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: 2026-01-24DOI: 10.1016/j.matdes.2026.115544
Haejin Kwak , Youngran Seo , Hui Won Eom , Thomas P. Moffat , Dongwon Yoo , Myung Jun Kim
As transistor scaling approaches its physical limits, advanced semiconductor packaging has emerged as a promising solution by enabling system-level integration and supporting the More-than-Moore paradigm. One of the most critical aspects of semiconductor packaging is the formation of high-quality metal interconnections that can reliably connect multiple dies. Cu electrodeposition has become increasingly important due to its ability to fabricate complex interconnect structures without defects. These processes typically rely on multiple organic additives in the electrolyte, whose multiplicity increases cost and complicates process control. In this study, we present a newly designed organic suppressor for single-suppressor through-silicon via (TSV) filling via Cu electrodeposition. The molecule, composed of a triazine core linked to three ammonium-based side chains, is engineered to provide strong suppression while enabling mass-transfer-limited adsorption along the TSV depth. The differing time constant of the electrical versus mass transport response gives rise to the negative differential resistance behavior and the corresponding spatial bifurcation into active and passive regions. When coupled with the reentrant TSV geometry, such bifurcation results in extreme bottom-up filling. The new tris-ammonium-based suppressor and associated design strategy expand the range of molecule functionality and geometry that can be used in next-generation Cu electrodeposition processes.
{"title":"Single-additive TSV filling achieved with a tris-ammonium-based suppressor","authors":"Haejin Kwak , Youngran Seo , Hui Won Eom , Thomas P. Moffat , Dongwon Yoo , Myung Jun Kim","doi":"10.1016/j.matdes.2026.115544","DOIUrl":"10.1016/j.matdes.2026.115544","url":null,"abstract":"<div><div>As transistor scaling approaches its physical limits, advanced semiconductor packaging has emerged as a promising solution by enabling system-level integration and supporting the More-than-Moore paradigm. One of the most critical aspects of semiconductor packaging is the formation of high-quality metal interconnections that can reliably connect multiple dies. Cu electrodeposition has become increasingly important due to its ability to fabricate complex interconnect structures without defects. These processes typically rely on multiple organic additives in the electrolyte, whose multiplicity increases cost and complicates process control. In this study, we present a newly designed organic suppressor for single-suppressor through-silicon via (TSV) filling via Cu electrodeposition. The molecule, composed of a triazine core linked to three ammonium-based side chains, is engineered to provide strong suppression while enabling mass-transfer-limited adsorption along the TSV depth. The differing time constant of the electrical versus mass transport response gives rise to the negative differential resistance behavior and the corresponding spatial bifurcation into active and passive regions. When coupled with the reentrant TSV geometry, such bifurcation results in extreme bottom-up filling. The new tris-ammonium-based suppressor and associated design strategy expand the range of molecule functionality and geometry that can be used in next-generation Cu electrodeposition processes.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115544"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146057488","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: 2026-01-30DOI: 10.1016/j.matdes.2026.115560
Upendar Reddy Gandra , Novan Rifky Lutfhyansyah , Mohammed Ayaz Uddin , Haider Butt
Color vision deficiency (CVD), particularly red-green impairment, affects a large global population and is inadequately addressed by current corrective devices, which suffer from uniform tinting, poor spectral selectivity, and limited wearer comfort. Here, we present the fabrication of rhodamine B hydrazide (RhB-HZ)-embedded hydrogel contact lenses (RhB-HZ@CL) using digital light processing (DLP)-based 3D printing, offering a cost-effective and multifunctional alternative that has not been previously explored in contact lens fabrication. RhB-HZ is a derivative of Rhodamine B, 10–50 times cheaper than specialized chromophores, and undergoes a UV-triggered spirolactam ring-opening reaction, generating a stable pink coloration with a strong absorption maximum at 562 nm. This enables the selective blocking of 80–90% of the problematic 500–600 nm spectral region while preserving overall transparency under normal lighting conditions. Structural evaluations confirmed suitable water content and wettability, with the contact angle reduced from 81.64° (pristine) to 64.36–67.59° (RhB-HZ-loaded), ensuring improved tear-film stability. Thermal stability was maintained, with degradation onset occurring near 350 °C, validating the robustness of the processing. Mechanical testing revealed that at 0.01 wt% RhB-HZ, tear propagation strength increased to 5.95 ± 1.16 N with minimal compromise to tear initiation resistance (3.34 ± 0.83 N). Higher dye concentrations (0.03–0.05 wt%) led to reduced initiation forces (2.36–3.32 N) due to dye aggregation. Collectively, RhB-HZ@CL lenses integrate spectral selectivity, photostability, and biocompatibility with scalable, low-cost manufacturing, establishing them as a promising next-generation platform for discreet and effective CVD correction.
