High-velocity projectile impact induced 9R phase in ultrafine-grained aluminium

Design of a Thermally Stable Heat-Resistant (Al2O3+Al3Ti)/Al Composite with Excellent High-Temperature Mechanical Properties: Multimechanism Synergistic Strengthening Strategy

The effectiveness of the room-temperature strengthening strategy for aluminum (Al) is compromised at increased temperatures due to grain and precipitate phase coarsening. Overcoming the heightened activity of grain boundaries and dislocations poses a significant challenge in enhancing the high-temperature strength through traditional precipitation strengthening. This study presents novel strengthening strategies that integrate intergranular reinforcements, intragranular reinforcements, refined grain, and stacking faults within an (Al2O3+Al3Ti)/Al composite prepared using sol-gel and powder metallurgy technology. Excellent high-temperature tensile properties are achieved; also, a remarkable fatigue performance at increased temperatures that surpasses those of other existing Al alloys and composites is revealed. These superior characteristics can be attributed to its exceptionally stable microstructure and the synergistic strengthening mechanisms mentioned above. This work offers new insights into designing and fabricating thermally stable Al matrix composites for high-temperature applications.

Controllable Pseudoelasticity in Metallic Nanocrystals by Grain Boundary Engineering

Materials with pseudoelasticity can recover from large strains exceeding their elastic limits during unloading, making them promising damage-tolerant building blocks for advanced nanodevices. Nevertheless, a practical approach to realize controllable pseudoelastic behavior at nanoscale remains challenging. Here, we proposed a grain boundary (GB) engineering approach to endow metallic nanocrystals with a controllable pseudoelasticity. Both in situ nanomechanical testing and atomistic simulations demonstrate that such controllable pseudoelasticity is governed by the extension and contraction of an inherent stacking fault array at the GB. By precisely tuning GB misorientation and inclination, our simulation results reveal that metallic nanocrystals can exhibit tailored pseudoelastic performance across a broad spectrum of GBs in different face-centered cubic metals. These findings enrich our understanding of the intrinsic pseudoelasticity of GBs and provide a GB engineering approach toward metallic materials with reversible deformability.

Phase transformation path in Aluminum under ramp compression; simulation and experimental study

We present a framework based on non-equilibrium molecular dynamics (NEMD) to reproduce the phase transformation event of Aluminum under ramp compression loading. The simulated stress-density response, virtual x-ray diffraction patterns, and structure analysis are compared against the previously observed experimental laser-driven ramp compression in-situ x-ray diffraction data. The NEMD simulations show the solid–solid phase transitions are consistent to experimental observations with a close-packed face-centered cubic (fcc) (111), hexagonal close-packed (hcp) structure (002), and body-centered cubic bcc (110) planes remaining parallel. The atomic-level analysis of NEMD simulations identifiy the exact phase transformation pathway happening via Bain transformation while the previous in situ x-ray diffraction data did not provide sufficient information for deducing the exact phase transformation path.

High stress twinning in a compositionally complex steel of very high stacking fault energy

Deformation twinning is rarely found in bulk face-centered cubic (FCC) alloys with very high stacking fault energy (SFE) under standard loading conditions. Here, based on results from bulk quasi-static tensile experiments, we report deformation twinning in a micrometer grain-sized compositionally complex steel (CCS) with a very high SFE of ~79 mJ/m², far above the SFE regime for twinning (<~50 mJ/m²) reported for FCC steels. The dual-nanoprecipitation, enabled by the compositional degrees of freedom, contributes to an ultrahigh true tensile stress up to 1.9 GPa in our CCS. The strengthening effect enhances the flow stress to reach the high critical value for the onset of mechanical twinning. The formation of nanotwins in turn enables further strain hardening and toughening mechanisms that enhance the mechanical performance. The high stress twinning effect introduces a so far untapped strengthening and toughening mechanism, for enabling the design of high SFEs alloys with improved mechanical properties.

Mechanical twinning is difficult to trigger in face centered cubic alloys with high stacking fault energies (SFEs) under standard tensile loading. Here, the authors report high stress twinning in a bulk compositionally complex steel of very high SFE, enhancing the material’s mechanical performance.

Deformation-activated recrystallization twin: New twinning path in pure aluminum enabled by cryogenic and rapid compression

Bulk aluminum rarely forms deformation or annealing twins owing to its high stacking fault energy. We report a novel twinning mechanism mediated by dynamic recrystallization in 6N pure aluminum under high strain rate (∼1.3 × 10⁴ s⁻¹) impact at a cryogenic temperature (77 K). Discontinuous dynamic recrystallization occurs during rapid severe plastic deformation and generates inhomogeneous microstructures exhibiting low-angle and high-angle grain boundaries. Unexpectedly, Σ3 twin boundaries were able to develop during dynamic recrystallization. Although these recrystallization twins have similar morphology as that of annealing twins, their formation relies on deformation activation instead of thermal activation, which was suppressed by the cryogenic experiment. Besides, strong orientation dependence was observed for formation of these novel twins. Beyond annealing and deformation twin, deformation-activated recrystallization twin is a new path for pure aluminum twinning.

