Pub Date : 2026-03-01Epub Date: 2026-02-03DOI: 10.1016/j.matdes.2026.115609
Zehuan Li , Jie Xia , Dianfeng Chen , Dong Han , Jun Liu , Wenguang Tian , Dongyang Qin
Owing to the high bearing capacity, 1500 MPa-grade fastener fabricated by PH13-8 steel has been extensively used in the main bearing structure of aircraft. However, the density of the steel is as high as 8.2 × 103 kg/m3, which is adverse to the weight control of aircraft. By using 1500 MPa-grade Ti-5Al-5 V-5Mo-3Cr (Ti-5553) titanium alloy wire, we successfully manufactured the 12-point MJ6 × 1 Ti-5553 alloy bolt by hot uppset and cold thread-rolling. Although the shearing strength and the fatigue performance of Ti-5553 bolt are comparable to those of PH13-8 bolt, the tensile failure strength (TFS) is 11.3% lower. Furthermore, TFS of Ti-5553 bolt is also 11.3% lower than the ultimate tensile strength of bimodal Ti-5553 wire, exhibiting the obvious strength degradation. The strength degradation of the bolt is mainly caused by the stress concentration on the tip I-type mirco-crack evolved from the shearing band that forms during the cold thread-rolling. The excellent shearing strength and fatigue performance is strongly related to the bimodal structure. Our findings indicate that the shearing band in the root region of the thread should be eliminated by warm processing in order to improve the TFS of Ti-5553 bolt.
{"title":"Strength and fatigue of 1500 MPa-grade Ti-5553 alloy bolt","authors":"Zehuan Li , Jie Xia , Dianfeng Chen , Dong Han , Jun Liu , Wenguang Tian , Dongyang Qin","doi":"10.1016/j.matdes.2026.115609","DOIUrl":"10.1016/j.matdes.2026.115609","url":null,"abstract":"<div><div>Owing to the high bearing capacity, 1500 MPa-grade fastener fabricated by PH13-8 steel has been extensively used in the main bearing structure of aircraft. However, the density of the steel is as high as 8.2 × 10<sup>3</sup> kg/m<sup>3</sup>, which is adverse to the weight control of aircraft. By using 1500 MPa-grade Ti-5Al-5 V-5Mo-3Cr (Ti-5553) titanium alloy wire, we successfully manufactured the 12-point MJ6 × 1 Ti-5553 alloy bolt by hot uppset and cold thread-rolling. Although the shearing strength and the fatigue performance of Ti-5553 bolt are comparable to those of PH13-8 bolt, the tensile failure strength (TFS) is 11.3% lower. Furthermore, TFS of Ti-5553 bolt is also 11.3% lower than the ultimate tensile strength of bimodal Ti-5553 wire, exhibiting the obvious strength degradation. The strength degradation of the bolt is mainly caused by the stress concentration on the tip I-type mirco-crack evolved from the shearing band that forms during the cold thread-rolling. The excellent shearing strength and fatigue performance is strongly related to the bimodal structure. Our findings indicate that the shearing band in the root region of the thread should be eliminated by warm processing in order to improve the TFS of Ti-5553 bolt.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115609"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186061","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-01-25DOI: 10.1016/j.matdes.2026.115542
Florian Pixner , Marta Lipińska , Fernando Warchomicka , Martin Schnall , Małgorzata Lewandowska , Norbert Enzinger , Thomas Klein
The intrinsic solidification conditions in additive manufacturing affect microstructure formation and require new heat treatment procedures. The present study aims to identify heat treatment routes and in particular to evaluate the performance of direct ageing (DA) compared to established solution annealing with ageing (SA + A). Structures of nickel-based superalloys were therefore additively manufactured using wire-arc directed energy deposition and subjected to various heat treatments to determine the structure–property relationship. In the as-built state, the microstructure is characterized by its solidification structure, consisting of linear-shaped Cr-Ni-rich dendritic zones and segregated Nb-rich interdendritic zones filled with secondary phases. Solution annealing at 1200 °C/1h is required to entirely dissolve the segregated zones and secondary phases. The microstructure formed during ageing strongly depend on the initial conditions. In DA, the precipitation of strengthening γ” takes place at earlier stages, is limited to the Nb-rich interdendritic zone while the dendritic zone remains γ”-free, and leads to a directionally graded microstructure. In contrast, SA + A requires longer ageing times, however, leads to a homogeneous distribution of γ”. These variations in the microstructure are also reflected in the mechanical properties. While SA + A leads to high hardness and isotropic tensile properties, even higher tensile strengths can be achieved with DA.
