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.

Laser processing effects on Ti−45Nb alloy surface,corrosive and biocompatible properties

The Ti−45Nb(wt.%)alloy properties were investigated in relation to its potential biomedical use.Laser surface modification was utilized to improve its performance in biological systems.As a result of the laser treatment,(Ti,Nb)O scale was formed and various morphological features appeared on the alloy surface.The electrochemical behavior of Ti−45Nb alloy in simulated body conditions was evaluated and showed that the alloy was highly resistant to corrosion deterioration regardless of additional laser surface modification treatment.Nevertheless,the improved corrosion resistance after laser treatment was evident(the corrosion current density of the alloy before laser irradiation was 2.84×10^(−8)A/cm^(2),while that after laser treatment with 5 mJ was 0.65×10^(−8)A/cm^(2))and ascribed to the rapid formation of a complex and passivating bi-modal surface oxide layer.Alloy cytotoxicity and effects of the Ti−45Nb alloy laser surface modification on the MRC-5 cell viability,morphology,and proliferation were also investigated.The Ti−45Nb alloy showed no cytotoxic effect.Moreover,cells showed improved viability and adherence to the alloy surface after the laser irradiation treatment.The highest average cell viability of 115.37%was attained for the alloy laser-irradiated with 15 mJ.Results showed that the laser surface modification can be successfully utilized to significantly improve alloy performance in a biological environment.

Nickel-based superalloy architectures with surface mechanical attrition treatment: Compressive properties and collapse behaviour

Surface modifications can introduce natural gradients or structural hierarchy into human-made microlattices,making them simultaneously strong and tough.Herein,we describe our investigations of the mechanical properties and the underlying mechanisms of additively manufactured nickel–chromium superalloy(IN625)microlattices after surface mechanical attrition treatment(SMAT).Our results demonstrated that SMAT increased the yielding strength of these microlattices by more than 64.71%and also triggered a transition in their mechanical behaviour.Two primary failure modes were distinguished:weak global deformation,and layer-by-layer collapse,with the latter enhanced by SMAT.The significantly improved mechanical performance was attributable to the ultrafine and hard graded-nanograin layer induced by SMAT,which effectively leveraged the material and structural effects.These results were further validated by finite element analysis.This work provides insight into collapse behaviour and should facilitate the design of ultralight yet buckling-resistant cellular materials.

Laser surface melting AZ31B magnesium alloy with liquid nitrogen-assisted cooling

Laser surface melting（LSM） is a high-energy surface treatment that allows modification of the microstructure and surface properties of Mg alloys. In the present work, an attempt of LSM on magnesium alloy with liquid nitrogen-assisted cooling（LNSC） was carried out to get the higher cooling rate and improve the surface properties. The experimental results were compared with those of Ar gas protection at room temperature. The samples after LSM with LNSC resulted in a thinner melted layer, a highly homogeneous, refined melted microstructure and formed a lot of worm-like nanocrystals and local amorphous structures. Microhardness of the melted layer with LNAC was improved to HV 90-148 as compared to HV 65-105 of the samples with Ar gas protection. The corrosion resistance of the melted layer in a 3.5% Na Cl solution（mass fraction） was improved because of the grain refinement and redistribution of β-Mg17Al12 phases following rapid quenching associated with the process.

Haemocompatibility of Ti-3Zr-2Sn-3Mo-25Nb biomedical alloy with surface heparinization using electrostatic self assembly technology

The haemocompatibility of Ti-3Zr-2Sn-3Mo-25Nb biomedical alloy was studied after surface heparinization. A layer of sol-gel TiO2 films was applied on the alloy samples followed by active treatment in the bio-functionalized solution for introducing the OH- and groups, and then the heparin was immobilized on the active TiO2 films through the electrostatic self assembly technology. It is shown that the heparinized films are mainly composed of anatase and rutile with smooth and dense surface. In vitro blood compatibility was evaluated by haemolysis test, clotting time and platelet adhesion behavior tests. The results show that the haemocompatibility of the alloy could be significantly improved by surface heparinization.

