Coherent Precipitation and Strengthening in Compositionally Complex Alloys: A Review

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.

The Effect of Lattice Misfits on the Precipitation at Dislocations: Phase-Field Crystal Simulation

An atomic-scale approach was employed to simulate the formation of precipitates with different lattice misfits in the early stages of the aging of supersaturated aluminum alloys. The simulation results revealed that the increase in lattice misfits could significantly promote the nucleation rate of precipitates, which results in a larger number and smaller size of the precipitates. The morphologies of the precipitates also vary with the degree of a lattice misfit. Moreover, the higher the lattice misfit, the earlier the nucleation of the second phase occurs, which can substantially inhibit the movement of dislocations. The research on the lattice misfit of precipitation can provide theoretical guidance for the design of high-strength aluminum alloys.

The enhancement of mechanical properties and uniform degradation of electrodeposited Fe-Zn alloys by multilayered design for biodegradable stent applications

Pure Fe is a potential biodegradable stent material due to its better biocompatibility and mechanical properties, but its degradation rate needs to be improved. Alloying with Zn to form Fe-Zn alloy is anticipated to meet the degradation rate requirements while retaining the iron's inherent properties. Therefore, Fe-Zn alloys with monolayered and multilayered structures were prepared by electrodeposition. The alloys' composition, microstructure, mechanical properties, in vitro degradation and biocompatibility were assessed. Results showed that the Zn content ranged from 2.1 wt% to 11.6 wt%. After annealing at 450°C, all the alloys consisted of α(Fe) solid solution and Zn-rich B2 ordered coherent phase, except for the alloy with 11.6 wt% Zn content, in which a Fe₃Zn₁₀ phase appeared. The layered structure consisted of alternating columnar-grain and nano-grain layers, which compensated for the intrinsic brittleness of electrodeposited metals and improved the galvanic effect of the alloy, thus increasing the strength and plasticity and changing the corrosion from localized to uniform while augmenting the corrosion rate. The yield strength of the multilayered alloy exceeded 350 MPa, its elongation was more than 20%, and its corrosion rate obtained by immersion test in Hank's solution reached 0.367 mm·y^-1. Fe-Zn alloys with lower Zn content had good cytocompatibility with the human umbilical vein endothelial cells and good blood compatibility. The above results verified that the multilayered Fe-Zn alloy prepared by electrodeposition presented enhanced mechanical properties, higher degradation rate, uniform degradation mechanism and good biocompatibility. It should be qualified for the application of biodegradable stents. STATEMENT OF SIGNIFICANCE: A potential biodegradable Fe-Zn alloy, which is difficult to be obtained by the metallurgical method, was prepared by electrodeposition to solve the low degradation rate of iron-based biomaterials. A multilayered microstructure design composed of alternating columnar-grain and nano-grain layers was achieved by changing the electrical parameters. The layered design compensated for the intrinsic poor plasticity of electrodeposited metals. It increased the galvanic effect of the alloy, thus augmenting the corrosion rate and changing the corrosion mode of the alloy from localized to uniform corrosion. The yield strength of multilayered alloy exceeded 350 MPa; its elongation was more than 20%. Moreover, the layered alloy had good cytocompatibility and blood compatibility. It indicates that the alloy is qualified for biodegradable stent application.

Atomic-Scale Insights into the Deformation Mechanism of the Microstructures in Precipitation-Strengthening Alloys

Clarifying the deformation behaviors of microstructures could greatly help us understand the precipitation-strengthening mechanism in alloys. However, it is still a formidable challenge to study the slow plastic deformation of alloys at the atomic scale. In this work, the phase-field crystal method was used to investigate the interactions between precipitates, grain boundary, and dislocation during the deformation processes at different degrees of lattice misfits and strain rates. The results demonstrate that the pinning effect of precipitates becomes increasingly strong with the increase of lattice misfit at relatively slow deformation with a strain rate of 10^-4. The cut regimen prevails under the interaction between coherent precipitates and dislocations. In the case of a large lattice misfit of 19.3%, the dislocations tend to move toward the incoherent phase interface and are absorbed. The deformation behavior of the precipitate-matrix phase interface was also investigated. Collaborative deformation is observed in coherent and semi-coherent interfaces, while incoherent precipitate deforms independently of the matrix grains. The faster deformations (strain rate is 10^-2) with different lattice misfits all are characterized by the generation of a large number of dislocations and vacancies. The results contribute to important insights into the fundamental issue about how the microstructures of precipitation-strengthening alloys deform collaboratively or independently under different lattice misfits and deformation rates.