{"title":"Light-responsive rhodamine-derivative embedded 3D-printed contact lenses with enhanced optical and mechanical properties for next-generation ophthalmic applications","authors":"Upendar Reddy Gandra , Novan Rifky Lutfhyansyah , Mohammed Ayaz Uddin , Haider Butt","doi":"10.1016/j.matdes.2026.115560","DOIUrl":"10.1016/j.matdes.2026.115560","url":null,"abstract":"<div><div>Color vision deficiency (CVD), particularly red-green impairment, affects a large global population and is inadequately addressed by current corrective devices, which suffer from uniform tinting, poor spectral selectivity, and limited wearer comfort. Here, we present the fabrication of rhodamine B hydrazide (RhB-HZ)-embedded hydrogel contact lenses (RhB-HZ@CL) using digital light processing (DLP)-based 3D printing, offering a cost-effective and multifunctional alternative that has not been previously explored in contact lens fabrication. RhB-HZ is a derivative of Rhodamine B, 10–50 times cheaper than specialized chromophores, and undergoes a UV-triggered spirolactam ring-opening reaction, generating a stable pink coloration with a strong absorption maximum at 562 nm. This enables the selective blocking of 80–90% of the problematic 500–600 nm spectral region while preserving overall transparency under normal lighting conditions. Structural evaluations confirmed suitable water content and wettability, with the contact angle reduced from 81.64° (pristine) to 64.36–67.59° (RhB-HZ-loaded), ensuring improved tear-film stability. Thermal stability was maintained, with degradation onset occurring near 350 °C, validating the robustness of the processing. Mechanical testing revealed that at 0.01 wt% RhB-HZ, tear propagation strength increased to 5.95 ± 1.16 N with minimal compromise to tear initiation resistance (3.34 ± 0.83 N). Higher dye concentrations (0.03–0.05 wt%) led to reduced initiation forces (2.36–3.32 N) due to dye aggregation. Collectively, RhB-HZ@CL lenses integrate spectral selectivity, photostability, and biocompatibility with scalable, low-cost manufacturing, establishing them as a promising next-generation platform for discreet and effective CVD correction.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115560"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185940","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.2026.115541
Tianyu Zhang , Wenwen Wang , Wenqi Guo , Haigen Zhao , Xiaoxiang Wu , Changkui Yu , Yuanhang Gao , Mi Zhang , Zijin Liu , Yanling Pei , Shusuo Li , Shengkai Gong
Ni-based single crystal superalloys (Ni-SXs) generally precipitate unfavorable topologically close-packed (TCP) phases at elevated temperatures. Conventional design strategies primarily aim to suppress TCP phase formation; however, this approach often involves an unavoidable trade-off between material cost and creep resistance. To tackle the dilemma, we designed a creep-coordinated TCP phase (σ phase) in a Ni-SX through harnessing the (001)σ stacking disordering defects. Here, based on atomic-scale analysis and first-principles calculations, we systematically elucidate the roles of the (001)σ stacking disordering defects in facilitating creep-coordinated behaviors of the σ phase, which include the self-regulation of interface mismatches, the transformation of growth patterns, and the cooperative deformations with the matrix. These behaviors enable the σ phase to optimize the adaptability for interface mismatches, promote morphological spheroidization, and break through the traditionally hard and brittle nature, thereby supporting the outstanding creep performance of the Ni-SX. Our work presents an effective and sustainable strategy for improving the microstructure stability and performance of Ni-SXs, providing novel insights into high-performance alloy design through manipulating the TCP (σ) phase.
