Search Results (260)

Despite polycarbonate (PC) being a widely used engineering plastic, its notch and crack sensitivity pose challenges in critical applications. To address this, PC was blended with elastomeric polymers to explore the improvement in toughness. This study systematically investigates the toughening mechanisms of PC blended with acrylonitrile–butadiene–styrene (ABS), copolyether ester elastomer (COPE), and ABS and styrene–ethylene–butylene–styrene (SEBS) copolymer grafted with maleic anhydride (MA). The morphology and mechanical behavior were evaluated under quasi-static and medium-strain-rate tensile tests and Charpy impact tests using optical, electronic, and atomic force microscopy and Raman mapping spectroscopy. The morphological analysis reveals cavitation and crazing phenomena for COPE and SEBS-g-MA systems, and mostly debonding for ABS, indicating an improvement in toughening. While the addition of ABS improves the PC plastic deformation, modifying ABS with maleic anhydride enhances the elastic modulus. Blending PC with SEBS-g-MA increases the strain at break, and the addition of COPE significantly improves the deformation behavior of PC (by around 115%). This comparative study provides valuable insights into the performance of different PC–elastomer blends under similar conditions, supporting the selection of appropriate materials for given applications. Full article

The interest in hydrogen is rapidly expanding because of rising greenhouse gas emissions and the depletion of fossil resources. The current work focuses on employing affordable Al alloys for hydrogen production and storage to identify the most efficient alloy that performs best in each situation. In the first part of this work, hydrogen was generated from water electrolysis. The Al alloys that are being examined as electrodes in a water electrolyzer are 1050-T0, 5052-T0, 6061-T0, 6061-T6, 7075-T0, 7075-T6, and 7075-T7. The flow rate of hydrogen produced, energy consumption, and electrolyzer efficiency were measured at a constant voltage of 9 volts to identify the Al alloy that produces a greater hydrogen flow rate at higher process efficiency. The influence of the electrode surface area and water electrolysis temperature were also studied. The second part of this study examines these Al alloys’ resistance to hydrogen embrittlement for applications involving compressed hydrogen gas storage, whether they are utilized as the primary vessel in Type 1 pressure vessels or as liners in Type 2 or Type 3 pressure vessels. Al alloys underwent electrochemical charging by hydrogen and Charpy impact testing, after which a scanning electron microscope (SEM) was used to investigate the fracture surfaces of both uncharged and H-charged specimens. The structural constituents of the studied alloys were examined using X-ray diffraction analysis and were correlated to the alloys’ performance. Sensitivity analysis revealed that the water electrolysis temperature, electrode surface area, and electrode material type ranked from the highest to lowest in terms of their influence on improving the efficiency of the hydrogen production process. The 6061-T0 Al alloy demonstrated the best performance in both hydrogen production and storage applications at a reasonable material cost. Full article

This study explores the effects of tempering on the precipitation behavior and impact toughness of high-nickel steel. The specimens underwent double quenching at 870 °C and 770 °C, followed by tempering at various temperatures. Advanced characterization techniques including optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) were used to elucidate precipitation phenomena. Additionally, electron backscatter diffraction (EBSD) was employed to assess the misorientation distribution after tempering. Charpy impact tests were performed on specimens tempered at different temperatures to evaluate their toughness. The findings reveal that with increasing tempering temperature, the fraction of low-angle grain boundaries decreases, which correlates positively with enhanced impact toughness. The results demonstrate that tempering at 580 °C optimizes the material’s microstructure, achieving an impact toughness value of approximately 163 J. Full article

This study aimed to investigate the potential of antimony-doped tin oxide (ATO) as a reinforcing agent for polyamide 12 (PA12) in 3D printing by examining four mixtures with varying ATO concentrations (2.0 to 8.0 wt.%, with a 2.0 wt.% interval). These mixtures were used to fabricate filaments for the manufacturing of specimens through the material extrusion method. The mechanical properties of the resulting PA12/ATO composites and PA12 pure samples were evaluated through tensile, Charpy impact, flexural, and microhardness tests. Additionally, rheology, structure, morphology, thermal properties, pore size, and consistency in the dimensions of the samples were evaluated. Thermogravimetric analysis, along with differential scanning calorimetry, scanning electron microscopy, energy-dispersive and Raman spectroscopy, and micro-computed tomography, were conducted. The results were correlated and interpreted. The greatest reinforcement was achieved with the PA12/ATO 4.0 wt.% mixture, which exhibited a 19.3% increase in tensile strength and an 18.6% increase in flexural strength compared with pure PA12 (the control samples). The Charpy impact strength and microhardness were also improved by more than 10%. These findings indicate the merit of composites with ATO in additive manufacturing, particularly in the production of components with improved mechanical performance. Full article