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Deformation-activated recrystallization twin is enabled by cryogenic impact in pure Al

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This new twinning path occurs during discontinuous dynamic recrystallization

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Nucleation of these twinning grains prefers boundary edge and corner

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Occurrence of new twinning mechanism depends on deformation orientation

Research on homogeneous nucleation and microstructure evolution of aluminium alloy melt

In this paper, based on the embedded atom method (EAM) potential, molecular dynamics simulations of the solidification process of Al-4 at.%Cu alloy is carried out. The Al-Cu alloy melt is placed at different temperatures for isothermal solidification, and each stage of the entire solidification process is tracked, including homogeneous nucleation, nucleus growth, grain coarsening and microstructure evolution. In the nucleation stage, the transition from high temperature to low temperature manifests a change from spontaneous nucleation mode to divergent nucleation mode. The critical nucleation temperature of the Al-Cu alloy is determined to be about 0.42 T _m (T _m is the melting point of Al-4 at.%Cu) by calculating the nucleation rate and the crystal nucleus density. In the nucleus growth stage, two ways of growing up are observed, that is, a large crystal nucleus will absorb a smaller heterogeneous crystal nucleus, and two very close crystal nuclei will merge. In the microstructure evolution of the isothermally solidified Al-Cu alloy, it is emerged that the interior of all nanocrystalline grains are long-period stacking structure composed of face centred cubic (FCC) and hexagonal close-packed (HCP). These details provide important information for the production of Al-Cu binary alloy nano-polycrystalline products.

Hierarchical nanotwins in single-crystal-like nickel with high strength and corrosion resistance produced via a hybrid technique

High-density growth nanotwins enable high-strength and good ductility in metallic materials. However, twinning propensity is greatly reduced in metals with high stacking fault energy. Here we adopted a hybrid technique coupled with template-directed heteroepitaxial growth method to fabricate single-crystal-like, nanotwinned (nt) Ni. The nt Ni primarily contains hierarchical twin structures that consist of coherent and incoherent twin boundary segments with few conventional grain boundaries. In situ compression studies show the nt Ni has a high flow strength of ∼2 GPa and good deformability. Moreover, the nt Ni has superb corrosion behavior due to the unique twin structure in comparison to coarse grained and nanocrystalline counterparts. The hybrid technique opens the door for the fabrication of a wide variety of single-crystal-like nt metals with unique mechanical and chemical properties.

Melt-driven erosion in microparticle impact

Impact-induced erosion is the ablation of matter caused by being physically struck by another object. While this phenomenon is known, it is empirically challenging to study mechanistically because of the short timescales and small length scales involved. Here, we resolve supersonic impact erosion in situ with micrometer- and nanosecond-level spatiotemporal resolution. We show, in real time, how metallic microparticles (~10-μm) cross from the regimes of rebound and bonding to the more extreme regime that involves erosion. We find that erosion in normal impact of ductile metallic materials is melt-driven, and establish a mechanistic framework to predict the erosion velocity.

Supersonic particle impacts can cause permanent damage to space vehicles and satellites, but how exactly remains unclear. Here, the authors visualise for the first time the high impact of single tin microparticles on a tin substrate and show erosion of ductile metallic materials is melt-driven.

Ultra-strong nanotwinned Al-Ni solid solution alloys with significant plasticity

Twin boundaries have been proven effective for strengthening metallic materials while maintaining plasticity. Al, however, has low twinning propensity due to its high stacking fault energy. Here we show, by using a small amount of Ni solutes, high-density twin boundaries and stacking faults in sputtered Al-Ni solid solution alloys. Density function theory calculations show that the Ni solute facilitates the formation of stacking faults and stabilizes nanotwins in Al-Ni solid solution alloys. In situ micropillar compression studies reveal a high flow stress (exceeding 1.7 GPa), comparable to high strength martensitic steels and Ni alloys. Furthermore, significant plasticity was observed in these nanotwinned Al-Ni alloy films due to the existence of high density twin boundaries and 9R phase.

High-Strength Nanotwinned Al Alloys with 9R Phase

Light-weight aluminum (Al) alloys have widespread applications. However, most Al alloys have inherently low mechanical strength. Nanotwins can induce high strength and ductility in metallic materials. Yet, introducing high-density growth twins into Al remains difficult due to its ultrahigh stacking-fault energy. In this study, it is shown that incorporating merely several atomic percent of Fe solutes into Al enables the formation of nanotwinned (nt) columnar grains with high-density 9R phase in Al(Fe) solid solutions. The nt Al-Fe alloy coatings reach a maximum hardness of ≈5.5 GPa, one of the strongest binary Al alloys ever created. In situ uniaxial compressions show that the nt Al-Fe alloys populated with 9R phase have flow stress exceeding 1.5 GPa, comparable to high-strength steels. Molecular dynamics simulations reveal that high strength and hardening ability of Al-Fe alloys arise mainly from the high-density 9R phase and nanoscale grain sizes.