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The 2000 series aluminium alloys are an attractive option for lightweight structures, but solidification cracking in fusion welding remains an issue in additive manufacturing technologies. Al-Cu-Li alloys, in particular, have gained considerable attention due to their excellent strength-to-weight ratio and corrosion and fatigue resistance, making them highly suitable for aerospace components. Nevertheless, their narrow solidification range makes them highly susceptible to cracking, porosity formation, and elemental evaporation during fusion-based AM processes. These challenges underscore the necessity for advanced processing technologies and the development of suitable feedstock materials to ensure weld integrity and optimal performance. Although Al–Cu–Li alloys are highly valued in the aerospace sector, the application of wire arc additive manufacturing (WAAM) is currently limited by the lack of commercially available wire compositions. This study focuses on the use of powder metallurgy Al-Cu-Li wires in wire arc additive manufacturing, specifically using plasma metal deposition technology, to explore welding characteristics. This research demonstrates the development of an alternative wire using powder metallurgy for WAAM. Powder metallurgy wires were deposited on 5053 and 7075 aluminium substrates, and their microstructure, chemical composition, and mechanical properties were analysed. Key findings include significant elemental losses of Li and Cu during deposition—approximately 55% and 25%, respectively—as well as noticeable variations in microstructure, porosity, and grain morphology, depending on the substrate. Deposits on the 5083 aluminium exhibited more equiaxed grains and a higher chemical homogeneity compared to those on the 7075 substrate. This work establishes a link between material design and additive manufacturing by demonstrating that powder metallurgy Al–Cu–Li wires can be effectively processed by WAAM, achieving controlled elemental losses and a uniform microstructure that enhances weld integrity in aerospace components.

The requirement of good mechanical properties, lower Young’s modulus, superior corrosion resistance, and excellent biocompatibility makes β-type titanium alloys attractive materials for orthopedic implants. In this study, Ti-25Nb-5Fe and Ti-40Nb β-type titanium alloys were designed and produced by powder metallurgy route using titanium hydride, niobium, and iron powders. The effect of sintering conditions on microstructure, corrosion, and tribocorrosion behavior was explored. Electrochemical behavior was investigated in saline solution (9 g/L NaCl) at body temperature by using potentiodynamic polarization and electrochemical impedance spectroscopy. Tribocorrosion behavior was evaluated by reciprocating against an alumina ball at open circuit potential, as well, under anodic and cathodic potentiostatic conditions in saline solution (9 g/L NaCl) at body temperature. The physical, electrochemical, and tribo-electrochemical behaviors of both alloys were improved with increasing sintering time at 1250 °C from 2 to 4 hours and decreasing Fe particle size for Ti-25Nb-5Fe alloy. Degradation under tribocorrosion conditions was mainly governed by mechanical wear on Ti-25Nb-5Fe alloy; however, Ti-40Nb alloy exhibited an antagonistic effect between corrosion and wear during testing under anodic applied potential due to the formation of a denser tribolayer.

High production costs of Ti alloys usually hinders their use in industry sectors like the automotive and hence, low-cost titanium alloys could broaden titanium alloy usage. This work presents the study of three alloys— Ti-Fe, Ti-Fe-Al, and Ti-Fe-Cr—produced by powder metallurgy methods. The design of the compositions was aimed at reducing cost and enhance the oxidation and corrosion resistance while not decreasing the mechanical performance. The use of titanium hydride as raw material instead of Ti powder is highlighted as a key feature in the design and manufacturing procedure of the alloys. Introducing a dehydrogenation process during sintering favors the densification process while reducing the oxygen contamination and the production cost. There is a lack of studies focused on the implementation of affordable PM Ti alloys in high demanding environments. Therefore, a study of high temperature oxidation resistance and electrochemical behavior was performed.

This study presents and explains the results of the first steps in developing high strength aluminium alloy (Al–Cu–Li) wires for the ultimate purpose of using them as feedstock for DED (directed energy deposition) techniques, such as wire arc additive manufacturing (WAAM). Powder metallurgy (PM) is proposed as the method to produce the wires due to the high flexibility to adapt the composition and the lower temperatures used with respect to casting. Two PM routes are proposed. The first route comprises blending of the powders, uniaxial pressing, and hot extrusion of the green compact to obtain a bar; the second route includes a heat treatment of the green compact, to promote the diffusion of the alloying elements before hot extrusion. Further steps, such as rolling or drawing, are necessary to obtain the wire from the bar. This work studies the effects of the processing parameters on the properties of extruded bars and compares the results of the two routes employed, with special attention paid to the effects of heat treatment. The study confirms that heat treatment homogenises the microstructure and requires higher applied extrusion force and time. The results from characterisation show the presence of Al–Cu and Al–Cu–Li phases in the microstructure.

The use of titanium hydride as a raw material has been an attractive alternative for the production of titanium components produced by powder metallurgy, due to increased densification of Ti compacts, greater control of contamination and cost reduction of the raw materials. However, a significant amount of hydrogen that often remains on the samples could generate degradation of the mechanical properties. Therefore, understanding decomposition mechanisms is essential to promote the components’ long life. Several studies on titanium hydride (TiH2) decomposition have been developed; nevertheless, few studies focus on the effect of the alloying elements on the dehydrogenation process. In this work, the effects of the addition of different amounts of Fe (5 and 7 wt. %) and Nb (12, 25, and 40 wt. %) as alloying elements were evaluated in detail. Results suggest that α→β transformation of Ti occurs below 800 °C; β phase can be observed at lower temperature than the expected according to the phase diagram. It was found that β phase transformation could take place during the intermediate stage of dehydrogenation. A mechanism was proposed for the effect of allying elements on the dehydrogenation process.

