A Review: Laser Welding of Dissimilar Materials (Al/Fe,Al/Ti,Al/Cu)—Methods and Techniques,Microstructure and Properties

Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.     

Fabrication,Structure, and Thermal Properties of Mg–Cu Alloys as High Temperature PCM for Thermal Energy Storage

This work studied the thermophysical properties of Mg-24%Cu, Mg-31%Cu, and Mg-45%Cu (wt.%) alloys to comprehensively consider the possibility of using them as thermal energy storage (TES) phase change materials (PCMs) used at high temperatures. The microstructure, phase composition, phase change temperatures, and enthalpy of these alloys were investigated by an electron probe micro analyzer (EPMA), X-ray diffraction (XRD), and differential scanning calorimetry (DSC). The XRD and EPMA results indicated that the binary eutectic phase composed of α-Mg and Mg₂Cu exists in the microstructure of the prepared Mg–Cu series alloys. The microstructure of Mg-24%Cu and Mg-31%Cu is composed of α-Mg matrix and binary eutectic phases, and Mg-45%Cu is composed of primary Mg₂Cu and binary eutectic phases. The number of eutectic phases is largest in Mg-31%Cu alloy. The DSC curves indicated that the onset melting temperature of Mg-24%Cu, Mg-31%Cu, and Mg-45%Cu alloys were 485, 486, and 485 °C, and the melting enthalpies were 152, 215, and 91 J/g. Thermal expansion and thermal conductivity were also determined, revealing that the Mg–Cu alloys had a low linear thermal expansion coefficient and high thermal conductivity with respect to increasing temperatures. In conclusion, the thermal properties demonstrated that the Mg–Cu alloys can be considered as a potential PCM for TES.     

Microstructural and Thermo-Mechanical Characterization of Cast NiTiCu20 Shape Memory Alloy

Among NiTi-based alloys, one of the most promising and exploited alloys is NiTiCu, since the addition of Cu in substitution of Ni in the binary equiatomic NiTi has a significant influence on the martensitic transformation and the thermomechanical properties of the system. A high content of Cu improves the damping properties at the expense of phase homogeneity and workability. The present study focuses on an alloy with a high copper content, i.e., 20 at.%. For this specific composition, the correlation between the thermal treatments, microstructure, formation of secondary phases, and damping properties are investigated by several analyses. The microscopic observation, together with the compositional analysis, allowed the determination of four different phases in the alloy. Both the calorimetry and dynamic thermo mechanical measurements, which confirmed the high damping ability of the alloy, provided a characterization of the martensitic transition. Finally, the electron backscatter diffraction (EBSD) analysis detected the different crystallographic structures (i.e., cubic austenite, orthorhombic martensite, and cubic (face-centered) NiTi₂) and their orientation in the different phases. Therefore, the present work aims to improve the knowledge of the role of secondary phases in the optimization of the NiTiCu20 alloy as a valuable alternative to typical alloys used for damping purposes.     

High Strength Al–La,Al–Ce,and Al–Ni Eutectic Aluminum Alloys Obtained by High-Pressure Torsion

A comparative analysis of the effect of high-pressure torsion (HPT) on the microstructure and tensile properties of the Al–10% La, Al–9% Ce, and Al–7% Ni model binary eutectic aluminum alloys is carried out. An HPT of 20-mm diameter specimens in as-cast state was carried out under constrained conditions, at room temperature, pressure P = 6 GPa, and number of turns N = 5. It is shown that the formation of nano- and submicrocrystalline structures and the refinement of eutectic particles in aluminum alloys simultaneously provide a multiple increase in strength while maintaining a high plasticity margin. This combination of properties has been achieved for the first time for severely deformed binary aluminum eutectics. The relationship between the type of eutectic particles, the structure formation process and the mechanical properties of the aluminum alloys has been established. The thermal stability of severely deformed aluminum alloys at heating up to 200 °C has been studied.     

