Coarse Grain Research Articles

Surface mechanical rolling treatment-introduced gradient nanostructured Inconel 625 alloy with enhanced high-temperature wear resistance

Heterogeneous gradient nanostructures induced through surface treatment of nickel-based superalloys hold significant promise for enhancing wear resistance. In this study, a 700 µm ultra-thick gradient nanostructured (GNS) strengthening layer was fabricated on the surface of an Inconel 625 alloy plate via surface mechanical rolling treatment (SMRT). Subsequently, the tribological behaviors and wear resistance mechanisms of coarse-grained (CG) and GNS samples at temperatures ranging from 25 ℃ to 800 ℃ were comparatively investigated. The results indicated that the gradient nanostructures significantly enhanced the high-temperature wear resistance of the samples, which wear characterized by low coefficient of friction (COF), wear rate and thin friction layer. This enhancement was attributable to the stability and excellent hot hardness of the gradient nanostructures during friction.

Induction assisted autogenous plasma arc welding of HSLA steel

In this work, a high frequency induction heating (HFIH) assisted plasma arc welding (IPAW) technique is proposed to weld 6 mm thick S690QL high strength low alloy steel plates in square butt joint configuration and without using any filler material. A 3D finite element based coupled electromagnetic-thermal analysis is carried out to ascertain the weld's thermal characteristics. Microstructure evolution and mechanical performance are investigated using scanning electron microscopy, electron back scattered diffraction, transmission electron microscopy, tensile test, Charpy impact test and micro hardness test. The results demonstrate that 15 s initial static heating using a co-directional current coil with magnetic flux concentrator predominantly improves the weld penetration by 48 % and joint efficiency reaches 90 % to the base plate strength. Microstructural study shows that the addition of HFIH promotes low angle grain boundaries (LAGB) with bainite ferrite and granular bainite micro-constituents in the fusion zone, which causes localised yielding and failure in this zone during tensile test. Further investigation reveals that the HFIH encourages the formation of BI-type bainite ferrite laths of 1.3–2.2 μm width, combined with slender martensite-austenite (M-A) island at the bainite ferrite lath boundaries. The results also reveal that the induction heating promotes the formation of M23C6 precipitates and B2 structured Cu-enrich nano precipitates in the fusion zone (FZ). The microhardness distribution indicates that the FZ and coarse grain heat affected zone are significantly reduced due to the assistance of the HFIH. The impact test result shows a lower energy absorption by the IPAW weldments due to dominance of the LAGB with unfavourable strain distribution.

Competition between microstructural factors affecting growth of abnormally large grains in thin Cu foils

Grain boundary types and local boundary curvatures are generally considered to be important microstructural factors controlling grain boundary migration during grain growth. In this work, grain growth in thin copper foils is studied during annealing at a temperature of 1040 °C near the melting point by ex-situ experiments and Monte Carlo simulations. Few grains, stimulated by slight deformation at the sample edge, are observed to grow abnormally into the cube-oriented recrystallized microstructure with columnar grains spanning the foil thickness. The grain boundaries of these abnormally growing grains and the grain sizes in the adjacent polycrystalline recrystallized regions are analyzed. The experimental results suggest that spatial heterogeneities in the distribution of small recrystallized grains have a significant effect on the migrating boundaries. Potts model simulations confirm that grain boundary segments with small grains in front are more likely to migrate than segments facing coarser grains. The simulations also demonstrate the importance of grain morphology. Altogether, this work highlights the effects of a heterogeneous recrystallized microstructure on abnormal grain growth in thin foil samples.