{"title":"Interplay between solidification conditions and post heat treatments on properties of a nickel-based superalloy processed by wire directed energy deposition","authors":"Florian Pixner , Marta Lipińska , Fernando Warchomicka , Martin Schnall , Małgorzata Lewandowska , Norbert Enzinger , Thomas Klein","doi":"10.1016/j.matdes.2026.115542","DOIUrl":"10.1016/j.matdes.2026.115542","url":null,"abstract":"<div><div>The intrinsic solidification conditions in additive manufacturing affect microstructure formation and require new heat treatment procedures. The present study aims to identify heat treatment routes and in particular to evaluate the performance of direct ageing (DA) compared to established solution annealing with ageing (SA + A). Structures of nickel-based superalloys were therefore additively manufactured using wire-arc directed energy deposition and subjected to various heat treatments to determine the structure–property relationship. In the as-built state, the microstructure is characterized by its solidification structure, consisting of linear-shaped Cr-Ni-rich dendritic zones and segregated Nb-rich interdendritic zones filled with secondary phases. Solution annealing at 1200 °C/1h is required to entirely dissolve the segregated zones and secondary phases. The microstructure formed during ageing strongly depend on the initial conditions. In DA, the precipitation of strengthening γ” takes place at earlier stages, is limited to the Nb-rich interdendritic zone while the dendritic zone remains γ”-free, and leads to a directionally graded microstructure. In contrast, SA + A requires longer ageing times, however, leads to a homogeneous distribution of γ”. These variations in the microstructure are also reflected in the mechanical properties. While SA + A leads to high hardness and isotropic tensile properties, even higher tensile strengths can be achieved with DA.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115542"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185982","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-01-24DOI: 10.1016/j.matdes.2026.115535
Taiyuan Huang , Quan Tao , Rong Lu , Tairan Deng , Nan Li , Zhenwen Huang , Huijun Ruan , Yao Lu , Ting Lin
The acidic tumor microenvironment (TME) drives malignancy and treatment resistance, necessitating precise extracellular pH quantification for improved monitoring. Although acid-sensitive chemical exchange saturation transfer (acidoCEST) magnetic resonance imaging (MRI) holds promise in detecting pH value of the TME, current endogenous agents suffer from low sensitivity and specificity, and exogenous agents face biocompatibility and sensitivity concerns. In this work, we conjugated salicylic acid (SA) with polydopamine (PDA) to develop multifunctional nanoparticles (SA-PDA NPs). SA-PDA NPs integrated the pH-responsive acidoCEST MRI capability of SA with photothermal property of PDA. In vitro and in vivo experiments demonstrated that SA-PDA NPs possessed acidoCEST imaging capability, enabling accurate measurement of the acid pH of the TME in a melanoma mouse model. Moreover, SA-PDA NPs could inhibit the migration and invasion of tumor cells. When combined with 808 nm near infrared laser irradiation, SA-PDA NPs efficiently eradicated tumor tissues and prolonged the survival of melanoma-bearing mice without causing undesired side effects. Hence, this theranostic platform combines quantitative TME pH detection with localized photothermal therapy, offering precise monitoring and efficient treatment for solid tumors.