{"title":"Creep-coordinated behaviors of the σ phase with stacking disordering defects in a Ni-based single crystal superalloy","authors":"Tianyu Zhang , Wenwen Wang , Wenqi Guo , Haigen Zhao , Xiaoxiang Wu , Changkui Yu , Yuanhang Gao , Mi Zhang , Zijin Liu , Yanling Pei , Shusuo Li , Shengkai Gong","doi":"10.1016/j.matdes.2026.115541","DOIUrl":"10.1016/j.matdes.2026.115541","url":null,"abstract":"<div><div>Ni-based single crystal superalloys (Ni-SXs) generally precipitate unfavorable topologically close-packed (TCP) phases at elevated temperatures. Conventional design strategies primarily aim to suppress TCP phase formation; however, this approach often involves an unavoidable trade-off between material cost and creep resistance. To tackle the dilemma, we designed a creep-coordinated TCP phase (σ phase) in a Ni-SX through harnessing the (001)<sub>σ</sub> stacking disordering defects. Here, based on atomic-scale analysis and first-principles calculations, we systematically elucidate the roles of the (001)<sub>σ</sub> stacking disordering defects in facilitating creep-coordinated behaviors of the σ phase, which include the self-regulation of interface mismatches, the transformation of growth patterns, and the cooperative deformations with the matrix. These behaviors enable the σ phase to optimize the adaptability for interface mismatches, promote morphological spheroidization, and break through the traditionally hard and brittle nature, thereby supporting the outstanding creep performance of the Ni-SX. Our work presents an effective and sustainable strategy for improving the microstructure stability and performance of Ni-SXs, providing novel insights into high-performance alloy design through manipulating the TCP (σ) phase.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115541"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185886","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.2026.115605
Kaixi Jiang , Wei Yu , Zengshuo Zhang , Yishan Wang , Zhuo Zhang , Yu Bai , Hai Hao
This work proposes a novel manufacture method to enhance t1%he strength–ductility synergy of Al–Cu alloys by incorporating TiC/TiB2 particles. The composites were fabricated using an in-situ synthesized Al-30TiC/TiB2 master alloy, followed by ultrasonic-assisted casting and T8 heat treatment. A multiscale modeling approach combining ProCAST and Cellular Automata was established to simulate dendritic growth, solute distribution, and particle–matrix interactions. The results indicate that the introduction of TiC/TiB2 suppresses macro-segregation of Cu, promotes heterogeneous nucleation, and refines the microstructure. Compared with Al Cu alloy, the grain size was reduced by 92.7% in the as-cast state. The tensile strength increased by 14.6%, reaching 543 MPa, while the elongation increased from 8.4% to 9.4%. A dendrite growth model was established based on the diffusion blocking effect of nanoparticles. Quantitative analysis revealed that TiC/TiB2 particles inhibited dendritic growth, reducing the growth rate from 14.2 mm/s to 7.3 mm/s. Strengthening mechanism analysis confirms that Orowan strengthening is dominant (60.2%), followed by thermal mismatch (33.6%) and grain refinement (6.2%). This work significantly enhances the strength–ductility synergy of Al–Cu alloys by incorporating TiC/TiB2 micro–nano particles, while establishing a multiscale simulation framework to systematically elucidate the interaction mechanisms between particles and solute transport behavior.
{"title":"Strength-ductility synergy and multiscale particle-solute interaction mechanisms in Al-Cu composites reinforced by TiC/TiB2 nanoparticles","authors":"Kaixi Jiang , Wei Yu , Zengshuo Zhang , Yishan Wang , Zhuo Zhang , Yu Bai , Hai Hao","doi":"10.1016/j.matdes.2026.115605","DOIUrl":"10.1016/j.matdes.2026.115605","url":null,"abstract":"<div><div>This work proposes a novel manufacture method to enhance t1%he strength–ductility synergy of Al–Cu alloys by incorporating TiC/TiB<sub>2</sub> particles. The composites were fabricated using an in-situ synthesized Al-30TiC/TiB<sub>2</sub> master alloy, followed by ultrasonic-assisted casting and T8 heat treatment. A multiscale modeling approach combining ProCAST and Cellular Automata was established to simulate dendritic growth, solute distribution, and particle–matrix interactions. The results indicate that the introduction of TiC/TiB<sub>2</sub> suppresses macro-segregation of Cu, promotes heterogeneous nucleation, and refines the microstructure. Compared with Al Cu alloy, the grain size was reduced by 92.7% in the as-cast state. The tensile strength increased by 14.6%, reaching 543 MPa, while the elongation increased from 8.4% to 9.4%. A dendrite growth model was established based on the diffusion blocking effect of nanoparticles. Quantitative analysis revealed that TiC/TiB<sub>2</sub> particles inhibited dendritic growth, reducing the growth rate from 14.2 mm/s to 7.3 mm/s. Strengthening mechanism analysis confirms that Orowan strengthening is dominant (60.2%), followed by thermal mismatch (33.6%) and grain refinement (6.2%). This work significantly enhances the strength–ductility synergy of Al–Cu alloys by incorporating TiC/TiB<sub>2</sub> micro–nano particles, while establishing a multiscale simulation framework to systematically elucidate the interaction mechanisms between particles and solute transport behavior.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115605"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186033","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}
