Investigation of corrosion and mechanical properties of Al–Cu–SiC–xNi composite alloys

In this study, dry sliding wear behavior and corrosion resistance of Al–Cu–SiC–xNi (x: 0, 0.5, 1, 1.5 wt.%) composites were investigated. Effect of nickel content on the microstructure and hardness of the alloys was also studied. Wear tests were conducted using a ball on disc wear test device. Corrosion behavior of Al–Cu–SiC–xNi composite alloys in 3.5% NaCl solution was investigated by using potentiodynamic polarization, impedance spectroscopy and cronoamperometric methods. The results showed that the hardness of the composite alloy increases with increasing nickel content. Maximum wear resistance is reported with the addition of 1 wt.%Ni. It was determined that corrosion resistance of Al–Cu–SiC composite alloys improved with increasing nickel content in the alloy.     

A new resource-saving,low chromium and low nickel duplex stainless steel 15Cr–xAl–2Ni–yMn

A new family of resource-saving, low Cr and low Ni duplex stainless steels, with compositions of 15Cr–xAl–2Ni–yMn (x = 1.2–2.8, y = 8–12, wt.%) has been developed by examining the effect of Al and Mn on microstructure, mechanical property and corrosion property. The results show that 15Cr–1.2Al–2.0Ni–8Mn and 15Cr–2.0Al–2.0Ni–10Mn alloys have a balanced ferrite–austenite relation and that 15Cr–2.8Al–2.0Ni–12Mn alloy has a primary ferrite phase structure. The ferrite volume fraction increases with the solution treatment temperature and Al content while decreases with Mn content. No precipitate was found after solution-treated at 750 °C for 30 min. 15Cr–1.2Al–2.0Ni–8Mn alloy has a strong strain hardening effect, and 15Cr–2.0Al–2.0Ni–10Mn alloy has a good TRIP effect. Both of the 15Cr–1.2Al–2.0Ni–8Mn and 15Cr–2.0Al–2.0Ni–10Mn alloys have excellent impact toughness at low temperature with the impact energy higher than 125 J at −40 °C. The pitting corrosions always occur in austenite phase. Among the designed alloys, 15Cr–1.2Al–2.0Ni–8Mn and 15Cr–2.0Al–2.0Ni–10Mn are found to be excellent alloys with a proper phase proportion and a better combination of superior mechanical property and good pitting corrosion resistance.     

Mechanical and bio-corrosion properties of quaternary Mg–Ca–Mn–Zn alloys compared with binary Mg–Ca alloys

Binary Mg–xCa alloys and the quaternary Mg–Ca–Mn–xZn were studied to investigate their bio-corrosion and mechanical properties. The surface morphology of specimens was characterized by X-ray diffraction (XRD), Fourier-transformed infrared spectroscopy (FTIR), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The results of mechanical properties show that the yield strength (YS), ultimate tensile strength (UTS) and elongation of quaternary alloy increased significantly with the addition of zinc (Zn) up to 4 wt.%. However, further addition of Zn content beyond 4 wt.% did not improve yield strength and ultimate tensile strength. In contrast, increasing calcium (Ca) content has a deleterious effect on binary Mg–Ca alloys. Compression tests of the magnesium (Mg) alloys revealed that the compression strength of quaternary alloy was higher than that of binary alloy. However, binary Mg–Ca alloy showed higher reduction in compression strength after immersion in simulated body fluid. The bio-corrosion behaviour of the binary and quaternary Mg alloys were investigated using immersion tests and electrochemical tests. Electrochemical tests shows that the corrosion potential (E_corr) of binary Mg–2Ca significantly shifted toward nobeler direction from −1996.8 to −1616.6 mV_SCE with the addition of 0.5 wt.% manganese (Mn) and 2 wt.% Zn content. However, further addition of Zn to 7 wt.% into quaternary alloy has the reverse effect. Immersion tests show that the quaternary alloy accompanied by two secondary phases presented higher corrosion resistance compared to binary alloys with single secondary phase. The degradation behaviour demonstrates that Mg–2Ca–0.5Mn–2Zn alloy had the lowest degradation rate among quaternary alloys. In contrast, the binary Mg–2Ca alloy demonstrated higher corrosion rates, with Mg–4Ca alloy having the highest rating. Our analysis showed the Mg–2Ca–0.5Mn–2Zn alloy with suitable mechanical properties and excellent corrosion resistance can be used as biodegradable implants.     