Influence of laser parameters on the microstructures and surface properties in laser surface modification of biomedical magnesium alloys

Biodegradable implants from magnesium(Mg)alloys have emerged in the biomedical field especially in the orthopedic and cardiovascular stent applications owing to their low density,high specific strength,excellent machinability,good biocompatibility,and biodegradability.The primary shortcoming of Mg-based implants is their low corrosion resistance in the physiological environment,which results in premature mechanical integrity loss before adequate healing and the production of excessive hydrogen gas,which is harmful to the body tissues and negatively affects the biocompatibility of the implant.Laser surface modification has recently received attention because it can improve the surface properties such as surface chemistry,roughness,topography,corrosion resistance,wear resistance,hydrophilicity,and thus cell response to the surface of the material.The composition and microstructures including textures and phases of laser-treated surfaces depend largely on the laser processing parameters(input laser power,laser scan velocity,frequency,pulse duration,pressure,gas circulation,working time,spot size,beam focal position,and laser track overlap)and the thermophysical properties of the substrate(solubility,melting point,and boiling point).This review investigates the impacts of various laser surface modification techniques including laser surface melting,laser surface alloying,laser cladding,laser surface texturing,and laser shock peening,and highlights their significance in improving the surface properties of biodegradable Mg alloys for implant applications.Additionally,we explore how different laser process parameters affect its composition,microstructure,and surface properties in each laser surface modification technique.

Characterization of surface liquid segregation in SSM-HPDC aluminium alloys 7075,2024,6082 and A201

The surface liquid segregation(SLS) phenomenon in semi-solid metal-high pressure die casting(SSM-HPDC) plates of 7075,2024,6082 and A201 was investigated by different techniques.Depth profiles were determined by firstly measuring the chemical composition of the surface of the plates using a Thermo Quantris optical emission spectrometer(OES).Material was then removed by a grinding process followed by measurement of the amount of material removed and chemical analysis.Chemical profiles of the main alloying elements were plotted for the cross-section of the plates in the as-cast and T6(after solution treatment) temper conditions.Vickers hardness profiles from the surface to the centre of the plates were determined.Metallographic samples of cross-sections of the castings were prepared and evaluated using a scanning electron microscope.The results show that surface liquid segregation in SSM-HPDC alloys causes significant differences in properties between the surface and the bulk of these castings in both the F and T6 temper conditions.

Influence of Production Sequence of Aluminum Alloy Hot Rolling on Strip Surface Quality

With the intensification of market competition in the aluminum alloy strip processing industry,it is dif-ficult to control the mass production of the same specifications,which is bound to affect the hot rolling production.This paper studied the effect of the hot rolling order of aluminum alloy on the surface quality of strip,such as roll printing,color difference,anodic oxidation,etc.,reasonable discharge sequence and corresponding optimization measures were formulated.

Influence of cross correlation step length on the surface stress of thin laser cladding Fe314 alloy coatings

To measure the surface stress of thin laser cladding coatings with Rayleigh waves based on the cross correlation function, this pa- per introduced the influence of cross correlation step length on the stress measurement. Flat-shaped specimens made of laser cladding Fe314 alloy coatings were performed by static tensile tests, and Rayleigh wave signals were collected during the test process with an ultrasonic pulser and receiver instrument combined with two Rayleigh wave transducers. The difference in time of flight between two signals was de- termined based on the cross correlation function. The microstructure was observed by scanning electronic microscopy. The influence of the stress on the propagation velocity of Rayleigh waves and the relationship between the difference in time of flight and tensile stress under dif- ferent cross correlation step lengths were analyzed. The inhomogeneous deformation of the coatings affects the relationship between the dif- ference in time of flight and tensile stress; the stress measurement of the coatings is nearly constant with the increase of cross correlation step length when it attains one cycle.