Strength enhancement through grain refinement in the AISI 304L stainless steel often leads to a notable reduction in ductility due to the suppression of the transformation-induced plasticity (TRIP) effect. Accordingly, the potential of Si addition for performance improvement of AISI 304L stainless steel through coupled metastability engineering and martensite strengthening was investigated. The 304L, 304L-Si3, and 304L-Si5 (at%) alloys with controlled stacking fault energy (SFE) were examined under different grain sizes. Tensile behavior, work-hardening response, phase transformation kinetics, and strengthening mechanisms were systematically investigated. The results revealed that Si addition effectively reduces SFE and promotes TRIP effect at fine grain sizes, resulting in superior work-hardening capability, enhanced ductility, and improved tensile toughness compared to the base 304L alloy. Notably, the 304L-Si3 alloy provided a more favorable strength-ductility balance (strength ∼1031 MPa and elongation ∼73 %), surpassing many advanced high-strength steels. Kinetic analysis demonstrated that the 304L-Si3 alloy with a fully austenitic initial structure provides optimized martensitic transformation kinetics, retaining the transformation to higher strains and thereby leading to higher uniform elongations. Furthermore, Si alloying increases the intrinsic strength of the α′-martensite phase, with estimated strength values of ∼1.56, ∼1.67, and ∼1.70 GPa for the 304L, 304L-Si3, and 304L-Si5 alloys, respectively.
{"title":"Coupling metastability engineering and martensite strengthening in Si-alloyed AISI 304L stainless steel toward enhanced strength-ductility synergy","authors":"Mohammad Javad Sohrabi , Saeed Sadeghpour , Mohammad Sajad Mehranpour , Alireza Kalhor , Milad Zolfipour Aghdam , Farhad Hasanabadi , Hamed Mirzadeh , Kinga Rodak , Reza Mahmudi , Hyoung Seop Kim","doi":"10.1016/j.matdes.2026.115623","DOIUrl":"10.1016/j.matdes.2026.115623","url":null,"abstract":"<div><div>Strength enhancement through grain refinement in the AISI 304L stainless steel often leads to a notable reduction in ductility due to the suppression of the transformation-induced plasticity (TRIP) effect. Accordingly, the potential of Si addition for performance improvement of AISI 304L stainless steel through coupled metastability engineering and martensite strengthening was investigated. The 304L, 304L-Si3, and 304L-Si5 (at%) alloys with controlled stacking fault energy (SFE) were examined under different grain sizes. Tensile behavior, work-hardening response, phase transformation kinetics, and strengthening mechanisms were systematically investigated. The results revealed that Si addition effectively reduces SFE and promotes TRIP effect at fine grain sizes, resulting in superior work-hardening capability, enhanced ductility, and improved tensile toughness compared to the base 304L alloy. Notably, the 304L-Si3 alloy provided a more favorable strength-ductility balance (strength ∼1031 MPa and elongation ∼73 %), surpassing many advanced high-strength steels. Kinetic analysis demonstrated that the 304L-Si3 alloy with a fully austenitic initial structure provides optimized martensitic transformation kinetics, retaining the transformation to higher strains and thereby leading to higher uniform elongations. Furthermore, Si alloying increases the intrinsic strength of the <em>α′</em>-martensite phase, with estimated strength values of ∼1.56, ∼1.67, and ∼1.70 GPa for the 304L, 304L-Si3, and 304L-Si5 alloys, respectively.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115623"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186063","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: 2026-01-27DOI: 10.1016/j.matdes.2026.115568
Shailendra Kumar Verma , Soung Yeoul Ahn , Sushil Kumar , Gaon Yu , Hyeonseok Cho , Alireza Zargaran , Gitaek Lee , Sang Guk Jeong , Man Jae Sagong , Bon Woo Koo , Seung Hoon Lee , Jung-Wook Cho , Hyoung Seop Kim , Kyoungdoc Kim