An investigation of the microstructure and properties of rolled W-Al2O3 alloy

Pure tungsten and tungsten alloys have been widely used in metallurgy, energy, chemical industry, aerospace, national defense, electronics and other fields. However, there are inevitably some problems in the use of the process, such as high deformation resistance in the forming process prone to crack and fracture, coarse grain and low bending strength problems. Al2O3 particles were added to improve the comprehensive properties of tungsten alloys. In this paper, the W-0.2 wt%Al2O3 tungsten alloy sheets with different thicknesses of 3 mm, 2 mm, and 1 mm were prepared by induction sintering combined with hot rolling. For comparison, the pure tungsten sheet with a thickness of 3 mm was fabricated by the same preparation process. Comparative assessments were made on the microstructure, hardness, and three-point bending properties across types of three thicknesses of W-Al2O3 sheets and pure tungsten sheet with a thickness of 3 mm. The outcomes demonstrate that the microstructure and properties of the tungsten alloy vary considerably depending on the applied rolling degree, which exerts a profound impact on the grain size, morphology, and distribution within the tungsten alloy matrix. Furthermore, the tungsten alloy consistently exhibits significant enhancements over pure tungsten. Characterization of the rolled tungsten alloy revealed that the incorporation of alumina contributes to a reduction in shear band formation and an improvement in texture strength, thereby substantiating its positive impact on the overall mechanical properties of the alloy.

Effect of Extrusion Ratio on Mechanical Behavior and Microstructure Evolution of 7003 Aluminum Alloy at High-Speed Impact.

The extrusion ratio (ER) is one of the most important factors affecting the service performance of aluminum profiles. In this study, the influence of ER on the mechanical behavior and microstructure evolution of 7003 aluminum alloy at high-speed impact with strain rates ranging from 700 s-1 to 1100 s-1 was investigated. The studied alloy with an ER of 56 formed coarse grain rings during the heat treatment. The microstructure of the alloys with ERs of 20 and 9 is relatively uniform. The results indicate that under high-speed impact, the mechanical response behavior of the 7003-T6 alloy with different ERs is different. For the alloy with an ER of 56, strain hardening is the main mechanism of plastic deformation. In contrast, a flow stress reduction occurs at middle deformation stage for the ones with ERs of 20 and 9 due to concentrated deformation, which is more significant in the alloy with an ER of 20. Under high-speed impact, the alloy with an ER of 56 undergoes uneven plastic deformation due to the presence of coarse grain rings. The deformation is mainly borne by the region of coarse grains near the edge, and the closer to the center, the smaller the deformation. The deformation of the alloys with ERs of 20 and 9 is relatively uniform, but exhibits localized concentrated deformation in the area near the edge. The significant plastic deformation within deformation band causes a local temperature rise, resulting in a slight decrease in flow stress after the peak. These results can provide reliable data support for the application of 7003 aluminum alloy in the vehicle body crash energy absorption structure.

Gravel-inlaid mud clasts as indicators of transport processes of subaqueous sediment gravity-flows

Much sedimentological research aims to understand the depositional processes by establishing the relationship between the transport processes of subaqueous sediment gravity flows (SSGFs) and the characteristics of their deposits. A distinctive type of gravel-inlaid mud clasts, which has been largely overlooked, is embedded with occasional granules or pebbles, and exhibits various angular shapes that are present in cores of SSGF deposits worldwide. SSGF deposits from four cored wells in the Liushagang Formation of the Weixi'nan depression, China, have been analyzed to explore the characteristics, distribution, and potential formation mechanisms of gravel-inlaid mud clasts, thereby revealing the transport processes of SSGFs. In the research area, SSGF deposits are dominated by gravelly high-density turbidites, sandy high-density turbidites, low-density turbidites, and hybrid event beds. Gravel-inlaid mud clasts are common in massive sandstones and bipartite or tripartite beds, exhibiting various distribution patterns. The erosional contact at the base of these beds, where coarse grains are partially embedded within the muddy substrate, indicates that gravel-inlaid mud clasts originate through processes of erosion and delamination. Their distribution from the lower to the upper part of massive sandstones and bipartite or tripartite beds suggests a floating process from base to top. The formation and distribution of gravel-inlaid mud clasts demonstrate the downflow transformation from high-density turbidity currents to low-strength debris flows, driven by the erosion of the underlying muddy substrate, ultimately resulting in the formation of hybrid event beds. The lofting of gravel-inlaid mud clasts increases the cohesion of the upper part of the high-density turbidity current, facilitating its transformation into a low-strength debris flow. Furthermore, the occurrence of gravel-inlaid mud clasts within massive sandstones clearly demonstrates that they are products of high-density turbidity currents rather than sandy debris flows. The identification of gravel-inlaid mud clasts and their distribution within deep-water deposits can be regarded as a reliable indicator for reconstructing SSGF transport processes from high-density turbidity currents to low-strength debris flows, ultimately transitioning into low-density turbidity currents.

