Open Access Spotlight: New findings in sustainable alloy synthesis, adhesion science and fatigue modelling
Showcasing the latest freely accessible research from across the IOM3 journals portfolio.
The Open Access Spotlight showcases recent Open Access research from the IOM3 journals portfolio. This monthly round‑up highlights research that is freely available to read and reflects the commitment IOM3 holds to widening access, strengthening knowledge exchange and promoting open research practices across materials, minerals and mining.
IOM3 members also receive free online access (login required) to all IOM3 publications, along with more than 70 additional titles from Sage’s engineering and materials science portfolio, complementing the Open Access content featured here.
• Scaling-up a hydrogen reduction process to synthesise iron–nickel alloy from a mixture of metal oxide powder
Mineral Processing and Extractive Metallurgy Vol. 135, No. 3
Arun Kamalasekaran, Pelle Mellin, Pär Göran Jönsson, Christopher Hulme
pp. 193–202
DOI: 10.1177/2572664126143946
This study demonstrates that carbon dioxide emissions and high energy use associated with conventional pyrometallurgical alloy production can be avoided by reducing metal oxides with hydrogen in the solid state. An iron nickel alloy was produced by solid state hydrogen reduction of a 50 weight percent Fe2O3 NiO powder mixture, with X ray diffraction confirming complete reduction to body centred cubic and face centred cubic phases and melt extraction revealing only trace oxygen. These results support pilot scale iron nickel production and indicate that this approach could be extended to large scale alloy synthesis from metallurgical by products.
• Moisture: The most important factor in leaf low adhesion?
Tribology - Materials, Surfaces & Interfaces Vol. 20, No. 3
Joseph Jaffé, Kate Tomlinson, Roger Lewis
pp. 189–205
DOI: 10.1177/17515831261434461
This paper investigates the mechanisms behind leaf‑induced low adhesion, focusing on how leaf layer moisture compares with ambient humidity in influencing traction loss. Through controlled climate‑chamber testing supported by laboratory and field measurements, the study shows that moisture within the leaf layer is the dominant factor governing adhesion behaviour. The relationship between moisture and traction is established, demonstrating that environmental humidity alone cannot account for the observed reductions in adhesion.
• Investigation of tool life and machining efficiency of vacuum brazed diamond-coated milling tools
Tribology - Materials, Surfaces & Interfaces Vol. 20, No. 3
Oğuzhan Öz, Erkan ÖZKAN
pp. 206–219
DOI: 10.1177/17515831261437884
This study examines the wear behaviour and machining efficiency of vacuum brazed diamond coated milling tools when cutting Mugla White and Usak White marbles under controlled spindle speed, feed rate and depth of cut conditions. Machining responses including surface roughness, cutting force, specific energy consumption, and material removal rate were assessed alongside detailed wear analysis and optimisation tests confirmed distinct ideal parameters for each marble. The results show that the lower mechanical strength of Mugla White leads to higher material removal but greater tool wear, demonstrating how microstructural differences and operating conditions shape tool degradation and overall machining performance.
• Recent advances in low-pressure powder injection moulding: A short review of wax-based, backbone-free systems
Powder Metallurgy Vol. 69, No. 4
Seyed Mohammad Majdi
pp. 285–291
DOI: 10.1177/00325899261460580
This review traces recent progress in wax‑based, backbone‑free LPIM, covering advances in feedstock formulation, quantitative mould‑filling simulation, thermal wick‑debinding and sintering of irregular metallic powders. It shows that wax‑based systems now support high solid loadings with low viscosities, that mould‑filling simulations have become quantitatively benchmarked but still exhibit sizeable pressure‑prediction gaps, and that optimized debinding–sintering schedules enable water‑atomized powders to achieve properties comparable to gas‑atomized feedstocks. The review also outlines five areas for future work, including improving simulation accuracy, clarifying LPIM’s density–shrinkage behaviour, extending the process to reactive alloys, exploring links with additive manufacturing, and developing more sustainable binder and debinding routes.
• A surface integrity-informed crystal-plasticity based modelling of fatigue crack initiation in aerospace-grade Ti-6Al-4V
Materials Science and Technology Vol. 42, No. 10: Fatigue 2024 Special Issue
Mauro Francisco Arcidiacono, Salaheddin Rahimi
pp. 998–1012
DOI: 10.1177/02670836251365326
A crystal plasticity finite element approach is used to investigate fatigue crack initiation in machined Ti‑6Al‑4V, drawing on an EBSD‑reconstructed microstructure that captures prior deformation, residual stress, and milling‑induced roughness. The analysis shows that crack initiation is highly localised and governed by the interplay of surface geometry, strain accumulation, and crystallographic variation, with basal and prismatic slip systems emerging as the most susceptible according to Extreme Value Statistics. The results indicate that Schmid factor alone cannot account for observed fatigue hotspots, as local stress states, grain interactions and surface‑imposed constraints also strongly influence where cracks form.
• The effect of machining parameters on surface integrity and fatigue performance of 42CrMo4 + QT high-strength steel
Materials Science and Technology Vol. 42, No. 10: Fatigue 2024 Special Issue
Martin Matušů, Jan Papuga, Karel Trojan, Antonín Trefil, Alaitz Zabala, Vladimír Mára, Petr David
pp. 1013–1032
DOI: 10.1177/02670836251362509
The study investigates how machining parameters shape the surface integrity and fatigue behaviour of 42CrMo4 + QT steel. It finds that the combination of a 100 m/min cutting speed, 0.1 mm/min feed, 0.4 mm tool nose radius, 0.3 mm finishing depth and coolant application delivers the strongest fatigue response. Cutting speed emerges as the most decisive factor, while surface roughness and residual stresses do not consistently account for the fatigue outcomes observe.
