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• A Parametric Study on the L-PBF Process of an AlSi10Mg Alloy for High-Speed Productivity of Automotive Prototype Parts
  Yeonha Chang, Hyomoon Joo, Wanghyun Yong, Yeongcheol Jo, Seongjin Kim, Hanjae Kim, Yeon Woo Kim, Kyung Tae Kim, Jeong Min Park
  Journal of Powder Materials.2024; 31(5): 390.     CrossRef

Lead-free perovskite ceramics, which have excellent energy storage capabilities, are attracting attention owing to their high power density and rapid charge-discharge speed. Given that the energy-storage properties of perovskite ceramic capacitors are significantly improved by doping with various elements, modifying their chemical compositions is a fundamental strategy. This study investigated the effect of Zn doping on the microstructure and energy storage performance of potassium sodium niobate (KNN)-based ceramics. Two types of powders and their corresponding ceramics with compositions of (1-x)(K,Na)NbO₃-xBi(Ni_2/3Ta_1/3)O₃ (KNN-BNT) and (1-x)(K,Na)NbO₃-xBi(Ni_1/3Zn_1/3Ta_1/3) O₃ (KNN-BNZT) were prepared via solid-state reactions. The results indicate that Zn doping retards grain growth, resulting in smaller grain sizes in Zn-doped KNN-BNZT than in KNN-BNT ceramics. Moreover, the Zn-doped KNNBNZT ceramics exhibited superior energy storage density and efficiency across all x values. Notably, 0.9KNN-0.1BNZT ceramics demonstrate an energy storage density and efficiency of 0.24 J/cm³ and 96%, respectively. These ceramics also exhibited excellent temperature and frequency stability. This study provides valuable insights into the design of KNNbased ceramic capacitors with enhanced energy storage capabilities through doping strategies.

This study focused on improving the phase stability and mechanical properties of yttria-stabilized zirconia (YSZ), commonly utilized in gas turbine engine thermal barrier coatings, by incorporating Gd₂O₃, Er₂O₃, and TiO₂. The addition of 3-valent rare earth elements to YSZ can reduce thermal conductivity and enhance phase stability while adding the 4-valent element TiO₂ can improve phase stability and mechanical properties. Sintered specimens were prepared with hot-press equipment. Phase analysis was conducted with X-ray diffraction (XRD), and mechanical properties were assessed with Vickers hardness equipment. The research results revealed that, except for Z10YGE10T, most compositions predominantly exhibited the t-phase. Increasing the content of 3-valent rare earth oxides resulted in a decrease in the monoclinic phase and an increase in the tetragonal phase. In addition, the t(400) angle decreased while the t(004) angle increased. The addition of 10 mol% of 3-valent rare-earth oxides discarded the t-phase and led to the complete development of the c-phase. Adding 10 mol% TiO₂ increased hardness than YSZ.

Iron oxide (Fe₂O₃) nanoclusters exhibit significant potential in the biomedical and pharmaceutical fields due to their strong magnetic properties, stability in solutions, and compatibility with living systems. They excel in magnetic separation processes, displaying high responsiveness to external magnetic fields. In contrast to conventional Fe₂O₃ nanoparticles that can aggregate in aqueous solutions due to their ferrimagnetic properties, these nanoclusters, composed of multiple nanoparticles, maintain their magnetic traits even when scaled to hundreds of nanometers. In this study, we develop a simple method using solvothermal synthesis to precisely control the size of nanoclusters. By adjusting precursor materials and reducing agents, we successfully control the particle sizes within the range of 90 to 420 nm. Our study not only enhances the understanding of nanocluster creation but also offers ways to improve their properties for applications such as magnetic separation. This is supported by our experimental results highlighting their size-dependent magnetic response in water. This study has the potential to advance both the knowledge and practical utilization of Fe₂O₃ nanoclusters in various applications.

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• Enzymatic properties of iron oxide nanoclusters and their application as a colorimetric glucose detection probe
  Dahyun Bae, Minhee Kim, Jin-sil Choi
  RSC Advances.2025; 15(6): 4573.     CrossRef

