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Magnesium-based AX53 alloy was manufactured by a simple stir-casting method. In addition to the standard alloy constituting elements (Ca, Al), elemental Si was added in (0.1, 0.3, 0.6, and 1.0wt.%) during the melting process. SEM and EDX characterized the microstructure and elemental analyses of cast AX53 alloy with/without Si additions, respectively. The effects of Si on the corrosion characteristics of AX53 alloy in 3.5% NaCl have been investigated by weight reduction analysis, potentiodynamic polarization, and electrochemical impedance spectroscopy measurements. The SEM and EDX analyzed the morphology and composition of corrosion products, respectively. Also, the behavior of AX53 alloy with different investigated inhibitors such as nano-TiO₂, nano-ZrO₂, and mixed nano-(TiO₂+ZrO${}_2)$ was assessed. It was observed that the modification of 0.1% Si AX53 alloy by nano-TiO₂ reduces the CR of the alloy. The CR increases with Si additions increasing, generally, the addition of an inhibitor reduces the corrosion rate, and the reductions depend on the type of inhibitor.

Mg-Cu-Zn ultrafine eutectic composites with different length scale heterogeneity, consisting of micrometer size dendrites and/or ultrafine scale bimodal eutectics, exhibit high yield strength as well as good plasticity at room temperature compression. Among these alloys, micron-scale α-Mg dendrites reinforced ultrafine eutectic composites exhibit high yield strength of 310 ~ 420 MPa and large plasticity of 7 ~ 12%. Meanwhile, a Mg₇₂Cu₅Zn₂₃ alloy comprising a bimodal eutectic structure without the micron-scale α-Mg dendrites shows the optimized mechanical properties the highest yield strength of 455 MPa combined with a considerable plastic strain of ~5%.

Ultrafine eutectic alloys have been developed in Ti-Ni, Ti-Fe and Ti-(Ni, Fe)-Sn alloys. The Ti₇₆Ni₂₄ and (Ti₇₄Ni₂₆)₉₇Sn₃ ultrafine eutectic alloys consist of a mixture of α-Ti and Ti₂Ni phases, and β-Ti(Sn) and Ti₂Ni phases, respectively, whereas the Ti_70.5Fe_29.5 and (Ti_70.5Fe_29.5)₉₇Sn₃ alloys are composed by a mixture of β-Ti(Sn) and FeTi phases with relatively spherical colony. The compression tests of Ti₇₆Ni₂₄, (Ti₇₄Ni₂₆)₉₇Sn₃ and Ti_70.5Fe_29.5 ultrafine eutectic alloys reveal a strength of 1400 ~ 1800 MPa with very limited plastic strain of 0.1 ~ 1%. On the contrary, a (Ti_70.5Fe_29.5)₉₇Sn₃ alloy exhibits high strength of 2270 MPa with enhanced plastic strain of 3.1%. Based on these results, it is feasible to suggest that the eutectic morphology and interfacial coherency between the Ti solid solution and intermetallic phases influence to control the macroscopic plasticity of the Ti-Ni and Ti-Fe ultrafine eutectic alloys.

An inverse template method that relies on the use of a controlled porous spacer material was implemented to produce periodic magnesium (Mg) foams. Bulk infiltration pressures were varied to determine a processing-property map. The microstructure and mechanical properties of the resulting periodic Mg foams were investigated using optical and scanning electron microscopy (SEM), and compression testing, respectively. SEM was also used to analyze the surface topology of the periodic foams and compare it to the original template material. It was found that the casting pressure has a great effect not only on the success of the infiltration but also the surface roughness and other microstructural features of the foam.

Al–Si–Cu alloys were cast with the unique gradient solidification technique to produce alloys with two cooling rates corresponding to secondary dendrite arm spacing (SDAS) of ~9 and ~27 μm covering the microstructural fineness of common die cast components. The microstructure was studied with optical microscopy and scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS) and electron backscattered diffraction (EBSD). The alloy with higher cooling rate, lower SDAS, has a more homogeneous microstructure with well distributed network of eutectic and intermetallic phases. The results indicate the presence of Al–Fe–Si phases, Al–Cu phases and eutectic Si particles but their type, distribution and amount varies in the two alloys with different SDAS. EBSD analysis was also performed to study the crystallographic orientation relationships in the microstructure. One of the major highlights of this study is the understanding of the eutectic formation mechanism achieved by studying the orientation relationships of the aluminum in the eutectic to the surrounding primary aluminum dendrites.