{"title":"Quantitative acidic tumor microenvironment monitoring and efficient photothermal therapy using salicylic acid-conjugated polydopamine nanoparticles","authors":"Taiyuan Huang , Quan Tao , Rong Lu , Tairan Deng , Nan Li , Zhenwen Huang , Huijun Ruan , Yao Lu , Ting Lin","doi":"10.1016/j.matdes.2026.115535","DOIUrl":"10.1016/j.matdes.2026.115535","url":null,"abstract":"<div><div>The acidic tumor microenvironment (TME) drives malignancy and treatment resistance, necessitating precise extracellular pH quantification for improved monitoring. Although acid-sensitive chemical exchange saturation transfer (acidoCEST) magnetic resonance imaging (MRI) holds promise in detecting pH value of the TME, current endogenous agents suffer from low sensitivity and specificity, and exogenous agents face biocompatibility and sensitivity concerns. In this work, we conjugated salicylic acid (SA) with polydopamine (PDA) to develop multifunctional nanoparticles (SA-PDA NPs). SA-PDA NPs integrated the pH-responsive acidoCEST MRI capability of SA with photothermal property of PDA. In vitro and in vivo experiments demonstrated that SA-PDA NPs possessed acidoCEST imaging capability, enabling accurate measurement of the acid pH of the TME in a melanoma mouse model. Moreover, SA-PDA NPs could inhibit the migration and invasion of tumor cells. When combined with 808 nm near infrared laser irradiation, SA-PDA NPs efficiently eradicated tumor tissues and prolonged the survival of melanoma-bearing mice without causing undesired side effects. Hence, this theranostic platform combines quantitative TME pH detection with localized photothermal therapy, offering precise monitoring and efficient treatment for solid tumors.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115535"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185996","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-02-02DOI: 10.1016/j.matdes.2026.115602
Jianming Zhang , Wenzhong Lou , Hengzhen Feng , Wenxing Kan , Yi Lu
To meet the requirements for micro thruster system in microsatellites and solve the integration problems caused by large laser ignition devices, this study developed a miniature laser ignition device using a 2 × 2 VCSEL(vertical-cavity surface-emitting laser) chip array. The device incorporates dual-aspheric lenses system for beam shaping. The device’s spot characteristics and power output were systematically characterized. A three-dimensional ignition model that includes heat transfer, chemical reaction heat, and laser energy effects was established. This model simulates the heating process of the propellant under multi-spot laser irradiation and examines factors affecting ignition delay time. Ignition tests using B/KNO3 propellant showed 100% reliable ignition at laser output powers between 3.55 and 6.23 W. As the laser power density increases, the propellant surface rapidly reaches its decomposition temperature. This increase in burning rate leads to shorter burn duration. The connection between burn rate and ignition delay time confirms the accuracy of the ignition model. The compact laser ignition device proposed in this paper enables reliable ignition of microsatellite thruster systems.
{"title":"Development and performance evaluation of the laser ignition device for micro thruster systems","authors":"Jianming Zhang , Wenzhong Lou , Hengzhen Feng , Wenxing Kan , Yi Lu","doi":"10.1016/j.matdes.2026.115602","DOIUrl":"10.1016/j.matdes.2026.115602","url":null,"abstract":"<div><div>To meet the requirements for micro thruster system in microsatellites and solve the integration problems caused by large laser ignition devices, this study developed a miniature laser ignition device using a 2 × 2 VCSEL(vertical-cavity surface-emitting laser) chip array. The device incorporates dual-aspheric lenses system for beam shaping. The device’s spot characteristics and power output were systematically characterized. A three-dimensional ignition model that includes heat transfer, chemical reaction heat, and laser energy effects was established. This model simulates the heating process of the propellant under multi-spot laser irradiation and examines factors affecting ignition delay time. Ignition tests using B/KNO<sub>3</sub> propellant showed 100% reliable ignition at laser output powers between 3.55 and 6.23 W. As the laser power density increases, the propellant surface rapidly reaches its decomposition temperature. This increase in burning rate leads to shorter burn duration. The connection between burn rate and ignition delay time confirms the accuracy of the ignition model. The compact laser ignition device proposed in this paper enables reliable ignition of microsatellite thruster systems.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115602"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186079","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-02-03DOI: 10.1016/j.matdes.2026.115617