Grain refinement of Fe4N compound layer in nitrided steel

This study elucidated the microstructure of the Fe4N (γ’) compound layer in specimens subjected to the nitriding to the specimens with various finished surfaces. Gyrofinishing produces a specimen surface with an ultra-fine-grained (UFGed) structure and a rough surface, whereas the buff-finished specimen exhibited a coarse grain but smooth surface. The γ’ grains formed on the gyrofinished specimens after nitriding were considerably finer and more equiaxial compared with those on the buff-finished specimen. The γ’ nucleated from the grain boundary in the matrix, indicating that the grain boundaries act as a nucleation site. Therefore, the UFGed structure promotes the nucleation of γ’ during the nitriding, resulting in fine grains. Numerous pores were formed in the γ’ layer of the gyrofinished specimen owing to the rough surface. The UFGed structure and surface roughness before nitriding are key factors for controlling the microstructure in the γ’ compound layer.

Enhancing mechanical properties of medium Mn steel by warm rolling based on laminated elemental segregation

The hot-rolled microstructure of medium Mn steel has coarse grains and severe elemental segregation, resulting in low strength and plasticity. Constructing a multiphase structure, refining the microstructure, and regulating elemental segregation enhance the mechanical properties. In this study, liquid nitrogen treatment created a layered distribution of austenite and martensite. Warm rolling was then used to reduce layer thickness and refine grain structure. After liquid nitrogen and warm rolling treatments, the strength and plasticity of medium Mn steel increased to 1270 MPa and 23.3%, respectively, far exceeding the hot-rolled state (724 MPa, 12.8%). Warm rolling also triggers austenite reverted transformation (ART) and introduces high-density dislocations, further improving austenite stability. This strengthening effect is higher than that from intercritical annealing alone. Improved austenite stability delays the transformation induced plasticity (TRIP) effect, preventing brittle fracture and enhancing deformation coordination between layers, significantly increasing the plastic deformation capacity of medium Mn steel.

On the plastic deformation mechanism of Al0.6CoCrFeNi high entropy alloy: In-situ EBSD study and crystal plasticity modeling

In this study, in-situ tensile tests with electron back-scattered diffraction (EBSD) were conducted to reveal the microstructural effects on the plastic deformation behavior of dual-phase Al0.6CoCrFeNi high entropy alloys (HEAs). The in-situ EBSD results demonstrated a uniform distribution of dislocation density in the fine grain (FG) samples, whereas high dislocation density was predominantly localized near body-centered cubic (BCC) phases in the coarse grain (CG) samples. The difference in mechanical properties between face-centered cubic (FCC) and BCC phases caused stress concentration and cracking at the boundaries during tension. The FCC phase within FG samples exhibited excellent plasticity, effectively impeding the propagation and coalescence of microcracks emanating from the BCC phase into longer cracks. For CG samples, brittle cracks formed in BCC phases are easy to merge, thus evolving into long cracks. Crystal plasticity finite element analysis revealed that as the strain increases, stress distribution in FG samples tended to become more homogeneous, whereas for CG samples high stress concentration consistently occurred within BCC phases. The deformation characteristics of FG were attributed to the synergistic effect generated by the FCC phase with heterogeneous grain size and the BCC phase characterized by small grain size.

Effect of High Deformation without Preheating on Microstructure and Corrosion of Pure Mg

In this study, the relationship between the extrusion ratio and the corrosion resistance of pure Mg deformed using extrusion with an oscillating die (KoBo) without preheating of the initial billet was investigated. The materials investigated in this study were extruded at high deformation ratios, R1 5:1, R2 7:1, and R3 10:1, resulting in significant grain refinement from the very coarse grains formed in the initial billet to a few µm in the KoBo-extruded samples at room temperature, which is not typical for hexagonal structures. Our research clearly shows that KoBo extrusion improves the corrosion performance of pure Mg, but there is no straightforward dependence between the extrusion ratios and corrosion resistance improvement. Although it was expected that the smallest grain size should provide the highest corrosion resistance, the dislocation density accumulated in the grain interiors during deformation at the highest extrusion ratio, R3 10:1, supports dissolution reactions. This, in turn, provides the answers for the greater grain size observed after deformation at R2 7:1, where dynamic recovery prevailed over dynamic recrystallization. This situation led to the annihilation of dislocation, leading to better corrosion resistance of the respective alloy. Therefore, the alloy with the greatest grain size has the best corrosion resistance.

