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Shaban M, Alsunaydih FN, Kouta H, El-Sanabary S, Alrumayh A, Alateyah AI, Alawad MO, El-Garaihy WH, El-Taybany Y. Optimization of wear parameters for ECAP-processed ZK30 alloy using response surface and machine learning approaches: a comparative study. Sci Rep 2024; 14:9233. [PMID: 38649457 DOI: 10.1038/s41598-024-59880-0] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/07/2023] [Accepted: 04/16/2024] [Indexed: 04/25/2024] Open
Abstract
The present research applies different statistical analysis and machine learning (ML) approaches to predict and optimize the processing parameters on the wear behavior of ZK30 alloy processed through equal channel angular pressing (ECAP) technique. Firstly, The ECAPed ZK30 billets have been examined at as-annealed (AA), 1-pass, and 4-passes of route Bc (4Bc). Then, the wear output responses in terms of volume loss (VL) and coefficient of friction (COF) have been experimentally investigated by varying load pressure (P) and speed (V) using design of experiments (DOE). In the second step, statistical analysis of variance (ANOVA), 3D response surface plots, and ML have been employed to predict the output responses. Subsequently, genetic algorithm (GA), hybrid DOE-GA, and multi-objective genetic algorithm techniques have been used to optimize the input variables. The experimental results of ECAP process reveal a significant reduction in the average grain size by 92.7% as it processed through 4Bc compared to AA counterpart. Furthermore, 4Bc exhibited a significant improvement in the VL by 99.8% compared to AA counterpart. Both regression and ML prediction models establish a significant correlation between the projected and the actual data, indicating that the experimental and predicted values agreed exceptionally well. The minimal VL at different ECAP passes was obtained at the highest condition of the wear test. Also, the minimal COF for all ECAP passes was obtained at maximum wear load. However, the optimal speed in the wear process decreased with the number of billets passes for minimum COF. The validation of predicted ML models and VL regression under different wear conditions have an accuracy range of 70-99.7%, respectively.
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Affiliation(s)
- Mahmoud Shaban
- Department of Electrical Engineering, College of Engineering, Qassim University, 56452, Unaizah, Saudi Arabia
- Department of Electrical Engineering, Faculty of Engineering, Aswan University, Aswan, 81542, Egypt
| | - Fahad Nasser Alsunaydih
- Department of Electrical Engineering, College of Engineering, Qassim University, 56452, Unaizah, Saudi Arabia
| | - Hanan Kouta
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fouad, 42526, Egypt
| | - Samar El-Sanabary
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fouad, 42526, Egypt
| | - Abdulrahman Alrumayh
- Department of Mechanical Engineering, College of Engineering, Qassim University, 56452, Unaizah, Saudi Arabia
| | - Abdulrahman I Alateyah
- Department of Mechanical Engineering, College of Engineering, Qassim University, 56452, Unaizah, Saudi Arabia.
| | - Majed O Alawad
- Center of Excellence for Nanomaterials for Clean Energy Applications, King Abdulaziz City for Science and Technology (KACST), 12354, Riyadh, Saudi Arabia
| | - Waleed H El-Garaihy
- Department of Mechanical Engineering, College of Engineering, Qassim University, 56452, Unaizah, Saudi Arabia.
- Mechanical Engineering Department, Faculty of Engineering, Suez Canal University, Ismailia, 41522, Egypt.