The paper describes the type of changes in the structure and mechanical properties of 3D printed shapes under the influence of mineral oil. The effects of a room (23 °C) and elevated temperature (70 °C) on 3D prints manufactured by the FDM method and stored in oil for 15, 30, and 60 days on the change of properties and structure were investigated. The samples were produced from ABS (poly(acrylonitrile-co-butadiene-co-styrene)), ASA (poly(acrylonitrile-co-styrene-co-acrylate), PLA (poly(lactic acid)), and HIPS (high-impact polystyrene). Tests related to the strength of the materials, such as the static tensile test and Charpy impact test, were carried out. The structure was evaluated using a scanning electron microscope, and changes in chemical structure were determined by conducting FTIR (Fourier transform infrared spectroscopy) and TGA (thermogravimetric analysis) tests. The analysis of the results provided important information about the impact of mineral oil on specific materials. This is critical for designing and manufacturing components that can withstand mineral oil exposure in real-world environments. The materials underwent varying changes. Strength increased for PLA by about 28%, remained unchanged for ABS and HIPS during exposure for 30 days, and decreased for ASA with extended exposure up to 14%. Full article

This article is focused on the development and characterization of a series of biodegradable and eco-friendly colour masterbatches (MBs), based on natural pigments and biodegradable polylactic acid (PLA) and polybutylene succinate (PBS). Four commercial natural pigments were used, spirulina, curcumin, beetroot and chlorophyllin, to develop the colour masterbatches using a twin-screw extruder. The natural pigment-based MBs were added at 2, 4 and 6 wt%, as additives to study the effect on the properties of injected biodegradable parts (PLA and PBS). The injected samples were characterized in terms of their mechanical (tensile and Charpy impact tests) and visual properties (according to CieLab). In addition, the ageing of the coloured material was followed by colorimetric analysis after its exposure under a Xenon lamp. The mechanical results showed that the addition of coloured masterbatches in different percentages (2–6 wt%) did not significantly change the properties of the materials with respect to the as-received ones. A noticeable colour difference in the injected samples was observed after the first 50 h of artificial light exposure. Regarding environmental concerns, the study showed that the carbon footprint of natural pigments and electricity consumption during extrusion and pelletizing were lower. Full article

Nowadays, powder-based manufacturing processes are recognized as cost-efficient methods frequently employed for producing parts with intricate shapes and tight tolerances in large quantities. However, like any manufacturing method, powder-based technologies also have several disadvantages. One of the most significant issues lies in the degree of porosity. By modifying the morphology of the gas-atomized spherical 17-4PH stainless steel powder via prior ball milling and then raising both the pressure of cold compaction (1.6 GPa) and sintering temperature (1275 °C), the porosity could be reduced considerably. In our novel powder metallurgical (PM) experimental process, an exceptionally high green density of 92% could be reached by employing die wall lubrication instead of internal lubrication and utilizing induction heating for rapid sintering. After sintering (at temperatures of 1200, 1250, and 1275 °C), the samples aged in the H900 condition were then mechanically tested (Charpy impact, HV hardness, and tensile tests) as a function of porosity. Sintering at 1275 °C for one hour enabled porosity reduction to below 4%, resulting in 1200 MPa yield strength and 1350 MPa ultimate tensile strength with significant (16%) fracture strain. These values are comparable to those of the same alloy products fabricated via ingot metallurgy (IM) or additive manufacturing (AM). Full article

The unusual combination of the fundamentally contradictory properties of high tensile strength and high fracture toughness found in maraging steel makes it well suited for safety-critical applications that require high strength-to-weight materials. In certain instances, additive manufacturing (AM) has produced materials that may be desirable for safety-critical applications where impact toughness is a key property, such as structural parts for the aerospace industry or armor plates for military applications. Understanding the influence of process parameters and defect structure on the properties of maraging steel parts produced via laser powder bed fusion (LPBF) is a fundamental step towards the broader use of AM technologies for more demanding applications. In this research, the impact energy of V-notched specimens made of 1.2709 maraging steel produced by LPBF was determined via Charpy impact testing. Specimens were produced using different processing parameter sets. By combining the process parameters with the porosity values of the parts, we demonstrate that an almost full prediction of the impact properties can be achieved, paving the way for significantly reducing the expenses of destructive testing. Full article