Source of plastic contamination of the rivers ending to the Gorgan Bay, southeast of the Caspian Sea, Iran

The widespread presence of microplastics (MPs) in freshwater systems as an emerging environmental pollutant has caused a global environmental problem. The present study investigates the distribution and abundance of source pathway and abundance of microplastics in surface sediment samples from rivers discharging into the Gorgan Bay, southeast of the Caspian Sea. A total of 57 surface sediment samples were taken from 19 stations to investigate the potential hot spots of pollution in the four rivers leading to the Gorgan Bay. The average level of microplastics was 333 ± 268 particles/kg. The highest amount is in the estuary of the Qarasu River (1080 ± 380 particles/kg) due to the accumulation of fishing, boating and tourism activities and the lowest amount in the forest area (80 ± 19 particles/kg) in the Klak River. The most common type of microplastic was fiber (68%). Microplastic pollution in the studied rivers is mostly black and gray (75.39%), and about 53% of them were sized less than 1000 μm. Spectroscopic analysis (Fourier Transform Infrared (FT-IR) of the MP showed that 37% were polyethylene, polyethylene (37%) and polypropylene (27%) were the dominating groups. The sediments’ size was significantly correlated (p>0.05) with the presence of microplastics. Sediments with a coarse grain (sand) demonstrated a great potential to store microplastics. The results of this study can be used for the management and protection policies of Gorgan Bay.

Spontaneous Dimerization and Distinct Packing Modes of Transmembrane Domains in Receptor Tyrosine Kinases.

The insulin receptor (IR) and the insulin-like growth factor-1 receptor (IGF1R) are homodimeric transmembrane glycoproteins that transduce signals across the membrane on binding of extracellular peptide ligands. The structures of IR/IGF1R fragments in apo and liganded states have revealed that the extracellular subunits of these receptors adopt Λ-shaped configurations to which are connected the intracellular tyrosine kinase (TK) domains. The binding of peptide ligands induces structural transitions in the extracellular subunits leading to potential dimerization of transmembrane domains (TMDs) and autophosphorylation in TKs. However, the activation mechanisms of IR/IGF1R, especially the role of TMDs in coordinating signal-inducing structural transitions, remain poorly understood, in part due to the lack of structures of full-length receptors in apo or liganded states. While atomistic simulations of IR/IGF1R TMDs showed that these domains can dimerize in single component membranes, spontaneous unbiased dimerization in a plasma membrane having physiologically representative lipid composition has not been observed. We address this limitation by employing coarse-grained (CG) molecular dynamics simulations to probe the dimerization propensity of IR/IGF1R TMDs. We observed that TMDs in both receptors spontaneously dimerized independent of their initial orientations in their dissociated states, signifying their natural propensity for dimerization. In the dimeric state, IR TMDs predominantly adopted X-shaped configurations with asymmetric helical packing and significant tilt relative to the membrane normal, while IGF1R TMDs adopted symmetric V-shaped or parallel configurations with either no tilt or a small tilt relative to the membrane normal. Our results suggest that IR/IGF1R TMDs spontaneously dimerize and adopt distinct dimerized configurations.

A Coarse-Grained SPICA Makeover for Solvated and Bare Sodium and Chloride Ions.

Aqueous ionic solutions are pivotal in various scientific domains due to their natural prevalence and vital roles in biological and chemical processes. Molecular dynamics has emerged as an effective methodology for studying the dynamic behavior of these systems. While all-atomistic models have made significant strides in accurately representing and simulating these ions, the challenge persists in achieving precise models for coarse-grained (CG) simulations. Our study introduces two optimized models for sodium and chloride ions within the nonpolarizable surface property fitting coarse-grained force field (SPICA-FF) framework. The two models represent solvated ions, such as the original FF model, and unsolvated or bare ions. The nonbonded Lennard-Jones interactions were reparameterized to faithfully reproduce bulk properties, including density and surface tension, in sodium chloride solutions at varying concentrations. Notably, these optimized models replicate experimental surface tensions at high ionic strengths, a property not well-captured by the ions of the original model in the SPICA-FF. The optimized unsolvated model also proved successful in reproducing experimental osmotic pressure. Additionally, the newly reparameterized ion models capture hydrophobic interactions within sodium chloride solutions and show qualitative agreement when modeling structural changes in phospholipid bilayers, aligning with experimental observations. For aqueous solutions, these optimized models promise a more precise representation of the ion behavior.

