Complex Alloys Research Articles

Compositionally Complex Alloy MnFeCoNiCu for Brazing Nickel‐Based Superalloy Haynes 214

The microstructural and mechanical properties of a MnFeCoNiCu braze filler are analyzed and compared to a conventional nickel‐based braze filler alloy on Haynes 214 as the base material. Tensile tests reveal that the samples brazed with the MnFeCoNiCu compositionally complex alloy (CCA) exhibit superior ductility increased by a factor of 1.6 compared to those brazed with the nickel‐based filler. The ultimate tensile strength remains comparable (factor 1.03). Contact angles recorded during the brazing process indicate comparable wetting properties between the two fillers. Based on experimental investigations and Thermo–Calc predictions, improved brazing parameters are proposed for the CCA filler on Haynes 214. These recommendations include lower brazing temperatures, shortened holding times, and faster cooling rates.

Mechanistic understanding of speciated oxide growth in high entropy alloys

Complex multi-element alloys are gaining prominence for structural applications, supplementing steels, and superalloys. Understanding the impact of each element on alloy surfaces due to oxidation is vital in maintaining material integrity. This study investigates oxidation mechanisms in these alloys using a model five-element equiatomic CoCrFeNiMn alloy, in a controlled oxygen environment. The oxidation-induced surface changes correlate with each element’s interactive tendencies with the environment, guided by thermodynamics. Initial oxidation stages follow atomic size and redox potential, with the latter becoming dominant over time, causing composition inversion. The study employs in-situ atom probe tomography, transmission electron microscopy, and X-ray absorption near-edge structure techniques to elucidate the oxidation process and surface oxide structure evolution. Our findings deconvolute the mechanism for compositional and structural changes in the oxide film and will pave the way for a predictive design of complex alloys with improved resistance to oxidation under extreme conditions.

First-principles and cluster expansion study of the effect of magnetism on short-range order in Fe–Ni–Cr austenitic stainless steels

Short-range order (SRO), the regular and predictable arrangement of atoms over short distances, alters the mechanical properties of technologically relevant structural materials such as medium/high entropy alloys and austenitic stainless steels. In this study, we present a generalized spin cluster expansion (CE) model and show that magnetism is a primary factor influencing the level of SRO present in austenitic Fe–Ni–Cr alloys. The spin CE consists of a chemical cluster expansion combined with an Ising model for Fe–Ni–Cr austenitic alloys. It explicitly accounts for local magnetic exchange interactions, thereby capturing the effects of finite temperature magnetism on SRO. Model parameters are obtained by fitting to a first-principles data set comprising both chemically and magnetically diverse face-centered cubic configurations. The magnitude of the magnetic exchange interactions are found to be comparable to the chemical interactions. Compared to a conventional implicit magnetism CE built from only magnetic ground state configurations, the spin CE shows improved performance on several experimental benchmarks over a broad spectrum of compositions, particularly at higher temperatures due to the explicit treatment of magnetic disorder. We find that SRO is strongly influenced by alloy Cr content, since Cr atoms prefer to align antiferromagnetically with nearest neighbors but become magnetically frustrated with increasing Cr concentration. Using the spin CE, we predict that increasing the Cr concentration in typical austenitic stainless steels promotes the formation of SRO and increases order–disorder transition temperatures. This study underscores the significance of considering magnetic interactions explicitly when exploring the thermodynamic properties of complex transition metal alloys. It also highlights guidelines for customizing SRO through adjustments of alloy composition.

Strong-Yet-Ductile Eutectic Alloys Employing Cocoon-Like Nanometer-Sized Dislocation Cells.

Eutectic alloys (EAs) with superior fluidity are known to be the easiest to cast into high-quality ingots, making them the alloys of choice for making large-sized structural parts. However, conventional EAs (CEAs) have never reached strength-ductility combinations on par with the best in other alloy categories. Via thermomechanical processing of cast Ni-32.88wt%Fe-9.53wt%Al CEAs, a cocoon-like nano-meshed (as fine as 26 nm) network of dislocations (CNN-D) is produced via recovery annealing, through the rearrangement of cold-work-accumulated dislocations anchored by dense pre-existing nanoprecipitates. In lieu of traditional plasticity mechanisms, such as TWIP and TRIP, the CNN-D is particularly effective in eutectic lamellae with alternating phases, as it instigates nanometer-spaced planar slip bands that not only dynamically refine the microstructure but also transmit from the FCC (face-centered-cubic) layers into the otherwise brittle B2 layers. These additional mechanisms for strengthening and strain hardening sustain stable tensile flow, resulting in a striking elevation of both strength and ductility to outrank not only all previous CEAs, but also the state of the art-additively manufactured eutectic high-entropy alloys. The CNN-D thus adds a novel microstructural strategy for performance enhancement, especially for compositionally complex alloys that increasingly make use of nanoprecipitates or local chemical order.

