The development of advanced aluminium hybrid metal matrix composites (AHMMCs) reinforced with rare earth oxides (REOs) remains a concern for the research community to produce lightweight materials for many advanced engineering applications with improved mechanical characteristics. To ensure the effective manufacturing of REOs-based composites, further research into the behavior of reinforcement with the matrix microstructure following composite preparation is required, as well as which strengthening process is best suited to improving mechanical qualities. The present paper aims to investigate the reinforcement SiC/Al2O3/CeO2 effect on the microstructure of Al hybrid composites prepared using stir casting. Hybrid aluminium composites contains 5 to 15% wt.% of (silicon carbide and aluminium oxide) and 0.5 to 2.5 wt.% CeO2 . The in-depth understanding of the microstructural formation mechanisms was analysed using the EBSD results. Variable mis-orientation threshold values obtained by EBSD were used to recognize the grain and subgrain structures. Low-angle grain boundaries (LAGBs) were defined within the range of 3 degrees-15 degrees, while high-angle grain boundaries (HAGBs) were considered as those with mis-orientation angles greater than 15 degrees. Geometry necessary boundaries (GNBs) and LAGBs develop as a result of dynamic recovery (DRV) at tested places with minimal or moderate plastic deformation in all composites tested. The texture evolution at various locations is presented by the inverse pole figures.

In this study, a series of (Ti50Zr50) x (Ni33Co33Fe33)100-x high-entropy bulk metallic glasses (HE-BMGs), with x ranging from 30 to 70 at.%, were synthesized using vacuum arc melting followed by suction casting. The influence of compositional variation on phase formation, thermal stability, mechanical hardness, and tribological performance was systematically investigated. Thermodynamic parameters, including mixing enthalpy, configurational entropy, atomic size mismatch, and the Omega parameter, predicted strong glass-forming ability across all compositions. X-ray diffraction and differential scanning calorimetry confirmed fully amorphous structures with wide supercooled liquid regions (Delta T = 53.7-68.1 degrees C), indicating high thermal stability. Vickers microhardness decreased from 875.76 HV to 663.16 HV as Ti-Zr content increased, corresponding to an approximate 24% reduction in hardness. Tribological tests revealed that the specific wear rate increased from 7.76 & times; 10-6 to 21.24 & times; 10-6 mm3/Nm, while the coefficient of friction rose from 0.355 to 0.507 with increasing Ti-Zr content. Fe-Co-Ni-rich alloys exhibited superior wear resistance and lower friction. These results demonstrate that compositional balancing is critical for optimizing the mechanical and tribological performance of HE-BMGs for lightweight, wear-resistant structural applications.

PurposeThe present work is a step forward in developing spark plasma sintered titanium alloy (Ti64) and multilayer graphene (MLG) nanocomposites with enhanced mechanical and tribological properties for industrial applications. This study aims to conduct a detailed experimental investigation of the spark plasma process during the fabrication of Ti64-MLG nanocomposites. It gives an insight into understanding the role of adding MLG in influencing the properties of Ti64.Design/methodology/approachConducts a detailed parametric analysis of the spark plasma sintering (SPS) process during the fabrication of Ti64-MLG nanocomposites. Experimental runs were designed using the central composite rotatable design approach.FindingsAnalysis of variance predicted Wt.% of MLG as the significant parameter with a contribution of 54.75 % and 48.72 %, followed by the sintering temperature, contributing 43.44 % and 46.22 % in determining corrosion current density and wear rate, respectively. A minimum wear rate of 14.50 & times; 10-6 g/m, corresponding to a 54.40 % improvement compared to bare Ti64, is achieved for Ti64-0.8 Wt.% MLG fabricated at 1000 degrees C.Originality/valueTi64-MLG nanocomposites demonstrating improved wear and corrosion resistance have been developed in this study. Additionally, regression models illustrating the relationship between the output responses, that is, wear rate and corrosion current density of the nanocomposites as a function of input parameters, that is, sintering temperature and Wt.% of MLG, have been established.