The aluminum-based composites (AMCs) are known for a variety of functions like building, aerospace, automotive, marine, and aeronautical applications. In this research, Al-4032 alloy-based 6% SiC (by weight) composite has been fabricated using stir casting and the effects of prominent machining parameters on energy consumption and surface finish have been examined using carbide inserts in turning. Microstructures of as-cast specimens has been analyzed using the optical microscope, scanning electron microscopy, and energy-dispersive spectroscopy. The CNC turning has been performed at varying machining parameters like cutting speed, feed rate, and depth of cut, following an RSM-based design matrix. The desirability function approach has been employed to obtain the best combination of parameters for achieving the desired objectives. The experimental outcome demonstrates that the machined composite is considerably influenced by built-up edge (BUE) formation and interfacial bonding of particles. The result establishes that the inclusion of SiC in the Al-4032 matrix demonstrates improved mechanical properties and superior machined surface with the optimized turning operation.

Recent developments in the field of manufacturing techniques and alloy development of light materials are reviewed. In the field of manufacturing Aluminium based components, special attention is given to casting, including liquid forging and semi-solid forming technology while for sheet metal forming technology the focus is on material properties and process technology in superplastic forming. For the manufacturing of Magnesium-based components, special attention is given to casting processes and alloy development for casting. For wrought Magnesium, material properties control is covered. For Titanium-based components, an overview of the latest additions to high strength alloys are given, including non-linear elasticity as demonstrated by materials like GUM Metal™. Advanced forming technology such as Levi Casting are also treated.

Musculoskeletal diseases, especially osteoporosis, are serious health threats to many individuals including the aging elderly, astronauts, and long-duration-functional-resting (e.g. spinal cord injury) patients. The degree of bone loss and muscle atrophy due to disuse is closely associated with increased fracture risk, affecting the morbidity and mortality of the population. Many appropriate animal models have been developed to fully investigate the mechanisms responsible for musculoskeletal adaptations under disuse environment; more importantly, these models are the key in discovering new interventions for osteoporosis. Hindlimb suspension (HLS) is a well-accepted functional disuse model employed on rodents. In this model, the animal's hindlimbs are lifted and suspended for a period of time (days to weeks), thus removing daily weight-bearing activities to the hindlimbs. This chapter will mainly focus on the technical aspects of HLS as a functional disuse model for studying musculoskeletal tissues. Detailed materials and methods are provided for investigators to easily design and efficiently set up a HLS study. The limitations of HLS and other alternative functional disuse models (i.e. casting and neurectomy) are also discussed for further consideration.

PAM-CAST™/SIMULOR^® provides the foundry industry with a reliable simulation package including filling, solidification and defects prediction for casting process optimisation. Through the active collaboration of Aluminium Pechiney and foundry industries, PAM-CAST™/SIMULOR^® has been validated on a wide range of applications from gravity to low and high pressure die casting. Recently, a specific thixocasting module based on a non-newtonian fluid behavior and Bingham power law has been developped and successfully applied to simulate semi-solid casting processes of aluminum and magnesium alloys. Results show that ,with an accurate representation of the metal flow inside the mold cavity, defects such as misruns and air entrapments can be identified allowing process engineers to optimize their gating geometry and mold designs. Future functionalities, including a fully coupled Finite Element thermo-mechanical solver are currently being validated.

Numerical simulation of thermal stress during casting solidification process can predict crack, residual stress concentration, deformation. Though stress simulation involves too many complex problems such as numerical model, mechanical boundary condition and high thermo-mechanical parameters, it still retains as a difficult hotspot of macro-simulation of casting nowadays. Based on finite difference method (FDM), a 3D FDM/FDM numerical simulation system for temperature and stress analysis during casting solidification process was developed. To verify the system, a standard stress frame model and a practical casting were simulated. Pouring experiments have been carried out in the laboratory. The results of simulation coincided with those obtained from experiment and practical results. When adopting FDM to calculate casting thermal stress, thermal analysis and stress analysis can use the same FD model, which can avoid matching between different models and reduce the errors of temperature load transferring. It makes the simulation of fluid-flow, temperature and stress unify into one model.