Materials最新文献

Aircraft structures are highly susceptible to fatigue damage, particularly in thin-walled aluminum alloy components such as skin panels. Damage in the form of holes or material loss drastically reduces fatigue life and compromises structural safety, which makes effective repair strategies essential. This study presents an experimental investigation into the fatigue performance of EN AW-2024-T3 aluminum alloy plates with central openings subjected to uniform shear. Repair nodes were applied using two approaches: conventional riveted metal patches and adhesively bonded composite patches. Variants of patch geometry, thickness, and diameter were evaluated to determine their influence on load transfer, buckling response, and fatigue life. The results show that central holes significantly shorten fatigue life, with a 20 mm hole causing a 67% reduction and a 50 mm hole causing a 95% reduction when compared with undamaged plates. Riveted metal patches restored only part of the lost performance, as stress concentrators introduced by fastener holes initiated new fatigue cracks. In contrast, adhesively bonded composite patches provided a substantial improvement, extending fatigue life beyond that of the riveted solutions, improving buckling shape, and delaying crack initiation. Larger patches, particularly those combined with metallic inserts, proved most effective in restoring structural functionality. The findings confirm the effectiveness of bonded composite repairs as a lightweight and reliable method for extending fatigue life and enhancing the safety of damaged aircraft structures. The study highlights the importance of patch geometry and stiffness in the design of repair nodes.

To address the inherent defects in the fabrication of AlCrN titanium alloy coatings and enhance interfacial bonding strength as well as tribological performance, an AlCrN coating was employed as an absorption layer and subjected to laser shock processing to form an AlCrN/TC4 transition layer. Subsequently, a secondary AlCrN coating was deposited to construct a gradient coating architecture. The surface and cross-sectional morphologies and elemental distributions under varying laser energies were systematically investigated, and the influence of laser energy on the adhesion and wear resistance of the gradient coatings was analyzed. The results demonstrate that with increasing laser impact energy, the thickness of the AlCrN/TC4 transition layer gradually decreases from 3.75 μm to 1.32 μm, accompanied by significant changes in elemental distribution across the surface and cross-section. The interfacial bonding strength of the gradient coating increases substantially from 13.6 N to 43.3 N, while the average friction coefficient rises from 0.436 to 0.507. Concurrently, the wear track depth is reduced, and the wear rate decreases from 86.46 × 10^-5 mm³/(N·m) to 7.67 × 10^-5 mm³/(N·m). Laser shock peening promotes elemental diffusion, enabling the formation of a diffusion-aided interlayer. The incorporation of this diffused zone facilitates the successful construction of a high-quality TC4 titanium alloy gradient coating, effectively broadening the film-substrate interface, enhancing surface hardness, and significantly improving both interfacial adhesion and wear resistance.

Unlike classical multi-layered micro-perforated panels (MPPs), which rely on sub-millimeter orifices for sound dissipation, we propose a multi-layered porous Helmholtz resonators absorber. It consists of alternately layered perforated porous material panels and perforated rigid panels with millimeter- to centimeter-scale orifices, primarily relying on porous materials for sound energy dissipation. Theoretically, perforated porous material panels are modeled as homogeneous fluid layers using double porosity theory, and the total surface impedance is derived through bottom-to-top impedance translation. A double-layered prototype was tested to validate the theoretical and numerical models, achieving near-perfect absorption peaks at 262 Hz and 774 Hz, with a subwavelength total thickness of 11 cm and a broadband absorption above an absorption coefficient of 0.7 from 202 Hz to 1076 Hz. Simulations of sound pressure, particle velocity, power dissipation, and sound intensity flow confirm that Helmholtz resonances in each layer enhance sound entry into resistive porous materials, causing absorption peaks. Parameter studies show this absorber maintains high absorption peaks across wide ranges of orifice diameters and panel thicknesses. Finally, an optimized triple-layer porous Helmholtz resonators absorber achieves an ultra-broadband absorption above a coefficient of 0.95 from 280 Hz to 1349 Hz with only 16.5 mm thickness. Compared with conventional MPPs, this design features significantly larger orifices that are easier to fabricate and less susceptible to blockage in harsh environments, offering an alternative solution for low-frequency and broadband sound absorption.

