Optimal conditions for HA plasma spray-coating on Ti6Al4V alloy were investigated in order to obtain enhanced bone-bonding ability with Ti6Al4V alloy. The properties of plasma spray coated film were analyzed by SEM, XRD, surface roughness measurement, and adhesion strength test because the film's transformed phase and crystallinity were known to be influential to bone-bonding ability withTi6Al4V alloy. The films were formed by a plasma spray coating technique with various combinations of plasma power, spray distance, and auxiliary He gas pressure. The film properties were analyzed in order to determine the optimal spray coating parameters with which we will able to achieve enhanced bone-bonding ability with Ti6Al4V alloy. The most influential coating parameter was found to be the plasma spray distance to the specimen from the spray gun nozzle. Additionally, it was observed that a relatively higher film crystallinity can be obtained with lower auxiliary gas pressure. Moderate adhesion strength can be achievable at minimal plasma power. That is, adhesion strength is minimally dependent on the plasma power. The combination of shorter spray distance, lower auxiliary gas pressure, and moderate spray power can be recommended as the optimal spray conditions. In this study, optimal plasma spray coated films were formed with spray distance of 70 mm, plasma current of 800 A, and auxiliary gas pressure of 60 psi.

In this work, AlON-Al2O3 coatings were prepared on Al2021 alloy by the electrolytic plasma processing (EPP) method. The experimental electrolytes include: 2 g/l NaOH as the electrolytic conductive agent, 10 g/l Na2AlO2 as the alumina formative agent, and 0.5 g/l NaNO2, NaNO3, and NH4NO3 as the nitride inducing agents. The effects of different nitrogen inducing agents were studied by a combined compositional and structural analyses of the ceramic coatings carried out by Xray diffractometry (XRD) and scanning electron microscopy (SEM) for the specimens EPP-treated at room temperature for 15 min under a hybrid voltage of 260 DC along with an AC 50 Hz power supply (200 V). Microhardness tests and wear tests were carried out to correlate the evolution of the microstructure and the resulting mechanical properties. Potentiodynamic polarizations and immersion corrosion tests were carried out in 3.5wt% NaCl water solutions under static conditions in order to evaluate the corrosion behavior of the coated samples. The results demonstrate that NaNO2 is proven to be a good nitrogen inducing agent to produce high quality AlON-Al2O3 ceramic coatings.

The effect of Al addition on the precipitation behavior of a binary Mg-Zn alloy was investigated based on thechanges in the morphology, distribution and element concentration of precipitates formed during aging treatment. The as-castMg-6.0 mass%Zn (Mg-6Zn) and Mg-6.0 mass%Zn-3.0 mass%Al (Al-added) were homogenized at 613K for 48h and at 673Kfor 12h; they were then solid solution treated at 673K for 0.5 h and 1 h, respectively. The Mg-6Zn and Al-added alloys wereaged at 403 K and 433K. The peak hardness of the Al-added alloy was higher than that of the Mg-6Zn alloy at each agingtemperature. Rod-like, plate-like, blocky, and lath-like precipitates were observed in the Al-added alloy aged at 433K for230.4ks, although the rod-like and plate-like precipitates were observed in the TEM microstructure of the Mg-6Zn alloy agedat 433K for 360 ks. Moreover, the precipitates in the Al-added alloy were refined and densely distributed compared with thosein the Mg-6Zn alloy. The Cliff-Lorimer plots obtained by the EDS analysis of the rod-like and plate-like phases in theAl-added alloy peak aged at 433K for 230.4ks were examined. It was confirmed that the phases had higher concentrationof solute Al atom than was present in the phases, indicating that the properties of precipitates can be changed by Al addition.

The microstructure and tensile properties of Al-Mn/Al-Si hybrid aluminum alloys prepared by electromagnetic duocasting were investigated. Only the Al-Mn alloy showed the typical cast microstructure of columnar and equiaxed crystals. The primary dendrites and eutectic structure were clearly observed in the Al-Si alloy. There existed a macro-interface of Al-Mn/Al-Si alloys in the hybrid aluminum alloys. The macro-interface was well bonded, and the growth of primary dendrites in Al-Si alloy occurred from the macro-interface. The Al-Mn/Al-Si hybrid aluminum alloys with a well-bonded macro-interface showed excellent tensile strength and 0.2% proof stress, both of which are comparable to those values for binary Al-Mn alloy, indicating that the strength is preferentially dominated by the deformation of the Al-Mn alloy side. However, the degree of elongation was between that of binary Al-Mn and Al-Si alloys. The Al-Mn/Al-Si hybrid aluminum alloys were fractured on the Al-Mn alloy side. This was considered to have resulted from the limited deformation in the Al-Mn alloy side, which led to relatively low elongation compared to the binary Al-Mn alloy.

