were fabricated using stir casting where silicon carbide and alumina were the reinforcements. Different types of properties (physical-density, mechanical-tensile, hardness, chemical-corrosion etc.) were measured and compared with base metals/alloys. The properties were significantly varied. The highest density was obtained for pure aluminium with 5% Al2O3 whereas the lowest was obtained for AA-4032 alloy. The highest hardness was obtained for AA-4032 with 5% Al2O3 whereas the lowest was obtained for pure Al with 5% Al2O3. The highest strength was obtained for AA-6061 with 5% coarse SiC whereas the lowest was obtained for pure Al. The highest impact strength was obtained for AA-4032 with 5% Al2O3 whereas the lowest was obtained for AA-6061. The corrosion resistance of all composites was lower than that of the base materials.

Processing of nanostructured metallic matrix composites by a modified accumulative roll bonding method with structural and mechanical considerations

Particulate reinforced metallic matrix composites have attracted considerable attention due to their lightweight, high strength, high specific modulus, and good wear resistance. A1/B4C composite strips were produced in this work by a modified accumulative roll bonding process where the strips were rotated 90° around the normal direction between successive passes. Transmission electron microscopy and X-ray diffraction analyses reveal the development of nanostructures in the Al matrix after seven passes. It is found that the B4C reinforcement distribution in the matrix is improved by progression of the process. Additionally, the tensile yield strength and elongation of the processed materials are increased with the increase of passes.

Effect of Nb on the corrosion behavior of continuous bulk metallic glass-coated steel wire composites

（Zr41.2Ti13.sCu12.sNi10Be22.5）100-~Nb~ （at%, x=0 and 8） bulk metallic glasses （BMGs） were coated on the surface of Q195 steel wires by a continuous coating process. The potentiodynamic polarization tests of these BMGs were conducted in 3.5wt% NaC1 aqueous solution. It is found that the addition of 8at% Nb into Zr41.2Ti13.sCu12.sNi10Be22.5 alloy results in the improvement of corrosion resistance with the pitting potential of -52 mV, the open circuit potential of-446 mV, and the corrosion current density of 9.86x 10-6 mA/cm2. This may be attributed to that Nb is beneficial to passivate and stabilize Zr and Ti.

Effects of infiltration parameters on mechanical and microstructural properties of tungsten wire reinforced Cu_(47)Ti_(33)Zr_(11)Ni_6Sn_2Si_1 metallic glass matrix composites

Cu47Ti33Zr11Ni6Sn2Si1-based bulk metallic glass matrix composites reinforced with tungsten wires were fabricated by infiltration process at different temperatures （850, 900, 950 and 1000 °C） and time （10, 20 and 30 min） in a quartz or a steel tube. The mechanical tests were carried out by scanning electron microscopy （SEM） and X-ray diffraction （XRD）. The results show that the maximum strength and total strain of the composite are 1778 MPa and 2.8% fabricated in steel tube at 900 °C for 10 min, and 1582 MPa and 3.6% fabricated in quartz tube at 850 °C for 10 min, respectively.

Preparation of Cu-based Bulk Metallic Glass Matrix Composites

Cu47Ti34Zr11Ni8 bulk metallic glass （BMG） matrix composites containing in situ formed TiC particles and 5-TiCu dendrite phase were developed by copper mold cast. The thermal stability and microstructure of the composites are investigated. Room temperature compression tests reveal that the composite samples exhibit higher fracture strength and distinct plastic strain of 0.2%-0.5%, comparing with that of the corresponding Cu47Ti34Zr11Ni8 monolithic BMG.

Application of semisolid process to Zr-based metallic glass matrix composites

The effect of the cooling slope on the structure of Zr-based metallic glass matrix composites was investigated by changing the cooling slope.The synthesis of bulk metallic glass composites was made by a process combining cooling slope casting and Cu mold casting for Zr66.4Nb6.4Cu10.5Ni8.7Al8 alloys.The results show that the semisolid slurry which consists of the spheroidal or rosette-type BCC crystals and the liquid phase which forms metallic glass phase can be formed by the cooling slope process in this alloy system.However,the semisolid slurry cannot reach to the mold.It is considered that higher viscosity of the liquid phase which forms metallic glass phase causes this result.Thus,parameters of the cooling slope have to be examined further.

Synthesis,structure and mechanical properties of Zr-Cu-based bulk metallic glass composites

The unusual glass-forming ability（GFA） of the Zr48Cu36Ag8Al8 alloy and the high ductility of the Zr48Cu36Ag8Al8 metallic glass-matrix composites containing Ta powder were reported.The bulk metallic glass rod with a diameter of 25 mm was successfully synthesized using copper mold casting for the Zr48Cu36Ag8Al8 alloy.High GFA of this alloy was found to be related to a large supercooled liquid region and a quaternary eutectic point with low melting temperature.The bulk metallic glass matrix composites were prepared by introducing extra Ta particles into the Zr48Cu36Ag8Al8 melt.The composites consist of Ta particles homogenously distributed in the Zr48Cu36Ag8Al8 metallic glass matrix.The optimum content of Ta powder is 10at%for the composite with the highest plasticity,which shows a plastic strain of 31%.