Mechanical Properties Enhancement of the Au-Cu-Al Alloys via Phase Constitution Manipulation

To enhance the mechanical properties (e.g., strength and elongation) of the face-centered cubic (fcc) α-phase in the Au-Cu-Al system, this study focused on the introduction of the martensite phase (doubled B19 (DB19) crystal structure of Au₂CuAl) via the manipulation of alloy compositions. Fundamental evaluations, such as microstructure observations, phase identifications, thermal analysis, tensile behavior examinations, and reflectance analysis, have been conducted. The presence of fcc annealing twins was observed in both the optical microscope (OM) and the scanning electron microscope (SEM) images. Both strength and elongation of the alloys were greatly promoted while the DB19 martensite phase was introduced into the alloys. Amongst all the prepared specimens, the 47Au41Cu12Al and the 44Au44Cu12Al alloys performed the optimized mechanical properties. The enhancement of strength and ductility in these two alloys was achieved while the stress plateau was observed during the tensile deformation. A plot of the ultimate tensile strength (UTS) against fracture strain was constructed to illustrate the effects of the introduction of the DB19 martensite phase on the mechanical properties of the alloys. Regardless of the manipulation of the alloy compositions and the introduction of the DB19 martensite phase, the reflectance stayed almost identical to pure Au.     

Microstructure and Thermal Analysis of Metastable Intermetallic Phases in High-Entropy Alloy CoCrFeMo0.85Ni

CoCrFeMoNi high entropy alloys (HEAs) exhibit several promising characteristics for potential applications of high temperature coating. In this study, metastable intermetallic phases and their thermal stability of high-entropy alloy CoCrFeMo_0.85Ni were investigated via thermal and microstructural analyses. Solidus and liquidus temperatures of CoCrFeMo_0.85Ni were determined by differential thermal analysis as 1323 °C and 1331 °C, respectively. Phase transitions also occur at 800 °C and 1212 °C during heating. Microstructure of alloy exhibits a single-phase face-centred cubic (FCC) matrix embedded with the mixture of (Co, Cr, Fe)-rich tetragonal phase and Mo-rich rhombohedron-like phase. The morphologies of two intermetallics show matrix-based tetragonal phases bordered by Mo-rich rhombohedral precipitates around their perimeter. The experimental results presented in our paper provide key information on the microstructure and thermal stability of our alloy, which will assist in the development of similar thermal spray HEA coatings.     

Study on Stability of Mechanical Properties for Porous Fe-Cr-Al Alloys after Long-Term Aging

Nowadays, both the ferrite phase and B2-structured intermetallic in the Fe-Cr-Al alloy system are developed as porous materials, which have been further applied as high-temperature filter materials in industry. This work presents a comparative study of the mechanical properties of porous Fe20Cr5Al, Fe10Cr10Al and Fe10Cr20Al aged at 480 °C for 500 h. The changes in tensile strength, elongation and hardness were determined, and the microstructure changes as well as slight oxidation states of the aged samples were investigated. The results show that the precipitated Cr-rich phase in porous Fe20Cr5Al can increase the hardness and decrease the ductility, while intergranular oxidation can degrade the mechanical performance of the three porous Fe-Cr-Al materials. It is noted that porous Fe10Cr20Al exhibits relatively superior mechanical stability during long-term aging. Meanwhile, by introducing boron, the mechanical performance of the aged porous Fe-Cr-Al alloys can be stabilized since the possible internal oxidation of the exposed grain boundaries is inhibited.     

The Effect of Silicon Phase Morphology on Microstructure and Properties of AlSi10Mg Alloys Fabricated by Selective Laser Melting

This paper investigated the effect of silicon phase morphology and size on microstructure, mechanical properties, and corrosion resistance of the AlSi10Mg alloys fabricated by selective laser melting (SLM). Using different heat treatment conditions for SLM-fabricated alloys, the microstructure characteristics and mechanical properties are analyzed. The corrosion behavior analysis is also performed using potentiodynamic polarization, electrochemical and immersion tests. Results show that the AlSi10Mg alloy directly fabricated by SLM has a continuous eutectic silicon network, which has a small driving force for corrosion and facilitates the deposition of corrosion products and generates a dense protective film. On the contrary, the formation of large isolated and uniformly distributed silicon particles produces a greater corrosion driving force after heat treatment, which makes most of the corrosion products transfer to the solution. The corrosion resistance of AlSi10Mg alloy directly fabricated by SLM is better than that of the alloys with heat treatment. Moreover, the heat treatment reduces the hardness of AlSi10Mg alloys due to the decrease in the solid solution strengthening effect.     