The effect of the alloy systems Al-Mg alloy and Al-Si alloy in this study on the characteristics of die-casting were investigated using solidification simulation software (MAGMAsoft). Generally, it is well known that the casting characteristics of Al-Mg based alloys, such as the fluidity, feedability and die soldering behaviors, are inferior to those of Al-Si based alloys. However, the simulation results of this study showed that the filling pattern behaviors of both the Al-Mg and Al-Si alloys were found to be very similar, whereas the Al-Mg alloy had higher residual stress and greater distortion as generated due to solidification with a larger amount of volumetric shrinkage compared to the Al-Si alloy. The Al-Mg alloy exhibited very high relative numbers of stress-concentrated regions, especially near the rib areas. Owing to the residual stress and distortion, defects were evident in the Al-Mg alloy in the areas predicted by the simulation. However, there were no visible defects observed in the Al-Si alloy. This suggests that an adequate die temperature and casting process optimization are necessary to control and minimize defects when die casting the Al-Mg alloy. A Tatur test was conducted to observe the shrinkage characteristics of the aluminum alloys. The result showed that hot tearing or hot cracking occurred during the solidification of the Al-Mg alloy due to the large amount of shrinkage.

The mechanical behavior and microstructural evolution during high temperature tensile deformation of recrystallizedNi3Al polycrystals doped with boron were investigated as functions of initial grain size, tensile strain rate and temperature. Inorder to obtain more precise information on the deformation mechanism, tensile specimens were rapidly quenched immediatelyafter deformation at a cooling rate of more than 2000Ks−1, and were then observed by transmission electron microscopy (TEM).Mechanical tests in the range of 923K to 1012K were carried out in a vacuum of less than 3×10−4 Pa using an Instron-typemachine with various but constant cross head speeds corresponding to the initial strain rates from 1.0×10−4 to 3.1×10−5s−1.After heating to deformation temperature, the specimen was kept for more than 1.8ks before testing. The following results wereobtained: (1) Flow behavior was affected by initial strain size; with decreasing initial grain size, the level of a stress peak inthe true stress-true strain curve decreased, the steady state region was enlarged and elongation increased. (2) On the basis ofTEM observation of rapidly quenched specimens, it was confirmed that dynamic recrystallization certainly occurred ondeformation of fine-grained (3.3µm) and intermediate-grained (5.0µm) specimens at an initial strain rate of 3.1×10−5s−1 andat 973K. (3) There were some dislocation-free grains among the new recrystallized grains. The obtained results suggest thatboth dynamic recrystallization and grain boundary sliding are operative during high temperature deformation.

Technological mode progress demands the use of materials at high temperature and pressure. Constant load creep tests have been carried out over the range of stresses at high temperatures. One of the most critical factors in considering such applications as the most critical one is the creep behavior. In order to investigate the creep behavior in this study, the stress exponents during creep were determined over the temperature range of 275℃ to 325℃ and the stress range of 36MPa to 72MPa. The applicability of modified Monkman-Grant relationship was also discussed.

Sheet aluminum alloys have been used in manufacturing of machine structures. In fatigue crack propagation behavior of thin sheet aluminum alloys, it is important that fatigue crack growth rate is affected by crack closure phenomenon. In this work, we analyzed the characteristics of fatigue crack propagation behavior in experiment of constant stress condition for thin sheet Al 2024-T3 alloys, and identified the retardation behavior of crack growth by comparing experimental results of thin and thick plate specimen. We attempt to operate the fatigue life estimating process using the fatigue related material constants from referred fatigue crack propagation analysis. And we analyzed the experimental and prediction results of fatigue life of thin sheet aluminum alloy in order to identify the relation between retardation behavior of fatigue crack growth and crack closure phenomenon.

In this work, effect of various process-control agents (PCAs) on the mechanical alloying of amorphous alloy of has been investigated. The dependence of the particle shape, size and crystallization behavior of the amorphous alloy powders on the type of PCAs and their concentrations was investigated by using X-ray diffraction, field-emission scanning electron microscopy and differential scanning calorimetry. It was found that the additive of toluene could affect positively the amorphization and thermally induced crystallization processes, as well as the size refinement, morphology and particle-size distribution of as-milled powders in comparison with alloy obtained without PCA.

The amorphization process and the thermal properties of amorphous TiCuNiAl powder during milling by mechanical alloying were examined by X-ray diffractometry (XRD), differential scanning calorimetry (DSC), and transmission electron microscopy (TEM). The chemical composition of the samples was examined by an energy dispersive X-ray spectrometry (EDX) facility attached to the scanning electron microscope (SEM). The as-milled powders showed a broad peak (2 = 42.4) with crystalline size of about 5.0 nm in the XRD patterns. The entire milling process could be divided into three different stages: agglomeration (0 < t 3 h), disintegration (3 h < t 20 h), and homogenization (20 h < t 40 h) (t: milling time). In the DSC experiment, the peak temperature T and crystallization temperature T were 466.9 and 444.3, respectively, and the values of T, and T increased with a heating rate (HR). The activation energies of crystallization for the as-milled powder was 291.5 kJ/mol for T.

