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This work investigates silver (Ag) microalloying as an efficient route to enhance the mechanical response of AlSi10Mg consolidated by vacuum hot pressing. Pre-alloyed AlSi10Mg powders were modified with 0–8 wt% Ag and densified in a single step without post-heat treatment. Comprehensive characterization, including Vickers hardness testing, dry sliding wear evaluation, and three-point bending experiments, revealed a clear optimum at 6 wt% Ag. The alloy exhibited a peak hardness of 74 HV (approximately 63% higher than the base alloy), a ∼42% reduction in wear rate (from 14.2 × 10−3 to 8.3 × 10−3 mm3 m−1), and a flexural strength of 476 MPa with a deflection of 3.8 mm values comparable to those reported for SLM-built AlSi10Mg and nearly fourfold higher than the unmodified hot-pressed alloy. These improvements are attributed to Ag-induced grain refinement, the formation of hard intermetallic phases (confirmed by SEM/EDS), and enhanced densification facilitated by Ag during sintering. Beyond 6 wt%, Ag agglomeration caused a decline in properties, underscoring the need for compositional optimization. Unlike previous studies focused on casting or additive manufacturing, this powder metallurgy-based strategy provides a cost-effective alternative by eliminating complex processing steps while delivering competitive mechanical performance. This study establishes clear composition-process-property linkages and highlights strong potential for deploying these alloys in lightweight structural components.

In this work, the TiAl4822/Ti6Al4V metal–intermetallic laminate (MIL) composite was fabricated using vacuum hot pressing (VHP). The interfacial morphologies and mechanical properties of the composites were investigated. No discernible defect was observed in the well-bonded interface region. This interface region comprised two distinct areas: the Ti2Al (6 μm) region near the TiAl layer and the Ti3Al (4 μm) region near the Ti6Al4V layer. Electron backscatter diffraction analysis revealed that dynamic recrystallization (DRX) took place at the interface during the hot pressing process. The ductile brittle nature of Ti6Al4V and TiAl4822 layers and the formation of fine grains within the interface are conducive to enhancing toughness and tensile strength. Room temperature tensile testing exhibited that the tensile strength of TiAl4822/Ti6Al4V MIL composite was 636.9 MPa, approximately 225 MPa higher than single TiAl4822 alloy. The Ti6Al4V layer, as well as the formation of fine grain interface, effectively inhibited further propagation of the main crack through crack passivation, crack deflection, and load transformation. The bending strength of the TiAl4822/Ti6Al4V MIL composite was 1114.1 MPa. The fracture toughness of the TiAl4822/Ti6Al4V MIL composite reached 33.15 MPam1/2, which increased by 78.2% compared with single TiAl4822 alloy.

Limited research has been undertaken regarding the homogeneity of CoCrPtB alloy billets. A CoCrPtB alloy was processed through casting and vacuum hot pressing. This investigation delved into the interconnection between the secondary dendrite arm spacing (SDAS) in the as-hot-pressed samples and their corresponding attributes, specifically Vickers hardness and magnetic properties. Systematic sampling was conducted on the cross-sectional layer and longitudinal surface. Upon examination of the cross-sectional layer proximate to the uppermost region of the hot casting, a discernible parabolic trend was observed for the SDAS that exhibited a gradual increment from the peripheral regions toward the central area along the width. Simultaneously, the fraction of the dendrite phase displayed a consistent linear decline, attaining its peak value at the central portion of the billet. Conversely, on the longitudinal surface, SDAS and the fraction of the dendrite phase remained fairly uniform within the same column sampling regions. However, a notable divergence was identified in the central section, characterized by an augmented SDAS and diminished dendrite phase content. This inherent microstructural inhomogeneity within the CoCrPtB alloy engendered discernible disparities in material properties.

Bulk metallic glasses (i.e., BMGs) have attracted a lot of research and development interest due to their unique properties. Embedding BMG composites with nanocrystals can further extend their applications. In this study, Ta-nanocrystal-embedded metallic glass powder was prepared via the mechanical alloying of (Cu60Zr30Ti10)91Ta9 composition for 5 h using starting elemental powders. The structural evolution during the mechanical alloying process was examined using X-ray diffraction, scanning electron microscopy, synchrotron extended X-ray absorption fine structure, transmission electron microscopy, and differential scanning calorimetry. The 5 h as-milled powder was then consolidated into a bulk sample using vacuum hot pressing with an applied pressure of 0.72, 0.96, and 1.20 GPa. The effects of the applied pressure during vacuum hot pressing on the structure of the obtained BMG were investigated. The experimental results show that Ta-nanocrystal-embedded metallic glass composite powder was prepared successfully after 5 h of mechanical alloying. The 5 h as-milled composite powder exhibited a large supercooled region of 43 K between the glass transition temperature of 743 K and the crystallization temperature of 786 K. Using vacuum hot pressing at 753 K for 30 mins with an applied pressure, dense nanocrystal-embedded BMG composites were synthesized. The relative density and the crystallization temperature of the BMG composites increased with increasing applied pressure. The nanocrystal-embedded BMG composites prepared at 753 K for 30 mins with an applied pressure of 1.20 GPa exhibited a relative density of 98.3% and a crystallization temperature of 786 K. These nanocrystals were Ta, Cu51Zr14, and other possible Cu–Zr–Ti alloys (e.g., Cu10Zr7) that were randomly dispersed within the glassy matrix.