Yu-Sheng Chiou , Chao-Chia Cheng , Yang-Chun Chiu , Benjamin Tien-Hsi Lee
We report and implement a temperature-controlled design that modulates material reactivity via electrochemical processing to fabricate silicon nanostructures. The resulting structures exhibit quantum confinement-induced photoluminescence (PL), a critical characteristic for realizing silicon photonic devices on heavily boron-doped silicon. This effect is achieved simply by lowering the electrolyte temperature to -20°C via a dry-ice bath. The temperature-oriented design effectively alters the interfacial reaction dynamics and overcomes the doping concentration-induced limitations in nanostructuring heavily boron-doped silicon, enabling stable PL without post-oxidation or modification of the intrinsic material properties. Typically, anodization of heavily boron-doped silicon at room temperature produces a black, velvet-like mesoporous surface that absorbs incident light and exhibits no PL; in contrast, anodization at -20°C generates a distinct bright red emission under UV illumination. Transmission electron microscopy revealed the formation of silicon nanocrystals approximately 3–4 nm in size, which are responsible for the observed quantum confinement. Moreover, the etching behavior at -20°C is predominantly isotropic, whereas at room temperature, it becomes anisotropic. This study establishes low-temperature electrochemical processing as a versatile and scalable route for tailoring semiconductor nanostructures, thereby broadening the applicability of silicon-based quantum-dot technologies.
{"title":"Dry-Ice-Bath Anodization of Heavily Boron-Doped Silicon: A Physically Controlled Process for Creating Quantum-Confined Nanostructures","authors":"Yu-Sheng Chiou , Chao-Chia Cheng , Yang-Chun Chiu , Benjamin Tien-Hsi Lee","doi":"10.1016/j.matdes.2026.115617","DOIUrl":"10.1016/j.matdes.2026.115617","url":null,"abstract":"<div><div>We report and implement a temperature-controlled design that modulates material reactivity via electrochemical processing to fabricate silicon nanostructures. The resulting structures exhibit quantum confinement-induced photoluminescence (PL), a critical characteristic for realizing silicon photonic devices on heavily boron-doped silicon. This effect is achieved simply by lowering the electrolyte temperature to -20°C via a dry-ice bath. The temperature-oriented design effectively alters the interfacial reaction dynamics and overcomes the doping concentration-induced limitations in nanostructuring heavily boron-doped silicon, enabling stable PL without post-oxidation or modification of the intrinsic material properties. Typically, anodization of heavily boron-doped silicon at room temperature produces a black, velvet-like mesoporous surface that absorbs incident light and exhibits no PL; in contrast, anodization at -20°C generates a distinct bright red emission under UV illumination. Transmission electron microscopy revealed the formation of silicon nanocrystals approximately 3–4 nm in size, which are responsible for the observed quantum confinement. Moreover, the etching behavior at -20°C is predominantly isotropic, whereas at room temperature, it becomes anisotropic. This study establishes low-temperature electrochemical processing as a versatile and scalable route for tailoring semiconductor nanostructures, thereby broadening the applicability of silicon-based quantum-dot technologies.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115617"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186081","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-01-24DOI: 10.1016/j.matdes.2026.115553
Mandeep Singh, Chi-Ho Ng, Muhammad Adeel Zafar, Matthew Dargusch, M.J. Bermingham
Many titanium alloys are notoriously difficult to machine materials, and there is a need to understand new ways to improve their machinability. This study explores the effect of trace element additions, specifically boron (B) and lanthanum hexaboride (LaB6), on the machinability of Ti-6Al-4V (Ti-64). Alloys containing these additives were prepared via casting and evaluated through slot milling tests to assess cutting forces, tool wear, chip morphology, and surface quality. The addition of boron led to the formation of titanium boride (TiB) particles, which contributed to high cutting forces, increased built-up edge (BUE) formation, and irregular chip segmentation. Conversely, LaB6 additions led to the formation of both TiB and La-rich particles, where the La-rich particles enhanced material flow, resulting in reduced cutting forces, uniform chip formation, and improved machined surface quality. These findings offer valuable insights into the design of free-machining titanium alloys and may facilitate more efficient manufacturing of Ti-64 components.
