Typically, anodic oxidation of metals results in the formation of hexagonally arranged nanoporous or nanotubular oxide, with a specific oxidation state of the transition metal. Recently, the majority of transition metals have been anodized; however, the formation of copper oxides by electrochemical oxidation is yet unexplored and offers numerous, unique properties and applications. Nanowires formed by copper electrochemical oxidation are crystalline and composed of cuprous (CuO) or cupric oxide (Cu₂O), bringing varied physical and chemical properties to the nanostructured morphology and different band gaps: 1.44 and 2.22 eV, respectively. According to its Pourbaix (potential-pH) diagram, the passivity of copper occurs at ambient and alkaline pH. In order to grow oxide nanostructures on copper, alkaline electrolytes like NaOH and KOH are used. To date, no systemic study has yet been reported on the influence of the operating conditions, such as the type of electrolyte, its temperature, and applied potential, on the morphology of the grown nanostructures. However, the numerous reports gathered in this paper will provide a certain view on the matter. After passivation, the formed nanostructures can be also post-treated. Post-treatments employ calcinations or chemical reactions, including the chemical reduction of the grown oxides. Nanostructures made of CuO or Cu₂O have a broad range of potential applications. On one hand, with the use of surface morphology, the wetting contact angle is tuned. On the other hand, the chemical composition (pure Cu₂O) and high surface area make such materials attractive for renewable energy harvesting, including water splitting. While compared to other fabrication techniques, self-organized anodization is a facile, easy to scale-up, time-efficient approach, providing high-aspect ratio one-dimensional (1D) nanostructures. Despite these advantages, there are still numerous challenges that have to be faced, including the strict control of the chemical composition and morphology of the grown nanostructures, their uniformity, and understanding the mechanism of their growth.

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

A series of trials to fusion weld commercially pure titanium (CPTi) to stainless steel 304 (SS304) have been conducted using laser beam welding (LBW) and gas tungsten arc welding (GTAW). Neither technique produced adequate weld joints with LBW showing a more promising result, while GTAW yielded separation of the workpieces immediately after welding. Cracking and fracturing took place mainly on the SS304 side, which was explained by the differences in the materials’ thermal properties. Various intermetallic phases formed during welding that were identified using energy dispersive X-ray spectroscopy (EDS) and electron backscattered diffraction (EBSD) technique and were compared with an isothermal ternary phase diagram of Fe-Cr-Ti. Their corresponding hardness values are reported and correlated with alloy compositions.

The objective of the presented work was to develop a new forging process for a pinion shaft as a component of a wind turbine. A study of near-net-shape forming using Deform 3D software was performed to reduce operational cost, time, and material scrap; enhance specific properties; increase productivity. Near-net forged products have good dimensional accuracy and continuous metal flow lines, which are characteristic of improved mechanical properties. To avoid the traditional trial-and-error experimental method, the process and tool design were accomplished with a careful and detailed numerical simulation approach. In the present work, the Finite Element Method was used to develop a process model for the existing hot forging process of the 18CrNiMo7-6 steel pinion shaft used in a wind turbine. The developed numerical process model was validated via experiment including a comparison of the metal flow lines from the FEM model with the metallography results of the forged part. Two new die designs were proposed, and the simulation results were compared to the actual process to achieve improved geometry. The results for the new geometries showed improvements in terms of the die cavity filling for the new proposed dies and better results in grain flow orientation. Compared to the initial non-optimized die, the new designs improved the mechanical properties and savings associated with the lower volume of required raw material and fewer finishing operations. Considering the applied stresses and wear in the new near-net shape, the die geometry shall be updated to accommodate more severe solicitations. Naturally, all the improvements carried out are dependent on other factors such as the conditions of the equipment, operator skills, lubrication, and other variables. A surface heat treatment is also suggested for stress relief as a reliability improvement.