Ideal maximum strengths and defect-induced softening in nanocrystalline-nanotwinned metals

Fatigue behavior of freestanding nickel-molybdenum-tungsten thin films with high-density planar faults

This research addresses the fatigue behavior of freestanding nickel-molybdenum-tungsten (Ni-Mo-W) thin films with high-density planar faults. The as-deposited Ni-Mo-W thin films demonstrate an unprecedented fatigue life, withstanding over a million cycles at a Goodman stress amplitude (Sa,Goodman) of 2190 MPa - nearly 80% of the tensile strength. The texture, columnar grain width, planar fault configuration (spacing and orientation), and tensile strength were unchanged after annealing at 500 °C for 24 hours, and the film endured over 2 × 105 cycles at Sa,Goodman of 1050 MPa. The fatigue life of annealed Ni-Mo-W thin films is comparable to those of nanocrystalline Ni-based alloys, but has deteriorated significantly compared to that of the as-deposited films. The high fatigue strength of Ni-Mo-W thin films is ascribed to extremely dense planar faults suppressing fatigue crack initiation, and planar fault-dislocation interaction and grain boundary plasticity are proposed as mechanisms responsible for the fatigue failure. Provisionally the latter is a more convincing account of the experimental results, in which changes in the grain boundary characteristics after annealing cause higher susceptibility to stress concentration during cyclic loading. The fatigue behavior revealed in this work consolidates the thermal and mechanical reliability of Ni-Mo-W thin films for potential nano-structural applications.

Engineering Reversible Lattice Structure for High-Capacity Co-Free Li-Rich Cathodes with Negligible Capacity Degradation

Co-free Li-rich Mn-based cathode materials are garnering great interest because of high capacity and low cost. However, their practical application is seriously hampered by the irreversible oxygen escape and the poor cycling stability. Herein, a reversible lattice adjustment strategy is proposed by integrating O vacancies and B doping. B incorporation increases TM─O (TM: transition metal) bonding orbitals whereas decreases the antibonding orbitals. Moreover, B doping and O vacancies synergistically increase the crystal orbital bond index values enhancing the overall covalent bonding strength, which makes TM─O octahedron more resistant to damage and enables the lattice to better accommodate the deformation and reaction without irreversible fracture. Furthermore, Mott-Hubbard splitting energy is decreased due to O vacancies, facilitating electron leaps, and enhancing the lattice reactivity and capacity. Such a reversible lattice, more amenable to deformation and forestalling fracturing, markedly improves the reversibility of lattice reactions and mitigates TM migration and the irreversible oxygen redox which enables the high cycling stability and high rate capability. The modified cathode demonstrates a specific capacity of 200 mAh g-1 at 1C, amazingly sustaining the capacity for 200 cycles without capacity degradation. This finding presents a promising avenue for solving the long-term cycling issue of Li-rich cathode.

Phase Engineering of Nanostructural Metallic Materials: Classification, Structures, and Applications

Metallic materials are usually composed of single phase or multiple phases, which refers to homogeneous regions with distinct types of the atom arrangement. The recent studies on nanostructured metallic materials provide a variety of promising approaches to engineer the phases at the nanoscale. Tailoring phase size, phase distribution, and introducing new structures via phase transformation contribute to the precise modification in deformation behaviors and electronic structures of nanostructural metallic materials. Therefore, phase engineering of nanostructured metallic materials is expected to pave an innovative way to develop materials with advanced mechanical and functional properties. In this review, we present a comprehensive overview of the engineering of heterogeneous nanophases and the fundamental understanding of nanophase formation for nanostructured metallic materials, including supra-nano-dual-phase materials, nanoprecipitation- and nanotwin-strengthened materials. We first review the thermodynamics and kinetics principles for the formation of the supra-nano-dual-phase structure, followed by a discussion on the deformation mechanism for structural metallic materials as well as the optimization in the electronic structure for electrocatalysis. Then, we demonstrate the origin, classification, and mechanical and functional properties of the metallic materials with the structural characteristics of dense nanoprecipitations or nanotwins. Finally, we summarize some potential research challenges in this field and provide a short perspective on the scientific implications of phase engineering for the design of next-generation advanced metallic materials.