| | - Yasmine El-Taybany
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fouad, 42526, Egypt
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Alateyah AI, Alawad MO, Aljohani TA, El-Garaihy WH. Effect of ECAP Route Type on the Microstructural Evolution, Crystallographic Texture, Electrochemical Behavior and Mechanical Properties of ZK30 Biodegradable Magnesium Alloy. MATERIALS (BASEL, SWITZERLAND) 2022; 15:6088. [PMID: 36079470 PMCID: PMC9457749 DOI: 10.3390/ma15176088] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/09/2022] [Revised: 08/28/2022] [Accepted: 08/31/2022] [Indexed: 06/15/2023]
Abstract
In this study, billets of the ZK30 (Mg-3Zn-0.6 Zr-0.4 Mn, wt%) alloy were Equal Channel Angle Pressing (ECAP) processed for up to four passes of routes Bc (with rotating the sample 90° in the same direction between the subsequent passes), A (without sample rotation), and C (with sample rotating 180°) after each pass at a temperature of 250 °C and a ram speed of 10 mm/min using a die with an internal channel angle of 90°. The microstructural evolution and the crystallographic texture were investigated using a Scanning Electron Microscope (SEM) equipped with the Electron Back-Scatter Diffraction (EBSD) technique. Corrosion measurements were conducted in ringer lactate which is a simulated body fluid. The Vickers microhardness test and tensile tests were conducted for the alloy before and after processing. The as-annealed billets exhibited a bimodal structure as fine grains (more than 3.39 µm) coexisted with almost-equiaxed coarse grains (less than 76.73 µm); the average grain size was 26.69 µm. Further processing until four passes resulted in enhanced grain refinement and full Dynamic Recrystallization (DRX). ECAP processing through 4-Bc, 4-A, and 4-C exhibited significant reductions in grain size until they reached 1.94 µm, 2.89 µm, and 2.25 µm, respectively. Four-pass processing also resulted in the transformation of low-angle grain boundaries into high-angle grain boundaries. The previous conclusion was drawn from observing the simultaneous decrease in the fraction of low-angle grain boundaries and an increase in the fraction of high-angle grain boundaries. The pole figures revealed that 4-Bc, 4-A, and 4-C reduced the maximum texture intensity of the as-annealed billets. The potentiodynamic polarization findings revealed that route Bc is the most effective route in improving the corrosion rate, whereas the Electrochemical Impedance Spectroscopy (EIS) revealed that routes A and Bc improved the corrosion resistance with nearly identical values. Finally, 4-Bc resulted in the highest increase in Vickers hardness, yield stress, and ultimate tensile strength with values of 80.8%, 19.3%, and 44.5%, alongside a 31% improvement in ductility, all compared to the AA condition.
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Affiliation(s)
- Abdulrahman I. Alateyah
- Department of Mechanical Engineering, College of Engineering, Qassim University, Unaizah 56452, Saudi Arabia
| | - Majed O. Alawad
- Materials Science Research Institute, King Abdulaziz City for Science and Technology (KACST), Riyadh 12354, Saudi Arabia
| | - Talal A. Aljohani
- Materials Science Research Institute, King Abdulaziz City for Science and Technology (KACST), Riyadh 12354, Saudi Arabia
| | - Waleed H. El-Garaihy
- Department of Mechanical Engineering, College of Engineering, Qassim University, Unaizah 56452, Saudi Arabia
- Mechanical Engineering Department, Faculty of Engineering, Suez Canal University, Ismailia 41522, Egypt
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Alateyah AI, Alawad MO, Aljohani TA, El-Garaihy WH. Influence of Ultrafine-Grained Microstructure and Texture Evolution of ECAPed ZK30 Magnesium Alloy on the Corrosion Behavior in Different Corrosive Agents. MATERIALS (BASEL, SWITZERLAND) 2022; 15:ma15165515. [PMID: 36013656 PMCID: PMC9410329 DOI: 10.3390/ma15165515] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/13/2022] [Revised: 07/08/2022] [Accepted: 08/08/2022] [Indexed: 05/12/2023]
Abstract
Magnesium-Zinc-Zirconium (Mg-Zn-Zr) alloys have caught considerable attention in medical applications where biodegradability is critical. The combination of their good biocompatibility, improved strength, and low cytotoxicity makes them great candidates for medical implants. This research investigation is focused on providing further insight into the effects of equal channel angular processing (ECAP) on the corrosion behavior, microstructure evolution, and mechanical properties of a biodegradable ZK30 alloy. Billets of Mg-3Zn-0.6 Zr (ZK30) alloy were processed through ECAP up to 4 passes of route Bc (rotating the billets 90° in the same direction between the subsequent passes) at 250 °C. Electron back-scatter diffraction (EBSD) was utilized to investigate the microstructural evolution as well as the crystallographic texture. Several electrochemical measurements were carried out on both a simulated body fluid and a 3.5% sodium chloride (NaCl) solution. Mechanical properties such as Vicker's hardness and tensile properties were also assessed. The as-annealed (AA) microstructure was dominated by equiaxed coarse recrystallized grains with an average grain size of 26.69 µm. After processing, a geometric grain subdivision took place due to the severe plastic deformation. Processed samples were characterized by grain refinement and high density of substructures. The 4-passes sample experienced a reduction in the grain size by 92.8% compared with its AA counterpart. The fraction of high-angle grain boundaries increased significantly after 4-passes compared to the 1-pass processed sample. With regards to the crystallographic texture, the AA condition had its {0001} basal planes mostly oriented parallel to the transversal direction. On the other hand, ECAP processing resulted in crystallographic texture changes, such as the shifting of the ZK30 shear plane to be aligned at 45° relative to the extrusion direction (ED). Furthermore, the maximum texture intensity was reduced from 14 times random (AA billets) to 8 times random after ECAP processing through 4-passes. The corrosion rate of the 4-passes sample was tremendously reduced by 99% and 45.25% compared with its AA counterpart in the simulated body fluid and the NaCl solution, respectively. The pitting corrosion resistance of ZK30 showed notable improvements in the simulated body fluid by 471.66% and 352% during processing through 1-pass and 4-passes, respectively, compared with the 3.5% NaCl findings. Finally, significant improvements in the tensile strength, hardness, and ductility were also achieved.