The aging characteristics of gas atomized Mg-6 wt.% Al-1 wt.% Zn alloy were investigated and compared to those of cast Mg-6 wt.% Al alloy. The gas atomized Mg-6 wt.% Al-1wt.% Zn alloy powders had spherical morphology between 1 and 100 in diameter. After compaction under the pressure of 700 MPa at for 10 min, the Mg-6 wt.% Al-1 wt.% Zn alloy showed a grain size of approximately 40 which is smaller than that of the cast Mg-6 wt.% Al alloy, and a relative compact density of approximately 93%. After ageing, the Mg-6 wt.% Al-1 wt.% Zn alloy showed much faster peak hardness than cast Mg-6 wt.% Al alloy. The Mg-6 wt.% Al-1 wt.% Zn alloy showed the new fine precipitations with ageing time, while the cast Mg-6 wt.% Al alloy was almost similar morphology.

In order to investigate the effect of rapid solidification on the microstructure and the mechanical properties of Al-Zn-Mg system alloys, water atomization was carried out, since the water atomization beared the highest solidification rate among the atomization processes. The as atomized alloy powders consisted of fine grains less than 4 in diameter, and the second particles were not detected on XRD. The microstructure as solidified was maintained even after the spark plasma sintering at the heating rate of 50 K/min. On the other hand, lower rate of 20 K/min induced a formation of particles, resulting in strengthening of the matrix. The density was almost constant at the temperature above 698K. The sintering temperature above 698K had no effect on the strength of the sintered materials.

To improve the filtration efficiency of porous materials used in filters, an extensive specific surface area is required to serve as a site for adsorption of impurities. In this paper, a method for creating a hybridized porous alloy using a powder metallurgical technique to build macropores in an Al-4 wt.% Cu alloy and subsequent surface modification for a microporous surface with a considerably increased specific surface area is suggested. The macropore structure was controlled by granulation, compacting pressure, and sintering; the micropore structure was obtained by a surface modification using a dilute NaOH solution. The specific surface area of surface-modified specimen increased about 10 times compare to as-sintered specimen that comprised of the macropore structure. Also, the surface-modified specimens showed a remarkable increase in micropores larger than 10 nm. Such a hybridized porous structure has potential for application in water and air purification filters, as well as membrane pre-treatment and catalysis.

Al-Ni alloy nano powders have been produced by the electrical explosion of Ni-plated Al wire. The porous nano particles were prepared by leaching for Al-Ni alloy nano powders in 20wt% NaOH aqueous solution. The structural properties of leached porous nano powder were investigated by nitrogen physisorption, X-ray diffraction (XRD) and transmission Microscope (TEM). The surface areas of the leached powders were increased with amounts of AI in alloys. The pore size distributions of these powders were exhibited maxima at range of pore diameters 3.0 to 3.5 nm from the desorption isotherm. The maximum values of those were decreased with amounts of Al in alloys.

High-energy mechanical milling (HEMM) and sintering into Al-Mg alloy melt were employed tofabricate an Al alloy matrix composite reinforced with submicron and micron sized Al2O3 particles. Al-basedmetal matrix composite (MMC) reinforced with submicron and micron sized Al2O3 particles was successfullyfabricated by sintering at 1000oC for 2h into Al-Mg alloy melt, which used high energy mechanical milled Al-SiO2-CuO-ZnO composite powders. Submicron/micron-sized Al2O3 particles and eutectic Si were formed by in situdisplacement reaction between Al, SiO2, CuO, and ZnO during sintering for 2h into Al-Mg alloy melt and werehomogeneously distributed in the Al-Si-(Zn, Cu) matrix. The refined grains and homogeneously distributedsubmicron/micron-sized Al2O3 particles had good interfacial adhesive, which gives good wear resistance withhigher hardness.

Al-Cu alloy nano powders have been produced by the electrical explosion of Cu-plated Al wire. The porous nano particles were prepared by leaching for Al-Cu alloy nano powders in 40wt% NaOH aqueous solution. The surface area of leached powder for 5 hours was 4 times larger than that of original alloy nano powder. It is demonstrated that porous nano particles could be obtained by selective leaching of alloy nano powder. It is expected that porous Cu nano powders can be applied for catalyst of SRM (steam reforming methanol).

The densification behavior of Al-20Si-5.5Fe-1.2Mg-0.5Mn powders was investigated through micro-structure analysis of sintered specimens. The specimens sintered in vacuum or in high purity (99.999%) nitrogen showed porous near-surface microstructures. The densification of near-surface part was enhanced by means of ultra-high purity (99.9999%) nitrogen atmosphere. The relationship between slow densification and oxide surfaces of Al alloy powders was discussed. And the effects of Mg addition, nitrogen gas, and humidity on densification were discussed. In addition, the rapid growth of primary Si crystals above the critical temperature was reported.