Tensile and compressive behavior of Ti-based bulk metallic glass composites

This article focuses on the tensile and compressive characteristics of a Ti-based bulk metallic glass composite （BMGC）. It is found that the yield stress, maximum strength, and fracture strain are 1380 MPa, 1516 MPa, and 4.3% for uniaxial tension, but 1580 MPa, 4010 MPa, and 29% for uniaxial compression, respectively. The composite displays a linear ＂work hardening＂ capacity under compression; however, the ＂work softening＂ behavior is observed in the true engineering stress-strain curve upon tensile loading. The fracture surfaces of specimens also exhibit dissimilar properties under the different loadings.

Dendritic and spherical crystal reinforced metallic glass matrix composites

Zr-based bulk metallic glass matrix composites （BMGMCs） with a composition of Zr60.0Ti14.7Nb5.3Cu5.6Ni4.4- Be10.0 （at%） were fabricated by an innovative process, i.e., semisolid processing plus Bridgman solidification. Different morphologies, distributions, and volume fractions of the crystalline phases can be achieved by tailoring the withdrawal velocity. The largest fi-acture strain of Zr60.0Ti14.7Nb5.3Cu5.6Ni4.4Be10.0 （at%） composites with the withdrawal velocity of 1.0 mm/s was found to be 16.7%. The mechanism of plasticity improvement is mainly attributed to the interpenetrated structure of the crystalline phase, which greatly confines the rapid propagation of shear bands.

Comparative study of bulk metallic glass composites with high-volume-fractioned dendritic and spherical b. c. c. phase precipitates

A dendritic β-phase reinforced bulk metallic glass(BMG) composite named as D2 was prepared by rapid quenching of a homogenous Zr60Ti14.67Nb5.33Cu5.56Ni4.44Be10 melt, and characterized by means of X-ray diffraction(XRD), scanning electron microscopy(SEM) observation and room-temperature compression test. The microstructure and mechanical properties were compared with those of the spherical β-phase reinforced composite named as composite S2. It was found that the composite D2 contains β-phase dendrites up to 56% in volume-fraction, and exhibits a ductile compressive behavior with plastic strain of 12.7%. As the high-volumefractioned β-phase dendrites transferred to coarse spherical particles of about 20 μm in diameter in the composite S2, a much improved plastic strain up to 20.4% can be achieved. Micrographs of the fractured samples reveal different interaction modes of the propagating shear bands with the dendritic and spherical β phase inclusions, resulting in different shear strains in the composite samples. The matrix of composite S2 undergoes a significantly larger shear strain than that of the composite D2 before ultimate failure, which is thought to be mainly responsible for the greatly increased global plastic strain of the S2 relative to D2.

Plasticity improvement of(Cu_(43)Zr_(48)Al_(9))_(98)Y_(2)bulk metallic glass composites by dispersed Ta particles

(Cu_(43)Zr_(48)Al_(9))_(98)Y_(2)-based bulk metallic glass composites(BMGCs)with dispersed Ta particles(3vol.%,6vol.%,9vol.%)were successfully fabricated through suction casting.The thermal properties,microstructure,and mechanical properties of the BMGCs were systematically investigated.Ta particles are homogeneously dispersed in the amorphous matrix.Ta particle reinforced BMGCs exhibit similar thermal properties and glass-forming ability with the Cu_(43)Zr_(48)Al_(9))_(98)Y_(2)base BMG.Compression test results show that the BMGC with 9vol.%Ta particles has superior mechanical performance with up to 15.7%compressive plastic strain,2,216 MPa yield strength,and 2,260 MPa fracture strength at room temperature.These homogeneously distributed Ta particles act as discrete obstacles in the amorphous matrix,restricting the highly localized shear band.This results in the formation of multiple shear bands around the Ta-rich particles,which lowers the stress concentration,allowing the shear band to propagate further and improve plasticity.

Probabilistic Modelling of Microstructural Evolution in Zr Based Bulk Metallic Glass Matrix Composites during Solidification in Additive Manufacturing

Bulk metallic glass and their composites (BMGMCs) are a new class of materials which possess superior mechanical properties as compared to existing conventional materials. Owing to this, they are potential candidates for tomorrow’s structural applications. However, they suffer from poor ductility and little or no toughness which render them brittle and they manifest catastrophic failure under applied force. Their behavior is dubious, unpredictable and requires extensive experimentation to arrive at conclusive results. In present study, an effort has been made to design bulk metallic glass matrix composites by the use of modeling and simulation. A probabilistic cellular automaton (CA) model is developed and described in present study by author which is used in conjunction with earlier developed deterministic model to predict microstructural evolution in Zr based BMGMCs in additive manufacturing liquid melt pool. It is elaborately described with an aim to arrive at quantitative relations which describe process and steps of operations. Results indicate that effect of incorporating all mass transfer and diffusion coefficients under transient conditions and precise determination of probability number play a vital role in refining the model and bringing it closer to a level that it could be compared to actual values. It is shown that proposed tailoring can account for microstructural evolution in metallic glasses.