{"title":"Towards free-machining titanium: role of boron and lanthanum hexaboride in Ti-6Al-4V","authors":"Mandeep Singh, Chi-Ho Ng, Muhammad Adeel Zafar, Matthew Dargusch, M.J. Bermingham","doi":"10.1016/j.matdes.2026.115553","DOIUrl":"10.1016/j.matdes.2026.115553","url":null,"abstract":"<div><div>Many titanium alloys are notoriously difficult to machine materials, and there is a need to understand new ways to improve their machinability. This study explores the effect of trace element additions, specifically boron (B) and lanthanum hexaboride (LaB<sub>6</sub>), on the machinability of Ti-6Al-4V (Ti-64). Alloys containing these additives were prepared via casting and evaluated through slot milling tests to assess cutting forces, tool wear, chip morphology, and surface quality. The addition of boron led to the formation of titanium boride (TiB) particles, which contributed to high cutting forces, increased built-up edge (BUE) formation, and irregular chip segmentation. Conversely, LaB<sub>6</sub> additions led to the formation of both TiB and La-rich particles, where the La-rich particles enhanced material flow, resulting in reduced cutting forces, uniform chip formation, and improved machined surface quality. These findings offer valuable insights into the design of free-machining titanium alloys and may facilitate more efficient manufacturing of Ti-64 components.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115553"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076819","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-02-08DOI: 10.1016/j.matdes.2026.115631
Xueyu Li , Zhile Li , Yinxiang Xie , Jun Du , Yuhao Li , Lai Wang , Lin Song , Rongrong Ren
Addressing the critical bottleneck of low reactive oxygen species (ROS) generation efficiency in sonodynamic therapy (SDT), this study proposes a supramolecular self-assembly enhancement strategy. Using dichloro(1,10-phenanthroline)platinum(II) (PtC) as a model molecule, antiparallel dimers were formed via Pt⋯Pt metallophilic interactions and π-π stacking. This induced H-aggregation, widening the energy gap and achieving aggregation-induced emission (AIE). Upon ultrasound activation, the self-assembled PtC nanoparticles exhibited significantly enhanced capabilities for generating singlet oxygen (1O2) and superoxide anion (•O2−) compared to the conventional sonosensitizer protoporphyrin IX (PpIX). In vitro, they induced mitochondrial damage, DNA fragmentation, and immunogenic cell death (ICD) via ROS burst. In vivo experiments confirmed their efficient accumulation in tumor tissues, which not only directly inhibited tumor proliferation but also activated dendritic cell maturation and T cell infiltration, triggering a systemic immune response. This work not only reveals the regulatory mechanism of electronic structure during the self-assembly of platinum complexes on sonodynamic efficacy but also provides a new design paradigm for developing novel sonosensitizers with both high-efficiency sonosensitization and immunostimulatory functions.