Microstructure evolution and aging behavior of surface-nanocrystallized WE43 Mg alloy by ultrasonic shot peening at a cryogenic temperature

In this study, the microstructure evolution and aging behavior of surface-nanocrystallized WE43 Mg alloy induced by ultrasonic shot peening at a cryogenic temperature were examined. The results reveal that the original coarse grains with an average grain size of 46.7 μm were refined to nanocrystalline grains with 31.5 nm in the nanocrystalline region, demonstrating a marked grain refinement effect. After aging treatment, the nanocrystalline region experienced two aging stages. During Stage Ⅰ, there was a rapid increase in hardness, and in Stage Ⅱ, it reached a maximum of 154.2 HV, representing a 105.6% improvement over the solution-treated alloy. Further microstructural characterization indicates that solute segregation initially occurred along the grain boundaries, leading to a rapid increase in hardness during Stage Ⅰ. Subsequently, two types of precipitates were observed both at the grain boundaries and within the grains during Stage Ⅱ, with the combined effects of solute segregation and precipitation contributing to a further increase in hardness.

Constructing a temperature transferable coarse-grained model of cis-1,4-polyisoprene with the structural and thermodynamic consistency aided by machine learning

Polyisoprene (PI) is a widely used polymer and constructing a systematic coarse-grained (CG) PI model with the structural and thermodynamic consistency with the underlying atomic model over a wide range of thermodynamic conditions is very important for the predictive capability of CG model on overall properties of PI polymer materials and the establishment of their structure-property relationship. However, as the number of tunable CG potential parameters and target properties grows, traditional parameter tuning methods become impractical. In this work, we present a novel approach for determining the optimal CGPI non-bonded potential parameters by employing Particle Swarm Optimization as the calibrator with machine learning-based models trained using molecular dynamics data. The resulting CG model is further augmented with temperature factors through a multistate parameterization approach. This enhancement ensures the model's temperature transferability of structure and thermodynamics in a wide temperature of 150K∼750K.

Effect of annealing temperature on the microstructure and properties of TiZr2Ta alloy

The microstructure, mechanical properties, and corrosion resistance of annealed TiZr2Ta alloys were investigated. The results indicate that the corrosion resistance and wear resistance of the alloy have improved. This improvement is attributed to the annealing process, which eliminates residual stress and facilitates the formation and regeneration of surface oxide films. However, increasing the annealing temperature will lead to abnormal grain growth in the microstructure. The abnormal growth can be attributed to the energy released during the phase transition, which promotes the movement of grain boundaries. The high content of coarse grains in the alloy does not improve its mechanical properties or corrosion resistance.

Achieving enhanced strength-ductility and wear resistance in directed energy deposited super duplex stainless steel via inoculating NbN particles

In wire-based directed energy deposition (DED), super duplex stainless steel (SDSS) typically encounters issues including coarse grains, a contradictory relationship between strength and ductility, and inferior wear resistance properties. Herein, we report the introduction of micron-sized NbN particles into DEDed SDSS to achieve an optimized combination of fine microstructure, high strength, impressively larger ductility and better wear resistance. During the DED process, NbN inoculant dissolves and re-precipitates, forming fine NbN and σ particles around 100 nm in size. These NbN particles act as nucleation sites for equiaxed grains, refining both ferrite and austenite. In addition, Nb and N elements left from NbN dissolution enhance the solution strengthening effect. These factors collectively boost hardness and strength in DEDed SDSS. Furthermore, the high Nb level in DEDed SDSS facilitates a dense Cr2O3 layer formation on the specimen surface during wear tests, enhancing wear resistance. Increased Nb and N also lower stacking fault energy (SFE) of SDSS austenite, promoting the occurrence of deformation twinning, and the improvement of work hardening and ductility during plastic deformation. This work shows the great potential of wire-arc DED technology to fabricate SDSS with unique microstructures, excellent wear resistance, and an exceptional combination of strength and ductility for practical applications.

