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This study delves into the innovative realm of synthesizing surface alloyed materials by utilizing copper-based metamorphic powders subjected to high-intensity electron beam irradiation. The process involves depositing metamorphic particles onto a stainless-steel substrate, and subsequently exposing the assembly to a powerful electron beam, resulting in the development of distinct surface alloyed layers. A notable advancement was achieved by introducing a second layer of metamorphic powders over the existing alloyed layer, followed by further treatment with the electron beam. The alloyed layers, characterized by a volumetric concentration ranging from 60 to 67%, exhibited a fascinating phenomenon— the formation of abundant borate crystals with the chemical formula Al2.56Fe1.75Ni0.84. This crystal presence significantly elevated the hardness of the surface alloyed layers, showcasing an impressive five to sevenfold increase compared to the substrates.

Carburizing, austenitic, and boronizing were used to enhance the friction and wear properties of AISI 1080 and 1566 steel surfaces. They were subjected to austenitic, solid boronizing, liquid and gaseous carburizing processes. An examination done and observed the microstructure, X-ray diffraction patterns, and hardness distributions of the material. For the wear testing, pin-on-disc specimen topologies were employed, and removal efficiencies were estimated based on the sliding distance and the required force applied. In addition, the abrasiveness of the sample surfaces was assessed. The heat treatment capacity of AISI 1020 steel was investigated and compared to the heat treatment capabilities of other steel samples to establish how much heat can be applied to the steel.

Aluminum alloy AA2024 stands out as a widely utilized age-hardening alloy in aircraft applications worldwide. Despite its superior weldability in comparison to its 6000-series counterparts, AA2024 still reveals vulnerability in the welded joint. Specifically, in the T6 condition, the joint strength is only about 40% of the strength exhibited by the base metal. Faced with this challenge, design engineers often resort to selecting thicker base metal plates due to notable disparities in strength values, particularly concerning yield strength. AA2024 alloy is welded using low heat input electron beam welding. This weld is eliminated all demerits in other fusion welding process. However, heat affected zone is always a weaker region in all the fusion welding process. Post weld heat treatment process, namely, solution treatment and artificial ageing was performed to dimmish the width of weaker region.