Journal of Alloys and Metallurgical Systems最新文献

{"title":"The effect of heat treatment temperature on the wear resistance of 42CrMo steel hardfacing with Fe–Cr–C alloy","authors":"Junke Hao,&nbsp;Huiying Que","doi":"10.1016/j.jalmes.2026.100235","DOIUrl":"10.1016/j.jalmes.2026.100235","url":null,"abstract":"<div><div>Fe–Cr–C hardfacing alloys are widely used in hardfacing applications because of their high strength. In this study, a Fe–Cr–C hardfacing layer was deposited on a 42CrMo steel plate by manual arc welding. The effects of post-weld heat treatment at 400 ℃, 600 ℃, and 800 ℃ on residual stress in the hardfaced layer were examined by finite element simulation. The simulation results showed that heat treatment at 600 ℃ effectively reduced the residual stress. Optical microscopy, X-ray diffraction, energy-dispersive spectroscopy, microhardness, wear testing and scanning electron microscope were then used to evaluate how heat treatment influences the microstructure and wear behavior of the hardfacing alloy. After hardfacing, a dendritic structure formed at the weld interface. Following heat treatment at 600 ℃, carbides diffused along grain boundaries into the ferrite matrix, and the dendritic structure transformed into a carbide-rich dendritic morphology. After heat treatment at 600 °C, the hardness of the hardfacing alloy increased to 551.3 HV, the friction coefficient rose to 1.17, and the volume wear loss decreased by 26.1 %. The wear mechanism of the hardfacing alloy was dominated by abrasive wear. These results indicate that, for 42CrMo steel hardfaced with a Fe–Cr–C alloy, selecting an appropriate heat treatment temperature can not only relieve residual stress but also enhance the wear resistance of the material.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100235"},"PeriodicalIF":0.0,"publicationDate":"2026-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146077440","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of Er addition and thermomechanical processing on the in vitro corrosion and cytocompatibility of Mg–Zn–Y alloys","authors":"Raisa Tahsin Promy ,&nbsp;Md. Walid Ahmed Nafiz ,&nbsp;Syed Muhammad Al Amin ,&nbsp;Chanchal Kumar Roy ,&nbsp;Fahmida Gulshan","doi":"10.1016/j.jalmes.2026.100233","DOIUrl":"10.1016/j.jalmes.2026.100233","url":null,"abstract":"<div><div>Controlling the corrosion rate of magnesium-based biodegradable alloys remains a key challenge for biomedical applications. This study investigates the effect of Er addition and thermomechanical processing (rolling and extrusion) on the cytocompatibility and corrosion behavior of Mg-1.88Zn-0.58Y alloys. X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and optical microscopy (OM) identified the presence of secondary phases such as Mg<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span>Zn and W-phases in both alloys and Mg₂₄Er₅ only in the Mg-1.81Zn-0.8Y-0.33Er alloy. Corrosion behavior was evaluated by immersion tests in periodically replenished Kokubo’s simulated body fluid (SBF) for up to 21 days, with continuous pH monitoring. Hydrogen evolution tests, potentiodynamic polarization (PDP), and electrochemical impedance spectroscopy (EIS) supported the immersion findings, and post-corrosion SEM-EDS and Fourier-transform infrared spectroscopy (FTIR) analyses elucidated the underlying reasons. In both alloys, hot extrusion enhanced the formation of a protective Mg(OH)<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> layer and reduced the corrosion rate. The extruded Mg-1.88Zn-0.58Y alloy exhibited the lowest weight-loss rate (14.45 to 9.79 mm year⁻¹ from day 1 to day 21), hydrogen release (<span><math><mo>∼</mo></math></span>2.9 mL cm<span><math><msup><mrow></mrow><mrow><mo>−</mo><mn>2</mn></mrow></msup></math></span> d<span><math><msup><mrow></mrow><mrow><mo>−</mo><mn>1</mn></mrow></msup></math></span>), and corrosion current density (<span><math><mrow><mn>31</mn><mo>.</mo><mn>58</mn><mspace></mspace><mi>μ</mi><mi>A</mi></mrow></math></span> cm⁻²). The Er-containing alloy showed poor corrosion resistance in the as-cast and rolled states (45.96 and 38.88 mm year⁻¹ after 21 days, respectively), but significant improvement in the extruded condition (10.04 mm year⁻¹). Er containing quaternary alloys exhibited much higher H<span><math><msub><mrow></mrow><mrow><mn>2</mn></mrow></msub></math></span> evolution rate of <span><math><mo>∼</mo></math></span>17.2 mL cm<span><math><msup><mrow></mrow><mrow><mo>−</mo><mn>2</mn></mrow></msup></math></span> d<span><math><msup><mrow></mrow><mrow><mo>−</mo><mn>1</mn></mrow></msup></math></span> (after 24 h) for the as cast sample, considerably more than the acceptable limit for human body. Overall, the Er addition to the ternary alloy resulted in poor corrosion resistance. MTT cytotoxicity assays on Vero cells confirmed non-cytotoxic behavior (<span><math><mo>&gt;</mo></math></span>95% viability), while the Er-containing Mg-1.81Zn-0.8Y-0.33Er alloy extract produced strong selective toxicity against HeLa cells (<span><math><mo>&lt;</mo></math></span>5% viability).