{"title":"Supramolecular self-assembly driven platinum-based small molecule for enhanced sonodynamic-immunotherapy","authors":"Xueyu Li , Zhile Li , Yinxiang Xie , Jun Du , Yuhao Li , Lai Wang , Lin Song , Rongrong Ren","doi":"10.1016/j.matdes.2026.115631","DOIUrl":"10.1016/j.matdes.2026.115631","url":null,"abstract":"<div><div>Addressing the critical bottleneck of low reactive oxygen species (ROS) generation efficiency in sonodynamic therapy (SDT), this study proposes a supramolecular self-assembly enhancement strategy. Using dichloro(1,10-phenanthroline)platinum(II) (PtC) as a model molecule, antiparallel dimers were formed via Pt⋯Pt metallophilic interactions and π-π stacking. This induced H-aggregation, widening the energy gap and achieving aggregation-induced emission (AIE). Upon ultrasound activation, the self-assembled PtC nanoparticles exhibited significantly enhanced capabilities for generating singlet oxygen (<sup>1</sup>O<sub>2</sub>) and superoxide anion (•O<sub>2</sub><sup>−</sup>) compared to the conventional sonosensitizer protoporphyrin IX (PpIX). In vitro, they induced mitochondrial damage, DNA fragmentation, and immunogenic cell death (ICD) via ROS burst. In vivo experiments confirmed their efficient accumulation in tumor tissues, which not only directly inhibited tumor proliferation but also activated dendritic cell maturation and T cell infiltration, triggering a systemic immune response. This work not only reveals the regulatory mechanism of electronic structure during the self-assembly of platinum complexes on sonodynamic efficacy but also provides a new design paradigm for developing novel sonosensitizers with both high-efficiency sonosensitization and immunostimulatory functions.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115631"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185320","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-01-28DOI: 10.1016/j.matdes.2026.115557
A. Kumar, M. Bernet, L. Deillon, M. Bambach, M. Afrasiabi
Multi-material spark plasma sintering (SPS) enables architected components with tailored properties, but it also poses challenges in controlling differential densification, geometric precision, and interface alignment under complex electro-thermo-mechanical conditions. Because experimental trial-and-error provides only limited insight into these coupled mechanisms, predictive process modeling is needed. Here, we develop and experimentally validate a fully coupled electro–thermo–mechanical finite element model for multi-material SPS of copper-nickel systems. A central contribution is the direct transfer of porosity-dependent constitutive parameters, independently calibrated from single-material SPS experiments, to multi-material configurations, without any additional fitting. The model accurately captures the temperature and densification evolution across three representative interface orientations (horizontal, inclined, and vertical), with deviations below 1%, providing a quantitative validation of parameter transferability. From an engineering perspective, the framework predicts final geometries and interface displacements with dimensional errors below 7%, enabling predictive design of powder deposition and interface placement. The simulations further show that interface orientation controls current-path distortion and localized Joule heating in highly conductive materials, whereas differences in porosity are the dominant driver of interface displacement. Beyond the Cu–Ni system studied here, the proposed multiphysics framework provides a transferable modeling strategy to support geometry control and interface design in thermomechanically similar multi-material SPS components.
{"title":"Predicting interface behavior and final geometry in multi-material spark plasma sintering: design insights from validated multiphysics process modeling","authors":"A. Kumar, M. Bernet, L. Deillon, M. Bambach, M. Afrasiabi","doi":"10.1016/j.matdes.2026.115557","DOIUrl":"10.1016/j.matdes.2026.115557","url":null,"abstract":"<div><div>Multi-material spark plasma sintering (SPS) enables architected components with tailored properties, but it also poses challenges in controlling differential densification, geometric precision, and interface alignment under complex electro-thermo-mechanical conditions. Because experimental trial-and-error provides only limited insight into these coupled mechanisms, predictive process modeling is needed. Here, we develop and experimentally validate a fully coupled electro–thermo–mechanical finite element model for multi-material SPS of copper-nickel systems. A central contribution is the direct transfer of porosity-dependent constitutive parameters, independently calibrated from single-material SPS experiments, to multi-material configurations, without any additional fitting. The model accurately captures the temperature and densification evolution across three representative interface orientations (horizontal, inclined, and vertical), with deviations below 1%, providing a quantitative validation of parameter transferability. From an engineering perspective, the framework predicts final geometries and interface displacements with dimensional errors below 7%, enabling predictive design of powder deposition and interface placement. The simulations further show that interface orientation controls current-path distortion and localized Joule heating in highly conductive materials, whereas differences in porosity are the dominant driver of interface displacement. Beyond the Cu–Ni system studied here, the proposed multiphysics framework provides a transferable modeling strategy to support geometry control and interface design in thermomechanically similar multi-material SPS components.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115557"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090774","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-02-02DOI: 10.1016/j.matdes.2026.115594
Lei Gan , Hongmeng Xu , Zhengchun Qian , Huanbo Cheng
Establishing the relationship between the energy input, particle thermal damage, microstructure, and properties is crucial for designing the particle reinforced metal matrix composite coating (PRMMCC) and developing the process maps of laser melt injection (LMI). The influence of varying energy density inputs and particle size on the surface morphology, cross-sectional characteristics, microstructure, particle thermal damage, and mechanical properties of WC particle reinforced 316L coatings was investigated. The macro thermal damage of particles was compared with the semi-quantitative evaluation results of micro thermal damage. The forms of thermal damage and evolutionary mechanisms of particles were elucidated, and the correlation between the macro thermal damage of particles and the evolutionary laws of the PRMMCC’s microstructure and mechanical properties was explored. The findings demonstrated that the PRMMCCs exhibited cracking and balling effects due to the high particle content and discontinuous molten pool at low macro thermal damage degree. Excessive macro thermal damage to particles ultimately led to the deterioration of mechanical properties. The appropriate range of macro thermal damage of LMI was determined. A process map based on the typical characteristics of the PRMMCCs was developed for LMI of WC reinforced 316L composite coating to guide coating design and industrial production.
