Improving Mechanical and Corrosion Properties of 6061 Al Alloys via Differential Speed Rolling and Plasma Electrolytic Oxidation.

This study explores the combined potential of severe plastic deformation (SPD) via differential speed rolling (DSR) and plasma electrolytic oxidation (PEO) to enhance the material performance of 6061 Al alloys. To this end, DSR was carried out at a roll-speed-ratio of 1:4 to obtain ~75% total thickness reduction and a final microstructure of <1 µm. The rest of the samples were annealed to obtain various grain sizes of ~1, ~25, and ~55 µm. Through DSR, the hardness of the material increased from ~64 to ~102 HV. Different grain sizes altered the plasma behavior which further influence the growth of the coating layer, where the fine grain size produced a compact structure beneficial for corrosion protection. This synergy offers tailored materials ideal for high-performance applications across diverse industries, combining enhanced bulk properties from DSR with optimized surface attributes from PEO.

Moldflow Simulation and Characterization of Pure Copper Fabricated via Metal Injection Molding.

Metal injection molding (MIM) is a representative near-net-shape manufacturing process that fabricates advanced geometrical components for automobile and device industries. As the mechanical performance of an MIM product is affected by green-part characteristics, this work investigated the green part of pure copper processed with MIM using the injection temperature of ~180 °C and injection pressure of ~5 MPa. A computational analysis based on the Moldflow program was proposed to simulate the effectivity of the process by evaluating the confidence of fill, quality prediction, and pressure drop of three distinctive regions in the green part. The results showed that the ring and edge regions of the green parts showed localized behavior, which was related to processing parameters including the position of the gate. A microstructural observation using scanning electron microscopy and a 3D X-ray revealed that both the surface and body matrix consisted of pores with some agglomeration of micro-pores on the edges and ring part, while any critical defects, such as a crack, were not found. A microhardness analysis showed that the three regions exhibited a reasonable uniformity with a slight difference in one specific part mainly due to the localized pore agglomeration. The simulation results showed a good agreement with the microstructures and microhardness data. Thus, the present results are useful for providing guidelines for the sound condition of MIM-treated pure copper with a complex shape.

Effect of Reduction Sequence during Rolling on Deformed Texture and Anisotropy of Ferritic Stainless Steel.

This investigation studied the effect of reduction sequence during rolling of ferritic stainless steel on texture and anisotropy. A series of thermomechanical processes were performed on the present samples utilizing rolling deformation, with a total height reduction of 83% but with different reduction sequences, 67% + 50% (route A) and 50% + 67% (route B). Microstructural analysis showed that no significant difference was found in terms of the grain morphology between route A and route B. In terms of the texture, as compared to route A, route B developed a sharper texture on all components along the γ-fiber and a considerably higher fraction of boundaries that displayed 38°111 misorientations with respect to the surrounding deformed grains. In consequence, optimal deep drawing properties were achieved, where rm was maximized and Δr was minimized. Moreover, despite the similar morphology between the two processes, the resistance toward ridging was improved in the case of route B. This was explained in relation to the selective growth-controlled recrystallization, which favors the formation of microstructure with homogeneous distribution of the <111>//ND orientation.

Characterization of Green Part of Steel from Metal Injection Molding: An Analysis Using Moldflow.

Metal injection molding (MIM) is a quick manufacturing method that produces elaborate and complex items accurately and repeatably. The success of MIM is highly impacted by green part characteristics. This work characterized the green part of steel produced using MIM from feedstock with a powder/binder ratio of 93:7. Several parameters were used, such as dual gates position, injection temperature of ~150 °C, and injection pressure of ~180 MPa. Analysis using Moldflow revealed that the aformentioned parameters were expected to produce a green part with decent value of confidence to fill. However, particular regions exhibited high pressure drop and low-quality prediction, which may lead to the formation of defects. Scanning electron microscopy, as well as three-dimensional examination using X-ray computed tomography, revealed that only small amounts of pores were formed, and critical defects such as crack, surface wrinkle, and binder separation were absent. Hardness analysis revealed that the green part exhibited decent homogeneity. Therefore, the observed results could be useful to establish guidelines for MIM of steel in order to obtain a high quality green part.