Autonomous healing of fatigue cracks via cold welding

Fatigue in metals involves gradual failure through incremental propagation of cracks under repetitive mechanical load. In structural applications, fatigue accounts for up to 90% of in-service failure1,2. Prevention of fatigue relies on implementation of large safety factors and inefficient overdesign3. In traditional metallurgical design for fatigue resistance, microstructures are developed to either arrest or slow the progression of cracks. Crack growth is assumed to be irreversible. By contrast, in other material classes, there is a compelling alternative based on latent healing mechanisms and damage reversal4-9. Here, we report that fatigue cracks in pure metals can undergo intrinsic self-healing. We directly observe the early progression of nanoscale fatigue cracks, and as expected, the cracks advance, deflect and arrest at local microstructural barriers. However, unexpectedly, cracks were also observed to heal by a process that can be described as crack flank cold welding induced by a combination of local stress state and grain boundary migration. The premise that fatigue cracks can autonomously heal in metals through local interaction with microstructural features challenges the most fundamental theories on how engineers design and evaluate fatigue life in structural materials. We discuss the implications for fatigue in a variety of service environments.

Efficient machine learning of solute segregation energy based on physics-informed features

Machine learning models solute segregation energy based on appropriate features of segregation sites. Lumping many features together can give a decent accuracy but may suffer the curse of dimensionality. Here, we modeled the segregation energy with efficient machine learning using physics-informed features identified based on solid physical understanding. The features outperform the many features used in the literature work and the spectral neighbor analysis potential features by giving the best balance between accuracy and feature dimension, with the extent depending on machine learning algorithms and alloy systems. The excellence is attributed to the strong relevance to segregation energies and the mutual independence ensured by physics. In addition, the physics-informed features contain much less redundant information originating from the energy-only-concerned calculations in equilibrium states. This work showcases the merit of integrating physics in machine learning from the perspective of feature identification other than that of physics-informed machine learning algorithms.

A nanodispersion-in-nanograins strategy for ultra-strong, ductile and stable metal nanocomposites

Nanograined metals have the merit of high strength, but usually suffer from low work hardening capacity and poor thermal stability, causing premature failure and limiting their practical utilities. Here we report a "nanodispersion-in-nanograins" strategy to simultaneously strengthen and stabilize nanocrystalline metals such as copper and nickel. Our strategy relies on a uniform dispersion of extremely fine sized carbon nanoparticles (2.6 ± 1.2 nm) inside nanograins. The intragranular dispersion of nanoparticles not only elevates the strength of already-strong nanograins by 35%, but also activates multiple hardening mechanisms via dislocation-nanoparticle interactions, leading to improved work hardening and large tensile ductility. In addition, these finely dispersed nanoparticles result in substantially enhanced thermal stability and electrical conductivity in metal nanocomposites. Our results demonstrate the concurrent improvement of several mutually exclusive properties in metals including strength-ductility, strength-thermal stability, and strength-electrical conductivity, and thus represent a promising route to engineering high-performance nanostructured materials.

Dislocation exhaustion and ultra-hardening of nanograined metals by phase transformation at grain boundaries

The development of high-strength metals has driven the endeavor of pushing the limit of grain size (d) reduction according to the Hall-Petch law. But the continuous grain refinement is particularly challenging, raising also the problem of inverse Hall-Petch effect. Here, we show that the nanograined metals (NMs) with d of tens of nanometers could be strengthened to the level comparable to or even beyond that of the extremely-fine NMs (d ~ 5 nm) attributing to the dislocation exhaustion. We design the Fe-Ni NM with intergranular Ni enrichment. The results show triggering of structural transformation at grain boundaries (GBs) at low temperature, which consumes lattice dislocations significantly. Therefore, the plasticity in the dislocation-exhausted NMs is suggested to be dominated by the activation of GB dislocation sources, leading to the ultra-hardening effect. This approach demonstrates a new pathway to explore NMs with desired properties by tailoring phase transformations via GB physico-chemical engineering.