Formation and thermal stability of two-phase microstructures in Al-containing refractory compositionally complex alloys

Phase separation into an A2+B2 two-phase microstructure in refractory compositionally complex alloys (RCCA) has been speculated as being spinodal in nature with continuous chemical distribution during the separation. However, these reactions might instead occur as precipitation by nucleation and growth. In order to unequivocally elucidate the distinct nature of phase separation sequence in RCCA from the system Ta-Mo-Ti-Cr-Al, atom probe tomography and electron microscopy techniques were utilized on samples that were annealed over multiple orders of magnitude in time. The composition 82(TaMoTi)-8Cr-10Al (at.%) was chosen, as it exhibits a two-phase microstructure, with a desired A2 matrix and embedded B2 phase. Quenching the samples from 1200°C resulted in a microstructure consisting of ordered clusters (2 nm) of distinct chemical composition. Subsequent annealing at 800°C to 1000°C leads to an increase in the volume fraction of the precipitating phase, which saturates after 10 h. Further annealing leads to the ripening of the microstructure; however, the absolute size of the precipitates stays <100 nm even after 1000 h. For the investigated conditions, the interface between matrix and precipitate can be considered sharp within the resolution of the applied techniques and no significant change in the transition of chemical composition across the interface is observed. Therefore, the phase separation mechanism is confirmed to be phase nucleation and growth in contrast to the possible spinodal decomposition, as hypothesized for other RCCA systems. The impact of precipitation and coarsening on the hardness of the alloy is discussed.

Cracking Behavior, Microstructure and Properties of Selective Laser Melted Al-Mn-Mg-Sc-Zr Alloy

In this paper, the cracking of Al-Mn-Mg-Sc-Zr alloys prepared by selective laser melting (SLM) was comprehensively explored and the influence of process parameters on the generation and propagation of cracks was deeply studied. It was found that the higher laser power and volume energy density will lead to a decrease in the relative density of the material. The lower laser power or volume energy density will lead to cracking of the alloy. The microstructure analysis indicated that plenty of manganese-rich second phases precipitated at the bottom of the melt pool, which increased the tendency of cracking occurred at the bottom of the melt pool. Through the optimization of the process parameters, the SLM forming process parameters of the Al-5.22Mn-1.16Mg-0.81Sc-0.46Zr alloy are successfully obtained, and the crack-free tensile samples are prepared. The microstructure and mechanical properties of the as-deposited aluminum-manganese alloy is analyzed. The bottom and inside of the melt pool are equiaxed grains. The size of the equiaxial grains at the bottom of the melt pool is less than 2 μm, and the coarse equiaxial grains inside the melt pool are approximately 5 μm. As-deposited alloy has a room temperature tensile strength of 455.2 ± 0.7 MPa and elongation of 15.4 ± 0.3%. This study provides guidance for selective laser melting forming of high-strength aluminum-manganese alloy parts, and promotes the industrial production of high-strength aluminum alloy near net forming complex parts.