The article describes the results of the study on laser welding of armor plates with a nominal thickness of 3.0 mm. The plates were made of Armox 500T steel characterized by a hardness of up to 540 HB, a minimum yield strength of 1250 MPa, an ultimate strength of up to 1750 MPa, and an elongation A5 minimum of 8%. The laser used for the welding tests was a solid state Yb:YAG laser. The influence of basic parameters such as laser output power, welding speed, and focal plane position on the weld geometry was determined during bead-on-plate welding tests. The optimal conditions for butt joint welding were determined, and the test joints were subjected to mechanical and impact tests, metallographic analysis, and hardness measurements. It has been shown that it is possible to laser weld Armox 500T armor plates, and at the same time it is possible to provide high quality butt joints, but this requires precise selection of welding parameters. A decrease in HAZ hardness of about 22–35% in relation to the hardness of the base material, ranging from 470 to 510 HV0.2, was found. The ultimate tensile strength of the test joints was approx. 20% lower than the Armox 500T steel. The bending tests revealed the low plasticity of the tested joints because the bending angle was just 25–35°. The results of Charpy V–notch test revealed that the impact toughness of the weld metal at −20 °C was approx. 30% lower than at room temperature. Full article

This study focuses on advancing the production of predominantly bainitic heavy plates to meet the API 5L X80 standard. The investigation involves a thorough evaluation of the influence of rolling parameters and austenite conditioning on both microstructural characteristics and mechanical properties. Accurate specifications for chemical composition, processing temperatures, and mean deformations were established using mathematical models and bibliographical references. Four rolling conditions were performed in a reversible single-stand mill, allowing for comprehensive comparison and critical analysis. Microstructural and mechanical characterizations were performed utilizing several techniques, including optical microscopy (OM), scanning electron microscopy (SEM), tensile tests, Charpy impact tests, and hardness tests to ensure adherence to API 5L standards. Additionally, the SEM-EBSD (electron backscattered diffraction) technique was employed for a complementary analysis. The EBSD analysis included crystallographic misorientation maps, mean kernel misorientation parameters (ϑ), low- and high-angle grains boundaries, mean equivalent diameter, and evaluation of the contribution of different strengthening mechanisms to yield strength. Results underscored the significant influence of austenite conditioning on both microstructure and mechanical properties. Considering the specificities of a reversible single-stand mill, it was concluded that, unlike the classic approach for ferritic or ferritic–pearlitic HSLA (high-strength low-alloy steel), when a product with a predominantly bainitic microstructure is required, the accumulated deformation in the austenite during the finishing rolling stage, as well as its temperature, must be meticulously controlled. It was shown that the greater the deformation and the lower the temperature, the more favorable the scenario for the undesired polygonal ferrite formation, which will deteriorate the material’s performance. Furthermore, an optimized production route was identified and adapted to the specificities of the employed rolling mill. The presented data have great importance for researchers, manufacturers, and users of API 5L X80 heavy plates. Full article

In this paper, a series of low-temperature CVN (Charpy V-notch impact test) and DWTT (drop-weight tear test) experiments were carried out to deal with the intensifying contradiction of strength and toughness of ultra-high-strength pipeline steel. The fracture behavior and toughening mechanisms of ultra-high-strength pipeline steel were investigated using scanning electron microscopy, transmission electron microscopy and backscattered electron diffraction systems. The results show that DWTT fractures in ultra-high-strength pipeline steel had a variety of unconventional morphological features compared to CVN fractures, including ridge protrusion in ductile fracture conditions and a large-size fracture platform in brittle fracture conditions. Therefore, DWTT fractures contained more information about the material fracturing process, and could better reflect the actual process of material fracturing. In ultra-high-strength pipeline steel, fine-grained granular bainite caused cracks to undergo large deflections or frequent small transitions, which consumed additional energy and improved toughness. In contrast, large-sized granular bainite, which consisted of low-angle grain boundaries, did not effectively prevent crack propagation when it encountered cracks, which was not conducive to improved toughness. Moreover, the M/A constituents in large-sized granular bainite aggregated, cracked, or fell off, which could easily lead to the formation of microcracks and was also detrimental to toughening. Full article

Welded joints in naval ship hull structures are weak areas under explosive load, but there are relatively few studies investigating the failure characteristics of welded joints through dynamic fracture and explosion tests. In order to explore and predict the failure characteristics of welded joints under explosive load, instrumented Charpy impact tests, explosion tests, and numerical simulations were carried out. The dynamic fracture toughness of ultra-high strength ship hull structural steel welded joints was obtained, and the dynamic stress intensity factors, together with the correlation between stress wave and crack propagation at different positions, were acquired. The results showed that the stress state at the crack tip of a Charpy impact specimen was consistent with that of a welded joint under explosive loads, and the crack initiated when the dynamic stress intensity factor exceeded the dynamic fracture toughness. The results indicated that the dynamic fracture toughness obtained by instrumented Charpy impact tests could be used to predict the crack initiation characteristics of welded structures under explosive load, and the stress wave at the crack tip was basically perpendicular to the crack propagation surface and promoted the rapid propagation of cracks. Full article