The Ag/WC electrical contacts were prepared via powder metallurgy using 60 wt% Ag, 40 wt% WC, and small amounts of Co₃O₄ with varying WC particle sizes. After the fabrication of the contact materials, microstructure observations confirmed that WC-1 had an average grain size (AGS) of 0.27 μm, and WC-2 had an AGS of 0.35 μm. The Ag matrix in WC-1 formed fine grains, whereas a significantly larger and continuous growth of the Ag matrix was observed in WC-2. This indicates the different flow behaviors of liquid Ag during the sintering process owing to the different WC sizes. The electrical conductivities of WC-1 and WC-2 were 47.8% and 60.4%, respectively, and had a significant influence on the Ag matrix. In particular, WC-2 exhibited extremely high electrical conductivity owing to its large and continuous Ag-grain matrix. The yield strengths of WC-1 and WC-2 after compression tests were 349.9 MPa and 280.7 MPa, respectively. The high yield strength of WC-1 can be attributed to the Hall–Petch effect, whereas the low yield strength of WC-2 can be explained by the high fraction of high-angle boundaries (HAB) between the WC grains. Furthermore, the relationships between the microstructure, electrical/mechanical properties, and deformation mechanisms were evaluated.

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• Enhanced Epoxy Composites Reinforced by 3D-Aligned Aluminum Borate Nanowhiskers
  Hyunseung Song, Kiho Song, Haejin Hwang, Changui Ahn
  Materials.2024; 17(19): 4727.     CrossRef

In this study, we evaluated the effects of acid leaching on the properties of Cr powder synthesized using self-propagating high-temperature synthesis (SHS). Cr powder was synthesized from a mixture of Cr2O3 and magnesium (Mg) powders using the SHS Process, and the byproducts after the reaction were removed using acid leaching. The properties of the recovered Cr powder were analyzed via X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), particle size analysis (PSA), and oxygen content analysis. The results show that perfect selective leaching of Cr is challenging because of various factors such as incomplete reaction, reaction kinetics, the presence of impurities, and incompatibility between the acid and metal mixture. Therefore, this study provides essential information on the properties under acidic conditions during the production of high-quality Cr powder using a self-propagating high-temperature synthesis method.

Aluminum alloy-based additive manufacturing (AM) has emerged as a popular manufacturing process for the fabrication of complex parts in the automotive and aerospace industries. The addition of an inoculant to aluminum alloy powder has been demonstrated to effectively reduce cracking by promoting the formation of equiaxed grains. However, the optimization of the AM process parameters remains challenging owing to their variability. In this study, the response surface methodology (RSM) was used to predict the crack density of AM-processed Al alloy samples. RSM was performed by setting the process parameters and equiaxed grain ratio, which influence crack propagation, as independent variables and designating crack density as a response variable. The RSM-based quadratic polynomial models for crack-density prediction were found to be highly accurate. The relationship among the process parameters, crack density, and equiaxed grain fraction was also investigated using RSM. The findings of this study highlight the efficacy of RSM as a reliable approach for optimizing the properties of AM-processed parts with limited experimental data. These results can contribute to the development of robust AM processing strategies for the fabrication of highquality Al alloy components for various applications.

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• Synergistic strengthening of crack-free Al–Zn–Mg–Cu alloys with hierarchical microstructures achieved via laser powder bed fusion
  Jungho Choe, Kyung Tae Kim, Jeong Min Park, Hyomoon Joo, Sang Guk Jeong, Eun Seong Kim, Soung Yeoul Ahn, Gang Hee Gu, Hyoung Seop Kim
  Materials Research Letters.2024; 12(8): 598.     CrossRef

Because magnets fabricated using Nd-Fe-B exhibit excellent magnetic properties, this novel material is used in various high-tech industries. However, because of the brittleness and low formability of Nd-Fe-B magnets, the design freedom of shapes for improving the performance is limited based on conventional tooling and postprocessing. Laserpowder bed fusion (L-PBF), the most famous additive manufacturing (AM) technique, has recently emerged as a novel process for producing geometrically complex shapes of Nd-Fe-B parts owing to its high precision and good spatial resolution. However, because of the repeated thermal shock applied to the materials during L-PBF, it is difficult to fabricate a dense Nd-Fe-B magnet. In this study, a high-density (>96%) Nd-Fe-B magnet is successfully fabricated by minimizing the thermal residual stress caused by substrate heating during L-PBF.

A Cu-15Ag-5P filler metal (BCuP-5) is fabricated on a Ag substrate using a high-velocity oxygen fuel (HVOF) thermal spray process, followed by post-heat treatment (300°C for 1 h and 400°C for 1 h) of the HVOF coating layers to control its microstructure and mechanical properties. Additionally, the microstructure and mechanical properties are evaluated according to the post-heat treatment conditions. The porosity of the heat-treated coating layers are significantly reduced to less than half those of the as-sprayed coating layer, and the pore shape changes to a spherical shape. The constituent phases of the coating layers are Cu, Ag, and Cu-Ag-Cu3P eutectic, which is identical to the initial powder feedstock. A more uniform microstructure is obtained as the heat-treatment temperature increases. The hardness of the coating layer is 154.6 Hv (as-sprayed), 161.2 Hv (300°C for 1 h), and 167.0 Hv (400°C for 1 h), which increases with increasing heat-treatment temperature, and is 2.35 times higher than that of the conventional cast alloy. As a result of the pull-out test, loss or separation of the coating layer rarely occurs in the heat-treated coating layer.