This study focuses on the formation and characterization of high-entropy bulk metallic glasses (HE-BMGs) through an equiatomic substitution approach. A series of (Ti50Zr50)x(Co33Fe33Ni33)100-x alloys were designed to explore their potential as glass-forming systems. For bulk metallic glass formation, the prediction of amorphous phase stability was carried out using thermophysical parameters (ΔSmix, ΔHmix, Ω, δ, VEC, and δ′). Thermal analysis of the alloys revealed high glass-forming ability (GFA), with Tg, Tx, and ΔT values confirming improved thermal stability. x-ray diffraction (XRD) patterns demonstrated the predominance of amorphous structures with minor intermetallic phases, while SEM investigations revealed typical BMG features, including dendritic and interdendritic regions arising from partial crystallization. EDS mapping confirmed elemental segregation, consistent with compositional complexity in HE-BMGs. Corrosion behavior in NaCl solution was found to depend strongly on Ti and Zr concentration, reflecting their role in passivation and stability. Additionally, wettability studies showed that (Ti50Zr50)x(Co33Fe33Ni33)100-x HE-BMGs can effectively tune surface properties. It highlights their promise for applications in protective coatings, structural components, and biointerfaces where both glass-forming ability and surface functionality are critical.

This study focuses on the formation and characterization of high-entropy bulk metallic glasses (HE-BMGs) through an equiatomic substitution approach. A series of (Ti50Zr50)x(Co33Fe33Ni33)100-x alloys were designed to explore their potential as glass-forming systems. For bulk metallic glass formation, the prediction of amorphous phase stability was carried out using thermophysical parameters (Delta Smix, Delta Hmix, Omega, delta, VEC, and delta '). Thermal analysis of the alloys revealed high glass-forming ability (GFA), with Tg, Tx, and Delta T values confirming improved thermal stability. x-ray diffraction (XRD) patterns demonstrated the predominance of amorphous structures with minor intermetallic phases, while SEM investigations revealed typical BMG features, including dendritic and interdendritic regions arising from partial crystallization. EDS mapping confirmed elemental segregation, consistent with compositional complexity in HE-BMGs. Corrosion behavior in NaCl solution was found to depend strongly on Ti and Zr concentration, reflecting their role in passivation and stability. Additionally, wettability studies showed that (Ti50Zr50)x(Co33Fe33Ni33)100-x HE-BMGs can effectively tune surface properties. It highlights their promise for applications in protective coatings, structural components, and biointerfaces where both glass-forming ability and surface functionality are critical.

High-entropy bulk metallic glass (HE-BMG) alloys have recently gained significant attention owing to their unique structural characteristics, outstanding mechanical performance, and potential for advanced engineering applications. In this work, we report the design and development of a Ti20Zr20Fe20Co20Ni20 HE-BMG alloy synthesized via vacuum arc melting. The alloy was systematically characterized to evaluate its phase evolution, microstructure, thermal stability, and mechanical properties. Thermophysical parameters, including Delta H-mix (mixing enthalpy), delta (atomic size difference) and Delta S-mix (mixing entropy), were employed to predict the formation of a glassy phase. X-ray diffraction confirmed an amorphous structure in the as-cast state, while annealed samples revealed intermetallic phase formation. Differential scanning calorimetry measurements indicated a distinct glass transition temperature (T-g), onset crystallization temperature (T-x), and a wide supercooled liquid region (Delta T), signifying excellent thermal stability and high glass-forming ability. Scanning electron microscopy revealed a dual-phase microstructure consisting of dendritic and interdendritic regions, with energy-dispersive spectroscopy confirming elemental segregation. The potentiodynamic polarization results confirm that the HE-BMG combines excellent corrosion resistance, favorable surface wettability, and structural stability. The Ti20Zr20Fe20Co20Ni20 HE-BMG demonstrates a unique balance of hardness, wear resistance, and tribological stability, surpassing many traditional alloys.

High-entropy bulk metallic glass (HE-BMG) alloys have recently gained significant attention owing to their unique structural characteristics, outstanding mechanical performance, and potential for advanced engineering applications. In this work, we report the design and development of a Ti 20 Zr 20 Fe 20 Co 20 Ni 20 HE-BMG alloy synthesized via vacuum arc melting. The alloy was systematically characterized to evaluate its phase evolution, microstructure, thermal stability, and mechanical properties. Thermophysical parameters, including ΔH mix (mixing enthalpy), δ (atomic size difference) and ΔS mix (mixing entropy), were employed to predict the formation of a glassy phase. X-ray diffraction confirmed an amorphous structure in the as-cast state, while annealed samples revealed intermetallic phase formation. Differential scanning calorimetry measurements indicated a distinct glass transition temperature (T g ), onset crystallization temperature (T x ), and a wide supercooled liquid region (ΔT), signifying excellent thermal stability and high glass-forming ability. Scanning electron microscopy revealed a dual-phase microstructure consisting of dendritic and interdendritic regions, with energy-dispersive spectroscopy confirming elemental segregation. The potentiodynamic polarization results confirm that the HE-BMG combines excellent corrosion resistance, favorable surface wettability, and structural stability. The Ti 20 Zr 20 Fe 20 Co 20 Ni 20 HE-BMG demonstrates a unique balance of hardness, wear resistance, and tribological stability, surpassing many traditional alloys.

