This paper reviews the recent development of fabrication methods of porous metals with open-channels. The open-channel metals are fabricated through powder sintering or solidification technique. The template wires are embedded in the sintered or solidified metals, such as aluminum, copper, titanium and its alloys, which are then removed by chemical dissolution or extraction methods. The hole size, hole length and porosity are uniquely controlled by thickness, length and number of template metallic wires, respectively. The pore size ranges from 102 to several 103 μm in diameter. The open-channel metals are characterized by a large aspect ratio of the length to the diameter of the holes in metals. Furthermore, the techniques can fabricate spiral and V-shaped pores in metals. Feasibility and usefulness of each fabrication method are discussed. The methodology for producing the open-channel metals is expected to provide expanded opportunities for application technologies such as functional materials like heat sinks and sound absorbers and light-weight structural materials.

There is a need to introduce modern sand binder systems in the South African foundry industry as a means of improving its competiveness through the reduction of scrap castings and compliance to environmental regulations. According to the Industrial Policy Action Plan (IPAP). The foundry industry will play an important role with regards to the economic infrastructure priority advocated in the National Development Plan (NDP) of South Africa. In this study, a new generation water glass binder is introduced in a local foundry for production of cores for export plumbing casting production. The new water glass introduced is unique in that it contains an inorganic breakdown agent. The core making operating parameters including binder content, temperature and cycle time are optimised through core making trials without any alterations on the coremaking machines. Production data was evaluated using an optimization feature of Microsoft excel software. The results provided a set of optimum operating variables to manufacture 80-100% good quality sand cores for casting applications with an environmentally friendly binder. The most favourable binder content is above 2.60%.The most favourable operating temperature range is 160-174 0C. Therefore temperature and related energy costs can be reduced. The shortfall is reduction in cycle time.

The effect of cooling rate on the microstructure evolution and the mechanical properties of ingots and rods of 2–5 mm diameter of (Ni0.92Zr0.08)100−xAlx (0 ≤ x ≤ 4 at.%) ultrafine eutectic composites have been investigated. The microstructure of the composites is comprised of micrometer size γ-Ni dendrites embedded in a nano/-ultrafine lamellar fcc γ-Ni and Ni5Zr matrix. The evolution of the microstructure at a wide range of cooling rates (10–104 K/s) has been analyzed in respect of volume fraction of the phases, lamellar spacing, and secondary dendritic arm spacing. All these composites exhibit high hardness up to 4.6 GPa and yield strength up to 1.6 GPa with large compressive plasticity up to 22% at room temperature. The effect of cooling rates on the strength and hardness, and the plasticity of the nanolamellar composites with wide range of alloy composition have been correlated.

In situ synthesis of Ag nanoparticles in polyvinylidene fluoride (PVDF) was investigated using different stabilizers such as 3-aminopropyltrimethoxysilane (APS) and 1-dodecanethiol (thiol). Although PVDF is a matrix, it also functions as a stabilizer. Results of UV-vis spectroscopy showed that when APS or PVDF was used, Ag nanoparticles were formed. Yet no formation occurred when thiol was used due to the complexation of Ag+ ions by thiol. Polar groups on stabilizers has an important effect on complexation process. APS, a nitrogen-based ligand, has hard base character inhibiting the complexation between Ag+ and APS. Consequently, Ag+ ions are reduced to Ag nanoparticles in N,N dimethyl formamide (DMF), which acts as a solvent and reducing agent. Transition Electron Microscopy (TEM) image showed a uniform distribution of spherical Ag nanoparticles in PVDF matrix in the presence of APS. The electrical properties of flexible nano-metal polymer were tested and the highest improvements in breakdown strength and energy density of 33 and 58 %, respectively were measured with 0.05 wt.% Ag content and APS as a stabilizer.