{"title":"Process maps of laser melt injection: coating property evolution with macro thermal damage of WC particles","authors":"Lei Gan , Hongmeng Xu , Zhengchun Qian , Huanbo Cheng","doi":"10.1016/j.matdes.2026.115594","DOIUrl":"10.1016/j.matdes.2026.115594","url":null,"abstract":"<div><div>Establishing the relationship between the energy input, particle thermal damage, microstructure, and properties is crucial for designing the particle reinforced metal matrix composite coating (PRMMCC) and developing the process maps of laser melt injection (LMI). The influence of varying energy density inputs and particle size on the surface morphology, cross-sectional characteristics, microstructure, particle thermal damage, and mechanical properties of WC particle reinforced 316L coatings was investigated. The macro thermal damage of particles was compared with the semi-quantitative evaluation results of micro thermal damage. The forms of thermal damage and evolutionary mechanisms of particles were elucidated, and the correlation between the macro thermal damage of particles and the evolutionary laws of the PRMMCC’s microstructure and mechanical properties was explored. The findings demonstrated that the PRMMCCs exhibited cracking and balling effects due to the high particle content and discontinuous molten pool at low macro thermal damage degree. Excessive macro thermal damage to particles ultimately led to the deterioration of mechanical properties. The appropriate range of macro thermal damage of LMI was determined. A process map based on the typical characteristics of the PRMMCCs was developed for LMI of WC reinforced 316L composite coating to guide coating design and industrial production.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115594"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2026-01-31DOI: 10.1016/j.matdes.2026.115582
Roohallah Surki Aliabad , Saeed Sadeghpour , Pentti Karjalainen , Markus Riihimäki , Alexander Dahlström , Sonia Guehairia , Tao Zhou , Peter Hedström , Harishchandra Singh , Jukka Kömi , Vahid Javaheri
This study reveals a previously unreported transformation pathway governing austenite evolution during slow continuous heating of cold-rolled medium-Mn steel (Fe–0.4C–6Mn–2Al–1Si–0.05Nb, wt.%). Using a correlative approach combining in-situ high-energy X-ray diffraction, electron microscopy, atom probe tomography, and DICTRA simulations, we demonstrate that introducing a considerable amount of pre-existing austenite () at the onset of the intercritical annealing region is beneficial for microstructural control which acts as both a solute reservoir and a structural template for the formation of newly formed austenite (). Upon heating between 500 and 800 °C, fine (Fe, Mn)-rich carbides precipitate from , serving as heterogeneous nucleation sites for while concurrently depleting C and Mn from . The subsequent dissolution of these carbides above ∼ 660 °C releases solutes into the surrounding matrix, driving localized partitioning and stabilizing . This process results in a bimodal microstructure comprising elongated, low-alloy and blocky, high-alloy embedded in a submicron ferritic matrix. At higher temperatures, solute dilution reduces austenite stability. A retained austenite of 55 vol% was achieved at 780 °C, consistent with thermodynamic predictions without prolonged isothermal holding. These findings establish the controlled decomposition–reconstruction of into as a viable strategy for tailoring austenite morphology and chemistry, enabling efficient stabilization of high retained austenite amounts in medium-Mn steels while minimizing alloying requirements.
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