Laser welding of aerospace-grade Ti6Al4V titanium alloy, focusing on optimizing welding parameters and analyzing the resulting microstructural and mechanical properties. The experiment examines the effects of varying laser power, pulse duration, and focus positions on weld quality, heat-affected zones, and mechanical strength. These parameters are systematically altered to understand their impact on the final weld characteristics. Characterization techniques such as scanning electron microscopy (SEM), tensile strength testing, and microhardness profiling are used to evaluate the microstructure, mechanical properties, and hardness distribution of the welds. These methods provide a comprehensive understanding of how the welding parameters influence the performance and integrity of the welded joints. The results demonstrate a correlation between laser parameters and weld integrity, revealing optimal settings for achieving minimal porosity and enhanced fatigue resistance. This research provides insights into the microstructure-property relationships in Nd laser-welded titanium alloys, contributing to improved weld quality in aerospace applications.

This article aims to evaluate the effect of ceria oxide as rare earth oxides (REOs) on the tribological properties of aluminum hybrid composites with varied concentrations of reinforcing elements such as silicon carbide, aluminum oxide, and ceria oxide. In order to accomplish this, composites were produced by varying the percentage of SiC/Al 2 O 3 in the Al-6061 matrix from 2.5 to 7.5 wt% and the quantity of CeO 2 from 0.5 to 2.5 wt%. The formation of the intermetallic phase (Al 4 Ce 3 ) as a result of the integration of cerium oxide into aluminum composites at concentrations between 0.5 and 2.5 wt% results in a wear rate improvement of up to 87.28%. The objective of developing Levenberg-Marquardt algorithm (LMA) neural networks is to forecast how the tribological behavior of hybrid composites would be altered by the addition of REOs based on data acquired from wear testing. The correlation value (R) and mean square error are found to be 0.987 and 4.3424e −10 , respectively, which is an indication of good fit for the model with high significance. The findings indicate that the LMA neural network models accurately forecast the tribological properties of REOs–aluminum hybrid composites.

A new kind Al-6061/SiC/Al 2 O 3 hybrid composite was prepared with traces amount of cerium oxide and its corrosion performance was evaluated by potentio-dynamic polarization electrochemical method. A new kind of intermetallic (γ-phase) has been observed in the microstructure with higher content of cerium oxide and Al elements. The corrosion resistance of Al-6061 alloy improved with addition of cerium oxide and this improvement could attribute to depression of the micro-galvanic couples. The corrosion rates were observed as 0.16 and 0.034 mpy corresponding to 3.5 and 2.5 wt% of NaCl corresponding to 2.5 wt% of cerium oxide. Moreover, the formation of cerium oxide and Al enrichment film over the surface of hybrid composites was also found to be main key factor for the inhibition of corrosion resistance. Another key factor that inhibits the further corrosion was observed as hydrophobicity between the aluminium liquid matrix and Al 2 O 3 /SiC reinforcement after incorporation of cerium oxide. Improvement in hydrophobicity of composites with Al 2 O 3 /SiC is due to increase in contact angle up to 100.78° after addition of 2.5 wt% cerium oxide. Micro-hardness and impact strength of the hybrid composites improved significantly after addition of traces amount of REOs from 0.5 to 2.5 wt%.