Recently, low-density steels have received increased attention as promising alternatives for automotive applications of the next generation of Advanced High-Strength Steels (AHSS), considering that vehicle´s weight decrease has been the subject of intense interest. It is well-known that the addition of rare earth metals (REM) has a remarkable effect on shape control and the modification of inclusions. Also, REM additions affect the grain size refinement as well as the tendency to form oxides and sulfides. The aim of this research work was to determine the effect of REM (Ce, La) addition on the microstructure and mechanical properties of the Fe-30Mn-8Al-1.8C low-density steel in as-cast condition. In order to clarify the REM effect on the Fe-Mn-Al-C system, non-microalloyed (LD-NM) and REM microalloyed (LD-REM) specimens were examined in detail by means of light optical and scanning electron microscopy for microstructural characterization. In the same way, the primary and secondary phases founded in the studied steels were identified by X-ray diffraction (XRD). Meanwhile, in order to evaluate the mechanical properties, ten microhardness measurements were carried out on the overall bulk by the Vickers hardness testing. In general, the results showed a dendritic refinement effect due to the addition of REM to low-density steel. REM acted as effective inoculants agents which reduced the primary and secondary arm spacing. Also, the strong segregation tendency at the grain boundaries in the liquid phase was limited. XRD profiles revealed the presence of austenite, ferrite, κ and DO3 phases. Low density steel microalloyed with REM showed a moderate increase in hardness compared to the non-microalloyed steel in the as-cast condition.

The effect of Si on Fe-rich intermetallic formation and the mechanical properties of the heat-treated squeeze cast Al–5.0Cu–0.6Mn–0.7Fe alloy was investigated. Our results show that increasing the Si content promotes the formation of Al15(FeMn)3(SiCu)2 (α-Fe) and varies the morphology of T (Al20Cu3Mn2), where the size decreases and the amount increases. The major reason is that Si promotes heterogeneous nucleation of the intermetallics leading to finer precipitates. Si addition significantly enhances the ultimate tensile strength and yield strength of the alloys. The strengthening effect is mainly owing to the dispersoid strengthening by increasing the volume fraction of the T phase and less harmful α-Fe with a compact structure, which makes it more difficult for the cracks to initiate and propagate during tensile test. The squeeze cast Al–5.0Cu–0.6Mn–0.7Fe alloy with 1.1% Si shows significantly improved mechanical properties than the alloy without Si addition, which has a tensile strength of 386 MPa, yield strength of 280 MPa, and elongation of 8.6%.

The effect of mold temperature on microstructure and mechanical properties of a rheo-squeeze casting (RSC) Mg–3Nd–0.2Zn–0.4Zr (NZ30K) alloy were investigated. The results indicated that the rise of mold temperature contributed to the increase of particle size and alloy density and the decrease of dislocation density. The rapid coarsening and then the normal growth of the particles during solution treatment were observed, and the long-rod-like Zn2Zr3 phase occurred. After age treatment, rod-like β′ precipitate was found in the conventional squeeze casting (CSC) alloy, while two types of precipitates including β′ phase and small plate-like β″ phase were observed in the RSC alloy. The amount of Zn2Zr3 phase was increased with rising mold temperature. Compared with the T6-treated CSC sample, the T6-treated RSC sample presented higher mechanical properties due to the larger precipitation strengthening contribution, and the yield strength, ultimate tensile strength, and elongation were up to 160 MPa, 296 MPa, and 7.7%.

To investigate the solute transport and redistribution in the slab continuous casting processes of high sulfur steel, a three-dimensional model coupling turbulent flow, heat and solute transportation was developed. And then a thermodynamic model for MnS precipitation was established to study the MnS precipitation and distribution in strand on a macroscale and its effect on solute macrosegregation was also explored. The results showed that the temperature and solutes concentration were the main factors for the precipitation of MnS. The effect of temperature was significant when the solid fraction was greater than 0.8. Due to the precipitation of MnS, the segregation ratio of solutes Mn and S on the center line declined from 1.05–1.15 to 0.97–1.01 and from 1.2–1.45 to 1.00–1.08, respectively. And the solute concentration of Mn and S declined and distributed more uniformly in the strand, and the macrosegregation of Mn and S was also suppressed greatly.