Transition from High-Entropy to Conventional Alloys: Which Are Better?

The study of the transition from high-entropy alloys (HEAs) to conventional alloys (CAs) composed of the same alloying components is apparently important, both for understanding the formation of HEAs and for proper evaluation of their potential with respect to that of the corresponding CAs. However, this transition has thus far been studied in only two types of alloy systems: crystalline alloys of iron group metals (such as the Cantor alloy and its derivatives) and both amorphous (a-) and crystalline alloys, TE-TL, of early (TE = Ti, Zr, Nb, Hf) and late (TL = Co, Ni, Cu) transition metals. Here, we briefly overview the main results for the transition from HEAs to CAs in these alloy systems and then present new results for the electronic structure (ES), studied with photoemission spectroscopy and specific heat, atomic structure, thermal, magnetic and mechanical properties of a-TE-TL and Cantor-type alloys. A change in the properties of the alloys studied on crossing from the HEA to the CA concentration range mirrors that in the ES. The compositions of the alloys having the best properties depend on the alloy system and the property selected. This emphasizes the importance of knowing the ES for the design of new compositional complex alloys with the desired properties.     

On the Hardness and Elastic Modulus of Phases in SiC-Reinforced Al Composite: Role of La and Ce Addition

The use of silicon carbide particles (SiCp) as reinforcement in aluminium (Al)-based composites (Al/SiCp) can offer high hardness and high stiffness. The rare-earth elements like lanthanum (La) and cerium (Ce) and transition metals like nickel (Ni) and copper (Cu) were added into the matrix to form intermetallic phases; this is one way to improve the mechanical property of the composite at elevated temperatures. The α-Al₁₅(Fe,Mn)₃Si₂, Al₂₀(La,Ce)Ti₂, and Al₁₁(La,Ce)₃, π-Al₈FeMg₃Si₆ phases are formed. Nanoindentation was employed to measure the hardness and elastic modulus of the phases formed in the composite alloys. The rule of mixture was used to predict the modulus of the matrix alloys. The Halpin–Tsai model was applied to calculate the elastic modulus of the particle-reinforced composites. The transition metals (Ni and Cu) and rare-earth elements (La and Ce) determined a 5–15% increase of the elastic modulus of the matrix alloy. The SiC particles increased the elastic modulus of the matrix alloy by 10–15% in composite materials.     

Effect of Elevated Temperatures on the Mechanical Properties of a Direct Laser Deposited Ti-6Al-4V

In the present work, the mechanical properties of the DLD-processed Ti-6Al-4V alloy were obtained by tensile tests performed at different temperatures, ranging from 20 °C to 800 °C. Thereby, the process conditions were close to the conditions used to produce large-sized structures using the DLD method, resulting in specimens having the same initial martensitic microstructure. According to the obtained stress curves, the yield strength decreases gradually by 40% when the temperature is increased to 500 °C. Similar behavior is observed for the tensile strength. However, further heating above 500 °C leads to a significant increase in the softening rate. It was found that the DLD-processed Ti-6Al-4V alloy had a Young’s modulus with higher thermal stability than conventionally processed alloys. At 500 °C, the Young’s modulus of the DLD alloy was 46% higher than that of the wrought alloy. The influence of the thermal history on the stress relaxation for the cases where 500 °C and 700 °C were the maximum temperatures was studied. It was revealed that stress relaxation processes are decisive for the formation of residual stresses at temperatures above 700 °C, which is especially important for small-sized parts produced by the DLD method. The coefficient of thermal expansion was investigated up to 1050 °C.     