Filled-polymer coatings enable functional surfaces for selective metallisation, wetting control and local conductivity, but pulsed-laser texturing is often limited by process non-uniformity caused by scan kinematics and plume shielding. Here, we develop a three-tier numerical workflow for nanosecond pulsed-laser surface treatment of a thermoplastic coating containing glass microspheres (baseline case: PLA matrix with V_f = 0.20; spheres represented via an effective optical transport model). Tier 1 predicts spatially resolved ablation depth under raster scanning, using an incubation law and regime switching (no-removal/melt-limited/logarithmic ablation/blow-off) coupled to a dynamic shielding factor. Tier 2 computes the 1D transient (pulse-averaged) temperature field and the thickness of the thermally softened layer. Tier 3 models post-pulse capillary redistribution of the softened layer to estimate groove reshaping. The simulations show that scan overlap and shielding dynamics dominate groove homogeneity more strongly than average power alone: under identical average power, variations in local pulse count and shielding lead to significant changes in depth statistics and regime fractions. The workflow produces quantitative maps and summary metrics (mean depth, P5-P95 range, uniformity index and regime fractions) and demonstrates how controlled reflow can smooth peaks while preserving groove depth. These results provide a predictive tool for laser parameter selection and process optimisation prior to experimental trials.

The relatively poor cycle stability of zinc-air batteries (ZABs) hinders their widespread application, while self-supporting electrode materials have shown great potential in enhancing the cycling stability of ZABs. To construct a self-supporting electrode, bamboo was employed as a sustainable precursor, and a two-step pyrolysis strategy was implemented to integrate ZIF-67-derived catalysts onto a hierarchically porous carbon framework, yielding the composite material Co-N@CB. Benefiting from its structural and electronic advantages, Co-N@CB exhibits outstanding electrocatalytic performance. The overpotential for the oxygen evolution reaction (OER) in alkaline electrolyte is 1.5 V at 10 mA cm^-2, with a potential gap (ΔE) of 0.69 V. This material is directly used as the air cathode in ZABs, delivering over 10,000 stable cycles. This excellent cycling stability arises from the strong carbon framework provided by bamboo and the enhanced electrical conductivity achieved through the pyrolytic graphitization of ZIF-67. This study paves the way for further exploration of biomass-based self-supporting electrodes toward high-performance ZABs and emerging micro/nanoscale sensing technologies.

This article examines how hybrid polypropylene fibers of three different lengths affect the mechanical and fracture properties of lightweight structural concrete with lightweight ceramic aggregate. Four mixtures were produced: a reference lightweight concrete and three fiber-reinforced variants with total dosages of 3, 6, and 9 kg/m³ in a fixed length ratio of 4:1:1. Standard tests determined the bulk density, cube compressive strength, splitting tensile strength, modulus of elasticity, and fracture parameters using a three-point bend test. Compared to the reference concrete, the fibers did not significantly change the compressive strength but consistently increased the tensile strength and energy absorption after cracking. The highest fracture energy and toughness were obtained at the highest dosage, while excessive fiber content reduced the static compressive modulus.

This research presents a comprehensive evaluation of semi-elastic polyurethane adhesives used for bonding wooden flooring, with a particular focus on both domestic (oak) and exotic hardwood species (teak, iroko, wenge, merbau). Given the increasing interest in sustainable construction practices and the growing use of diverse wood species in flooring systems, this study aimed to assess the mechanical, morphological, and surface properties of adhesive joints under both standard laboratory and thermally aged conditions. Mechanical testing was conducted according to PN-EN ISO 17178 standards and included shear and tensile strength measurements on wood-wood and wood-concrete assemblies. Specimens were evaluated in multiple aging conditions, simulating real-world application environments. Shear strength increased post-aging, with the most notable improvement observed in wenge (21.2%). Tensile strength between wooden lamellas and concrete substrates remained stable or slightly decreased (up to 18.8% in wenge), yet all values stayed above the 1 MPa minimum requirement, confirming structural reliability. Surface properties of the wood species were characterized through contact angle measurements and 3D optical roughness analysis. Teak exhibited the highest contact angle (74.9°) and the greatest surface roughness, contributing to mechanical interlocking despite its low surface energy. Oak and iroko showed high wettability and balanced roughness, supporting strong adhesion. Scanning electron microscopy (SEM) revealed stable adhesive penetration across all species and aging conditions, with no signs of delamination or interfacial failure. The study confirms the suitability of polyurethane adhesives for durable, long-lasting bonding in engineered and solid wood flooring systems, even when using extractive-rich or dimensionally sensitive tropical species. The results emphasize the critical role of surface morphology, wood anatomy, and adhesive compatibility in achieving optimal bond performance. These findings contribute to improved material selection and application strategies in flooring technology. Future research should focus on bio-based adhesive alternatives, chemical surface modification techniques, and in-service performance under cyclic loading and humidity variations to support the development of eco-efficient and resilient flooring systems.