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Affiliation(s)
- Abdulrahman I. Alateyah
- Department of Mechanical Engineering, College of Engineering, Qassim University, Unaizah 56452, Saudi Arabia
- Correspondence: (A.I.A.); (W.H.E.-G.); Tel.: +966-055-313-3322 (A.I.A.)
| | - Majed O. Alawad
- Materials Science Research Institute, King Abdulaziz City for Science and Technology (KACST), Riyadh 12354, Saudi Arabia
| | - Talal A. Aljohani
- Materials Science Research Institute, King Abdulaziz City for Science and Technology (KACST), Riyadh 12354, Saudi Arabia
| | - Waleed H. El-Garaihy
- Department of Mechanical Engineering, College of Engineering, Qassim University, Unaizah 56452, Saudi Arabia
- Mechanical Engineering Department, Faculty of Engineering, Suez Canal University, Ismailia 41522, Egypt
- Correspondence: (A.I.A.); (W.H.E.-G.); Tel.: +966-055-313-3322 (A.I.A.)
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UĞUZ Ö, GÜMÜŞ M, SERT Y, KOCA İ, KOCA A. Utilization of pyrazole-perimidine hybrids bearing different substituents as corrosion inhibitors for 304 stainless steel in acidic media. J Mol Struct 2022. [DOI: 10.1016/j.molstruc.2022.133025] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/21/2023]
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Méndez-Figueroa HG, Ossandón S, Ramírez Fernández JA, Galván Martínez R, Espinoza Vázquez A, Orozco-Cruz R. Electrochemical evaluation of an Acanthocereus tetragonus aqueous extract on aluminum in NaCl (0.6 M) and HCl (1 M) and its modelling using forward and inverse artificial neural networks. J Electroanal Chem (Lausanne) 2022. [DOI: 10.1016/j.jelechem.2022.116444] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Corrosion Behavior in Magnesium-Based Alloys for Biomedical Applications. MATERIALS 2022; 15:ma15072613. [PMID: 35407944 PMCID: PMC9000648 DOI: 10.3390/ma15072613] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/15/2022] [Revised: 03/13/2022] [Accepted: 03/15/2022] [Indexed: 12/14/2022]
Abstract
Magnesium alloys exhibit superior biocompatibility and biodegradability, which makes them an excellent candidate for artificial implants. However, these materials also suffer from lower corrosion resistance, which limits their clinical applicability. The corrosion mechanism of Mg alloys is complicated since the spontaneous occurrence is determined by means of loss of aspects, e.g., the basic feature of materials and various corrosive environments. As such, this study provides a review of the general degradation/precipitation process multifactorial corrosion behavior and proposes a reasonable method for modeling and preventing corrosion in metals. In addition, the composition design, the structural treatment, and the surface processing technique are involved as potential methods to control the degradation rate and improve the biological properties of Mg alloys. This systematic representation of corrosive mechanisms and the comprehensive discussion of various technologies for applications could lead to improved designs for Mg-based biomedical devices in the future.
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Abstract
This study aims to establish the effects of equal channel angular pressing (ECAP) processing on the corrosion behavior and hardness values of the AZ31 Mg alloy. The AZ31 billets were processed through ECAP successfully at 250 °C and their microstructural evolution was studied using optical and field emission scanning electron microscopy. The corrosion resistance of the AZ31 alloy was studied before and after processing through ECAP. The homogeneity of the hardness distribution was studied using both sections cut parallel and perpendicular to the extrusion direction. ECAP processing resulted in highly deformed central regions with elongated grains aligned parallel to the extrusion direction, whereas the peripheral regions showed an ultra-fine-grain recrystallized structure. After processing, small ultra-fine secondary particles were found to be homogeneously dispersed alongside the grain boundaries of the α-Mg matrix. Regarding the corrosion properties, measurements showed that ECAP processing through 1-P and 2-Bc resulted in decreasing their corrosion rate to 67.7% and 78.3%, respectively, of their as-annealed counterpart’s. The corrosion resistance of the ECAPed Mg alloy increased with the number of processing passes. This was due to the refinement of the grain size of the α-Mg matrix and secondary phases till ultra-fine size, caused by the accumulation of strain during processing. On the other hand, ECAP processing through 2-Bc resulted in increasing the Vickers hardness values by 132% and 71.8% at the peripheral and central areas, respectively, compared to the as-annealed counterpart.