Microstructure and mechanical properties of Mg–0.43Nd–xY–0.08Zn–0.11Zr (x = 0, 0.03, 0.06, and 0.12 at.%) alloys were investigated. The results indicated that Mg24Y5 phase was formed in the as-cast Y-containing alloys, the grains were refined and the amount of needle-like Mg12Nd phase in the α-Mg grain interior was increased with increasing Y addition. After solution treatment, the Mg24Y5 phase and needle-like Mg12Nd phase nearly completely dissolved into the α-Mg matrix and long-rod-like Zn2Zr3 phase occurred. The amount of Zn2Zr3 phase was increased with increasing Y content after age treatment. Mg–0.43Nd–0.12Y–0.08Zn–0.11Zr alloy exhibited the best combination of strength and elongation in all conditions, especially in the temperature range of 200–300 °C, and an Arrhenius model was established to study the plastic flow behavior. The improvement in mechanical properties was attributed to the grain refining, solution strengthening and enhanced precipitation hardening of Zn2Zr3 phase and β-type phase.

Boron carbide (B4C) ceramic particles were used as reinforcement material to produce aluminum (Al) matrix composites by squeeze casting method. Four different B4C contents as 0, 3, 5, and 10 wt%, and three different squeeze pressures as 0, 75, and 150 MPa were used in which the samples consisted of pure Al without B4C and the samples obtained without applying pressure were used as control samples. To determine the effect of squeezing pressure and the amount of B4C added on machinability and mechanical properties, average chip length and surface roughness of the samples were evaluated and hardness measurements were accomplished, yield and ultimate tensile strengths were determined, respectively. Also, the changes in density and microstructure were investigated. B4C reinforcement was found to decrease the average chip length and density of the samples while increasing the hardness and surface roughness. On the other hand, application of squeeze pressure had a positive effect on the densification and mechanical properties of the samples.

The history of the manufacture of the magnificent bronze castings produced in ancient China has been reinterpreted a number of times during the past hundred years or so. These bronzes were first believed to be fabricated by lost wax (cire perdue) casting, but this gave way to a belief that piece mold casting was the dominant, if not the sole method of manufacture from the Shang (1700-1100 BCE) until possibly as late as the Tang dynasty (618-907 CE). This has been reinforced by the finding, a number of years ago, of the Houma piece mold foundry, as well a number of more recent similar finds. However, this stance was challenged by the discovery of openwork bronze objects as early as in the 1920s, and more strongly challenged in the late 1970s by finds of intricately cast interwoven openwork bronze objects at the Tomb of the Marquis of Yi, dated to the Warring States Period (475-221 BCE). Since then many other similar bronze objects have been found. Questions exist concerning the very existence of the lost-wax process as early as the Spring and Autumn Period (771 to 476 BCE), and was it independently developed in China, or was it introduced from the outside.

Kesterite Cu2ZnSn(S,Se)4 (CZTSSe) absorbers are considered promising alternatives to commercial thin film technologies including CdTe and Cu(In,Ga)Se2 (CIGSe) owing to the earth abundance and non-toxicity of their constituents. However, to be competitive with the existing technologies, the photovoltaic performance of CZTSSe solar cells needs to be improved beyond the current record conversion efficiency of 12.6%. In this study, nanoscale elemental mapping using Auger nanoprobe microscopy (NanoAuger) and nano secondary ion mass spectrometry (NanoSIMS) are used to provide a clear picture of the compositional variations between the grains and grain boundaries in Cu2ZnSn(S,Se)4 kesterite thin films. NanoAuger measurements revealed that the top surfaces of the grains are coated with a Zn-rich (Zn,Sn)O x layer. While thick oxide layers were observed at the grain boundaries, their chemical compositions were found to be closer to SnO x . NanoSIMS elemental maps confirmed the presence of excess oxygen deeper within the grain boundary grooves, as a result of air annealing of the CZTSSe films.