We systematically investigate the solidification microstructure and elemental segregation in Inconel 738LC fabricated via laser-based powder bed fusion of metals (PBF-LB/M) under three representative process conditions. Microstructural characterizations confirm a strong correlation between thermal input, solidification behavior, and microstructural anisotropy. Within the conditions, the high laser power and scan speed result in low porosity, low micro-cracks, and minimum lack-of-fusion defects. A combination of three-dimensional finite element method (FEM) simulations and phase-field modeling (PFM) quantify the thermal gradients, cooling rates, and predicts dendritic growth behavior. Optimized laser power and scan speed lead to a relatively low thermal gradient, which gives dendrite impingement. The dendrite impingement decreases undercooling, thereby lowering solute partitioning ratio between cell core and cell boundary. The high laser power condition induces a relatively low interface velocity with a larger tip radius, lowering solute segregation of γ’ forming elements based on the Gibbs-Thomson effect. Thus, the high laser power condition gives a relatively low volume fraction of MC carbides, possibly enhancing γ’ precipitation for strength during the post heat treatment process. This work provides new insights into the process-structure–property relationship in PBF-LB/M of IN738LC and establishes a modeling framework for predicting microstructure and segregation phenomena in Ni-based superalloy.
{"title":"Solidification microstructure and elemental segregation in laser-based powder bed fusion additively manufactured IN738LC Ni-based superalloy","authors":"Shailendra Kumar Verma , Soung Yeoul Ahn , Sushil Kumar , Gaon Yu , Hyeonseok Cho , Alireza Zargaran , Gitaek Lee , Sang Guk Jeong , Man Jae Sagong , Bon Woo Koo , Seung Hoon Lee , Jung-Wook Cho , Hyoung Seop Kim , Kyoungdoc Kim","doi":"10.1016/j.matdes.2026.115568","DOIUrl":"10.1016/j.matdes.2026.115568","url":null,"abstract":"<div><div>We systematically investigate the solidification microstructure and elemental segregation in Inconel 738LC fabricated via laser-based powder bed fusion of metals (PBF-LB/M) under three representative process conditions. Microstructural characterizations confirm a strong correlation between thermal input, solidification behavior, and microstructural anisotropy. Within the conditions, the high laser power and scan speed result in low porosity, low micro-cracks, and minimum lack-of-fusion defects. A combination of three-dimensional finite element method (FEM) simulations and phase-field modeling (PFM) quantify the thermal gradients, cooling rates, and predicts dendritic growth behavior. Optimized laser power and scan speed lead to a relatively low thermal gradient, which gives dendrite impingement. The dendrite impingement decreases undercooling, thereby lowering solute partitioning ratio between cell core and cell boundary. The high laser power condition induces a relatively low interface velocity with a larger tip radius, lowering solute segregation of γ’ forming elements based on the Gibbs-Thomson effect. Thus, the high laser power condition gives a relatively low volume fraction of MC carbides, possibly enhancing γ’ precipitation for strength during the post heat treatment process. This work provides new insights into the process-structure–property relationship in PBF-LB/M of IN738LC and establishes a modeling framework for predicting microstructure and segregation phenomena in Ni-based superalloy.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115568"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185987","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: 2026-01-13DOI: 10.1016/j.matdes.2026.115490
Shengqi Zang , Yi Shuai , Wenyin Zhu , Bo Chen , Jinjin Wang , Qintao Wang , Can Xiao
Critical-size bone defects in the oral and maxillofacial regions present significant clinical challenges due to their limited healing capacity. This study investigates the combined regenerative potential of a chitosan/anorganic bovine xenograft (C/ABX) scaffold incorporating platelet-derived growth factor-BB (PDGF) and bone morphogenetic protein-7 (BMP-7). The C/ABX/BMP-7/PDGF scaffold exhibited an interconnected porous structure and a sustained, biphasic release profile of growth factors. It demonstrated excellent biocompatibility and significantly enhanced the proliferation and osteogenic differentiation of human dental pulp stem cells (hDPSCs) in vitro, leading to the upregulation of key genes such as RUNX2, OCN, OPN, and COL1. In a rat calvarial defect model, the dual-factor scaffold, particularly when seeded with hDPSCs, markedly promoted new bone formation and vascular development compared to other experimental groups. This was evidenced by increased bone volume, trabecular thickness, and heightened expression of angiogenic (CD31) and osteogenic (OPN) markers. These findings highlight the potent synergistic effect of BMP-7 and PDGF within biomimetic scaffolds, providing a promising, multifaceted strategy for the clinical management of oral and maxillofacial bone defects.
