Solid-state welding (SSW) is a relatively new technique, and ongoing research is being performed to fulfill new design demands, deal with contemporary material advancements, and overcome welding defects associated with traditional welding techniques. This work provides an in-depth examination of the advancements in the solid-state welding of steels through diffusion bonding (DB) and friction stir welding (FSW). Considerable attention was given to DB of steel, which overcame the difficulties of segregation, cracking, and distortion stresses that are usually formed in liquid-phase welding techniques. The defects that affected DB included two types: two-dimensional defects of a metallic lattice, i.e., phases and grain boundaries, and three-dimensional defects, i.e., precipitation. FSW, on the other hand, was distinguishable by the use of relatively low heat input when compared to fusion welding processes such as tungsten inert gas (TIG), resulting in the formation of a limited heat-affected zone. Moreover, fine grain structures were formed in the FSW interface because of the stirring tool’s severe plastic deformation, which positively affected the strength, ductility, and toughness of the FSW joints. For instance, higher strength and ductility were reported in joints produced by FSW than in those produced by TIG. Nevertheless, the HAZ width of the specimens welded by FSW was approximately half the value of the HAZ width of the specimens welded by TIG. Some defects associated with FSW related to the diffusion of elements, such as C/Cr atoms, through the weld zone, which affected the local chemical composition due to the formation of rich/depleted regions of the diffused atoms. Moreover, the lack-of-fill defect may exist when inappropriate welding conditions are implemented. On the other hand, the stirring tool was subjected to extensive wear because of the high hardness values, which negatively affected the economical usage of the FSW process. A summary of the results is presented, along with recommendations for future studies aimed at addressing existing difficulties and advancing the solid-state technology for steel.

Magnesium (Mg) alloys have unique properties. However, their applications are limited in working environments due to their poor corrosion resistance. Plasma electrolytic oxidation (PEO) is one of the most environmentally friendly and cost-effective ways that has been promoted to treat Mg alloys. In this study, we investigated the effect of electrical parameters on the microstructure, as well as the mechanical and corrosion resistance of AM60 alloy coated with PEO. The electrical parameters studied were current mode (unipolar and bipolar), frequency and duty ratio. The microstructure evolution of the coated AM60 substrates was studied using X-ray diffraction and scanning electron microscopy. Subsequently, the mechanical properties were determined using compression tests and microhardness measurements. The potentiodynamic polarization curves indicated that the PEO-coated samples experienced a significant decrease of 99.9% in the corrosion rate compared to the base metal. The electrochemical impedance spectroscopy findings showed that PEO coating increased the corrosion resistance of the AM60 magnesium alloy by 1071870% compared to the base metal. On the other hand, the PEO coated samples showed superior adhesion to the substrate. Moreover, the PEO coating led to an improvement in the hardness value by 114% compared to base metal, coupled with insignificant change in the compressive properties.

This study comprehensively investigates the impact of various parameters on aluminum matrix composites (AMCs) fabricated using the powder metallurgy (PM) technique. An Al-Cu matrix composite (2xxx series) was employed in the current study, and Al₂O₃ was used as a reinforcement. The performance evaluation of the Al-4Cu/Al₂O₃ composite involved analyzing the influence of the Al₂O₃ weight percent (wt. %), the height-to-diameter ratio (H/D) of the compacted samples, and the compaction pressure. Different concentrations of the Al₂O₃ reinforcement, namely 0%, 2.5%, 5.0%, 7.5%, and 10% by weight, were utilized, while the compaction process was conducted for one hour under varying pressures of 500, 600, 700, 800, and 900 MPa. The compacted Al-4Cu/Al₂O₃ composites were in the form of cylindrical discs with a fixed diameter of 20 mm and varying H/D ratios of 0.75, 1.0, 1.25, 1.5, and 2.0. Moreover, the machine learning (ML), design of experiment (DOE), response surface methodology (RSM), genetic algorithm (GA), and hybrid DOE-GA methodologies were utilized to thoroughly investigate the physical properties, such as the relative density (RD), as well as the mechanical properties, including the hardness distribution, fracture strain, yield strength, and compression strength. Subsequently, different statistical analysis approaches, including analysis of variance (ANOVA), 3D response surface plots, and ML approaches, were employed to predict the output responses and optimize the input variables. The optimal combination of variables that demonstrated significant improvements in the RD, fracture strain, hardness distribution, yield strength, and compression strength of the Al-4Cu/Al₂O₃ composite was determined using the RSM, GA, and hybrid DOE-GA approaches. Furthermore, the ML and RSM models were validated, and their accuracy was evaluated and compared, revealing close agreement with the experimental results.

In this study, a quantitative evaluation approach was used to investigate how certain ECAP processing parameters affect the microstructural evolution, Vicker’s microhardness values and tensile properties of pure Mg. The ECAP processing parameters were number of passes, ECAP die channel angle and processing route type. The response surface methodology (RSM) technique was used to design 16 runs of the experiment using Stat-Ease design expert software. Billets of pure Mg were processed up to four passes of routes Bc, A and C at 225 °C. Two ECAP dies were used with internal channel angles of 90° and 120°. Experimental findings were used to establish empirical models to assess the influence of the ECAP processing parameters on grain size and mechanical properties of ECAPed billets. The established relationships were examined and validated for their adequacy and significance using ANOVA as well as several statistical criteria. Response surface plots and contour graphs were established to offer better understanding of the intended relationships. In addition, the optimum processing parameters for grain size, hardness values and tensile properties were defined. Both experimental results and the theoretical model revealed that route Bc is the most effective route in grain refining. The experimental findings showed that four passes of route Bc through the die channel angle 90° revealed a significant reduction in the grain size by 86% compared to the as-annealed counterparts. Similar to the grain size refining, four-passes processing through the ECAP die with an internal channel angle of 90° leads to improved Vicker’s microhardness values. Additionally, four passes of route Bc using the 90° die angle recorded a significant HV increase at the edge and central areas by 112% and 78%, respectively, compared to the as-annealed counterpart. On the other hand, according to the optimization findings, two passes of route Bc using a die angle of 120° resulted in the best ultimate tensile strength for pure Mg, whereas four passes of route Bc revealed the optimum ductility at fracture.