Effects of Zn Contents on Microstructure and Mechanical Properties of Semisolid Rheo-Diecasting Al-xZn-2Mg-1.5Cu Alloys

The microstructure and mechanical properties of semisolid rheo-diecasting Al-xZn-2Mg-1.5Cu alloys with different Zn contents were investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD), hardness testing (HV) and room temperature tensile testing. Results show that the as-cast microstructure mainly consists of spherical α-Al and Mg(Al, Cu, Zn)₂ phases. Furthermore, a small amounts of Al₇Cu₂Fe phases were also detected along the grain boundary. Increasing the Zn contents from 8–12%, the volume fraction of the Mg(Al, Cu, Zn)₂ phases increases from 4.9–7.4%. After solution heat treatment at 470 °C for 8 h, most of the Mg(Al, Cu, Zn)₂ dissolves into the α-Al matrix, while the Al₇Cu₂Fe phase keeps with remains. The yield strength linearly increases from 482 ± 5 MPa of 8% Zn to 529 ± 5 MPa of 12% Zn. While, the ultimate strength of 10% Zn is 584 ± 2 MPa, which is higher than that of the other two alloys. Moreover, the average elongation dramatically decreases from 13% for the 8% Zn alloy to 2% for the 12% Zn alloy.     

Bearing Aluminum-Based Alloys: Microstructure,Mechanical Characterizations,and Experiment-Based Modeling Approach

Due to the engine’s start/stop system and a sudden increase in speed or load, the development of alloys suitable for engine bearings requires excellent tribological properties and high mechanical properties. Including additional elements in the Al-rich matrix of these anti-friction alloys should strengthen their tribological properties. The novelty of this work is in constructing a suitable artificial neural network (ANN) architecture for highly accurate modeling and prediction of the mechanical properties of the bearing aluminum-based alloys and thus optimizing the chemical composition for high mechanical properties. In addition, the study points out the impact of soft and more solid phases on the mechanical properties of these alloys. For this purpose, a huge number of alloys (198 alloys) with different chemical compositions combined from Sn, Pb, Cu, Mg, Zn, Si, Ni, Bi, Ti, Mn, Fe, and Al) were cast, annealed, and tested for determining their mechanical properties. The annealed sample microstructure analysis revealed the formation of soft structural inclusions (Sn-rich, Sn-Pb, and Pb-Sn phases) and solid phase inclusions (strengthened phase, Al₂Cu). The mechanical properties of ultimate tensile strength (σ_u), Brinell hardness (HB), and elongation to failure (δ) were used as control responses for constructing the ANN network. The constructed network was optimized by attempting different network architecture designs to reach minimal errors. Besides the excellent tribological characteristics of the designed set of alloys, soft inclusions based on Sn and Pb and solid-phase Cu inclusions fulfilled the necessary level of mechanical properties for anti-friction alloys; the maximum mechanical properties reached were: σ_u = 197 ± 7 MPa, HB = 77 ± 4, and δ = 20.3 ± 1.0%. The optimal ANN architecture with the lowest errors (correlation coefficient (R) = 0.94, root mean square error (RMSE) = 3.5, and average actual relative error (AARE) = 1.0%) had two hidden layers with 20 neurons. The model was validated by additional experiments, and the characteristics of the new alloys were accurately predicted with a low level of errors: R ≥ 0.97, RMSE = 1–2.65, and AARE ˂ 10%.     

Structure and Superconductivity of Tin-Containing HfTiZrSnM (M = Cu,Fe, Nb,Ni) Medium-Entropy and High-Entropy Alloys

In an attempt to incorporate tin (Sn) into high-entropy alloys composed of refractory metals Hf, Nb, Ti and Zr with the addition of 3d transition metals Cu, Fe, and Ni, we synthesized a series of alloys in the system HfTiZrSnM (M = Cu, Fe, Nb, Ni). The alloys were characterized crystallographically, microstructurally, and compositionally, and their physical properties were determined, with the emphasis on superconductivity. All Sn-containing alloys are multi-phase mixtures of intermetallic compounds (in most cases four). A common feature of the alloys is a microstructure of large crystalline grains of a hexagonal (Hf, Ti, Zr)₅Sn₃ partially ordered phase embedded in a matrix that also contains many small inclusions. In the HfTiZrSnCu alloy, some Cu is also incorporated into the grains. Based on the electrical resistivity, specific heat, and magnetization measurements, a superconducting (SC) state was observed in the HfTiZr, HfTiZrSn, HfTiZrSnNi, and HfTiZrSnNb alloys. The HfTiZrSnFe alloy shows a partial SC transition, whereas the HfTiZrSnCu alloy is non-superconducting. All SC alloys are type II superconductors and belong to the Anderson class of “dirty” superconductors.     