</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100233"},"PeriodicalIF":0.0,"publicationDate":"2026-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146078003","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-temperature cyclic oxidation and microstructural behavior of CoMoCrSi-based composite coatings with Al2O3 and YSZ on T91 steel","authors":"Rakshith Kumar Shetty ,&nbsp;Ajit M. Hebbale ,&nbsp;T.V. Chandramouli ,&nbsp;M.R. Ramesh ,&nbsp;Jana Petru","doi":"10.1016/j.jalmes.2026.100232","DOIUrl":"10.1016/j.jalmes.2026.100232","url":null,"abstract":"<div><div>This investigation focuses on the cyclic oxidation behaviour and microstructural evolution of Cobalt-Molybdenum-Chromium-Silicon coatings reinforced with alumina and yttria stabilised zirconia (YSZ) deposited on T91 steel by the atmospheric plasma spraying method. Characterization of the as-sprayed coatings was done to provide a consistent base line for comparison of the intercoatings. Cyclic oxidation experiments at 800 °C for 50 oxidation cycles was carried out with surface and cross section analyses using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) for the evaluation of oxidation scale formation, element distribution and phase stability. After cyclic oxidation, XRD showed an appearance of stable oxide constituents, which demonstrates the formation of protective scales on the coating surfaces. In comparison with unreinforced and alumina reinforced coatings, the YSZ reinforced coating displayed comparatively superior oxidation behavior as reflected in the more stable oxidation and less degradation during cyclic exposure. SEM examination of oxidized surfaces showed that the ceramic additions helped to increase coating integrity, improve scale adherence and reduce oxygen penetration. These effects were amplified for the YSZ-containing coating, showing a good response for high temperature oxidation. Overall, the addition of ceramic reinforcements, especially of YSZ, improved the phase stability and oxidation resistance of the CoMoCrSi-based coatings, which supports the suitability of the coatings for demanding boiler environments.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100232"},"PeriodicalIF":0.0,"publicationDate":"2026-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145926083","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of process parameters on bead geometry and microstructure of the stainless steel fabricated by wire arc additive manufacturing","authors":"Huifeng Qin ,&nbsp;Wensha Zhu ,&nbsp;Huajun Zhang","doi":"10.1016/j.jalmes.2025.100231","DOIUrl":"10.1016/j.jalmes.2025.100231","url":null,"abstract":"<div><div>The selection of appropriate wire arc additive manufacturing (WAAM) parameters is crucial for controlling bead morphology and dimensional accuracy in multi-layer metallic structures. This study investigates cold metal transfer (CMT)-based WAAM of 316 L stainless steel with a particular focus on two key process variables—deposition current and auxiliary wire feed speed—to establish their combined influence on bead geometry and microstructure. Unlike existing AWF-CMT WAAM studies, <strong>this work first determines the maximum stable arc travel speed for both T-CMT and AWF-CMT modes</strong>, providing an essential process boundary for high-efficiency manufacturing. Single-layer tracks were fabricated using S316L wire following an orthogonal experimental design, enabling a systematic evaluation of parameter interactions. The results reveal that arc travel speed, deposition current, and auxiliary wire feed speed exert strong coupled effects on bead width and height. Furthermore, microstructural characterization using optical microscopy and electron backscatter diffraction <strong>demonstrates that auxiliary-wire-assisted CMT produces significant quantitative grain refinement</strong>, <u>the T-CMT deposits exhibit a relatively coarser grain structure, whereas the AWF-CMT process produces a more refined and more uniform microstructure in the deposited region</u>, reducing the average grain size from 130μm (T-CMT) to 86μm(AWF-CMT). This study therefore establishes a new process–structure relationship for AWF-CMT WAAM and demonstrates that 316 L components manufactured with this technique exhibit markedly improved microstructural quality, confirming its suitability for industrial deployment.