Strengthening of metals by grain refinement is limited by the inverse Hall-Petch effect. Here, the authors show nanograined metals can be strengthened by exhausting lattice dislocations via triggering of phase transformation at grain boundaries, instead of further grain refinement.

Hierarchical twinning governed by defective twin boundary in metallic materials

Dense networks of deformation twins endow metals and alloys with unprecedented mechanical properties. However, the formation mechanism of these hierarchical twin structures remains under debate, especially their relations with the imperfect nature of twin boundaries (TBs). Here, we investigate the intrinsic deformability of defective TBs in face-centered cubic metallic materials, where the inherent kinks on a set of primary TBs are demonstrated to facilitate the formation of secondary and hierarchical nanotwins. This defect-driven hierarchical twinning propensity is critically dependent on the kink height, which proves to be generally applicable in a variety of metals and alloys with low stacking fault energies. As a geometric extreme, a fivefold twin can be constructed via this self-activated hierarchical twinning mechanism. These findings differ from the conventional twinning mechanisms, enriching our understanding of twinning-mediated plasticity in metallic materials.

Enhancing strength and ductility via crystalline-amorphous nanoarchitectures in TiZr-based alloys

Crystalline-amorphous composite have the potential to achieve high strength and high ductility through manipulation of their microstructures. Here, we fabricate a TiZr-based alloy with micrometer-size equiaxed grains that are made up of three-dimensional bicontinuous crystalline-amorphous nanoarchitectures (3D-BCANs). In situ tension and compression tests reveal that the BCANs exhibit enhanced ductility and strain hardening capability compared to both amorphous and crystalline phases, which impart ultra-high yield strength (~1.80 GPa), ultimate tensile strength (~2.3 GPa), and large uniform ductility (~7.0%) into the TiZr-based alloy. Experiments combined with finite element simulations reveal the synergetic deformation mechanisms; i.e., the amorphous phase imposes extra strain hardening to crystalline domains while crystalline domains prevent the premature shear localization in the amorphous phases. These mechanisms endow our material with an effective strength-ductility-strain hardening combination.

Improving the oxygen redox reversibility of Li-rich battery cathode materials via Coulombic repulsive interactions strategy

The oxygen redox reaction in lithium-rich layered oxide battery cathode materials generates extra capacity at high cell voltages (i.e., >4.5 V). However, the irreversible oxygen release causes transition metal (TM) dissolution, migration and cell voltage decay. To circumvent these issues, we introduce a strategy for tuning the Coulombic interactions in a model Li-rich positive electrode active material, i.e., Li1.2Mn0.6Ni0.2O2. In particular, we tune the Coulombic repulsive interactions to obtain an adaptable crystal structure that enables the reversible distortion of TMO6 octahedron and mitigates TM dissolution and migration. Moreover, this strategy hinders the irreversible release of oxygen and other parasitic reactions (e.g., electrolyte decomposition) commonly occurring at high voltages. When tested in non-aqueous coin cell configuration, the modified Li-rich cathode material, combined with a Li metal anode, enables a stable cell discharge capacity of about 240 mAh g-1 for 120 cycles at 50 mA g-1 and a slower voltage decay compared to the unmodified Li1.2Mn0.6Ni0.2O2.

A Pragmatic Perspective of the Antibacterial Properties of Metal-Based Nanoparticles

A consideration of the antibacterial efficacy of metal-based nanoparticles, from the point of view of their physicochemical properties, suggests that such efficacy arises from the protein coronas that form around them, and that the contents of the coronas depend on the chemical groups found on the nanoparticle surfaces. We offer a new perspective and new insights, making use of our earlier observations of the physicochemical properties of nanoparticle surfaces, to propose that the nanoparticle serves as a mediator for the formation and activation of the protein corona, which attacks the bacterium. That is, the nanoparticle enhances the body’s natural defenses, using proteins present in body fluids.