Owing to excellent mechanical properties, Titanium (Ti) alloys have been of great interest in recent years. However, due to their poor wear resistance application of these alloys is restricted in the areas involving wear and friction. To address such challenges, in the current work, multilayer graphene (MLG) reinforced titanium matrix composites have been fabricated via the spark plasma sintering process. The content of MLG in Ti6Al4V powder is varied between 0% and 1.2%. The present work explores the influence mechanism of MLG addition in Ti6Al4V by investigating fabricated nanocomposites’ microstructure, nanohardness and wear behaviour. Microstructural study reveals an in-situ reaction between a carbon source from MLG and Ti from the Ti6Al4V to form a secondary phase TiC. Moreover, due to the formation of TiC, an increase in the nanohardness value of sintered nanocomposites Ti6Al4V/1.2 wt.% MLG (5.39 GPa) was recorded when compared to fabricated Ti6Al4V alloy (3.23 GPa). Dry sliding wear tests were performed under loads of 3–7 kg. It was observed that Ti6Al4V/1.2 wt.% MLG nanocomposite shows the maximum wear resistance across various sliding velocities with a minimum wear rate of 15 × 10 −6 g/m. It is evident from the results obtained that MLG plays a vital role in improving the microstructural, mechanical, and tribological properties of sintered nanocomposites.

Monel 400, a type of nickel alloy which is adopted in numerous engineering fields, such as high-temperature devices. Owing to its better strength and thermal diffusion, it can be difficult to machine with conventional methods. In order to avoid the disadvantages of conventional methods, various advanced material removal techniques have been developed. One of these is Wire Electro Discharge Machining (WEDM). This process is an evolution of the electrical discharge method. In the process of WEDM, difficult materials with intricate forms are usually machined. In this study, the performance of this method on Monel 400 has been analyzed. The three independent variables that are considered when it comes to analyzing the performance of this process are the pulse on, the applied current, and the pulse off. The experiments were performed using the design approach of Taguchi, which involves using an L27 orthogonal array. The single response analysis performed by Taguchi revealed that the process parameters can influence the output variables that are desired by the users. Through the use of the Taguchi-grey relational analysis method, the multiple aspects optimization of the process was performed. The results of the exploration divulged that the proposed method can improve the effectiveness of this process.

Due to their inherent properties and superior performance over titanium-based materials, nickel-based superalloys are widely utilized in the manufacturing industry. Monel 400 is among them. This nickel-copper alloy possesses exceptional corrosion resistance and mechanical properties. Monel 400 is primarily utilized in the chemical industry, heat exchangers, and turbine component manufacturing. Due to the properties of Monel 400, it is deemed as hard to machine materials with the aid of conventional methods. For investigating the performance of this process, a three-level analysis was carried out. Pulse on duration and applied current at three levels are the independent parameters used for designing the experiments. In this present article, a single-response analysis technique is used which is known as Taguchi to investigate the impact of the various process parameters on the output variables. They focused on three response factors namely the rate of material removal, deviation in the dimension, and perpendicularity error. An efficient predictive model has been developed with the help of regression analysis. To enhance the performance of Wire Electrical Discharge Machining (WEDM) process, Taguchi based grey approach has been adopted. The findings of the study revealed that the proposed approach could assist to enhance the overall effectiveness of the process.

Helical coils are commonly employed in a variety of process industries due to their superior fluid mixing capabilities, the flexibility of fabrication, and simple design. Frictional pressure losses occur in flow-through helically coiled tubes, affecting the heat transfer rate across the coils. An inquiry is carried out in the current experimental study to discover friction factors and heat transfer rates within the coil tubes of test fluids flowing in the laminar flow area. Non-Newtonian test fluids comprised ichorous solutions of Carboxy Methyl Cellulose (CMC) at concentrations of 0.5 percent, 1 percent, and 2 percent, whereas Newtonian test fluids consisted of water. With the use of an appropriate viscosity expression, Newtonian consonances are demonstrated to apply to several non-Newtonian fluids with certain constraints. In a laminar flow, the shear stress in a helical coil is greater than in a straight conduit. It has been proved that the experimental data can be fruitfully correlated across a broad extent of fluid data and coil radius stretch. The investigated data obtained has been correlated with Standard a deviation of 15.6% with the range 25<D_e < 2000 and 40<P_r < 226.