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• Evaluation and Prediction of Mechanical Properties According to Welding Methods of Ni 825/A516-70N Clad Plates
  Cheolhong Hwang, Jeongseok Oh, Jini Park, Myungwoo Joe, Sunhwan Kim, Kyunghoon Yoo, Sungwoong Kim, Youngjoo Kim, Sangyeob Lee, Joonsik Park
  Korean Journal of Metals and Materials.2024; 62(11): 844.     CrossRef

In this study, a new manufacturing process for a multilayer-clad electrical contact material is suggested. A thin and dense BCuP-5 (Cu-15Ag-5P filler metal) coating layer is fabricated on a Ag plate using a high-velocity oxygen-fuel (HVOF) process. Subsequently, the microstructure and bonding properties of the HVOF BCuP-5 coating layer are evaluated. The thickness of the HVOF BCuP-5 coating layer is determined as 34.8 μm, and the surface fluctuation is measured as approximately 3.2 μm. The microstructure of the coating layer is composed of Cu, Ag, and Cu-Ag-Cu3P ternary eutectic phases, similar to the initial BCuP-5 powder feedstock. The average hardness of the coating layer is 154.6 HV, which is confirmed to be higher than that of the conventional BCuP-5 alloy. The pull-off strength of the Ag/BCup-5 layer is determined as 21.6 MPa. Thus, the possibility of manufacturing a multilayer-clad electrical contact material using the HVOF process is also discussed.

Tungsten carbide is widely used in carbide tools. However, its production process generates a significant number of end-of-life products and by-products. Therefore, it is necessary to develop efficient recycling methods and investigate the remanufacturing of tungsten carbide using recycled materials. Herein, we have recovered 99.9% of the tungsten in cemented carbide hard scrap as tungsten oxide via an alkali leaching process. Subsequently, using the recovered tungsten oxide as a starting material, tungsten carbide has been produced by employing a self-propagating high-temperature synthesis (SHS) method. SHS is advantageous as it reduces the reaction time and is energy-efficient. Tungsten carbide with a carbon content of 6.18 wt % and a particle size of 116 nm has been successfully synthesized by optimizing the SHS process parameters, pulverization, and mixing. In this study, a series of processes for the highefficiency recycling and quality improvement of tungsten-based materials have been developed.

In this study, we report the microstructure and characteristics of Ag-SnO₂-Bi₂O₃ contact materials using a controlled milling process with a subsequent compaction process. Using magnetic pulsed compaction (MPC), the milled Ag-SnO₂-Bi₂O₃ powders have been consolidated into bulk samples. The effects of the compaction conditions on the microstructure and characteristics have been investigated in detail. The nanoscale SnO2 phase and microscale Bi2O3 phase are well-distributed homogeneously in the Ag matrix after the consolidation process. The successful consolidation of Ag-SnO₂-Bi₂O₃ contact materials was achieved by an MPC process with subsequent atmospheric sintering, after which the hardness and electrical conductivity of the Ag-SnO₂-Bi₂O₃ contact materials were found to be 62–75 HV and 52–63% IACS, respectively, which is related to the interfacial stability between the Ag matrix, the SnO2 phase, and the Bi2O3 phase.

Smart materials capable of changing their characteristics in response to stimuli such as light, heat, pH, and electric and magnetic fields are promising for application to flexible electronics, soft robotics, and biomedicine. Compared with conventional rigid materials, these materials are typically composed of soft materials that improve the biocompatibility and allow for large and dynamic deformations in response to external environmental stimuli. Among them, smart magnetic materials are attracting immense attention owing to their fast response, remote actuation, and wide penetration range under various conditions. In this review, we report the material design and fabrication of smart magnetic materials. Furthermore, we focus on recent advances in their typical applications, namely, soft magnetic actuators, sensors for self-assembly, object manipulation, shape transformation, multimodal robot actuation, and tactile sensing.

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• Advanced Magnetic Actuation: Harnessing the Dynamics of Sm2Fe17–xCuxN3 Composites
  Kangmo Koo, Young-Tae Kwon, Ji Young Park, Yong-Ho Choa
  ACS Applied Materials & Interfaces.2024; 16(9): 11872.     CrossRef