Iranian Journal of Materials Science and Engineering

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Abstract: The effect of phase development on peel strength of alumina-copper metalized joint has been investigated. The alumina-copper joint was prepared in three stages. The alumina substrate was, first, metalized at 1500°C in H2-furnace by a new formulation. In the second step, a nickel layer was electroplated on the metalized layer with approximately 10µm thickness. Finally, copper strips were bonded to metalized alumina with Ag-Cu (72-28) filler metal. The peel strength of the joint was 9.5±0.5 Kg/cm which shows approximately 30% increase in comparison to previous works. By study of fracture surface and crack propagation path, it has been concluded that this increase is due to the formation of more spinel phase.

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Magnesium alloys are increasingly valued for biomedical applications due to their biocompatibility. This study investigates Mg-AZ31B alloy samples treated with quartz and alumina grits (<200 μm) at varied pressures, followed by anodization in an eco-friendly alkaline electrolyte. The results show that increased blasting pressure produces a rougher surface. Anodization time significantly affects the thickness of the anodic film, leading to a transition in surface morphology from fine to coarse structures with complete film coverage. Characterization by XRD reveals that the anodic film mainly comprises magnesium oxide and hydroxide phases. Open Circuit Potential (OCP) measurements demonstrate enhanced corrosion resistance post-anodization, particularly notable at 40 minutes on alumina-blasted samples. ANOVA confirms that both blasting pressure and anodization time significantly influence coating thickness and OCP, indicating the formation of a dense anodized layer.

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Additive manufacturing (AM) of metallic parts has gained significant attention in recent years due to its ability to produce components without traditional tooling such as molds, melting furnaces, or extensive raw material preparation. Its unique capability to fabricate complex geometries has revolutionized part design and enabled substantial weight reduction. This review first outlines the development trajectory of metal-based AM, with a particular focus on laser-based fusion methods, including Laser Powder Bed Fusion (LPBF) and Direct Laser Deposition (DLD). Understanding this evolution helps researchers identify both the capabilities and limitations of AM technologies, thereby enhancing their application in areas such as prototyping, mass production, and repair. Each metal possesses unique physical and chemical properties, which often make traditional manufacturing methods more challenging—especially for alloys with high strength, hardness, or temperature resistance. In this context, the review then focuses on nickel-based superalloys (NBSAs), which are widely used in high-temperature and high-stress environments but are particularly difficult to process using conventional techniques. Their application serves as a representative case study for evaluating the performance and feasibility of AM techniques for advanced materials. Furthermore, the future prospects of AM are discussed, including advancements in monitoring systems, integration of machine learning, and the development of AM-specific alloys. As a novel aspect, this work compares LPBF and DLD in terms of their advantages, limitations, and resulting material properties, along with a comparison to traditional manufacturing methods such as casting and wrought processing.