{"title":"Synergistic bone regeneration via dual growth factor-loaded chitosan/anorganic bovine xenograft scaffolds with different pore structures","authors":"Shengqi Zang , Yi Shuai , Wenyin Zhu , Bo Chen , Jinjin Wang , Qintao Wang , Can Xiao","doi":"10.1016/j.matdes.2026.115490","DOIUrl":"10.1016/j.matdes.2026.115490","url":null,"abstract":"<div><div>Critical-size bone defects in the oral and maxillofacial regions present significant clinical challenges due to their limited healing capacity. This study investigates the combined regenerative potential of a chitosan/anorganic bovine xenograft (C/ABX) scaffold incorporating platelet-derived growth factor-BB (PDGF) and bone morphogenetic protein-7 (BMP-7). The C/ABX/BMP-7/PDGF scaffold exhibited an interconnected porous structure and a sustained, biphasic release profile of growth factors. It demonstrated excellent biocompatibility and significantly enhanced the proliferation and osteogenic differentiation of human dental pulp stem cells (hDPSCs) <em>in vitro</em>, leading to the upregulation of key genes such as <em>RUNX2, OCN, OPN, and COL1</em>. In a rat calvarial defect model, the dual-factor scaffold, particularly when seeded with hDPSCs, markedly promoted new bone formation and vascular development compared to other experimental groups. This was evidenced by increased bone volume, trabecular thickness, and heightened expression of angiogenic (CD31) and osteogenic (OPN) markers. These findings highlight the potent synergistic effect of BMP-7 and PDGF within biomimetic scaffolds, providing a promising, multifaceted strategy for the clinical management of oral and maxillofacial bone defects.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115490"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185989","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.2026.115630
Vojtech Lukes , Paloma Sirvent , Luis Alonso , Miguel Ángel Garrido-Maneiro , Pedro Poza
A robust validation of the one-dimensional isentropic model for predicting particle velocities in the cold spray process was carried out using a substantially larger and diverse experimental dataset to enable its safe application for data generation. We conducted high-speed laser imaging measurements over three stagnation pressures and four gas temperatures using aluminum and copper powders. To further assess the model’s accuracy, three Al particle-size distributions were also evaluated. Velocity data from the plume centerline matched model assumptions. The model reproduced key trends—velocity increases with temperature and pressure, and particle-size effects—with mean absolute deviations of 5.37% for Al and 5.26% for Cu. Although the overall trend was consistent, deviations up to 12–17% were observed in just two Al cases. In the case of Cu, all predictions presented deviations lower than 7% due to its higher sphericity, matching better with the model assumptions. While coarse-particle predictions were highly accurate, fine fractions were slightly overestimated, likely due to turbulence and nozzle shock waves not captured in the model. These results confirm that, with its extended validation, the model is a reliable, fast, and cost-effective alternative to Computational Fluid Dynamics simulations (CFD) for early-stage cold spray design and data generation.