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100231"},"PeriodicalIF":0.0,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145791507","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"An attempt toward machine learning-driven optimization of manufacturing processes for metal-supported solid oxide fuel cells using nickel and iron oxides as raw support materials","authors":"Hirofumi Sumi ,&nbsp;Mizuki Momai ,&nbsp;Yuki Yamaguchi","doi":"10.1016/j.jalmes.2025.100230","DOIUrl":"10.1016/j.jalmes.2025.100230","url":null,"abstract":"<div><div>A novel fabrication method for metal-supported solid oxide fuel cells (SOFCs) is proposed using nickel and iron oxides as raw support materials. This approach enables the co-sintering of all components in their oxide states via conventional ceramic processing. To minimize cell warpage, which is a critical issue in mechanical integrity, machine learning models, including random forest and linear regression, are employed to optimize the manufacturing process parameters. The random forest regression model demonstrated superior predictive accuracy (RMSE = 0.01454 and <em>R</em>² = 0.7310) than the linear regression model (RMSE = 0.02253 and <em>R</em>² = 0.4642), effectively capturing the non-linear relationships between the manufacturing process parameters and cell warpage. The electrolyte thickness, presintering temperature, and Ni/(Fe+Ni) atomic ratio are identified as key factors influencing cell warpage. Material characterizations using X-ray diffraction and coefficient of thermal expansion measurements validate these predictions. Although the open circuit voltage remains below the theoretical electromotive force owing to residual microstructural defects in the electrolyte, the cell warpage successfully reduced from 0.07578 to 0.03825 by increasing the presintering temperature from 1150 to 1250 °C. These results demonstrate the potential of machine learning for guiding manufacturing process optimization of mechanically robust and high-performance metal-supported SOFCs.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100230"},"PeriodicalIF":0.0,"publicationDate":"2025-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145738965","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comprehensive comparison of dynamic strain localisation and mechanical behaviour in traditional and additively manufactured Ti6Al4V","authors":"Govind Gour ,&nbsp;Antonio Pellegrino","doi":"10.1016/j.jalmes.2025.100228","DOIUrl":"10.1016/j.jalmes.2025.100228","url":null,"abstract":"<div><div>Titanium alloys are widely used in aerospace, defence, automotive, and biomedical engineering owing to their high specific strength and excellent corrosion resistance. Additive manufacturing has emerged as a promising alternative to conventional production methods, offering the capability to fabricate complex geometries while reducing processing time and material waste. In this study, the high strain rate deformation behaviour of Ti6Al4V produced by selective laser melting is investigated using a Split Hopkinson Tension Bar system equipped with a multi-camera high-speed imaging setup. A comprehensive experimental programme is conducted on specimens manufactured in three different build orientations to assess the influence of processing direction on dynamic strain localisation and true stress–strain response. The post-necking behaviour is examined and compared with that of conventionally forged Ti6Al4V, revealing notable differences in ductility and strain localisation mechanisms. In addition, the high strain rate compressive behaviour of both material variants and their temperature dependence are investigated using a Split Hopkinson Compression Bar system equipped with thermal conditioning. The deformation and failure mechanisms of additively manufactured specimens produced in different orientations are further examined through post-mortem analysis of the fracture surfaces.