Strain localisation and failure at twin-boundary complexions in nickel-based superalloys

Enhancing Strength and Ductility of a Ni-26.6Co-18.4Cr-4.1Mo-2.3Al-0.3Ti-5.4Nb Alloy via Nanosized Precipitations, Stacking Faults, and Nanotwins

The addition of Co to Ni-based alloys can reduce the stacking fault energy. In this study, a novel Ni-26.6Co-18.4Cr-4.1Mo-2.3Al-0.3Ti-5.4Nb alloy was developed by increasing the Co addition to 26.6 wt.%. A new strategy to break the trade-off between strength and ductility is proposed by introducing dense nanosized precipitations, stacking faults, and nanoscale twins in the as-prepared alloys. The typical characteristics of the deformed alloy include dense dislocations tangles, nanotwins, stacking faults, and Lomer-Cottrell locks. In addition to the pinning effect of the bulky δ precipitates to the grain boundaries, the nanosized γ' particles with a coherent interface with the matrix show significant precipitation strengthening. As a result, the alloy exhibits a superior combination of yield strength of 1093 MPa and ductility of 29%. At 700 °C, the alloy has a high yield strength of 833 MPa and an ultimate tensile strength of 1024 MPa, while retaining a ductility of 6.3%.

Role of slip in hydrogen-assisted crack initiation in Ni-based alloy 725

We conduct in situ tensile straining experiments to investigate the role of hydrogen and slip in crack initiation in nickel-based alloy 725. Our experiments reveal no tendency for hydrogen to enhance localized slip and no necessity of slip for crack initiation. We use electrochemical charging to introduce hydrogen into samples, melt extraction to measure hydrogen content, and digital image correlation to analyze localized plastic strains during in situ tensile tests in a scanning electron microscope. Cracks initiate both in regions with and without nearby localized slip. Moreover, the fraction of cracks initiating with no nearby slip is greater at higher hydrogen content. Slip-assisted crack initiation generally occurs at locations where intergranular slip is arrested, especially at intersections of slipping coherent twin boundaries with thin twin lamellae. Cracks that initiate without nearby slip occur at a wider variety of microstructural features, including inclusions, triple junctions, and surface flaws.

Hydrogen Embrittlement as a Conspicuous Material Challenge─Comprehensive Review and Future Directions

Hydrogen is considered a clean and efficient energy carrier crucial for shaping the net-zero future. Large-scale production, transportation, storage, and use of green hydrogen are expected to be undertaken in the coming decades. As the smallest element in the universe, however, hydrogen can adsorb on, diffuse into, and interact with many metallic materials, degrading their mechanical properties. This multifaceted phenomenon is generically categorized as hydrogen embrittlement (HE). HE is one of the most complex material problems that arises as an outcome of the intricate interplay across specific spatial and temporal scales between the mechanical driving force and the material resistance fingerprinted by the microstructures and subsequently weakened by the presence of hydrogen. Based on recent developments in the field as well as our collective understanding, this Review is devoted to treating HE as a whole and providing a constructive and systematic discussion on hydrogen entry, diffusion, trapping, hydrogen-microstructure interaction mechanisms, and consequences of HE in steels, nickel alloys, and aluminum alloys used for energy transport and storage. HE in emerging material systems, such as high entropy alloys and additively manufactured materials, is also discussed. Priority has been particularly given to these less understood aspects. Combining perspectives of materials chemistry, materials science, mechanics, and artificial intelligence, this Review aspires to present a comprehensive and impartial viewpoint on the existing knowledge and conclude with our forecasts of various paths forward meant to fuel the exploration of future research regarding hydrogen-induced material challenges.

Interfacial excess of solutes across phase boundaries using atom probe microscopy

Three-dimensional elemental mapping in atom probe microscopy provides invaluable insights into the structure and composition of interfaces in materials. Quasi-atomic resolution facilitates access to the solute decoration of grain boundaries, advancing the knowledge on local segregation and depletion phenomena. More recent developments unlocked three-dimensional mapping of the interfacial excess across grain boundaries. Such detailed understanding of the local structure and composition of these interfaces enabled advancements in processing methods and material development. However, many engineering alloys, such as Ni-based superalloys, have much more complex microstructures with various solutes and precipitates in close proximity to grain boundaries. The complex interaction of grain boundary segregation and grain boundary precipitates requires precise compositional control. However, abrupt changes in solute solubility across phase boundaries obscure the interfacial excess in proximity to grain boundaries. Therefore, this study provides a methodological framework of the quantitative characterization of phase boundaries in proximity to grain boundaries using atom probe microscopy. The detailed mass spectrum ranging of MC, M23C6, and M6C carbides is explored in order to achieve satisfactory compositional information. Proximity histograms and correlating concentration difference profiles determine the interface location, where a Gibbs dividing surface is not accessible. This enables reliable direct calculation of the interfacial excess across phase boundaries. Intuitively interpretable and quantitative 'interface plots' are introduced, and showcased for phase boundaries between γ-matrix, γ' precipitates, GB-γ', MC, M23C6, and M6C carbides. The presented framework advances access to the local composition in proximity to grain boundaries and may be applicable to other engineering alloys or materials with functional properties.

