Challenges and Opportunities for Integrating Dealloying Methods into Additive Manufacturing

Elucidating the Transition of 3D Morphological Evolution of Binary Alloys in Molten Salts with Metal Ion Additives

Molten salts serve as effective high-temperature heat transfer fluids and thermal storage media used in a wide range of energy generation and storage facilities, including concentrated solar power plants, molten salt reactors and high-temperature batteries. However, at the salt-metal interfaces, a complex interplay of charge-transfer reactions involving various metal ions, generated either as fission products or through corrosion of structural materials, takes place. Simultaneously, there is a mass transport of ions or atoms within the molten salt and the parent alloys. The precise physical and chemical mechanisms leading to the diverse morphological changes in these materials remain unclear. To address this knowledge gap, this work employed a combination of synchrotron X-ray nanotomography and electron microscopy to study the morphological and chemical evolution of Ni-20Cr in molten KCl-MgCl2, while considering the influence of metal ions (Ni2+, Ce3+, and Eu3+) and variations in salt composition. Our research suggests that the interplay between interfacial diffusivity and reactivity determines the morphological evolution. The summary of the associated mass transport and reaction processes presented in this work is a step forward toward achieving a fundamental comprehension of the interactions between molten salts and alloys. Overall, the findings offer valuable insights for predicting the diverse chemical and structural alterations experienced by alloys in molten salt environments, thus aiding in the development of protective strategies for future applications involving molten salts.

Deep Eutectic Solvent-Assisted Corrosion Boosting Bulk FeCoNiCrMo High-Entropy Alloys as Highly Efficient Oxygen Evolution Reaction Catalyst

The key to enhancing water electrolysis efficiency lies in selecting highly efficient catalysts. Currently, high-entropy alloys (HEAs) are utilized in electrocatalysis applications owing to their diverse elemental composition, disordered elemental distribution, and the high solubility of each element, endowing them with excellent catalytic performance. The experiments were conducted using isoatomic FeNiCrMo HEA as a precursor, with a high-activity three-dimensional nanoporous structure rapidly synthesized via electrochemical one-step dealloying in a choline chloride-thiourea (ChCl-TU) deep eutectic solvent (DES). The results indicate that the dealloyed Fe20Co20Ni20Cr20Mo20 HEA mainly consists of two phases: face-centered cubic and σ phases. The imbalance in the distribution of elements in these two phases leads to quite different corrosion speeds with the FCC phase being preferentially corroded. Furthermore, synergistic electron coupling between surface atoms in the three-dimensional nanoporous structure strengthens the behavior of the oxygen evolution reaction (OER). At a current density of 40 mA cm-2, the overpotential after dealloying decreased to 370 mV, demonstrating excellent stability. The technique demonstrated in this work provides a novel approach to improve the catalytic activity of OER.

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.

Evolution of micro-pores in Ni-Cr alloys via molten salt dealloying

Porous materials with high specific surface area, high porosity, and high electrical conductivity are promising materials for functional applications, including catalysis, sensing, and energy storage. Molten salt dealloying was recently demonstrated in microwires as an alternative method to fabricate porous structures. The method takes advantage of the selective dissolution process introduced by impurities often observed in molten salt corrosion. This work further investigates molten salt dealloying in bulk Ni-20Cr alloy in both KCl-MgCl2 and KCl-NaCl salts at 700 ℃, using scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction (XRD), as well as synchrotron X-ray nano-tomography. Micro-sized pores with irregular shapes and sizes ranging from sub-micron to several microns and ligaments formed during the process, while the molten salt dealloying was found to progress several microns into the bulk materials within 1-16 h, a relatively short reaction time, enhancing the practicality of using the method for synthesis. The ligament size increased from ~ 0.7 μm to ~ 1.3 μm in KCl-MgCl2 from 1 to 16 h due to coarsening, while remaining ~ 0.4 μm in KCl-NaCl during 16 h of exposure. The XRD analysis shows that the corrosion occurred primarily near the surface of the bulk sample, and Cr2O3 was identified as a corrosion product when the reaction was conducted in an air environment (controlled amount sealed in capillaries); thus surface oxides are likely to slow the morphological coarsening rate by hindering the surface diffusion in the dealloyed structure. 3D-connected pores and grain boundary corrosion were visualized by synchrotron X-ray nano-tomography. This study provides insights into the morphological and chemical evolution of molten salt dealloying in bulk materials, with a connection to molten salt corrosion concerns in the design of next-generation nuclear and solar energy power plants.

Electroless Dealloying of Thin-Film Nanocrystalline Au-Ag Alloys: Mechanisms of Ligament Nucleation and Sources of Its Synthesis Variability

Control of ligament size in nanoporous gold through process inputs in chemical dealloying holds the potential to exploit its size dependent properties in applications in energy and biomedicine. While its morphology evolution is regulated by the kinetics of coarsening, recent studies are focused on the early stage of dealloying (e.g., ∼ 5-42 at. % in residual alloy content) to understand mechanisms of ligament nucleation and its role in altering process-structure relationships. This paper examines this stage in chemical dealloying of nanocrystalline Au₄₉Ag₅₁ thin films and finds that ligaments are nucleated uniformly through its thickness due to the dealloying front rapidly propagating through the thickness of the film. Further, through the establishment of process-structure relationships with large data sets (i.e., 80 samples), this paper quantifies sources of variability that alter the kinetics of ligament growth such as aging of the precursor (e.g., grain growth) and solution evaporation. It is found that ligament diameter is better predicted by the residual silver content rather than by the dealloying time even amidst both effects and independent control of ligament diameter and solid area fraction is demonstrated within a limited window.

Recent Advancements in the Fabrication of Functional Nanoporous Materials and Their Biomedical Applications

Functional nanoporous materials are categorized as an important class of nanostructured materials because of their tunable porosity and pore geometry (size, shape, and distribution) and their unique chemical and physical properties as compared with other nanostructures and bulk counterparts. Progress in developing a broad spectrum of nanoporous materials has accelerated their use for extensive applications in catalysis, sensing, separation, and environmental, energy, and biomedical areas. The purpose of this review is to provide recent advances in synthesis strategies for designing ordered or hierarchical nanoporous materials of tunable porosity and complex architectures. Furthermore, we briefly highlight working principles, potential pitfalls, experimental challenges, and limitations associated with nanoporous material fabrication strategies. Finally, we give a forward look at how digitally controlled additive manufacturing may overcome existing obstacles to guide the design and development of next-generation nanoporous materials with predefined properties for industrial manufacturing and applications.

Design nanoporous metal thin films via solid state interfacial dealloying

Thin-film solid-state interfacial dealloying (thin-film SSID) is an emerging technique to design nanoarchitecture thin films. The resulting controllable 3D bicontinuous nanostructure is promising for a range of applications including catalysis, sensing, and energy storage. Using a multiscale microscopy approach, we combine X-ray and electron nano-tomography to demonstrate that besides dense bicontinuous nanocomposites, thin-film SSID can create a very fine (5-15 nm) nanoporous structure. Not only is such a fine feature among one of the finest fabrications by metal-agent dealloying, but a multilayer thin-film design enables creating nanoporous films on a wider range of substrates for functional applications. Through multimodal synchrotron diffraction and spectroscopy analysis with which the materials' chemical and structural evolution in this novel approach is characterized in details, we further deduce that the contribution of change in entropy should be considered to explain the phase evolution in metal-agent dealloying, in addition to the commonly used enthalpy term in prior studies. The discussion is an important step leading towards better explaining the underlying design principles for controllable 3D nanoarchitecture, as well as exploring a wider range of elemental and substrate selections for new applications.