Effect of Rare Earth Metals (Y,La) and Refractory Metals (Mo,Ta, Re) to Improve the Mechanical Properties of W–Ni–Fe Alloy—A Review

Tungsten heavy alloys are two-phase metal matrix composites that include W–Ni–Fe and W–Ni–Cu. The significant feature of these alloys is their ability to acquire both strength and ductility. In order to improve the mechanical properties of the basic alloy and to limit or avoid the need for post-processing techniques, other elements are doped with the alloy and performance studies are carried out. This work focuses on the developments through the years in improving the performance of the classical tungsten heavy alloy of W–Ni–Fe through doping of other elements. The influence of the percentage addition of rare earth elements of yttrium, lanthanum, and their oxides and refractory metals such as rhenium, tantalum, and molybdenum on the mechanical properties of the heavy alloy is critically analyzed. Based on the microstructural and property evaluation, the effects of adding the elements at various proportions are discussed. The addition of molybdenum and rhenium to the heavy alloy gives good strength and ductility. The oxides of yttrium, when added in a small quantity, help to reduce the tungsten’s grain size and obtain good tensile and compressive strengths at high temperatures.     

Effect of Heat Treatment on Microstructure and Selective Corrosion of LPBF-AlSi10Mg by Means of SKPFM and Exo-Electron Emission

The paper deals with the evolution of the microstructure of AlSi10Mg alloy obtained by laser powder bed fusion (LPBF), as a function of the post-processing heat treatment temperature. This was approached by complementary methods including FE-scanning electron microscopy, scanning Kelvin probe force microscopy and exo-electron emission techniques. The fast cooling rate of the LPBF process as compared to traditional casting produces a very fine microstructure with high mechanical properties and corrosion resistance. However, the LPBF-AlSi10Mg alloy can be susceptible to selective corrosion at the edge of the melt pools generated by the laser scan tracks. Post-process thermal treatments of the Al alloy induce a marked modification of the silicon network at melt pool edges, in particular at high temperature such as 400 °C. It was found that this is associated to a more homogeneous distribution of Volta potential. Analysis of exo-electron emission confirms the silicon diffusion during thermal treatment. The modification of the silicon network structure of the LPBF-AlSi10Mg during thermal treatment reduces the susceptibility to selective corrosion.     

Effects of the Addition of Co or Ni Atoms on Structure and Magnetism of FeB Amorphous Alloy: Ab Initio Molecular Dynamics Simulation

The effects of the substitution of Fe by Co or Ni on both the structure and the magnetic properties of FeB amorphous alloy were investigated using first-principle molecular dynamics. The pair distribution function, Voronoi polyhedra, and density of states of Fe_80−xTM_xB₂₀ (x = 0, 10, 20, 30, and 40 at.%, TM(Transition Metal): Co, Ni) amorphous alloys were calculated. The results show that with the increase in Co content, the saturation magnetization of Fe_80−xCo_xB₂₀ (x = 0, 10, 20, 30, and 40 at.%) amorphous alloys initially increases and then decreases upon reaching the maximum at x = 10 at.%, while for Fe_80−xNi_xB₂₀ (x = 0, 10, 20, 30, and 40 at.%), the saturation magnetization decreases monotonously with the increase in Ni content. Accordingly, for the two kinds of amorphous alloys, the obtained simulation results on the variation trends of the saturation magnetization with the change in alloy composition are in good agreement with the experimental observation. Furthermore, the relative maximum magnetic moment was recorded for Fe₇₀Co₁₀B₂₀ amorphous alloy, due to the induced increased magnetic moments of the Fe atoms surrounding the Co atom in the case of low Co dopant, as well as the increase in the exchange splitting energy caused by the enhancement of local atomic symmetry.     