In this paper, the microstructure, the room-temperature and high-temperature tensile mechanical properties of monolithic TA15 alloy and TiB whisker-reinforced TA15 titanium matrix composites (TiBw/TA15) fabricated by vacuum hot-pressing sintering were investigated. The microstructure results showed that there were no obvious differences in the microstructure between monolithic TA15 alloy and TiBw/TA15 composites, except whether or not the grain boundaries contained TiBw. After sintering, the matrix microstructure presented a typical Widmanstätten structure and the size of primary β grain was consistent with the size of spherical TA15 titanium metallic powders. This result demonstrated that TiBw was not the only factor limiting grain coarsening of the primary β grain. Moreover, the grain coarsening of α colonies was obvious, and high-angle grain boundaries (HAGBs) were distributed within the primary β grain. In addition, TiBw played an important role in the microstructure evolution. In the composites, TiBw were randomly distributed in the matrix and surrounded by a large number of low-angle grain boundaries (LAGBs). Globularization of α phase occurred prior, near the TiBw region, because TiBw provided the nucleation site for the equiaxed α phase. The room-temperature and high-temperature tensile results showed that TiBw distributed at the primary β grain boundaries can strengthen the grain boundary, but reduce the connectivity of the matrix. Therefore, compared to the monolithic TA15 alloy fabricated by the same process, the tensile strength of the composites increased, and the tensile elongation decreased. Moreover, with the addition of TiBw, the fracture mechanism was changed to a mixture of brittle fracture and ductile failure (composites) from ductile failure (monolithic TA15 alloy). The fracture surfaces of TiBw/TA15 composites were the grain boundaries of the primary β grain where the majority of TiB whiskers distributed, i.e., the surfaces of the spherical TA15 titanium metallic powders.

Currently, hot isostatic pressing (HIP) is widely used to produce highly alloyed high speed steels (HSSs) in an industrial scale; however, the HIP’s production cost is very high. Another powder consolidation approach with low production cost, namely vacuum hot-pressing (VHP), has hitherto received limited attention. The present work aims to develop an innovative solid-state VHP approach, producing HSSs with large cross-sectional sizes via a VHP facility having low loading capacity, thus further decreasing production cost. In doing so, VHP is performed at a sufficiently high temperature such that the pressure leading to full densification can be significantly reduced to a magnitude as low as several MPa; simultaneously, VHP is completed within a timeframe as short as several seconds to minutes, retaining fine carbide sizes; subsequently, the as-VHP HSS is diffusion-bonding treated (DBT-ed) at a relatively low temperature, achieving full metallurgical bond between powders while minimizing carbide growth. In the present work, T15 HSS was processed using the above VHP approach. The VHP temperature as high as 1200 °C was selected and consequently, the minimal pressure leading to full densification was decreased to ~7 MPa. By controlling displacement of pressing punch to a value corresponding to full densification, the VHP was competed for only 15 min. The almost fully dense as-VHP T15 HSS exhibits submicrometric carbide sizes smaller than those in the as-HIP counterpart, but incomplete metallurgical bond between powders. After diffusion bonding treatment at a relatively low temperature of 1100 °C for 2–4 h, the extent of metallurgical bond between powders is significantly enhanced with insignificant carbide growth. After regular quenching and tempering, the VHP plus DBT-ed T15 HSSs exhibit smaller average primary carbide sizes and similar hardness and three-point bend fracture strength, relative to those in the HIP counterpart after similar quenching and tempering.