The influence of surface roughness and deformation on dechromization of a Cu-Cr alloy

In order to realize the dechromization of a Cu-Cr alloy in HCl solution, the influence of surface roughness and deformation on dechromization of the Cu-Cr alloy was studied by means of metallographic observation, TEM, SEM/EDX, and CH1660A electrochemical instrument. The results showed that the bigger the sample＇s deformation and surface roughness, the shorter the incubation time of dechromization of the Cu-Cr alloy, and the trend of dechromization increases. Simultaneously, the deformation can increase the dechromization rate, invite stress corrosion, and decrease the compactibifity of the microstructure of the dechromization layer. And yet the surface roughness does not obviously affect the dechromization rate and the compactibility of the dechromization layer.

Microstructure and surface texture driven improvement in in-vitro response of laser surface processed AZ31B magnesium alloy

The present work explored effects of laser surface melting on microstructure and surface topography evolution in AZ31B magnesium alloy.Thermokinetic effects experienced by the material during laser surface melting were simulated using a multiphysics finite element model.Microstructure and phase evolution were examined using scanning electron microscopy,X-ray diffraction,and electron back scatter diffraction.Surface topography was evaluated using white light interferometry.The interaction of surface melted samples with simulated body fluid was monitored by contact angle measurements and immersion studies up to 7 days.Laser surface melting led to formation of a refined microstructure with predominantly basal crystallographic texture.Concurrently,the amount ofβphase(Mg_(17)Al_(12))increased with an increase in the laser fluence.βphase preferentially decorated the cell boundaries.In terms of topography,the surface became progressively rougher with an increase in laser fluence.As a result,upon immersion in simulated body fluid,the laser surface melted samples showed an improved wettability,corrosion resistance,and precipitation of mineral having composition closer to the hydroxyapatite bone mineral compared to the untreated sample.

Effects of low-frequency electromagnetic field on the surface quality of 7050 aluminum alloy ingots during the hot-top casting process

To improve the quality of 7050 aluminum alloy ingots, low-frequency electromagnetic （LFE） field was applied during the conventional hot-top casting process. Macrostructures and microstructures of the ingots by the conventional and LFE hot-top casting processes were studied. The experimental results show that when the LFE field is turn off during the hot-top casting process, cold folding appears, and the as-cast structure becomes very coarse. Additionally, the thickness of the shell zone is much thinner during the low-frequency electromagnetic hot-top casting process than that during the conventional hot-top casting process. Some reasons for low-frequency electromagnetic field improving the surface quality, refining the structure of the ingot, and minimizing the thickness of the shell zone have been studied.

Application of response surface methodology to maximize tensile strength and minimize interface hardness of friction welded dissimilar joints of austenitic stainless steel and copper alloy

An attempt was made to optimize friction welding parameters to attain a minimum hardness at the interface and a maximum tensile strength of the dissimilar joints of AISI 304 austenitic stainless steel （ASS） and copper （Cu） alloy using response surface methodology （RSM）. Three-factor, five-level central composite design matrix was used to specify experimental conditions. Twenty joints were fabricated using ASS and Cu alloy. Tensile strength and interface hardness were measured experimentally. Analysis of variance （ANOVA） method was used to find out significant main and interaction parameters and empirical relationships were developed using regression analysis. The friction welding parameters were optimized by constructing response graphs and contour plots using design expert software. The developed empirical relationships can be effectively used to predict tensile strength and interface hardness of friction welded ASS-Cu joints at 95% confidence level. The developed contour plots can be used to attain required level of optimum conditions to join ASS-Cu alloy by friction welding process.