Carbon nanotube (CNT) reinforced A356 aluminum alloys cast nanocomposites containing lower CNT contents were successfully fabricated where the way of introducing diluted Al–8 wt% CNT master nanocomposite in A356 melts was used. The differential thermal analysis and x-ray diffraction results showed that aluminum carbide phases (Al4C3) were formed before Al melting. The formation of Al4C3 was then proved to improve the wettability of CNTs during Al melting. Effect of CNT addition on microstructure and mechanical properties of CNTs/A356 nanocomposites were investigated by optical microscopy, scanning electron microscopy, transmission electron microscopy, and universal tensile testing machine. The results showed that CNTs (<0.4 wt%) were well distributed in the CNTs/A356 nanocomposites. CNTs could greatly refine the microstructure of A356 alloy. The mechanical properties of CNTs/A356 nanocomposites were also enhanced by CNT addition. Fractography analysis revealed that CNTs were distributed uniformly throughout the fracture surface.

The effect on the mechanical properties at room temperature of Li and Ag additions to the Fe–Al (40 at.%)-based alloy produced by conventional casting were evaluated in this work. Alloying elements were added into a previously molted Fe–(40 at.%) aluminum-based alloy, stirred, and then cast into sand molds to directly produce tensile specimens. To determine the mechanical properties, tensile tests and hardness measurements were performed. The additions of both Ag and Li showed an increase in ductility and tensile strength of the intermetallic alloys. In addition, hardness was substantially increased with the Li addition. Lithium additions promoted a solid solution hardening, whereas 3 at.% of Ag additions promoted ductility due to a microstructural modification and to the formation of a soft Ag3Al phase. Characterization by both optical and electronic microscopy, energy dispersive spectroscopy microanalysis, and x-ray diffraction supported the mechanical characterization.

A novel synchronous rolling-casting for metal (SRCM) process for producing metal components is developed. In this paper, the microstructure evolution and mechanical property of ZLl04 alloy with different pouring temperatures by SRCM are investigated. In the process, the pouring temperature has great effects on the microstructure and mechanical property primarily through the crystal change in the rolling-casting area. Temperature of liquids and solids of ZL104 alloy is measured by differential scanning calorimetry. Distribution and characteristics of the microstructure of samples are examined by optical microscopy, scanning electron microscopy equipped with energy dispersive spectrometer. The results show that the samples fabricated by SRCM present uniform structure and good performance with the pouring temperature at 620 °C when the velocity of the substrate is at 10 cm/s. The tensile strength of ZLl04 alloy reaches 211.89 Mpa, while the average vickers hardness is 81.5 HV.

A novel two-stage reheating process with new alloy design has been developed to improve the microstructure morphology of semisolid Al–Si casting aluminum alloy for thixoforming. The process consists of first reheating the material to the liquidus temperature, holding for 5 min, and then lowering to the predetermined two-stage reheating temperature between 843–863 K and holding for 10 min. The experimentally-obtained grain diameter, roundness, and the amount of liquid trapped within the solid phase were characterized, along with the microstructure obtained using the traditional feedstock reheating process. The Wilcox test (with α = 0.05) was then applied to statistically analyze the measured differences in the microstructures obtained using the two different processing routes. It was found that a refined near-spherical structure with uniform globule size, higher sphericity, lower coarsening rate constant, and less entrapped liquid was obtained via the new two-stage reheating process in comparison with the microstructure obtained using the traditional feedstock reheating process.

A research was carried out to investigate the microstructures and mechanical properties of high Mn containing Al–5Mg–Mn alloys cast under near-rapid cooling. The results indicated that the mechanical properties of the hot bands and cold rolled sheets were remarkably improved with Mn content increasing to 1.6 wt%. The near-rapid cooling process greatly refined the intermetallic constituents. The intermetallic Al6(Fe,Mn) particles found in the hot bands were rare and small when the content of Mn was hypoeutectic. In the samples with higher Fe and Si content, a large amount of Al6(Fe,Mn) and Mg2Si particles remained in the hot bands. But the hot bands still showed better mechanical properties due to the refinement of the intermetallic constituents by the near-rapid cooling process. The results were of commercial interest to the production of AA5083 alloy via continuous strip casting process.