In this research, a method combining the mechanical alloying with the vacuum sintering or hot pressing was adopted to obtain the compact of β-Zn4Sb3. Pure zinc and antimony powders were used as the starting material for mechanical alloying. These powders were mixed in the stoichiometry ratio of 4 to 3, or more Zn-rich. Single phase Zn4Sb3 was produced using a nominally 0.6 at. % Zn rich powder. Thermoelectric Zn4Sb3 bulk specimens have been fabricated by vacuum sintering or hot pressing of mechanically alloyed powders at various temperatures from 373 to 673 K. For the bulk specimens sintering at high temperature, phase transformation of β-Zn4Sb3 to ZnSb and Sb was observed due to Zn vaporization. However, single-phase Zn4Sb3 bulk specimens with 97.87% of theoretical density were successfully produced by vacuum hot pressing at 473 K. Electric resistivity, Seebeck coefficient, and thermal conductivity were evaluated for the hot pressed specimens from room temperature to 673 K. The results indicate that the Zn4Sb3 shows an intrinsic p-type behavior. The increase of Zn4Sb3 phase ratio can increase Seebeck coefficient but decrease electric conductivity. The maximum power factor and figure of merit (ZT) value were 1.31 × 10−3 W/mK2 and 0.81 at 600 K, respectively. The ZT value was lower than that reported in the available data for materials prepared by conventional melt growth and hot pressed methods, but higher than the samples fabricated by vacuum melting and heat treatment techniques.

This study presents a novel methodology for the fabrication of aluminum matrix composites (AMCs) reinforced with a hybrid of MAX phase (Ti3AlC2) and MXene (Ti3C2Tx) particles via vacuum hot-pressing sintering, aiming to enhance the mechanical properties and tribological performance of aluminum matrix composites. The hybrid-reinforced aluminum matrix composites were fabricated with Ti3AlC2/Ti3C2Tx reinforcements at a 1:1 mass ratio, incorporating reinforcement contents of 5 wt.%, 15 wt.%, and 25 wt.%, respectively. The optimized vacuum hot press sintering process was as follows: firstly, a cold press pressure of 20 MPa was applied to the composite powder, and then hot press sintering was carried out by means of segmental pressurization with a sintering pressure of 20 MPa, a temperature of 500 °C, and a heat preservation of 1 h before cooling in the furnace. It was found by micro-morphological characterization and mechanical property testing that with the increase of Ti3AlC2/Ti3C2Tx reinforcement content (5 wt.%→15 wt.%), the micro-hardness of the composites (31.9→76.1 HV0.2), compressive strength (41.7→151.9 MPa), and tribological properties (friction coefficient 0.68→0.50) were significantly improved; however, when the content of reinforcement exceeded 15 wt.%, the deterioration of properties triggered by the increase in pore defects and particle agglomeration leads instead to a decrease in compressive strength (by 12.3%), apparent modulus of elasticity (specimen’s compressive specific stiffness, by 9.8%) and frictional stability (coefficient of friction recovered to 0.62). The 15 wt.% hybrid reinforcement composites demonstrated optimal strength-toughness synergies, exhibiting a 361.6% increase in yield strength and a 597.1% increase in apparent modulus of elasticity compared to pure aluminum. Furthermore, the friction coefficient exhibited a 26.47% reduction in comparison to pure aluminum, thereby substantiating enhanced tribological performance. The observed enhancements are attributed to the synergistic effects of the MAX and MXene phases, where MXene improves interfacial wettability and densification, while MAX particles enhance overall strength through diffusion reinforcement.

AlSb is a line compound and the synthesis of single phase bulk AlSb has always proven to be a significant challenge. Synthesis of bulk single phase AlSb by powder metallurgy has not yet been reported. This work shows a novel synthetic route for successful production of single phase bulk AlSb using mechanical alloying and vacuum hot pressing. Thermoelectric properties of the semiconductor were measured and reported for the first time using powder metallurgy process. The intrinsic semiconductor showed a moderate Seebeck coefficient and a high thermal conductivity, consequently a low thermoelectric figure of merit (ZT). The thermoelectric figure of merit was also calculated and is shown in this study.

AlMgTi-based metal–intermetallic laminated composites were successfully fabricated through an innovative dual-step vacuum hot pressing. First, this study prepares the AlTi-based laminated composites by vacuum hot pressing at 650 °C. Then, the researchers place the Mg-Al-1Zn (AZ31) magnesium alloy between the prepared AlTi-based laminated composites at 430 °C for hot pressing. This study investigates the microstructure, phase composition, and microhardness distribution across interfaces of the intermetallics and metal. A multilayer phase (Mg17Al12, Al3Mg2, and transition layers) structure can be found from the diffusion layers between Al and AZ31. The microhardness of the material presents a wavy distribution in the direction perpendicular to the layers; the maximum can be up to 600.0 HV0.2 with a minimum of 28.7 HV0.2 The microhardness gradient of an AlMgTi-based composite is smoother due to the different microhardness of the layers, and reduces the interface stress concentration. The bending strength of AlMgTi-based composites can reach 265 MPa, and the specific strength is 105 × 103 Nm/kg, higher than AlTi-based composites.