Corrosion resistance of directionally solidified Al–6Cu–1Si and Al–8Cu–3Si alloys castings

The aim of this article is to compare the electrochemical corrosion resistance of two as-cast Al–6 wt.% Cu–1 wt.% Si and Al–8 wt.% Cu–3 wt.% Si alloys considering both the solutes macrosegregation profiles and the scale of the microstructure dendritic arrays. A water-cooled unidirectional solidification system was used to obtain the as-cast samples. Electrochemical impedance spectroscopy (EIS) and potentiodynamic anodic polarization techniques were used to analyze the corrosion resistance in a 0.5 M NaCl solution at 25 °C. It was found that the Al–8Cu–3Si alloy has better electrochemical corrosion resistance than the Al–6Cu–1Si alloy for any position along the casting length. At the castings regions where the Cu inverse profile prevailed (up to about 10 mm from the castings surface) the corrosion current density decreased up to 2.5 times with the decrease in the secondary dendrite arm spacing.     

Bond strength of Ti–5Cr based alloys to dental porcelain with Mo addition

Porcelain fused to metal crown (PFM) is widely used in dental restoration for its esthetics. Due to its excellent corrosion resistance, biocompatibility and mechanical properties, commercially pure titanium (c.p. Ti) and Ti–6Al–4V alloy have dramatically improved dental implants and prosthesis, despite the insufficient bond strength of titanium to porcelain. This study investigated the bond strength of new Ti–5Cr–xMo (x = 1–11 wt.%) alloys and low-fusing dental porcelain (Duceratin Plus, DeguDent Gmbh, Germany), and c.p. Ti and Ti–6Al–4V alloy were compared. The results show that Ti–5Cr–9Mo alloy has the highest bond strength (37.67 MPa), a result that is higher than that of c.p. Ti (30.72 MPa) and Ti–6Al–4V (30.01 MPa).     

Fatigue and wear evaluation of Ti-Al-Nb alloys for biomedical applications

In this work the fatigue and wear behavior of Ti–15Al–33Nb(at.%) and Ti–21Al–29Nb(at.%) was evaluated and compared to that for other titanium-based biomedical implant alloys, in particular Ti–6Al–4V(wt.%). Fatigue stress versus life curves were obtained for tests performed at room temperature in air at a stress ratio of R = 0.1 for maximum stresses between 75%–90% of the ultimate tensile strength. The results indicated that the fatigue strength and lives of the as-processed alloys are comparable to that for Ti–6Al–4V(wt.%). Heat treatment significantly increased the orthorhombic-phase volume fractions in the alloys and resulted in reduced fatigue strength. The wear resistance for the alloys was significantly greater than that for Ti–6Al–4V(wt.%). Based on the current results, it is proposed that titanium–aluminum–niobium alloys will be of considerable future interest for biomedical applications.     

Dry sliding wear behaviour of hypereutectic Al–Si piston alloys containing iron-rich intermetallics

The effect of iron-rich intermetallics on the wear behaviour of Al–Si hypereutectic alloys has been studied. Dry sliding wear tests have been conducted using a pin-on-disk machine under different normal loads of 18, 51, 74 and 100 N and at a constant sliding speed of 0.3 m/s. The addition of 1.2 wt.% Fe to the LM28 alloy increased the wear rate due to the formation of needle beta intermetallics. Introducing 0.6 wt.% Mn to the iron-rich alloy changed the beta intermetallics into the modified alpha phases, and therefore reduced the detrimental effect of iron. TIG welding method as a surface melting process was applied on the iron and manganese containing alloy and led to a fine microstructure and increased the wear resistance.     