The growing need for materials that are eco-friendly and sustainable in the industrial sector has shifted focus from synthetic fossil to natural fibers, alongside the utilization of recycled polymer textiles. This research introduces a novel method for using end-of-life textiles, such as polyester and polyamide fabrics, in the production of composite materials, aiming to lessen textile waste and enhance material longevity. The mechanical attributes of flax fabric (FF), flax–recycled polyamide fabric (F/RPA), and flax–recycled polyester fabric (F/RPES) composite laminates are assessed through tensile, flexural, interlaminar shear, and Charpy impact tests. The study revealed that the addition of end-of-life synthetic fibers improves tensile strength, while the trend in modulus values suggests that flax provides a high degree of stiffness to the composites, which is moderated by the addition of synthetic fibers. This effect is consistent across both tensile and flexural testing, although the impact on stiffness is more significant in bending. The inclusion of polyester fibers in the composite laminate resulted in significant enhancements, with an 11.1% increase in interlaminar shear maximum force, a 17.4% improvement in interlaminar shear strength, and a 67.1% rise in un-notch impact energy, compared to composites made with only flax fiber (FF). The microscopic examination uncovered the internal structure and demonstrated a clear, strong bond between the polyester and polyamide fiber layers with the flax fibers. Additionally, the life cycle assessment revealed that the F/RPES composite had less environmental impact than FF and F/RPA in all 18 categories analyzed. This indicates that the environmental footprint of producing F/RPES is smaller than that of both FF and F/RPA. Full article

The need for combining dissimilar materials is steadily increasing in the manufacturing industry, and the resulting products are expected to always have high performance. While there are various methods available for joining such material pairs, one of the commonly preferred techniques is fusion welding. In this study, three different steel materials (Protection 600T, DP450, and S275JR) were joined using gas metal arc welding (GMAW) in different combinations (similar/dissimilar). The microstructure and mechanical properties of the joints were evaluated. Tensile test, Vickers microhardness (HV 0.1), bending, Charpy V-notch impact testing, and microstructure examinations were conducted to analyze the weld and heat-affected zone. The tensile strengths of the base metal materials Protection 600T, DP450, and S275JR were found to be 1524.73 ± 18.7, 500.8 ± 10.4, and 508.5 ± 9.5 MPa, respectively. In welded samples of similar materials, the highest efficiency was found to be 103.05% for DP450/DP450, while in dissimilar welded joints, it was 105.5% for the DP450/S275JR pair. Hardness values for the base materials Protection 600T, DP450, and S275JR were measured as 526.5 ± 10.5, 153.8 ± 1.8, and 162.5 ± 5.2, respectively. In all welded samples, there was an increase in hardness in the weld zone (due to the welding wire) and the heat-affected zone (due to grain size refinement). While the impact energy values of similar material pairs were close to the base material impact energy values, the impact energy values of dissimilar material pairs varied according to the base materials. In addition, in joints made with similar materials, the bending force was close to the base materials, while a decrease in bending force was observed in joints formed with dissimilar materials. As a result, the welding of DP450 and S275JR materials was carried out efficiently. Protection 600T was welded with other materials, but its welding strength was limited to the strength of the material with low mechanical properties. Full article

The effect of pre-weld heat treatment on the microstructure and low-temperature impact toughness of the coarse-grained heat-affected zone (CGHAZ) after simulated welding was systematically investigated through the utilization of scanning electron microscopy (SEM) and electron back-scattering diffraction (EBSD). The Charpy impact test validated the presence of an optimal pre-weld heat treatment condition, resulting in the highest impact toughness observed in the CGHAZ. Three temperatures for pre-weld heat treatment (690, 720 and 750 °C) were used to obtain three different matrices (Steel 1, Steel 2, Steel 3) for simulated welding. The optimal pre-weld heat treatment is 720 °C for 15 min followed by water quench. Microstructure characterization showed that there is an evident microstructure comprising bainite (B) in Steel 1 and Steel 2 after pre-weld heat treatment, while the addition of martensite (M) with the pre-weld heat treatment temperature exceeds Ac₁ by almost 60 °C (Steel 3). These differences in microstructures obtained from pre-weld heat treatment influence the refinement of high-temperature austenite during subsequent simulated welding reheating processes, resulting in distinct microstructural characteristics in the CGHAZ. After the optimal pre-weld heat treatment, Steel 2 subjected to single-pass welding thermal simulation demonstrates a refined microstructure characterized by a high density of high-angle grain boundaries (HAGBs) within the CGHAZ, particularly evident in block boundaries. These boundaries effectively prevent the propagation of brittle cracks, thereby enhancing the impact toughness. Full article