Lightweight complex concentrated alloys (LWCCA), composed of elements with low density, have become a great area of interest due to the high demand in a large number of applications. Previous research on LWCCAs was focused on high entropy multicomponent alloy systems that provide low density and high capability of solid solution formation. Present research introduces two alloy systems (Al-Cu-Si-Zn-Mg and Al-Mn-Zn-Mg-Si) that contain readily available and inexpensive starting materials and have potential for solid solution formation structures. For the selection of appropriate compositions, authors applied semi-empirical criteria and optimization software. Specialized modeling software (MatCalc) was used to determine probable alloy structures by CALPHAD, non-equilibrium solidification and kinetic simulations. The selected alloys were prepared in an induction furnace. Specimens were heat treated to provide stable structures. Physicochemical, microstructural, and mechanical characterization was performed for the selected alloy compositions. Modeling and experimental results indicated solid solution-based structures in the as-cast and heat-treated samples. Several intermetallic phases were present at higher concentrations than in the conventional alloys. Alloys presented a brittle structure with compression strength of 486–618 MPa and hardness of 268–283 HV. The potential for uniform intermetallic phase distribution in the selected alloys makes them good candidates for applications were low weight and high resistance is required.

Rare earth elements (REEs) possess unique physical and chemical properties that render them indispensable in various industries, including electronics, energy production and storage, hybrid and electric vehicles, metallurgy, and petro-chemical processing. The criticality of REE underscores the need to enhance the efficiency of primary resource extraction and promote circularity through increased recycling from secondary sources. This paper provides a brief overview of REE recovery from secondary sources, particularly waste from electronic and electric equipment (WEEE). The discussion encompasses direct reuse of magnets, short-loop recycling (direct recycling), hydro- and pyrometallurgical processes, highlighting microwave (MW) technology. Original results are presented, focusing on the recovery of neodymium (Nd) from permanent magnet scraps from hard disk drives (HDD-PC) using microwave-assisted liquid metal extraction (LME) with magnesium (Mg) as the extractant. The subsequent separation of Nd from the Mg-Nd alloy via vacuum Mg distillation that is reused in the process is described. The experimental study demonstrates that the LME process, conducted in a microwave furnace, is a viable method for recovering Nd from permanent magnet scraps, which are essential for reducing the environmental impact of REE extraction and promoting a circular economy. By separating Nd from the alloy through vacuum distillation (450–550 mmHg), at temperatures of 850–900 °C for 8 h, a Nd sponge with a content of 95–98 wt.% Nd was obtained. The extracted content of Nd in the Mg alloy increases with increasing temperature and holding time. It was found that ≈ 97% of the Nd in the scrap was extracted from 2 to 5 mm crushed scrap at 800 °C for 8 h, using a LiF-LiCl-MgF₂ protecting flux in a furnace Ar atmosphere.

Solid oxide fuel cells (SOFC) are electrochemical conversion devices that produces electricity directly from oxidizing a fuel and their development became of high importance to drastically reduce the greenhouse emission. Rare earth elements (REEs) are widely used as materials and dopants in controlling the ionic conductivity of solid electrolytes for SOFCs. Their criticality and high costs for separation to individual REEs lead to first studies aiming to search possible use of mixed REEs with natural occurrence as extracted from concentrates. This paper focused on obtaining sintered pellets based on zirconia doped with natural mixture of REEs extracted from monazite and study their microstructure, impedance spectra and dielectric properties vs. operating temperatures to assess their potential applications as solid electrolyte. ZrO₂ doped powders with 8% natural mixture of REEs (8ZrMZ) were synthesized by hydrothermal process. ZrO₂ doped with 4% Y₂O₃ (4ZrY) and 8%Y₂O₃ (8ZrY) were also obtained by the same route and used as standard materials already used in commercial SOFCs. All powders were uniaxially pressed and sintered in air, with highest densities obtained for 1400 °C. The Niquist diagrams for 8ZrMZ samples show significantly lower ionic conductivity compared to standards 4ZrY and 8 ZrY. This may be attributed to the presence of detrimental Fe and Si impurities following the mixed REE after Th and U removal from monazite concentrates and the ratio of REEs in the dopant composition affecting the ionic conductivity due to possible association of structural defects. Research works are further needed to improve the receipt for using naturally mixed REEs and asses their possible use as a competitive dopant for solid electrolytes.

This study investigates the application of robocasting technology for fabricating high-density yttria-stabilized zirconia (8YSZ) electrolytes used in solid oxide fuel cells (SOFCs). The primary goal is to overcome the limitations of traditional manufacturing techniques, such as low density and poor microstructural control. Using a combination of hydrothermal synthesis, rheological testing, and robocasting, we achieved dense 8YSZ structures (over 95% density) with minimal porosity. The fabricated electrolytes underwent sintering and debinding processes, with thermal treatment profiles optimized for structural integrity. A microstructural analysis through SEM and XRD confirmed the formation of stable crystalline phase. This research opens new avenues for the use of additive manufacturing in electrochemical applications, particularly for producing complex ceramic components with superior characteristics.

This study investigates the additive manufacturing of 3D porous scaffolds based on walstromite-type silicate ceramics for bone tissue engineering applications. Walstromite powders were synthesized using the sol-gel method and printed using extrusion-based 3D printing. Both sintered and unsintered scaffolds were characterized using scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR), X-Ray diffraction (XRD) and energy dispersive X-ray spectroscopy (EDS) analyses to evaluate the effects of sintering on microstructure, porosity, and mechanical properties. Results indicate that the unsintered scaffolds exhibited significantly higher compressive strength due to the presence of organic binders, whereas the sintered scaffolds demonstrated enhanced porosity, facilitating cell infiltration and nutrient flow. Therefore, the sintering process reduced compressive strength, probably due to the loss of organic compounds and increased porosity. These findings underline the need for optimizing sintering parameters to balance mechanical integrity and porosity, ensuring that the scaffolds meet the mechanical and biological requirements for bone regeneration. Alternative sintering methods, such as microwave sintering, are also suggested for future research to minimize the mechanical degradation observed post-sintering.