The effect of silver on wear behaviour of zinc–aluminium-based ZA-12 alloy produced by gravity casting

The aim of this study was to investigate the effect of different weight concentrations of silver (0.1, 0.3, 0.5 and 0.7 wt.%) on the microstructure, hardness and wear properties of the gravity cast zinc–aluminium based alloy ZA-12. The alloys were manufactured under nitrogen protective atmosphere by a gravity casting process. Metallographic studies reveal that the addition of silver to the standard ZA-12 alloy changed the volume fraction and structure of the primary β-dendrites in the ZA-12 alloy. Also, it was observed that the addition of silver to ZA12 alloy enhanced the hardness and wear properties effectively. However, the corrosion resistance was decreased with increasing silver content. In addition to this, the highest hardness value among experimental alloys was obtained for the alloy containing 0.7 wt.% Ag with 116 HB. The wear rate for all applied loads is decreased with rising silver content. A similar trend was observed for the friction coefficient. The alloy containing 0.7 wt.% Ag exhibited the highest wear resistance at all loads.     

Effect of copper addition on wear and corrosion behaviours of Mg2Si particle reinforced composites

The purpose of this study is to investigate the effect adding Cu has on the wear and corrosion properties of “in situ” Mg₂Si particle reinforced Al–12Si–20Mg matrix composites, produced with help of the nucleation and growth of the reinforcement from the source matrix, in order to overcome the disadvantages of composites produced by externally reinforcing ceramic particles. Composites known as Al–12Si–20Mg–XCu were produced by adding Cu, at the rate of 1%, 2%, and 4%, to the Al–12Si–20Mg alloy in order to achieve this purpose. The microstructural characterisation, hardness, wear and corrosion properties of composites, produced using the casting method, were analysed. Dry environment wear experiments for investigated alloys were conducted using a pin-on-disc type wear device under different loads and at different sliding distances. The change in weight loss of the solution containing 30 g/l NaCl + 10 ml/l HCl, and the tafel extrapolation method were used to analyse corrosion behaviour. Results of microstructural characterisation concluded that as the amount of Cu added to the Al–12Si–20Mg alloy increased, the size and volume of the Mg₂Si particle, formed within the matrix, decreased, and CuAl₂ intermetallics formed within the matrix. Results of wear experiments concluded that adding Cu developed wear resistance under small loads; however, reduced wear resistance under high loads. According to results of corrosion experiment, corrosion resistance increased with the addition of Cu.     

Effects of indium addition on properties and wettability of Sn–0.7Cu–0.2Ni lead-free solders

This paper reports the investigation on indium addition into Sn–0.7Cu–0.2Ni lead-free solder to improve its various performances. The effects of indium addition on melting temperature, coefficient of thermal expansion (CTE), wettability, corrosion resistance and hardness of the solder alloys were studied. The results showed that when the addition of indium was ⩽0.3 wt.%, the change in melting temperature of Sn–0.7Cu–0.2Ni–xIn solders was negligible, but the melting range of the solder alloy increased. The CTE and spreading area of Sn–0.7Cu–0.2Ni–xIn solders on copper both increased with the addition of indium. An optimal CTE was 17.5 × 10⁻⁶/°C by adding 0.3 wt.% indium. At this concentration, the spreading area of solder on copper was about 15.6% larger than that of Sn–0.7Cu–0.2Ni indium-free solder. The corrosion resistance also increased with the addition of indium increasing, and the corrosion rate of Sn–0.7Cu–0.2Ni–0.3In solder was reduced by 32.8% compared with Sn–0.7Cu–0.2Ni alloy after 14 days in 5% hydrochloric acid solution at room temperature. However, a decrease of 11.7% in hardness of the solder was found when 0.3 wt.% indium was added.     