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Sidhu SS, Singh H, Gepreel MAH. A review on alloy design, biological response, and strengthening of β-titanium alloys as biomaterials. MATERIALS SCIENCE & ENGINEERING. C, MATERIALS FOR BIOLOGICAL APPLICATIONS 2021; 121:111661. [PMID: 33579432 DOI: 10.1016/j.msec.2020.111661] [Citation(s) in RCA: 37] [Impact Index Per Article: 12.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/26/2020] [Revised: 09/24/2020] [Accepted: 10/17/2020] [Indexed: 11/16/2022]
Abstract
From the past few years, developments of β-Ti alloys have been the subject of active research in the medical domain. The current paper highlights significant findings in the area of β-Ti alloy design, biological responses, strengthening mechanisms, and developing low-cost implants with a high degree of biocompatibility. It is evident that an astonishing demand for developing the low modulus-high strength implants can be fulfilled by synchronizing β stabilizer content and incorporating tailored thermo-mechanical techniques. Furthermore, the biological response of the implants is as important as the physical properties that regulate healing response; hence, the optimum selection of alloying elements plays a curial role for clinical success. The paper also presents the evolution of patents in this field from the year 2010 to 2020 showing the relevant innovations that may benefit a wide range of researchers.
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Effects of Ultrasonic Surface Rolling Processing and Subsequent Recovery Treatment on the Wear Resistance of AZ91D Mg Alloy. MATERIALS 2020; 13:ma13245705. [PMID: 33327580 PMCID: PMC7765076 DOI: 10.3390/ma13245705] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/26/2020] [Revised: 12/09/2020] [Accepted: 12/10/2020] [Indexed: 11/17/2022]
Abstract
AZ91D Mg alloy was treated by ultrasonic surface rolling processing (USRP) and subsequent recovery treatment at different temperatures. The dry sliding friction test was performed to investigate the effects of USRP and subsequent recovery treatment on the wear resistance of AZ91D Mg alloy by a ball-on-plate tribometer. The microstructure, properties of plastic deformation layer and worn morphology were observed by optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM), X-ray diffraction (XRD) analysis and microhardness tester. Results illustrate that the grains of AZ91D Mg alloy surface layer are refined to nanocrystallines. The maximum microhardness of the top surface of the USRP sample reaches 102.3 HV. When USRP samples are treated by recovery treatment at 150 °C, 200 °C and 250 °C, the microhardness of the top surface decreases to 90.68 HV, 79.29 HV and 75.06 HV, respectively. The friction coefficient (FC) and wear volume loss of the USRP-R-150 sample are the lowest among all the samples. The worn surface morphology of the USRP-R-150 sample is smoother than that of other samples, indicating that the wear resistance of AZ91D Mg alloy treated by USRP and recovery treatment at 150 °C is improved significantly.
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Ultrasonic Treatment Induced Fluoride Conversion Coating without Pores for High Corrosion Resistance of Mg Alloy. COATINGS 2020. [DOI: 10.3390/coatings10100996] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
Abstract
Fluoride conversion (MgF2) coating with facile preparation and good adhesion is promising to protect Mg alloy, but defects of pores in the coating lead to limited corrosion resistance. In this study, a compact and dense MgF2 coating was prepared by the combination of fluoride treatment and ultrasonic treatment. The ultrasonically treated MgF2 coating showed a compact and dense structure without pores at the frequency of 28 kHz. The chemical compositions of the coating were mainly composed of F and Mg elements. The corrosion potential of the ultrasonically treated Mg alloy shifted towards the noble direction in the electrochemical tests. The corrosion current density decreased due to the protectiveness of MgF2 coating without defects of pores or cracks. During immersion tests for 24 h, the ultrasonically treated Mg alloy exhibited the lowest H2 evolution (0.32 mL/cm2) and pH value (7.3), which confirmed the enhanced anti-corrosion ability of MgF2 coating. Hence, the ultrasonically treated fluoride coating had great potentials for their use in anti-corrosion applications of Mg alloy.
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