Correlation between the Dendritic Structure and Lattice Parameter of γ′-Phase in Single-Crystalline Turbine Blades Made of Superalloys

The dendritic structure and the distribution of the γ′-phase lattice parameter (a_γ′) along selected lines of the longitudinal section in a model single-crystalline blade made of CMSX-4^® nickel-based superalloy were studied. It was established that there is a correlation between the value of the a_γ′ and the predomination of initial or ending fragments of the secondary dendrite arms. It is most noticed for the areas where the dendrite growth conditions are similar to steady. They are located in the center and near the root’s selector extension (SE) area. The correlation has been related to the dendritic segregation mechanism. It was shown that in the single-crystalline blades obtained by the directional crystallization using a spiral selector, the “walls” of the primary dendrite arms that grow at a low angle to the blade axis are created. It was found for the first time that the value of the lattice parameter a_γ′ is decreased near such “walls”. Additionally, it was found that competitive growth of the dendrites may occur at a distance of even several millimeters from the bottom surface of the root. The first-time applied X-ray diffraction measurements of a_γ′ made in a single-pass along the line allow the analysis of the dendritic segregation in the whole blade cast.

Tailoring Compressive Strength and Absorption Energy of Lightweight Multi-Phase AlCuSiFeX (X = Cr, Mn, Zn, Sn) High-Entropy Alloys Processed via Powder Metallurgy

The development of lightweight HEAs with high strength and low cost is an urgent requirement. In this study, equimolar AlCuSiFeX (X = Cr, Mn, Zn, Sn) lightweight HEAs were fabricated by advanced powder metallurgy. The mechanical alloying was performed for 45 h, and the powder compacts were densified at 650 °C. The final results revealed that AlCuSiFeSn lightweight HEA was composed of a single face-centered cubic (FCC) and Cu₈₁Sn₂₂, whereas AlCuSiFeZn showed a dual FCC and body-centered cubic (BCC) structures. Similarly, AlCuSiFeMn alloy contained a BCC + FCC phase with a µ-phase, whereas a σ-phase was present in AlCuSiFeCr in addition to FCC + BCC phases. We also calculated various thermodynamic parameters to predict the solid-solution phase stability of each of the above lightweight HEAs. It was found that lightweight HEAs with additive elements Sn and Zn tend to predominant FCC phases, whereas those with Cr and Mn result in major BCC with hard µ and σ phases, which further improve their mechanical strength. A maximum fracture strain of 23% was obtained for AlCuSiFeSn followed by 19% for AlCuSiFeZn HEA. The compressive fracture mechanisms of these lightweight HEAs are also discussed and reported here.

Achieving high strength and ductility in ODS-W alloy by employing oxide@W core-shell nanopowder as precursor

With excellent creep resistance, good high-temperature microstructural stability and good irradiation resistance, oxide dispersion strengthened (ODS) alloys are a class of important alloys that are promising for high-temperature applications. However, plagued by a nerve-wracking fact that the oxide particles tend to aggregate at grain boundary of metal matrix, their improvement effect on the mechanical properties of metal matrix tends to be limited. In this work, we employ a unique in-house synthesized oxide@W core-shell nanopowder as precursor to prepare W-based ODS alloy. After low-temperature sintering and high-energy-rate forging, high-density oxide nanoparticles are dispersed homogeneously within W grains in the prepared alloy, accompanying with the intergranular oxide particles completely disappearing. As a result, our prepared alloy achieves a great enhancement of strength and ductility at room temperature. Our strategy using core-shell powder as precursor to prepare high-performance ODS alloy has potential to be applied to other dispersion-strengthened alloy systems.

Aggregation and coarsening of the second-phase oxide particles at grain boundaries have been a bottleneck for improving mechanical properties of oxide-dispersion-strengthened (ODS) alloys. Here the authors employ core-shell nanopowder precursors to achieve uniform dispersion of oxides in ODS alloys.

Composition rules of Ni-base single crystal superalloys and its influence on creep properties via a cluster formula approach