Nanostructured β-phase Ti–31.0Fe–9.0Sn and sub-μm structured Ti–39.3Nb–13.3Zr–10.7Ta alloys for biomedical applications: Microstructure benefits on the mechanical and corrosion performances

Nanostructured Ti–31.0Fe–9.0Sn and sub-micrometer structured Ti–39.3Nb–13.3Zr–10.7Ta (wt.%) β-type alloys, exhibiting different microstructures and dissimilar mechanical properties, have been prepared by copper mold casting. The microstructure, mechanical behavior and corrosion resistance, in simulated body fluid, of both alloys have been investigated and compared to those of commercial Ti–6Al–4V. Nanoindentation experiments reveal that the Ti–31.0Fe–9.0Sn rods exhibit very large hardness (H ≈ 9 GPa) and high Young's modulus. Conversely, the Ti–39.3Nb–13.3Zr–10.7Ta alloy is mechanically softer but it is interesting for biomedical application because of its rather low Young's modulus (E ≈ 71 GPa). Concerning the corrosion performance, Ti–35Nb–7Zr–5Ta shows a corrosion behavior comparable to Ti–Al6–V4, with no potential breakdown up to 0.4 V vs. Ag|AgCl. On the contrary, the Ti–31.0Fe–9.0Sn alloy exhibits a more anodic corrosion potential, but the value is still less negative than for pure elemental Fe and Ti. From all these properties and because of the absence of toxic elements in the compositions, the Ti–39.3Nb–13.3Zr–10.7Ta and Ti–31.0Fe–9.0Sn alloys are attractive for use as metallic biomaterials.     

Effect of grain refinement on mechanical properties and sliding wear resistance of extruded Sc-free 7042 aluminum alloy

The present study deals with an investigation on dry sliding wear behavior of grain refined Sc-free 7042 aluminum alloy by using a pin-on-disc wear test machine. Al–5Ti–1B and Al–15Zr master alloys were used as grain refining agents. The optimum amounts of added Ti and Zr in the alloy were found to be 0.03 wt.% and 0.3 wt.%, respectively. Extrusion was carried out and T6 heat treatment ware applied for all rod specimens before testing. Significant improvement in mechanical properties was obtained with the addition of grain refiners. The worn surfaces were characterized by energy dispersive X-ray spectrometry microanalysis. Results showed that the wear resistance of unrefined alloy increased with the addition of both grain refiners. Furthermore, the worn surface studies showed a mixed type of wear mechanisms; delaminating, adhesive and abrasive which took place at higher applied load.     

Cobalt-based orthopaedic alloys: Relationship between forming route,microstructure and tribological performance

The average longevity of hip replacement devices is approximately 10–15 years, which generally depends on many factors. But for younger generation patients this would mean that revisions may be required at some stage in order to maintain functional activity. Therefore, research is required to increase the longevity to around 25–30 years; a target that was initially set by John Charnley. The main issues related to metal-on-metal (MoM) hip replacement devices are the high wear rates when malpositioned and the release of metallic ions into the blood stream and surrounding tissues. Work is required to reduce the wear rates and limit the amount of metallic ions being leached out of the current MoM materials, to be able to produce an ideal hip replacement material. The most commonly used MoM material is the cobalt-based alloys, more specifically ASTM F75, due to their excellent wear and corrosion resistance. They are either fabricated using the cast or wrought method, however powder processing of these alloys has been shown to improve the properties. One powder processing technique used is spark plasma sintering, which utilises electric current Joule heating to produce high heating rates to sinter powders to form an alloy. Two conventionally manufactured alloys (ASTM F75 and ASTM F1537) and a spark plasma sintered (SPS) alloy were evaluated for their microstructure, hardness, tribological performance and the release of metallic content. The SPS alloy with oxides and not carbides in its microstructure had the higher hardness, which resulted in the lowest wear and friction coefficient, with lower amounts of chromium and molybdenum detected from the wear debris compared to the ASTM F75 and ASTM F1537. In addition the wear debris size and size distribution of the SPS alloy generated were considerably small, indicating a material that exhibits excellent performance and more favourable compared to the current conventional cobalt based alloys used in orthopaedics.     

