Achieving large uniform tensile ductility in nanocrystalline metals

Uniting tensile ductility with ultrahigh strength via composition undulation

Metals with nanocrystalline grains have ultrahigh strengths approaching two gigapascals. However, such extreme grain-boundary strengthening results in the loss of almost all tensile ductility, even when the metal has a face-centred-cubic structure-the most ductile of all crystal structures^1-3. Here we demonstrate that nanocrystalline nickel-cobalt solid solutions, although still a face-centred-cubic single phase, show tensile strengths of about 2.3 gigapascals with a respectable ductility of about 16 per cent elongation to failure. This unusual combination of tensile strength and ductility is achieved by compositional undulation in a highly concentrated solid solution. The undulation renders the stacking fault energy and the lattice strains spatially varying over length scales in the range of one to ten nanometres, such that the motion of dislocations is thus significantly affected. The motion of dislocations becomes sluggish, promoting their interaction, interlocking and accumulation, despite the severely limited space inside the nanocrystalline grains. As a result, the flow stress is increased, and the dislocation storage is promoted at the same time, which increases the strain hardening and hence the ductility. Meanwhile, the segment detrapping along the dislocation line entails a small activation volume and hence an increased strain-rate sensitivity, which also stabilizes the tensile flow. As such, an undulating landscape resisting dislocation propagation provides a strengthening mechanism that preserves tensile ductility at high flow stresses.

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.

Microscale residual stresses in additively manufactured stainless steel

Additively manufactured (AM) metallic materials commonly possess substantial microscale internal stresses that manifest as intergranular and intragranular residual stresses. However, the impact of these residual stresses on the mechanical behaviour of AM materials remains unexplored. Here we combine in situ synchrotron X-ray diffraction experiments and computational modelling to quantify the lattice strains in different families of grains with specific orientations and associated intergranular residual stresses in an AM 316L stainless steel under uniaxial tension. We measure pronounced tension–compression asymmetries in yield strength and work hardening for as-printed stainless steel, and show they are associated with back stresses originating from heterogeneous dislocation distributions and resultant intragranular residual stresses. We further report that heat treatment relieves microscale residual stresses, thereby reducing the tension–compression asymmetries and altering work-hardening behaviour. This work establishes the mechanistic connections between the microscale residual stresses and mechanical behaviour of AM stainless steel.

The impact of grain-scale residual stresses on the mechanical behaviour of 3D-printed metals and alloys remains unexplored. Here, the authors combine in situ synchrotron X-ray diffraction and computer simulations to link residual stresses in steel to its tensile behaviour.

Comparative Study on Microstructural Stability of Pre-annealed Electrodeposited Nanocrystalline Nickel During Pack Rolling

Microstructural stability is an important issue for nanocrystalline materials to be practically used in many fields. The present work shows how microstructure evolves with rolling strain in pre-annealed electrodeposited nanocrystalline nickel containing an initial strong fiber texture, on the basis of X-ray diffraction line profile analysis as well as transmission electron microscopy observation. The influence of shear strain on microstructural stability of the metal/roll contact interface is compared with that of the metal/metal contact interface; the latter would be closer to deformation in plane strain compression. From the statistical microstructural information, together with experimentally observed microstructure of deformed grains after the final rolling pass, it seems fair to conclude that the microstructure of the metal/metal contact interface is more stable during pack rolling than that of the metal/roll interface.

The Structure and Mechanical Properties of High-Strength Bulk Ultrafine-Grained Cobalt Prepared Using High-Energy Ball Milling in Combination with Spark Plasma Sintering

In this study, bulk ultrafine-grained and micro-crystalline cobalt was prepared using a combination of high-energy ball milling and subsequent spark plasma sintering. The average grain sizes of the ultrafine-grained and micro-crystalline materials were 200 nm and 1 μm, respectively. Mechanical properties such as the compressive yield strength, the ultimate compressive strength, the maximum compressive deformation and the Vickers hardness were studied and compared with those of a coarse-grained as-cast cobalt reference sample. The bulk ultrafine-grained sample showed an ultra-high compressive yield strength that was greater than 1 GPa, which is discussed with respect to the preparation technique and a structural investigation.

Coupled crystal orientation-size effects on the strength of nano crystals

We study the combined effects of grain size and texture on the strength of nanocrystalline copper (Cu) and nickel (Ni) using a crystal-plasticity based mechanics model. Within the model, slip occurs in discrete slip events exclusively by individual dislocations emitted statistically from the grain boundaries. We show that a Hall-Petch relationship emerges in both initially texture and non-textured materials and our values are in agreement with experimental measurements from numerous studies. We find that the Hall-Petch slope increases with texture strength, indicating that preferred orientations intensify the enhancements in strength that accompany grain size reductions. These findings reveal that texture is too influential to be neglected when analyzing and engineering grain size effects for increasing nanomaterial strength.

Viscoelasticity of colloidal polycrystals doped with impurities

We investigate how the microstructure of a colloidal polycrystal influences its linear visco-elasticity. We use thermosensitive copolymer micelles that arrange in water in a cubic crystalline lattice, yielding a colloidal polycrystal. The polycrystal is doped with a small amount of nanoparticles, of size comparable to that of the micelles, which behave as impurities and thus partially segregate in the grain boundaries. We show that the shear elastic modulus only depends on the packing of the micelles and varies neither with the presence of nanoparticles nor with the crystal microstructure. By contrast, we find that the loss modulus is strongly affected by the presence of nanoparticles. A comparison between rheology data and small-angle neutron-scattering data suggests that the loss modulus is dictated by the total amount of nanoparticles in the grain boundaries, which in turn depends on the sample microstructure.

Grain boundary rotations in solids

A new physical mechanism of plastic flow in solids is suggested and theoretically described. The mechanism represents stress-driven rotations of grain boundaries (GBs) in subsurface areas of solids. The stress and energy characteristics of the GB rotations are calculated. In the case of nickel, we find that such rotations are energetically favorable processes in a wide range of GB parameters. Our theory is consistent with the experimental observation [D. Jang and J. R. Greer, Scr. Mater. 64, 77 (2011).] of GB rotations in deformed nanocrystalline nickel nanopillars.

The nanostructured origin of deformation twinning

We have revealed the fundamental embryonic structure of deformation twins using in situ mechanical testing of magnesium single crystals in a transmission electron microscope. This structure consists of an array of twin-related laths on the scale of several nanometers. A computational model demonstrates that this structure should be a generic feature at the incipient stage of deformation twinning when there are correlated nucleation events. Our results shed light on the origin of twinning-induced plasticity and transformation toughening, critical to the development of advanced structural alloys with high strength, ductility, and toughness.