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"13 ","pages":"Article 100228"},"PeriodicalIF":0.0,"publicationDate":"2025-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145698156","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructural evolution of Mg-Nd-Zr alloy during multi-directional reverse shear processing","authors":"O. Tarasov ,&nbsp;V. Greshta ,&nbsp;D. Pavlenko ,&nbsp;D. Tkach ,&nbsp;O. Altukhov","doi":"10.1016/j.jalmes.2025.100226","DOIUrl":"10.1016/j.jalmes.2025.100226","url":null,"abstract":"<div><div>This study investigates the microstructural evolution and hardness response of a Mg–Nd–Zr alloy subjected to a novel hot multi-directional reverse shear (MDRS) process developed by the authors. The MDRS technique represents a severe plastic deformation route designed to enhance shear deformation. This method was applied to deform the magnesium alloy under near-isothermal conditions. Finite element modeling and experimental data show that MDRS provides a more uniform distribution of equivalent strain than traditional MDF/CCDF processing routes. After four consecutive cycles, the ratio of accumulated strain in the central region to that in the peripheral region (inhomogeneity coefficient) is 2.5 for MDF and 1.62 for MDRS, respectively. The as-cast microstructure consists of equiaxed α-Mg grains (∼47 μm) and grain-boundary Mg₁₂Nd-type and Zr-rich particles, as confirmed by combined XRD and SEM/EDS analysis. MDRS processing leads to a non-monotonic grain size evolution: refinement to ∼32 μm after one cycle, partial coarsening to ∼39.7 μm after three cycles, and subsequent stabilisation at ∼41 μm after five cycles. The formation of a near-normal grain size distribution and ∼120° triple junctions after five cycles indicates a thermodynamically stabilised grain boundary network. The grain size and grain boundaries are controlled by the competition between deformation-induced grain refinement, accompanied by Zener pinning of the boundaries by dispersed particles, and thermally activated grain growth driven by continuous dynamic recrystallization. Microhardness increases by 6–16 % compared with the initial state. Higher hardness values are associated with regions of higher accumulated strain and refined grains. In contrast, the slight decrease in central hardness after five cycles correlates with partial grain coarsening, which remains above the initial level. The established relationships between strain distribution, microstructure and hardness demonstrate that MDRS is an efficient route for producing Mg–Nd–Zr alloy workpieces with controlled gradient properties and improved performance, promising for Mg-based bioresorbable implants and lightweight structural applications.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"12 ","pages":"Article 100226"},"PeriodicalIF":0.0,"publicationDate":"2025-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145579201","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Carbon fibre for applications in aerospace: A review","authors":"Rizalman Mamat ,&nbsp;Muhammad Ikram Mohd Rashid ,&nbsp;A.Z. Syahir ,&nbsp;Erdiwansyah ,&nbsp;Ahmad Fitri Yusop ,&nbsp;Ahmad Tamimi","doi":"10.1016/j.jalmes.2025.100227","DOIUrl":"10.1016/j.jalmes.2025.100227","url":null,"abstract":"<div><div>The aerospace industry increasingly relies on advanced composite materials to enhance structural performance while reducing environmental impact. Among these materials, carbon fibre-reinforced polymers (CFRPs) have emerged as the dominant choice due to their exceptional strength-to-weight ratio, fatigue resistance, and thermal stability. This review aims to provide a comprehensive analysis of the development, properties, manufacturing techniques, and sustainability aspects of carbon fibre composites in aerospace applications. A systematic literature-based approach was employed to evaluate recent advancements in microstructural design, automated manufacturing, and recycling technologies. The findings reveal that carbon fibre composites achieve 30–50 % weight reduction and 20–25 % fuel savings compared to traditional aluminium and titanium alloys, while maintaining superior mechanical and thermal performance. Emerging AI-driven, digital twin-based manufacturing systems improve process reliability, reducing defect rates by up to 30 % and reducing production cycles by 25–35 %. Moreover, hybrid and nanoreinforced composites incorporating carbon nanotubes or graphene demonstrate 10–25 % improvements in interlaminar strength and damage tolerance. From a sustainability perspective, recycling methods such as pyrolysis and solvolysis enable the recovery of 90–95 % of carbon fibres with minimal property degradation, supporting circular economy goals. The novelty of this review lies in integrating materials science, digital manufacturing, and sustainability to establish a unified framework for next-generation aerospace composites. In conclusion, carbon fibre technology stands at the intersection of high performance, intelligent manufacturing, and environmental responsibility, driving the evolution toward lighter, stronger, and more innovative aerospace systems.