Arc-directed energy deposition using wire as feedstock is establishing itself as a 3D printing method capable of obtaining additively manufactured large structures. Contrasting results are reported in the literature about the effect of the deposition parameters on the quality of the deposited tracks, as it is highly dependent on the relationship and intercorrelations between the individual input parameters, which are generally deposition-technique-dependent. This study comprehensively analysed the effect of several deposition parameters and clarified their interactions in plasma metal deposition of Al alloys. It was found that, although no straightforward correlation between the individual input parameters investigated and the measured output deposition track’s quality aspects existed, the input current had the greatest effect, followed by the wire feed speed and its interaction with the input current. Moreover, the greatest effect of changing the shielding gas atmosphere, including the gas mixture, flow rate and plasma flow, was on the penetration depth, and fine-tuning the frequency/balance ratio and the preheating of the deposition substrates reduced the amount of porosity. This study demonstrates that well-deposited multi-layer walls made out of Al alloys can successfully be achieved via plasma metal deposition.

Chromium oxide powder (Cr2O3) was slip cast or pressed into small cylindrical pellets which were then sintered in air. The sintered pellets were attached to a current collector to form an assembled cathode. Constant-voltage (2.7 to 2.8 V) electrolysis, with a graphite anode, was performed in molten CaCl2 (950 degrees C). After electrolysis, the pellets were removed from the molten salt and washed in water. Scanning electron microscopy (SEM), energy-dispersive X-ray (EDX) analysis, and fusion elemental analysis all confirmed that, when electrolyzed for a period longer than 4 hours, the Cr2O3 pellets were fully reduced to Cr metal. The oxygen content in the product depended on electrolysis time. Typically, for a 6-hour electrolysis, less than 0.2 wt pct oxygen was found in the product, with the current efficiency and energy consumption being 75 pct and 5 kWh/kg, respectively. The fully reduced pellet had a friable strength and could be manually crushed into a powder composed of cubic crystallites, very uniform in size, that grew with the electrolysis time, up to 50 mum (15 hours). The unique product morphology (cubic crystallites) differs drastically from the nodular morphology observed in other metals prepared by similar methods and is rarely seen among various commercial metal powders. A reduction mechanism is proposed, emphasizing the surface metallization at the early stage of electrolysis through the propagation of the metal-oxide-electrolyte three-phase interline (3PI). [PUBLICATION ABSTRACT]

Cheap alloying elements and creative processing techniques are a way forward to open up more industrial opportunities for Ti in sectors where it is not extensively applied yet, rather than in aerospace and biomedical applications. This study focuses on understanding the joint effect of using a commercial steel powder to add Fe to pure Ti and its processing by press-and-sinter on the behaviour of low-cost PM Ti alloys. It is found that the calibrated addition of steel permits to develop new low-cost Fe-bearing Ti alloys that can satisfactorily be produced using the blending elemental PM approach. Densification of the samples and homogenization of the chemical composition are enhanced by the high diffusivity of Fe. The low-cost α+β alloys reach comparable physical and mechanical properties to those of wrought-equivalent PM Ti alloys, such as Ti-6Al-4V, and are therefore promising candidates for load-bearing lightweight products.

Aimed by reducing the total cost of products, powder metallurgy (PM) processing of Ti is a subject of high interest. However, using of conventional PM techniques presents difficulties due to the intrinsic characteristics of Ti, like low strain ability, and high reactivity, which lead to low compressibility. Moreover, Ti powders with small particle size are difficult to process by conventional PM techniques as they present a lower compressibility and also a poor flowability. On the other hand, the colloidal processing has been used for long in ceramics to achieve green bodies with high densities, complex shapes and homogeneous microstructures, but they are rarely used to shape metal powders because of its high density and high surface reactivity. However, the possibility to process fine particles makes these techniques interesting for metals with low density like Ti.The colloid-chemistry control of metallic powders in aqueous slurries is proposed as a way to prepare Ti porous parts with small particle size, throughout the formulation of aqueous slurries with solid contents as high as 50 vol.%. The chemical and chemical-physic stability of Ti powders 10 μm in size was determined by measuring the zeta potential as a function of pH, and dispersant concentration, while the later optimization of Ti slurries and their adequation for the use of different colloidal techniques, were studied in terms of rheology and the addition of the processing additives, such as gel or foaming agents. Techniques such as thermal gelling, foaming, and impregnation of exo-templates or robocasting were used to build Ti parts with random and/or tailored macroporosity. The shaped pieces made on Ti were sintered in vacuum at 1100 oC for 30 minutes, and their microstructure and mechanical properties were determined and compared with dense materials shaped by combining PM and colloidal techniques in previous works

The production of green hydrogen through proton exchange membrane water electrolysis (PEMWE) is a promising technology for industry decarbonization, outperforming alkaline water electrolysis (AWE). However, PEMWE requires significant investment, which can be mitigated through material and design advancements. Components like bipolar porous plates (BPPs) and porous transport films (PTFs) contribute substantially to costs and performance. BPPs necessitate properties like corrosion resistance, electrical conductivity, and mechanical integrity. Titanium, commonly used for BPPs, forms a passivating oxide layer, reducing efficiency. Effective coatings are crucial to address this issue, requiring conductivity and improved corrosion resistance. In this study, porous Ti64 structures were fabricated via powder technology, treating them with thermochemical nitriding. The resulting structures with controlled porosity exhibited enhanced corrosion resistance and electrical conductivity. Analysis through scanning electron microscopy (FE-SEM), X-ray diffraction (XRD), grazing incidence XRD and X-ray photoelectron spectroscopy (XPS) confirmed the effectiveness of the coating, meeting performance requirements for BPPs.