Revealing extreme twin-boundary shear deformability in metallic nanocrystals

Metals containing abundant coherent twin boundaries (TBs) are able to sustain substantial plastic deformation without fracture due to shear-induced TB migration and sliding. Retaining ductility in these metals, however, has proven difficult because detwinning rapidly exhausts TB migration mechanisms at large deformation, whereas TB sliding was only evidenced for loading on very specific crystallographic orientations. Here, we reveal the intrinsic shear deformability of twins in nanocrystals using in situ nanomechanical testing and multiscale simulations and report extreme shear deformability through TB sliding up to 364%. Sliding-induced plasticity is manifested for orientations that are generally predicted to favor detwinning and shown to depend critically on geometric inhomogeneities. Normal and shear coupling are further examined to delineate a TB orientation-dependent transition from TB sliding to TB cracking. These dynamic observations reveal unprecedented mechanical properties in nanocrystals, which hold implications for improving metal processing by severe plastic deformation.

Olivine Crystal Structure-Directed Twinning in Iron Germanium Sulfide (Fe2GeS4) Nanoparticles

Understanding the microstructure of complex crystal structures is critical for controlling material properties in next-generation devices. Synthetic reports of twinning in bulk and nanostructured crystals with detailed crystallographic characterization are integral for advancing systematic studies of twinning phenomena. Herein, we report a synthetic route to controllably twinned olivine nanoparticles. Microstructural characterization of Fe₂GeS₄ nanoparticles via electron microscopy (imaging, diffraction, and crystallographic analysis) demonstrates the formation of triplets of twins, or trillings. We establish synthetic control over the particle crystallinity and crystal growth. We describe the geometrical basis for twin formation, hexagonal pseudosymmetry of the orthorhombic lattice, and rank all of the reported olivine compounds according to this favorability to form twins. The work in this study highlights an area ripe for future exploration with respect to the advancement of solution-phase synthetic approaches that can control microstructure in compositionally complex, technologically relevant structures. Finally, we discuss the potential implications for olivine properties and performance in various applications.

Bulk Nanostructured Metal from Multiply-Twinned Nanowires

Using chemically synthesized silver nanowires with 5-fold twinning planes as a model system, a bottom-up process to generate a bulk nanostructured metal has been demonstrated. Although the nanowires would be shortened and deformed during densification, they are chosen as a model system because they are currently the most scalable and convenient way to obtain Ag particles with high twinning densities. Direct cold pressing of a silver nanowire filter cake did not generate a sufficiently cohesive sample, while hot pressing at 190 °C for 8 h resulted in extensive sintering, eliminating the nanowire morphology. Copper was then electroplated on the silver nanowires as a binder and filler to increase the densification upon hot pressing; despite nonuniform plating across the thickness of the filter cake, the thermal stability of the nanowires was increased, allowing hot pressing at 390 °C. Finally, a uniform copper coating on silver nanowires was achieved by electroless plating, leading to cohesive bulk metal after hot pressing.

Ultrastrong nanotwinned pure nickel with extremely fine twin thickness

The strength of nanocrystalline and nanotwinned metals stops increasing or even starts decreasing when their grain size or twin thickness is below a critical size-a phenomenon known as Hall-Petch breakdown-which hinders the attainment of ultrahigh strength. Here, we report continuous strengthening in nanotwinned pure Ni with twin thicknesses ranging from 81.0 to 2.9 nm. An unprecedented strength of 4.0 GPa was achieved at extremely fine twin thickness of 2.9 nm, which is about 12 times stronger than that of conventional coarse-grained nickel. This ultrahigh strength arises from the excellent stability of twin boundaries and their strong impedance to dislocation motion. In particular, we find that secondary nanotwins are activated to sustain plastic deformation, which also contribute to the high strength. These results not only advance the understanding of the strengthening mechanisms in nanotwinned metals but also offer an alternative pathway to develop engineering materials with ultrahigh strength.