Development of high Zr-containing Ti-based alloys with low Young's modulus for use in removable implants

This research focuses on the development of new titanium (Ti) alloys with a low Young's modulus for use in removable implants. In this study, Ti-30Zr alloy was selected as the base alloy, and the effect of Mo addition on the microstructures, Young's moduli, and tensile properties of Ti-30Zr-(0–8 wt.% Mo) alloys was investigated in this study to assess the mechanical compatibility of these alloys for biomedical applications. Further, the cytocompatibility of a part of the designed alloys was examined. The experimental results indicate that both the microstructures and the mechanical properties of the designed alloys are strongly affected by the Mo contents. The Ti-30Zr-(6, 7 wt.%) Mo alloys, located near the boundary of (β + ω)/β with a metastable structure, show a good combination of a low Young's modulus, high tensile strength, fairly large elongation. In addition, Ti–30Zr–7Mo alloy is highly cytocompatible.     

Novel Cu-bearing economical 21Cr duplex stainless steels

A new family of 21Cr–2 Ni–1.0Mo–0.2 N–xCu (x = 0.5, 1.0, 1.5) economical duplex stainless steels have been developed by examining the effect of Cu on the microstructure and properties of solution-treated specimens. The results have shown that these alloys have a balanced ferrite–austenite duplex structure. The ferrite content increases with the solution treatment temperature, but decreases with an increase in Cu. Some precipitates such as sigma phase, ε-Cu and Cr₂N were found when solution-treated at 780 °C for 30 min. The yield strength, tensile strength and fracture elongation values of experimental alloys solution-treated at 1020 °C for 30 min were about 540 MPa, 1000 MPa, and 35%, respectively. The pitting corrosion potentials of the solution-treated alloys were all above 500 mV in 1 mol/L NaCl solution at room temperature and the pitting corrosions always occur in ferrite phase. The mechanical properties and corrosion resistance of the designed alloys with lower production cost are better than those of AISI 316L austenitic stainless steel.     

Effect of boron addition on the cavitation erosion resistance of Fe-based hardfacing alloy

The cavitation erosion behavior of Fe–Cr–C–Si–xB (x = 0, 0.3 and 0.6 wt.%) alloys were investigated up to 50 h by using 20 kHz vibratory cavitation erosion test equipment. The boron-added alloys showed the improved cavitation erosion resistance compared to the boron-free alloy. This improvement was attributed to that the boron addition enhanced the grain boundary strength and refined the grain size of the matrix. However, the cavitation erosion rate of the 0.6 wt.% boron specimen was higher than that of the 0.3 wt.% boron specimen. The higher erosion rate of the 0.6 wt.% boron was due to the larger carbide volume in the matrix.     

Structure and mechanical properties of as-cast Ti–5Nb–xCr alloys

As-cast Ti–5Nb and a series of Ti–5Nb–xCr with Cr content ranging from 1 to 13 mass% prepared by using a commercial arc-melting vacuum-pressure casting system were investigated. Commercially pure titanium (c.p. Ti) was used as a control. X-ray diffraction (XRD) for phase analysis was conducted with a diffractometer. Three-point bending tests were performed to evaluate the mechanical properties of all specimens. The fractured surfaces were observed by using scanning electron microscopy (SEM). The experimental results indicated that these alloys obviously had different structures and mechanical properties with the addition of various amounts of Cr. When 1 mass% Cr was added, the structure was comprised mainly of the α′ phase, which was also found in Ti–5Nb. With the addition of 3 mass% Cr, α′ and α′′ phases were appeared. When the Cr content was increased to 5 mass% or greater, the β phase was completely retained. Moreover, the ω phase was detected in the Ti–5Nb–5Cr and Ti–5Nb–7Cr alloys. The largest quantity of ω phase and the highest bending modulus were found in the Ti–5Nb–5Cr alloy, while the Ti–5Nb–9Cr alloy had the lowest bending modulus. Moreover, the high strength/modulus ratios of the Ti–5Nb–3Cr (22.5) and Ti–5Nb–9Cr (21.3) alloys demonstrate its advantage for use as implant materials. Also, these two alloys exhibited the better elastic recovery angles of 28.3° in Ti–5Nb–3Cr and 22.2° in Ti–5Nb–9Cr. In the current search for better implant materials, α′ + α′′ phase Ti–5Nb–3Cr and β phase Ti–5Nb–9Cr alloys with low modulus, ductile property, excellent elastic recovery capability and reasonably high-strength seem to be the most feasible alloy for orthopedic and dental applications if some other necessary properties are obtained.     