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"12 ","pages":"Article 100227"},"PeriodicalIF":0.0,"publicationDate":"2025-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145579200","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Ensemble analysis of parameters optimizations of copper electroplated NiTinol Plate through Matlab and robotic swarm particle","authors":"Kavita Kripalani","doi":"10.1016/j.jalmes.2025.100225","DOIUrl":"10.1016/j.jalmes.2025.100225","url":null,"abstract":"<div><div>Ensemble analysis of parameters optimization using Artificial Intelligence (AI) techniques of full factorial Swarm Differential Algorithm (SDA) and further with Matlab was applied in experimental procedure conducted in copper electroplated NiTinol Plate by evaluating its surface roughness of NiTinol plate. This approach applied optimization module using Artificial Intelligence model of swarm particle optimization which enhanced the accuracy and reliability of the parameters implied control. The analysis was done based on parameter analysis of temperature, thickness of Copper electroplated NiTinol plate, current density. After Data prepossessing, support vector Regression (SVR) was analyzed for pragmatic. Further, datasets were splatted into trained AI Model using subsequently its each dataset and then validating sets by evaluating individual performances. Stacking was used for training meta-model for combined predictions of individual models. Optimized parameters using Swarm differential algorithm in MATLAB was deployed. The results of the ensemble analysis were used to further validate the parameters of temperature and current density of electroplated NiTi plates. Optimized parameters model was further used for predicting and controlling the surface roughness in electroplated NiTinol plate which hence enhanced its surface finish. The analysis of Nitinol electroplating using swarm intelligence technique optimized coating thickness and surface roughness thus enhanced solder ability providing a sacrificial layer of micro fabrication,corrosion resistant biocompatible surface layer. The approach utilized a simulated 10 × 10 grid of measurements to identify under plated regions and rough surface areas, followed by a Particle Swarm Optimization (PSO) and MATLAB based parameters optimization strategy.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"12 ","pages":"Article 100225"},"PeriodicalIF":0.0,"publicationDate":"2025-11-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145579008","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigating hot tearing in 6xxx-series aluminium alloys: A combined thermodynamic and experimental approach","authors":"Emidio Giansante ,&nbsp;Alberto Fabrizi ,&nbsp;Mohammad Pourgharibshahi ,&nbsp;Giulio Timelli","doi":"10.1016/j.jalmes.2025.100221","DOIUrl":"10.1016/j.jalmes.2025.100221","url":null,"abstract":"<div><div>The hot tearing of 6xxx-series aluminium alloys has been investigated over four levels of silicon (0.6, 0.8, 1.0, 1.2 wt%), magnesium (0.4, 0.6, 0.8, 1.0 wt%), iron (0.2, 0.4, 0.6, 0.8 wt%) and manganese (0.0, 0.2, 0.4, 0.6 wt%). Thermodynamic calculations based on the CALPHAD method were performed to evaluate the hot tearing index using the Kou criterion, and the results were compared with experimental data obtained by thermal analysis and microstructural investigations. The results revealed that the concentration of alloying elements, particularly silicon and magnesium, significantly affects the Kou index and the hot tearing behaviour of the material. An increase in iron content and the addition of manganese showed a beneficial effect on the resistance to hot tearing. The formation of branched α-AlFeSiMn compounds significantly reduced the development of hot tearing cracks, more so than the increased presence of the Mg₂Si phase. Comparison of Kou index values derived from both thermodynamic calculations and experimental solidification curves showed that the selection of the solid fraction range is crucial. Good agreement was achieved between the calculations and the experimental data when using a solid fraction interval of 0.87–0.94. Finally, the experimental results confirmed that a preliminary qualitative assessment of susceptibility to hot tearing can be made without resorting to more resource-intensive testing methods.</div></div>","PeriodicalId":100753,"journal":{"name":"Journal of Alloys and Metallurgical Systems","volume":"12 ","pages":"Article 100221"},"PeriodicalIF":0.0,"publicationDate":"2025-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145579198","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}