The present work investigated the composition evolution of the TMS series of Ni-base single crystal (SC) superalloys in light of the cluster formula approach systematically. The cluster formula of SC superalloys could be expressed with \documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$${[}\overline{{{\text{Al}}}} {-} \overline{{{\text{Ni}}}} 12{](}\overline{{{\text{Al}}}} {, }\overline{{{\text{Cr}}}} {)}m$$\end{document}[Al¯-Ni¯12](Al¯,Cr¯)m, in which all the alloying elements were classified into three groups, Al series (\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$\overline{{{\text{Al}}}}$$\end{document}Al¯), Cr series (\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$\overline{{{\text{Cr}}}}$$\end{document}Cr¯), and Ni series (\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$\overline{{{\text{Ni}}}}$$\end{document}Ni¯). It was found that the total atom number (Z) of the cluster formula units for TMS series of superalloys varies from Z ~ 17 to Z ~ 15.5, and then to Z ~ 16 with the alloy development from the 1st to the 6th generation, in which the superalloys with prominent creep resistance possess an ideal cluster formula of \documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$${[}\overline{{{\text{Al}}}} {-} \overline{{{\text{Ni}}}} 12{](}\overline{{{\text{Al}}}} 1.5\overline{{{\text{Cr}}}} 1.5{)}$$\end{document}[Al¯-Ni¯12](Al¯1.5Cr¯1.5) with Z = 16. Similar tendency of composition evolution also appears in the PWA and CMSX series of SC superalloys. Typical TMS series of superalloys with prominent creep properties generally exhibit a moderate lattice misfit of γ/γ′ which could render alloys with appropriate particle size of cuboidal γ′ precipitates to acquire a maximum strength increment by precipitation strengthening mechanism. More importantly, the relationship between the lattice misfit (δ) of γ/γ′ and the creep rupture lifetime (t_r) of superalloys was then established, showing a linear correlation in the form of lgt_r–lg|δ|^3/2 at both conditions of 900 °C/392 MPa and 1100 °C/137 MPa. Combined with the lattice misfit, the cluster formula approach would provide a new way to modify or optimize the compositions of Ni-base superalloys for further improvement of creep property.

New Advances in High-Entropy Alloys

Exploring new materials is an eternal pursuit in the development of human civilization [...].

Bragg coherent imaging of nanoprecipitates: role of superstructure reflections

Coherent precipitation of ordered phases is responsible for providing exceptional high-temperature mechanical properties in a wide range of compositionally complex alloys. Ordered phases are also essential to enhance the magnetic or catalytic properties of alloyed nanoparticles. The present work aims to demonstrate the relevance of Bragg coherent diffraction imaging (BCDI) for studying bulk and thin-film samples or isolated nanoparticles containing coherent nanoprecipitates/ordered phases. The structures of crystals of a few tens of nanometres in size are modelled with realistic interatomic potentials and are relaxed after introduction of coherent ordered nanoprecipitates. Diffraction patterns from fundamental and superstructure reflections are calculated in the kinematic approximation and used as input to retrieve the strain fields using algorithmic inversion. First, the case of single nanoprecipitates is tackled and it is shown that the strain field distribution from the ordered phase is retrieved very accurately. Then, the influence of the order parameter S on the strain field retrieved from the superstructure reflections is investigated. A very accurate strain distribution can be retrieved for partially ordered phases with large and inhomogeneous strains. Subsequently, the relevance of BCDI is evaluated for the study of systems containing many precipitates, and it is demonstrated that the technique is relevant for such systems. Finally, the experimental feasibility of using BCDI to image ordered phases is discussed in the light of the new possibilities offered by fourth-generation synchrotron sources.

Magnetic properties of the complex concentrated alloy system CoFeNi0.5Cr0.5Alx

We study the change in magnetisation with paramagnetic Al addition in the CoFeNi0.5Cr0.5-Alx (x: 0, 0.5, 1, and 1.5) complex concentrated alloy. The compositions were developed utilising the Mulliken electronegativity and d-electron/atom ratio. Spherical FeCr rich nanoprecipitates are observed for X: 1.0 and 1.5 in an AlCoNi-rich matrix. A ~ 5 × increase in magnetisation (from 22 to 96 Am2/kg) coincides with this nanoprecipitate formation-the main magnetic contribution is determined to be from FeCr nanoprecipitates. The magnetisation increase is strange as paramagnetic Al addition dilutes the ferromagnetic Fe/Co/Ni additions. In this paper we discuss the magnetic and structural characterisation of the CoFeNi0.5Cr0.5-Alx composition and attempt to relate it to the interfacial energy.