Grain polydispersity and coherent crystal reorientations are features to foster stress hotspots in polycrystalline alloys under load

The mechanical properties of metallic alloys are controlled through the design of their polycrystalline structure via heat treatments. For single-phase microstructures, they aim to achieve a particular average grain diameter to leverage stress hardening or softening. The stochastic nature of the recrystallization process generates a grain size distribution, and the randomness of the crystallographic orientation determines the anisotropy of a mechanical response. We developed a multiscale computational formalism to capture the collective mechanical response of polycrystalline microstructures at unprecedented length scales. We found that for an averaged grain size, the mechanical response is highly dependent on the grain size distribution. The simulations reveal the topological conditions that promote coherent grain texturization and grain growth inhibition during stress relaxation. We identify the microstructural features that are responsible for the appearance of stress hotspots. Our results provide the elusive evidence of how stress hotspots are ideal precursors for plastic and creep failure.

Antimicrobial Properties of the Ag, Cu Nanoparticle System

Microbes, including bacteria and fungi, easily form stable biofilms on many surfaces. Such biofilms have high resistance to antibiotics, and cause nosocomial and postoperative infections. The antimicrobial and antiviral behaviors of Ag and Cu nanoparticles (NPs) are well known, and possible mechanisms for their actions, such as released ions, reactive oxygen species (ROS), contact killing, the immunostimulatory effect, and others have been proposed. Ag and Cu NPs, and their derivative NPs, have different antimicrobial capacities and cytotoxicities. Factors, such as size, shape and surface treatment, influence their antimicrobial activities. The biomedical application of antimicrobial Ag and Cu NPs involves coating onto substrates, including textiles, polymers, ceramics, and metals. Because Ag and Cu are immiscible, synthetic AgCu nanoalloys have different microstructures, which impact their antimicrobial effects. When mixed, the combination of Ag and Cu NPs act synergistically, offering substantially enhanced antimicrobial behavior. However, when alloyed in Ag-Cu NPs, the antimicrobial behavior is even more enhanced. The reason for this enhancement is unclear. Here, we discuss these results and the possible behavior mechanisms that underlie them.

Defect-driven selective metal oxidation at atomic scale

Nanoscale materials modified by crystal defects exhibit significantly different behaviours upon chemical reactions such as oxidation, catalysis, lithiation and epitaxial growth. However, unveiling the exact defect-controlled reaction dynamics (e.g. oxidation) at atomic scale remains a challenge for applications. Here, using in situ high-resolution transmission electron microscopy and first-principles calculations, we reveal the dynamics of a general site-selective oxidation behaviour in nanotwinned silver and palladium driven by individual stacking-faults and twin boundaries. The coherent planar defects crossing the surface exhibit the highest oxygen binding energies, leading to preferential nucleation of oxides at these intersections. Planar-fault mediated diffusion of oxygen atoms is shown to catalyse subsequent layer-by-layer inward oxide growth via atomic steps migrating on the oxide-metal interface. These findings provide an atomistic visualization of the complex reaction dynamics controlled by planar defects in metallic nanostructures, which could enable the modification of physiochemical performances in nanomaterials through defect engineering.

Crystal defects critically influence surface chemical reactions in nanomaterials, yet the basic mechanisms at play are still elusive. Here, the authors show the atomic-scale dynamics of surface oxidation at coherent planar defects in Ag and Pd, revealing how twins and stacking-faults selectively oxidize metallic nanocrystals.

Epitaxial nanotwinned metals and alloys: synthesis-twin structure–property relations

Recent works of epitaxial nanotwinned metals and alloys with different stacking fault energies are reviewed to elaborate the relationship among synthesis conditions, intrinsic factors, twin structure and various properties.

Ultimate Strength of Nanotwinned Face-Centered Cubic Metals

In this work, we present a theoretical model to predict the ultimate strength of nanotwinned face-centered cubic (fcc) metals based on the activation energy for phase transformation (i.e., between the matrix and the twinned counterpart) mediated by the migration of {112}-type step on Σ3(111) twin boundaries. By integrating the Hall-Petch strengthening and grain boundary sliding into this model, we can accurately predict the strength of four representative nanotwinned (nt) fcc metals (nt-Cu, nt-Ag, nt-Ni, and nt-Al) within a broad range of grain sizes including the so-called nanocrystalline-nanotwinned regime. This framework is built on material parameters which directly connect the theoretical calculations with experimental measurements and reveals new insights into the design of ultrastrong metals and alloys.