{"title":"Consolidation of a 1D isentropic analytical model for predicting particle velocity in cold spray","authors":"Vojtech Lukes , Paloma Sirvent , Luis Alonso , Miguel Ángel Garrido-Maneiro , Pedro Poza","doi":"10.1016/j.matdes.2026.115630","DOIUrl":"10.1016/j.matdes.2026.115630","url":null,"abstract":"<div><div>A robust validation of the one-dimensional isentropic model for predicting particle velocities in the cold spray process was carried out using a substantially larger and diverse experimental dataset to enable its safe application for data generation. We conducted high-speed laser imaging measurements over three stagnation pressures and four gas temperatures using aluminum and copper powders. To further assess the model’s accuracy, three Al particle-size distributions were also evaluated. Velocity data from the plume centerline matched model assumptions. The model reproduced key trends—velocity increases with temperature and pressure, and particle-size effects—with mean absolute deviations of 5.37% for Al and 5.26% for Cu. Although the overall trend was consistent, deviations up to 12–17% were observed in just two Al cases. In the case of Cu, all predictions presented deviations lower than 7% due to its higher sphericity, matching better with the model assumptions. While coarse-particle predictions were highly accurate, fine fractions were slightly overestimated, likely due to turbulence and nozzle shock waves not captured in the model. These results confirm that, with its extended validation, the model is a reliable, fast, and cost-effective alternative to Computational Fluid Dynamics simulations (CFD) for early-stage cold spray design and data generation.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115630"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185303","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: 2026-02-11DOI: 10.1016/j.matdes.2026.115639
Libera Vitiello , Giuseppe Proietto Salanitri , Paolo Maria Riccobene , Maria Grazia Pia Musumeci , Roberto Fiorenza , Sabrina Carola Carroccio
The development of geometrically optimized photocatalytic devices is a key challenge for advancing environmental purification technologies. The incorporation of titanium dioxide (TiO2) nanoparticles into polymeric materials, combined with additive manufacturing, offers a promising route to fabricate photocatalytic structures with custom-designed architectures. This paper investigates how specific geometric design influences nanoparticle distribution and its effect on the photocatalytic performance. A commercial acrylic resin was loaded with different TiO2 concentrations (2.5, 5, 10 wt%), and optimal printing conditions were identified to achieve high-resolution structures. Characterization through cure depth measurements, ATR-FTIR spectroscopy, thermogravimetric analysis, scanning electron microscopy, and energy-dispersive X-ray spectroscopy confirmed effective photopolymerization and thermal stability, enabling evaluation of nanoparticle distribution in 3D-printed nanocomposites. Gyroid, lattice, and wheel geometries were designed to assess shape effects on titania distribution via photocatalytic testing. Topologically constrained and intralayer regions promote nanoparticle surface enrichment. Specifically, complex networks exhibit greater surface segregation than simple geometries, enhancing TiO2 photoactivity. The gyroid, characterized by the highest number of layers, displayed the best photocatalytic activity, with a 43% increase in the reaction rate constant compared to the wheel geometry at 10 wt% TiO2. These findings demonstrate that tailoring material formulation and geometry can maximize the performance of 3D-printed photocatalytic devices.
{"title":"Geometry effect on titania nanoparticle distribution and its impact on the photocatalytic properties of vat photopolymerization 3D-printed acrylic resin-based nanocomposites","authors":"Libera Vitiello , Giuseppe Proietto Salanitri , Paolo Maria Riccobene , Maria Grazia Pia Musumeci , Roberto Fiorenza , Sabrina Carola Carroccio","doi":"10.1016/j.matdes.2026.115639","DOIUrl":"10.1016/j.matdes.2026.115639","url":null,"abstract":"<div><div>The development of geometrically optimized photocatalytic devices is a key challenge for advancing environmental purification technologies. The incorporation of titanium dioxide (TiO<sub>2</sub>) nanoparticles into polymeric materials, combined with additive manufacturing, offers a promising route to fabricate photocatalytic structures with custom-designed architectures. This paper investigates how specific geometric design influences nanoparticle distribution and its effect on the photocatalytic performance. A commercial acrylic resin was loaded with different TiO<sub>2</sub> concentrations (2.5, 5, 10 wt%), and optimal printing conditions were identified to achieve high-resolution structures. Characterization through cure depth measurements, ATR-FTIR spectroscopy, thermogravimetric analysis, scanning electron microscopy, and energy-dispersive X-ray spectroscopy confirmed effective photopolymerization and thermal stability, enabling evaluation of nanoparticle distribution in 3D-printed nanocomposites. Gyroid, lattice, and wheel geometries were designed to assess shape effects on titania distribution via photocatalytic testing. Topologically constrained and intralayer regions promote nanoparticle surface enrichment. Specifically, complex networks exhibit greater surface segregation than simple geometries, enhancing TiO<sub>2</sub> photoactivity. The gyroid, characterized by the highest number of layers, displayed the best photocatalytic activity, with a 43% increase in the reaction rate constant compared to the wheel geometry at 10 wt% TiO<sub>2</sub>. These findings demonstrate that tailoring material formulation and geometry can maximize the performance of 3D-printed photocatalytic devices.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115639"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185708","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}
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