A 316 austenitic stainless-steel alloy, with modified alloy composition, manufactured by laser powder bed fusion (L-PBF) has been investigated. The modification of the alloy composition included addition of niobium (Nb), tungsten (W) and copper (Cu), together with a reduction in the amount of molybdenum (Mo) and an increased amount of carbon (C). To find suitable process parameters, a parameter study by varying laser power, hatch distance and scan speed was performed, centered on typical parameters used for normal 316 L. As-built material from a selected parameter configuration was then subjected to different stress relief annealing heat treatments and ageing heat treatments. The effectiveness of the stress annealing was ranked using a deformation-based method. Microstructural characterization, hardness and room temperature tensile testing were done to evaluate the effect of stress relief and aging heat treatments.

It was found that a higher volumetric energy was needed to build dense material, about ∼50 % higher compared to the volumetric energy input for normal 316 L. A subsequent aging heat treatment at 725 °C for 3 h increased the strength and hardness of the material. A reinforcement of the cellular microstructure by precipitation of carbides in between the cells is believed to be the main reason for this. To completely alleviate the residual stresses it was necessary to carry out a stress relief annealing process at 950 °C, which resulted in a removal of the cellular structure and a lower strength material.

Water pollution has jeopardized human health, and a safe supply of drinking water has been recognized as a worldwide issue. The increase in the accumulation of heavy metals in water from different sources has led to the search for efficient and environmentally friendly treatment methods and materials for their removal. Natural zeolites are promising materials for removing heavy metals from different sources contaminating the water. It is important to know the structure, chemistry, and performance of the removal of heavy metals from water, of the natural zeolites to design water treatment processes. This review focuses on critical analyses of the application of distinct natural zeolites for the adsorption of heavy metals from water, specifically, arsenic (As(III), As(V)), cadmium (Cd(II)), chromium (Cr(III), Cr(VI)), lead (Pb(II)), mercury(Hg(II)) and nickel (Ni(II)). The reported results of heavy-metal removal by natural zeolites are summarized, and the chemical modification of natural zeolites by acid/base/salt reagent, surfactants, and metallic reagents has been analyzed, compared, and described. Furthermore, the adsorption/desorption capacity, systems, operating parameters, isotherms, and kinetics for natural zeolites were described and compared. According to the analysis, clinoptilolite is the most applied natural zeolite to remove heavy metals. It is effective in removing As, Cd, Cr, Pb, Hg, and Ni. Additionally, an interesting fact is a variation between the natural zeolites from different geological origins regarding the sorption properties and capacities for heavy metals suggesting that natural zeolites from different regions of the world are unique.

The fatigue behavior of additively manufactured (AM) structural parts is sensitive to the surface and near-surface material conditions. Chemical post-processing surface treatments can be used to improve the surface condition of AM components, including complex geometries with surfaces difficult to access. In this work, surfaces of electron beam powder bed fusion (EB-PBF) produced Ti–6Al–4V were subject to two different chemical post-processing surface treatments, chemical milling and Hirtisation. As-built and machined surfaces, as well as hot isostatic pressing (HIP), treated conditions were also investigated. Fatigue testing was carried out in four-point bending. The investigation focused on the relationship between fracture mechanisms and fatigue life through fractographic study. It was found that a majority of fractures were initiated at internal surface-near defects or defects on the surface. Chemical post-processing was found to smoothen the surface but to leave a surface waviness. Material removal during post-processing could open up internal defects to the treated surface. In HIP-treated specimens, fractures initiated at defects open to the surface. Despite post-processing increasing the mean life of fatigue specimens, no significant improvements in the lowest tested life were observed for any specimen condition.

The alloy 21-6-9 is a nitrogen-strengthened austenitic stainless steel often used in aerospace applications due to its high strength, good fabrication properties, and toughness at cryogenic temperatures. However, minimal research has been conducted on alloy 21-6-9 using the additive manufacturing process laser powder-bed fusion (L-PBF). The L-PBF technique has been seen as a key to reducing production time and avoiding costly machining. Therefore, there is an interest in investigating L-PBF-processed 21-6-9 to determine the effects of L-PBF on properties at elevated and cryogenic temperatures. In this study, prior to tensile testing the alloy 21-6-9 underwent heat treatments that simulated aerospace applications and the alloy was analyzed and characterized to evaluate phase stability. The effects of elevated and cryogenic temperatures (77K) on the tensile behavior and microstructure were investigated using X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). The tensile tests showed that the yield strength and ultimate tensile strength improved, while ductility varied depending on the conditions and test environment. The ultimate tensile strength was approximately 80% higher at 77K than at room temperature, although the elongation decreased by around 90%, possibly due to the formation of strain-induced martensite.