Ideal plasticity and shape memory of nanolamellar high-entropy alloys

Understanding the relationship among elemental compositions, nanolamellar microstructures, and mechanical properties enables the rational design of high-entropy alloys (HEAs). Here, we construct nanolamellar AlxCoCuFeNi HEAs with alternating high- and low-Al concentration layers and explore their mechanical properties using a combination of molecular dynamic simulation and density functional theory calculation. Our results show that the HEAs with nanolamellar structures exhibit ideal plastic behavior during uniaxial tensile loading, a feature not observed in homogeneous HEAs. This remarkable ideal plasticity is attributed to the unique deformation mechanisms of phase transformation coupled with dislocation nucleation and propagation in the high-Al concentration layers and the confinement and slip-blocking effect of the low-Al concentration layers. Unexpectedly, this ideal plasticity is fully reversible upon unloading, leading to a remarkable shape memory effect. Our work highlights the importance of nanolamellar structures in controlling the mechanical and functional properties of HEAs and presents a fascinating route for the design of HEAs for both functional and structural applications.

In Situ Study of the Microstructural Evolution of Nickel-Based Alloy with High Proportional Twin Boundaries Obtained by High-Temperature Annealing

In this paper, we report an in situ study regarding the microstructural evolution of a nickel-based alloy with high proportional twin boundaries by using electron backscatter diffraction techniques combined with the uniaxial tensile test. The study mainly focuses on the evolution of substructure, geometrically necessary dislocation, multiple types of grain boundaries (especially twin boundaries), and grain orientation. The results show that the Cr20Ni80 alloy can be obtained with up to 73% twin boundaries by annealing at 1100 °C for 30 min. During this deformation, dislocations preferentially accumulate near the twin boundary, and the strain also localizes at the twin boundary. With the increasing strain, dislocation interaction with grain boundaries leads to a decreasing trend of twin boundaries. However, when the strain is 0.024, the twin boundary is found to increase slightly. Meanwhile, the grain orientation gradually rotates to a stable direction and forms a Copper, S texture, and α-fiber <110>. Above all, during this deformation process, the alloy is deformed mainly by two deformation mechanisms: mechanical twinning and dislocation slip.

Transient Liquid Phase Diffusion Bonding of Ni3Al Superalloy with Low-Boron Nickel-Base Powder Interlayer

As a technology for micro-deformed solid-phase connection, transient liquid phase (TLP) diffusion bonding plays a key role in the manufacture of heating components of aero engines. However, the harmful brittle phase and high hardness limit the application of TLP diffusion bonding in nickel-based superalloys. In this paper, a new strategy in which a low-boron and high-titanium interlayer can restrain the brittle phase and reduce the hardness of the TLP-diffusion-bonded joint is proposed. With this strategy, the Ni₃Al joint can achieve a high strength of 860.84 ± 26.9 MPa under conditions of 1250 °C, 6 h and 5 MPa. The microhardness results show that the average microhardness of the joint area is 420.33 ± 3.15 HV and is only 4.3% higher than that of the Ni₃Al base material, which proves that this strategy can effectively inhibit the formation of the harmful brittle phase in the joint area. The results of EBSD show that 7.7% of the twin boundaries exist in the isothermal solidification zone, and only small amounts of secondary precipitates are observed at the grain boundaries in the joint, which indicates that twin boundaries may play a dominant role in crack initiation. This study provides a feasible avenue to suppress the brittle phase in TLP-diffusion-bonded joints.

First-principles insights into hydrogen trapping in interstitial-vacancy complexes in vanadium carbide

Hydrogen trapping is a key factor in designing advanced vanadium alloys and steels, where the influence of carbon vacancies is still elusive. Herein we have investigated the effect of carbon vacancies on the hydrogen trapping of defect-complexes in vanadium carbide using first-principles calculations. When a carbon vacancy is present, the second nearest neighboring trigonal interstitial is a stable hydrogen trapping site. A C vacancy enhances the hydrogen trapping ability by reducing the chemical and mechanical effects on H atom solution energy. Electronic structure analysis shows that C vacancies increase the charge density and the Bader atomic volume, leading to a lower H atom solution energy. The strength of the V-H bond is predominant in determining the hydrogen trapping ability in the presence of a C vacancy, in contrast to that of a C-H bond when the C vacancy is absent.

Phase Volume Fraction-Dependent Strengthening in a Nano-Laminated Dual-Phase High-Entropy Alloy

A recently synthesized FCC/HCP nano-laminated dual-phase (NLDP) CoCrFeMnNi high entropy alloy (HEA) exhibits excellent strength-ductility synergy. However, the underlying strengthening mechanisms of such a novel material is far from being understood. In this work, large-scale atomistic simulations of in-plane tension of the NLDP HEA are carried out in order to explore the HCP phase volume fraction-dependent strengthening. It is found that the dual-phase (DP) structure can significantly enhance the strength of the material, and the strength shows apparent phase volume fraction dependence. The yield stress increases monotonously with the increase of phase volume fraction, resulting from the increased inhibition effect of interphase boundary (IPB) on the nucleation of partial dislocations in the FCC lamella. There exists a critical phase volume fraction, where the flow stress is the largest. The mechanisms for the volume fraction-dependent flow stress include volume fraction-dependent phase strengthening effect, volume fraction-dependent IPB strengthening effect, and volume fraction-dependent IPB softening effect, that is, IPB migration and dislocation nucleation from the dislocation-IPB reaction sites. This work can provide a fundamental understanding for the physical mechanisms of strengthening effects in face-centered cubic HEAs with a nanoscale NLDP structure.