The current study focused on developing a multifunctional Mg-based biodegradable composite that mitigates the trade-off between strength, antibacterial, and cytotoxicity behavior for orthopedic bone implants. The composite has been reinforced with natural mineral-based Hydroxyapatite and rare earth oxide (REO): Neodymium oxide. The effect of different concentrations of REO on the mechanical, antibacterial, and corrosion properties was analyzed. The antibacterial properties were assessed against gram-positive B. Subtilis and gram-negative E. Coli bacterial pathogens. Moreover, the cytotoxicity of the composites was assessed via Hemolysis percentage calculations. In addition, the microstructure characterization was performed via FESEM, XRD, and EDS techniques, and different intermetallic phase formations were recorded. Contact angle measurements were done via the sessile drop method to analyze the impact of rare earth oxide on the surface properties of the synthesized composites and their relationship with bacterial adhesion. The corrosion studies and swelling rates were performed under PBS and DMEM solutions. The composite with the addition of 1.5% REO outperformed the experiments with a compressive strength of 126.4 MPa, and a corrosion rate less than 0.2 mm/yr. The corrosion rates and degree of swelling were seen to be more stable in DMEM solution as compared to PBS. Improved antibacterial rates were observed against both pathogens after the addition of REO along with a hemolysis percentage less than 5% for Mg-HA-1.5Nd2 O3 . The composites showed increased hydrophobicity (>75%) by the addition of 1.5% REO. Hence, it was concluded that REO (Nd2 O3 ) addition to the Mg-Hydroxyapatite composite is a feasible choice as a biomaterial for bone implant applications.

One of the most common types of lightweight materials used in aerospace is magnesium alloy. It has a high strength-to-weight ratio and is ideal for various applications. Due to its corrosion resistance, it is commonly used to manufacture of fuselages. Unfortunately, the conventional methods of metal cutting fail to improve the performance of magnesium alloy. One amongst the most common methods used for making intricate shapes in harder materials is through Wire-Electro-Discharge (WEDM). In this study, we have used magnesium alloy as the work material. The independent factors were selected as pulse duration and peak current. The output parameters of the process are the Surface Roughness (SR) and the Material Removal Rate (MRR). Through a single aspect optimization technique, Taguchi was able to identify the optimal combination that would improve the effectiveness of the WEDM process. The findings of the experimentation revealed that the technique could significantly enhance the wire-cut process’s efficiency.

In the past few decades, titanium metal matrix composites have increased demand due to their vast application in the aerospace, biomedical and automotive industries. The spark plasma sintering process is one of the advanced techniques studied by various researchers during the fabrication of the TMCs. In the current work, the influence of sintering temperature and wt.% of multi-layer graphene (MLG) on hardness and elastic modulus of TMCs were studied. A parametric study of the SPS process was carried out by designing experiments using the response surface methodology. Analysis of variance was performed to investigate the influence of input factors and their interactions on the output responses. It was observed that both wt.% of MLG and sintering temperature had a substantial impact on the mechanical characteristics of the fabricated TMCs. Results show that sintering temperature contributed 42.15% and wt.% of MLG contribution was 55.40% in determining the hardness of the nanocomposites, while % contribution of sintering temperature and wt.% of MLG were 49.24% and 48.61%, respectively, in determining elastic modulus.

This research work is based on the machinability of an Inconel 800 alloy using TiAlN-coating and TiAlN-TiN-coating tools. In the CNC VMC Face milling process feed, depth of cut (DoC), and cutting speed consider input variables and surface roughness, Tool wear is measured for all machining conditions. To enhance the machining conditions a Taguchi L9 Design of Experiment was created. ANOVA analysis was used to identify the important variables influencing Flank wear (tool wear) and surface roughness. The signal-to-noise ratio for the ideal cutting combination was identified by evaluating the optimum surface roughness and tool wear. for the effect of coating, a comparison was done between the findings obtained using both TiAlN-coated and TiAlN-TiN tungsten carbide-coated tools. The best optimum surface roughness and tool wear of the experiment conducted under machining with TiAlN-TiN coated carbide tool resulted in .3433 µm and 128 µm respectively.

Magnesium alloy, known for its high strength and lightweight properties, finds widespread utilization in various technical applications. Aerospace applications, such as fuselages and steering columns, are well-suited for their utilization. These materials are frequently employed in automotive components, such as steering wheels and fuel tank lids, due to their notable corrosion resistance. The performance of magnesium alloy components remains unimproved by normal manufacturing methods due to the inherent characteristics of the material. This work introduces a contemporary approach to fabricating complex geometries through the utilization of Wire-Electro Discharge Machining (WEDM). The material utilized in this study was magnesium alloy. The investigation also considered the input parameters associated with the Wire Electrical Discharge Machining (WEDM) process, specifically the pulse duration and peak current. The findings of the study encompassed the material removal rate and surface roughness. Taguchi successfully employed a single aspect optimization technique to ascertain the ideal combination that would enhance the efficacy of the WEDM process. The findings of the investigation revealed that the proposed technique significantly improved the efficiency of the WEDM approach.