Aiming at the key problems of the material removal rate and surface integrity of existing tools in the lapping of sapphire hard and brittle crystals, an efficient lapping tool has been developed to explore a new process for HFVCD (hot filament chemical vapor deposition) diamond tools to efficiently lap sapphire wafers. With the premise of ensuring the surface roughness of the wafer is Ra ≤ 0.5 μm, the material removal rate is increased to more than 1 μm/h. To explore a high-efficiency lapping process for sapphire wafers using HFCVD diamond tools. The influence of key preparation parameters on the surface characteristics of CVD (chemical vapor deposition) diamond films was systematically investigated. Three types of CVD diamond coating tools with distinct surface morphologies were fabricated. These tools were subsequently employed to conduct lapping experiments on sapphire wafers in order to evaluate their processing performance. The experimental results demonstrate that the gas pressure, methane concentration, and substrate temperature collectively influenced the surface morphology of the diamond coatings. The fabricated coatings exhibited well-defined grain boundaries and displayed pyramidal, prismatic and spherical features, corresponding to high-quality microcrystalline and nanocrystalline diamond layers. In the lapping experiments, the prismatic CVD diamond coating tool exhibited the highest material removal rate, reaching approximately 1.7 μm/min once stabilized. The spherical diamond coating tool produced the lowest surface roughness on the lapped sapphire wafers, with a value of about 0.35 μm. Surface morphology-controllable diamond tools were used for the lapping processing of the sapphire wafers. This achieved a good surface quality and high removal rate and provided new ideas for the precision machining of brittle hard materials in the plane or even in the curved surface.

The utilization of recycled steel is essential for achieving carbon neutrality and sustainable engineering, yet repeated recycling inevitably leads to the accumulation of residual elements that are difficult to remove during conventional refining. Among them, copper (Cu) readily enriches in scrap-based steels and is a primary cause of surface hot shortness during high-temperature processing due to its segregation at the oxide/steel interface. While the compositional effects of Cu have been extensively studied, the influence of thermo-history associated with different industrial processing routes remains poorly understood. In this work, Cu enrichment during high-temperature oxidation was systematically investigated under thermo-histories representative of conventional hot rolling, thin slab continuous casting and rolling (TSCR), and strip casting. Plain carbon steels containing 0.05-0.30 wt.% Cu were oxidized at 1000-1200 °C, and interfacial microstructures were characterized using SEM-EDS. The results show that Cu enrichment is highly sensitive to both temperature and thermal exposure time, with a critical temperature range of 1100-1150 °C promoting the formation of continuous Cu-rich liquid films. Prolonged thermo-history in conventional hot rolling markedly enhances Cu enrichment, TSCR partially suppresses interfacial segregation, whereas strip casting effectively inhibits Cu enrichment even at elevated Cu contents. These findings highlight thermo-history as a dominant factor controlling Cu-induced surface hot shortness and provide guidance for process optimization in recycled steels.

The micro-geometry of the cutting edge plays a crucial role in material flow ahead of the cutting edge and chip formation, primarily influencing chip formation mechanisms and the minimum cutting thickness. In the context of turning 304 stainless steel, however, existing research still lacks a unified quantitative framework linking "cutting edge micro-geometry-material separation behavior (separation point/minimum uncut chip thickness)-microstructural evolution of the machined surface." This gap hampers mechanistic optimization design aimed at enhancing machining quality. This study examines the turning of 304 stainless steel by integrating analytical modeling, finite element simulation, and experimental validation to develop a predictive model for minimum cutting thickness. It analyzes the effects of tool nose radius and asymmetric edge morphology, and a microstructure evolution prediction subroutine is developed based on dislocation density theory. The results indicate that the minimum cutting thickness exhibits a positive correlation with the tool nose radius, and their ratio remains stable within the range of 0.25 to 0.30. Under asymmetric edge conditions, the minimum cutting thickness initially increases and then decreases as the K-factor varies. The developed subroutine, based on the dislocation density model, enables accurate prediction of dislocation density, grain size, and microhardness in the machined surface layer. Among the factors considered, the tool nose radius demonstrates the most pronounced influence on microstructure evolution. This research provides theoretical support and a technical reference for optimizing cutting-edge design and enhancing the machining quality of 304 stainless steel.