Surface modification of magnesium alloys using thermal and solid-state cold spray processes:Challenges and latest progresses

Potential engineering applications of magnesium(Mg)and Mg-based alloys,as the lightest structural metal,have made them a popular subject of study.However,the inferior corrosion and wear characteristics significantly limit their application range.It is widely recognized that surface treatment is the most commonly utilized technique for remarkably improving a substrate’s surface characteristics.Numerous methods have been introduced for the surface treatment of Mg and Mg-based alloys to improve their corrosion behavior and tribological performance.Among these,thermal spray(TS)technology provides several methods for deposition of various functional metallic,ceramic,cermet,or other coatings tailored to particular conditions.Recent researches have shown the tremendous potential for thermal spray coated Mg alloys for biomedical and industrial applications.In this context,the cold spray(CS)method,as a comparatively new TS coating technique,can generate the coating layer using kinetic energy rather than combined thermal and kinetic energies,like the high-velocity oxy-fuel(HVOF)spray method.Moreover,the CS process,as a revolutionary method,is able to repair and refurbish with a faster turnaround time;it also provides solutions that do not require dealing with the thermal stresses that are part of the other repair processes,such as welding or other TS processes using a high-temperature flame.In this review paper,the recently designed coatings that are specifically applied to Mg alloys(primarily for industrial applications)employing various coating processes are reviewed.Because of the increased utilization of CS technology for both 3D printed(additively manufactured)coatings and repair of structurally critical components,the most recent CS methods for the surface treatment,repair,and refurbishment of Mg alloys as well as their benefits and restrictions are then discussed and reviewed in detail.Lastly,the prospects of this field of study are briefly discussed,along with a summary of the presented work.

Surface modification of biomedical Mg-Ca and Mg-Zn-Ca alloys using selective laser melting: Corrosion behaviour, microhardness and biocompatibility

Magnesium alloys such as Mg–Ca and Mg–Zn–Ca are good orthopaedic materials;however their tendency to corrode is high.Herein we utilize selective laser melting(SLM)to modify the surface of these Mg alloys to simultaneously improve the corrosion behaviour and microhardness.The corrosion rate decreased from 2.1±0.2 mm/y to 1.0±0.1 mm/y for the laser-processed Mg–0.6Ca,and from 1.6±0.1 mm/y to 0.7±0.2 mm/y for laser-processed Mg–0.5Zn–0.3Ca.The microhardness increased from 46±1 HV to 56±1 HV for Mg–0.6Ca,and from 47±3 HV to 55±3 HV for Mg–0.5Zn–0.3Ca.In addition,good biocompatibility remained in the laser processed Mg alloys.The improved properties are attributed to laser-induced grain refinement,confined impurity elements,residual stress,and modified surface chemistry.The results demonstrated the potential of SLM as a surface engineering approach for developing advanced biomedical Mg alloys.

Micro structure and corrosion behavior of ALD AI2O3 film on AZ31 magnesium alloy with different surface roughness

There remains growing interest in magnesium(Mg)and its alloys,as they are the lightest structural metallic materials and potential metallic biomaterials.In spite of the greatest historical Mg usage at present,the wider use of Mg alloys remains restricted by the poor corrosion resistance.A nano amorphous film,as the composition of Al2O3,had now been deposited on the AZ31 Mg alloy substrate by atomic layer deposition(ALD).Grazing incidence X-ray diffraction(GIXRD),X-ray reflectivity(XRR),X-ray photoelectron spectroscopy(XPS),atomic force microscope(AFM)and scanning electron microscopy(SEM)had been employed to identify the chemical compositions,microstructure and Al2O3/Mg interface of specimens firstly.Then corrosion behavior had been evaluated by neutral salt spray test and electrochemical measurement.The results showed that nano amorphous film made a homogeneous cover on Mg alloy.The film could improve the corrosion resistance of Mg alloy greatly,not only with a positive shift in Ecorr and a decrease in icorr,but also with a more uniform corroded mode.Furthermore,the roughness was found to be an important factor for corrosion resistant,in the way that rougher surface was corroded worse,and greater improvement would be in corrosion resistant after nano amorphous film deposition.