Thermo-kinetic insights into deformation mechanism in the phase-transforming nanostructured Fe alloy

Solid-state phase transformations (SSPTs) being the most widely versatile routes to tailor microstructures are less utilized in the design of nanostructured (NS) alloys, resulting in a lack of understanding of the significance of SSPTs in tuning mechanical properties. Here, we combine nanostructuring with reverse austenite transformation to make a phase-transforming NS Fe alloy consisting of ultrafine ferrite and austenite grains. By comparison with the coarse-grained (CG) counterpart, the NS sample exhibits high strengths (i.e., the yield and the ultimate tensile strengths are 816 and 1170 MPa, respectively), good ductility with a uniform elongation of 53 %, and superior strain hardening capacity, under multiple strengthening mechanisms and the activation of transformation induced plasticity. Regarding the mechanism in forming the NS sample, grain refinement is revealed to markedly affect the austenite formation kinetics by generating sluggish growth behavior accompanied by sufficient solute partitioning. Then, we clarify the difference in mechanical responses of the phase-transforming NS and CG samples using a physically based microstructures-properties model. Further based on the thermo-kinetic theory of generalized stability, we show that the simultaneous increase of strength and ductility in the NS sample relative to the CG sample is originated from the deformation physics with higher driving force and higher generalized stability. From the thermo-kinetic perspective, our work demonstrates that the SSPTs hold substantial promise in optimizing the microstructures and the mechanical properties of NS Fe alloys and are expected to find wide application in the development of other NS materials.

Nanocrystalline copper for direct copper-to-copper bonding with improved cross-interface formation at low thermal budget

Direct copper-to-copper (Cu-Cu) bonding is a promising technology for advanced electronic packaging. Nanocrystalline (NC) Cu receives increasing attention due to its unique ability to promote grain growth across the bonding interface. However, achieving sufficient grain growth still requires a high thermal budget. This study explores how reducing grain size and controlling impurity concentration in NC Cu leads to substantial grain growth at low temperatures. The fabricated NC Cu has a uniform nanograin size of around 50 nm and a low impurity level of 300 ppm. To prevent ungrown NC and void formation caused by impurity aggregation, we propose a double-layer (DL) structure comprising a normal coarse-grained (CG) layer underneath the NC layer. The CG layer, with a grain size of 1 μm and an impurity level of 3 ppm, acts as a sink, facilitating impurity diffusion from the NC layer to the CG layer. Thanks to sufficient grain growth throughout the entire NC layer, cross-interface Cu-Cu bonding becomes possible under a low thermal budget, either at 100 °C for 60 min or at 200 °C for only 5 min.

The influence of various welding wires on microstructure, and mechanical characteristics of AA7075 Al-alloy welded by TIG process

Owing to their exceptional mechanical properties, the various welding wires used to combine aluminum can meet the needs of many engineering applications that call for components with both good mechanical and lightweight capabilities. This study aims to produce high-quality welds made of AA7075 aluminum alloy using the GTAW technique and various welding wires, such as ER5356, ER4043, and ER4047. The microstructure, macrohardness, and other mechanical characteristics, such as tensile strength and impact toughness, were analyzed experimentally. To check the fracture surface of the AA7075 welded joints, the specimens were examined using optical and scanning electron microscopy (SEM). A close examination of the samples that were welded with ER5356 welding wire revealed a fine grain in the weld zone (WZ). In addition, the WZ of the ER4043 and ER4047 welded samples had a coarse grain structure. Because the hardness values of the welded samples were lower in the WZ than in the base metal (BM) and heat-affected zone (HAZ), the joints filled with ER5356 welding wire provided the highest hardness values compared to other filler metals. Additionally, the ER4047 filler metal yielded the lowest hardness in the weld zone. The welding wire of ER5356 produced the greatest results for ultimate tensile stress, yield stress, welding efficiency, and strain-hardening capacity (Hc), whereas the filler metal of ER4043 produced the highest percentage of elongation. In addition, the ER4047 fracture surface morphology revealed coarser and deeper dimples than the ER5356 fine dimples in the welded joints. Finally, the highest impact toughness was obtained at joints filled with the ER4047 filler metal, whereas the lowest impact toughness was obtained at the BM.