Bond strength and corrosion resistance of bioglass coated magnesium alloy fabricated by uniaxial pressing and microwave hybrid heating

Bioactive ceramics coated magnesium alloys with a combination of suitable mechanical strength and adjustable corrosion resistance are desired for biodegradable implants. In this study, a dense bioglass coated magnesium alloy was fabricated by uniaxial pressing and microwave hybrid heating technique. The microstructure, bond strength and corrosion behavior of the samples were evaluated by means of scanning electron microscopy, X-ray diffraction, tensile bond test, electrochemical and immersion test. It was shown that uniaxial pressing conducted at the glass transition temperature significantly densified the sol–gel derived bioglass coating, which was free of pores and micro-cracks. The compact coating structure combined with mild interfacial stress not only improved the cohesion/adhesion strength (25.8 ± 2.6 MPa) but also enhanced corrosion resistance by retarding the penetration of corrosive solution. Furthermore, the formed CaP precipitates on the surface of the coating would provide another protection for the magnesium alloy to some extent.     

Investigation of the effect of Al–5Ti–1B grain refiner on dry sliding wear behavior of an Al–Zn–Mg–Cu alloy formed by strain-induced melt activation process

This study was undertaken to investigate the influence of Al–5Ti–1B master alloy and modified strain-induced melt activation process on the structural characteristics, mechanical properties and dry sliding wear behavior of Al–12Zn–3Mg–2.5Cu aluminum alloy. The optimum amount of Ti containing master alloy for proper grain refining was selected as 2 wt.%. The alloy was produced by modified strain-induced melt activation (SIMA) process. Reheating condition to obtain a fine globular microstructure was optimized. The optimum temperature and time in strain-induced melt activation process are 575 °C and 20 min, respectively. T6 heat treatment was applied for all specimens before tensile testing. Significant improvements in mechanical properties were obtained with the addition of grain refiner combined with T6 heat treatment. After the T6 heat treatment, the average tensile strength increased from 283 MPa to 587 MPa and 252 MPa to 564 MPa for samples refined with 2 wt.% Al–5Ti–1B before and after strain-induced melt activation process, respectively. Dry sliding wear performance of the alloy was examined in normal atmospheric conditions. The experimental results showed that the T6 heat treatment considerably improved the resistance of Al–12Zn–3Mg–2.5Cu aluminum alloy to the dry sliding wear.The results showed that ultimate strength and dry sliding wear performance of globular microstructure specimens was a lower value than that of Ti-refined specimens without strain-induced melt activation process.     

Investigation of the effect of Al-8B master alloy and strain-induced melt activation process on dry sliding wear behavior of an Al–Zn–Mg–Cu alloy

This study was undertaken to investigate the influence of Al–8B master alloy and modified strain-induced melt activation process on the structural characteristics and dry sliding wear behavior of Al–12Zn–3Mg–2.5Cu aluminum alloy. The optimum amount of B containing master alloy for proper grain refining was selected as 3.75 wt.%. The alloy was produced by modified strain-induced melt activation (SIMA) process. Reheating condition to obtain a fine globular microstructure was optimized. The optimum temperature and time in strain-induced melt activation process are 590 °C and 10 min, respectively. T6 heat treatment was applied for all specimens before wear testing. Significant improvements in wear properties were obtained with the addition of grain refiner combined with T6 heat treatment. Dry sliding wear performance of the alloy was examined in normal atmospheric conditions. The experimental results showed that the T6 heat treatment considerably improved the resistance of Al–12Zn–3 Mg–2.5Cu aluminum alloy to the dry sliding wear. The results showed that dry sliding wear performance of globular microstructure specimens was a lower value than that of B-refined specimens without strain-induced melt activation process.