Evaluation of surface roughness and optimization of cutting parameters in turning of AA2024 alloy under different cooling-lubrication conditions using RSM method

In the present study,the effect of reduction of cutting fluid consumption on the surface quality and tool wear was studied.Mathematical models were developed to predict the surface roughness using response surface methodology(RSM).Analysis of variance(ANOVA)was used to investigate the significance of the developed regression models.The results showed that the coefficient of determination values(R^2)for the developed models was 97.46%for dry,89.32%for flood mode(FM),and 99.44%for MQL,showing the high accuracy of fitted models.Also,under the minimum quantity lubrication(MQL)condition,the surface roughness improved by 23%−44%and 19%−41%compared with dry and FM,respectively,and the SEM images of machined surface proved the statement.The prepared SEM images of tool rake face also showed a considerable decrease in adhesion wear.Built-up edge and built-up layer were the two main products of the adhesion wear,and energy-dispersive X-ray spectroscopy(EDX)analysis of specific points on the tool faces helped to discover the chemical compositions of adhered materials.By changing dry and FM to MQL mode,dominant mechanism of tool wear in machining aluminum alloy was significantly decreased.Breakage wear that led to early failure of cutting edge was also controlled by MQL technique.

Modeling and analysis of surface roughness on machining of Nimonic C-263 alloy by PVD coated carbide insert

The effects of the cutting parameters （cutting speed, feed rate and depth of cut） on the surface roughness in machining the Nimonic C-263 alloy were investigated. The experiments were conducted using Taguchi＇s experimental design. The effect of cutting parameters on surface roughness was evaluated and the optimum cutting conditions for minimizing the surface roughness were determined. A second order model was established between the cutting parameters and surface roughness, using the response surface methodology. The experimental results revealed that among the parameters considered, the feed rate is the most significant which influences the surface roughness, followed by the cutting speed. The predicted values and measured values are fairly close, which indicates that the developed model can be effectively used to predict the surface roughness in machining the Nimonic C-263 alloy. The predicted values are validated using the additive law.

Influence of volume percentage of NanoTiB2 particles on tribological&mechanical behaviour of 6061-T6 Al alloy nano-surface composite layer prepared via friction stir process

The aim of present study is to analyze the influence of volume percentage(vol.%) of nano-sized particles(TiB_2: average size is 35 nm) on microstructure, mechanical and tribological behavior of 6061-T6 Al alloy surface nano composite prepared via Friction stir process(FSP). The microstructure of the fabricated surface nanocomposites is examined using optical microscopy(OM) and scanning electron microscope(SEM) for distribution of TiB_2 nano reinforcement particles, thickness of nano composite layer formed on the Aluminum alloy substrate and fracture features. The depth of surface nano composite layer is measured as 3683.82 m m along the cross section of stir zone of nano composite perpendicular to FSP. It was observed that increase in volume percentage of TiB_2 particles, the microhardness is increased up to132 Hv and it is greater than as-received Al alloy's microhardness(104 Hv). It is also observed that at 4volume percentage higher tensile properties exhibited as compared with the 2 and 8 vol. %. It is found that high wear resistance exhibited at 4 volume percentage as-compared with the 2 and 8 vol. %. The observed wear and mechanical properties are interrelated with microstructure, fractography and worn morphology.

Friction Stir Processing of Thixoformed AZ91D Magnesium Alloy and Fabrication of Surface Composite Reinforced by SiC_ps

The microstructural evolution characteristics of the thermomechanically affected zone （TMAZ） alloy during friction stir processing （FSP） of thixoformed （TF） AZ91D alloy were investigated. Simultaneously, a surface composite layer reinforced by SiC particles （SiCps） was prepared on the alloy by FSP and the corresponding tribological properties were examined. The experimental results indicate that dynamic recrystallization and mechanical separation （including splitting and fracture of the primary grains） are the main mechanisms of grain refinement for the TMAZ. A composite surface reinforced by uniformly distributed SiCps was prepared on the alloy. Compared with the corresponding permanent mould casting alloy and the TF alloy without composite surface, the TF alloy with composite surface has the highest wear resistance and lowest friction coefficient.