Development of Y2O3 Dispersion-Strengthened Copper Alloy by Sol-Gel Method

In this study, oxide dispersion-strengthened Cu alloy with a Y₂O₃ content of 1 wt.% was fabricated through citric acid sol-gel synthesis and spark plasma sintering (SPS). The citric acid sol-gel method provides molecular mixing for the preparation of precursor powders, which produces nanoscale and uniformly distributed Y₂O₃ particles in an ultrafine-grained Cu matrix. The effects of nanoscale Y₂O₃ particles on the microstructure, mechanical properties and thermal conductivity of the Cu-1wt.%Y₂O₃ alloy were investigated. The average grain size of the Cu-1wt.%Y₂O₃ alloy is 0.42 μm, while the average particle size of Y₂O₃ is 16.4 nm. The unique microstructure provides excellent mechanical properties with a tensile strength of 572 MPa and a total elongation of 6.4%. After annealing at 800 °C for 1 h, the strength of the alloy does not decrease obviously, showing excellent thermal stability. The thermal conductivity of Cu-1wt.%Y₂O₃ alloy is about 308 Wm⁻¹K⁻¹ at room temperature and it decreases with increasing temperature. The refined grain size, high strength and excellent thermal stability of Cu-1wt.%Y₂O₃ alloys can be ascribed to the pinning effects of nanoscale Y₂O₃ particles dispersed in the Cu matrix. The Cu-Y₂O₃ alloys with high strength and high thermal conductivity have potential applications in high thermal load components of fusion reactors.     

Development of Precipitation-Strengthened Al0.8NbTiVM (M = Co,Ni) Light-Weight Refractory High-Entropy Alloys

Single-phase solid-solution refractory high-entropy alloys (RHEAs) have been receiving significant attention due to their excellent mechanical properties and phase stability at elevated temperatures. Recently, many studies have been reported regarding the precipitation-enhanced alloy design strategy to further improve the mechanical properties of RHEAs at elevated temperatures. In this study, we attempted to develop precipitation-hardened light-weight RHEAs via addition of Ni or Co into Al_0.8NbTiV HEA. The added elements were selected due to their smaller atomic radius and larger mixing enthalpy, which is known to stimulate the formation of precipitates. The addition of the Ni or Co leads to the formation of the sigma precipitates with homogeneous distribution. The formation and homogeneous distribution of sigma particles plays a critical role in improvement of yield strength. Furthermore, the Al_0.8NbTiVM_0.2 (M = Co, Ni) HEAs show excellent specific yield strength compared to single-phase AlNbTiV and NbTiVZr RHEA alloys and conventional Ni-based superalloy (Inconel 718) at elevated temperatures.     

Interpretation of Specific Strength-Over-Resistivity Ratio in Cu Alloys

Reaching simultaneously high mechanical strength and low electrical resistivity is difficult as both properties are based on similar microstructural mechanisms. In our previous work, a new parameter, the tensile strength-over-electrical resistivity ratio, is proposed to evaluate the matching of the two properties in Cu alloys. A specific ratio of 310 × 10⁸ MPa·Ω⁻¹·m⁻¹, independent of the alloy system and thermal history, is obtained from Cu-Ni-Mo alloys, which actually points to the lower limit of prevailing Cu alloys possessing high strength and low resistivity. The present paper explores the origin of this specific ratio by introducing the dual-phase mechanical model of composite materials, assuming that the precipitate particles are mechanically mixed in the Cu solid solution matrix. The strength and resistivity of an alloy are respectively in series and parallel connections to those of the matrix and the precipitate. After ideally matching the contributions from the matrix and the precipitate, the alloy should at least reach half of the resistivity of pure Cu, i.e., 50%IACS, which is the lower limit for industrially accepted highly conductive Cu alloys. Under this condition, the specific 310 ratio is related to the precipitate-over-matrix ratios for strength and resistivity, which are both two times those of pure Cu.