Surfaces after chemical post-processing treatments of electron beam melting (EBM) produced Ti-6Al-4V have been studied. Targeted chemical treatment allowed the study of variation in surface quality with material removal depth. Characterization of surface and defect morphologies were made, comparing two chemical post-processing methods, Hirtisation® and chemical milling with different milling depths. Surface topography was characterized using white light interferometry and subsurface defect distribution was studied using X-ray computed tomography (XCT). The morphology of the surface at different milling depths was compared to the sub-surface information from XCT scans of the as-built material. Furthermore, Hot Isostatic Pressing (HIP) treated material was documented for comparison. Results show that post-processed surfaces contain a number of different defects of mixed morphology, position and origin. Post-processing deteriorates the surface quality with increased removal depth due to the presence of sub-surface defects. The position of sub-surface defects in relation to the material surface coincides with the depth at which contour-hatch interactions are likely to have occurred during the EBM building process. The distribution of this sub-surface defect population is anisotropic in the building (horizontal) plane and reasons for this are explored. Hirtisation® produces surfaces morphologically different from chemically milled surfaces. This difference was found to contribute to Hirtisation® producing surfaces with higher roughness (Sa) than chemically milled surfaces at comparable removal depth. HIP did remove all detectable sub-surface defects but microstructural artefacts indicating healed porosity were found.

The laser powder bed fusion (L-PBF) process is an additive manufacturing (AM) process of building parts that uses the high power of the laser to melt the fine powder bed and form a structure, as shown in figure 1 (a). As a result, L-PBF is a promising technique that has likely demonstrated great interest in producing a complex part with near-net-shape design in the area of high-performance applications [1-4]. However, the defects formed during the manufacturing process affect the mechanical properties of a component, as seen in Figure 1 (b). Therefore, track remelting is required to avoid defects and thus low process efficiency [4], as shown in Figure 1 (c). In this study, five different hatch distances of 20 µm, 50 µm, 80 µm, 110 µm, and 140 µm of 316 L stainless steel were studied. To understand the effect of different hatch distances on microstructure, including crystallographic orientation and hardness, EBSD and nanoindentation hardness techniques are used. In addition, the porosity formed is calculated and distinguished (different defects, such as lack of fusion, gas pores, and keyhole defects) using image analysis software MIPAR.(a)(b)(c) Figure 1:(a) Arrangement of the building of tracks and layers during the L-PBF process,(b) illustration of cavity formation, and (c) various times of remelting while building a new build track [4].

In this work, friction stir spot welding of 5754 aluminum alloy to dual phase steel was investigated using two different ratios of martensite and ferrite (0.38 and 0.61) for steel sheet initial microstructure and varying tool rotation speed (800, 1200 and 2000 rpm). The effect of these parameters on the joint formation was evaluated by studying the plunging force response during the process and the main characteristics of the joint at (i) macrolevel, i.e., hook morphology and bond width, and (ii) microlevel, i.e., steel hook and sheet microstructure and intermetallic compounds. The plunging force was reduced by increased tool rotation speed while there was no significant effect from the initial steel microstructure ratio of martensite and ferrite on the plunging force. The macrostructural characterization of the joints showed that the hook morphology and bond width were affected by the steel sheet initial microstructures as well as by the tool rotation speed and by the material flow driver; tool pin or shoulder. At microstructural level, a progressive variation in the ratio of martensite and ferrite was observed for the steel hook and sheet microstructure. The zones closer to the tool presented a fully martensitic microstructure while the zones away from the tool showed a gradual increase in the ferrite amount until reaching the ratio of ferrite and martensite of the steel sheet initial microstructure. Different types of FexAly intermetallic compounds were found in three zones of the joint; the hook tips, in the hooks close to the exit hole and in the corner of the exit hole. These compounds were characterized by a brittle behavior with hardness values varying from 456 to 937 HV01.