Cr content dependent lattice distortion and solid solution strengthening in additively manufactured CoFeNiCrx complex concentrated alloys – a first principles approach

In the previous study, the authors reported that multicomponent CoFeNiCrx (x = 0, 12, 18, 24 at%) complex concentrated alloys fabricated through laser directed energy deposition experienced a substantial reduction in the saturation magnetization (Ms) and the Curie transition temperature (Tc) with the increase in Cr content. The present investigation additionally explores the effect of Cr concentration on the structural and strengthening behavior in laser directed energy deposition processed CoFeNiCrx alloy system. The novel approach adopted in the present work included the integration of experimental and computational efforts involving laser direct energy deposition (L-DED) based synthesis/fabrication of a series of new CoFeNiCrx alloys through in-situ compositional tuning which is often difficult using conventional techniques and prediction of mechanical properties of these compositionally tuned alloys using a computational methodology based on the density functional theory (DFT). X-ray diffraction and nanoindentation studies revealed that while there was a slight reduction in lattice parameters, the elastic modulus increased by approximately 30 % and the yield strength increased by 25 % with increasing Cr content. The density functional theory framework was employed to interpret the influence of Cr atoms on local lattice distortions and observed yield strength. The calculated local lattice distortion, in terms of first nearest neighbors, significantly increased with Cr concentration, which is attributed to the enlargement of Cr atomic radius in the alloyed multielement environment in comparison to its radius in the elemental form. This distortion at the local level caused solid solution strengthening. The theoretically predicted solid solution strengthening values using the Varvenne model are consistent with experimental results.

Deburring of Soft, Complex Aluminium Alloy Parts

This Processs investigates the effectiveness of utilizing a vertical drill machine to integrate a brush for deburring soft aluminum parts. The aim is to enhance the efficiency and precision of the deburring process in manufacturing operations. The project involves the design and assembly of a specialized attachment to the drill machine, enabling seamless integration of the brush. Through experimental analysis, the performance of the integrated system is evaluated in terms of deburring quality, time efficiency, and cost-effectiveness compared to traditional deburring methods. The results demonstrate significant improvements in deburring effectiveness and productivity, highlighting the potential of this approach for enhancing manufacturing processes involving soft aluminum parts. This technique is so affordable price.

Electron beam powder bed fusion enables crack-free, high-strength and sufficiently ductile chemically complex intermetallic alloys

ABSTRACT In contrast to traditional intermetallics that are difficult to process and prone to cracking during additive manufacturing, our work demonstrates the successful fabrication of crack-free, high-performance CCIMAs via electron beam powder bed fusion (EBPBF). The microstructures of CCIMAs (NiCoFeAlTiB) fabricated by EBPBF are remarkably complex, exhibiting a multiphase composition where the disordered FCC phase forms the matrix interleaved with L12-ordered intermetallic phase. The unique combination of ordered lattices and high-entropy disordered phases, tuned by optimised EBPBF processing, imparts exceptional mechanical properties with a high tensile strength (∼1 GPa) and a sufficient ductility (∼11%). It is found that additional minor HCP and L21 precipitates can also effectively slow down and block the crack extension. This work demonstrates a pathway for crack-free fabrication of CCIMAs with tailored microstructures using EBPBF which may provide new insights and manufacturing strategies to unlock the potential of these advanced intermetallic alloys.

Unveiling the Mo effect on the microstructural stability of L12-strengthened chemically complex alloys

The influence of Mo on the coarsening behavior of L12-precipitates in chemically complex alloys (CCAs) was thoroughly investigated. Mo addition significantly impacted the morphology, misfit, and microstructural stability of L12-precipitates during aging treatment. Mo incorporation into the B sublattice sites of L12-precipitates (along with Al and Ti) increased their volume fraction and solvus temperature. It also weakened the segregation of solutes between the FCC-matrix and L12-precipitates, resulting in reduced misfit. However, during the aging processing, the misfits in all three CCAs continuously increased. Quantitative analysis revealed that a misfit of approximately 0.5 % yielded cubic morphology of L12-precipitate for CCAs with positive misfits. Further coarsening kinetics studies unveiled a transition from initial matrix-diffusion controlled coarsening to interface-reaction controlled coarsening. Notably, Mo addition prolonged the matrix-diffusion controlled stage and delayed the transition to interface-reaction controlled coarsening. These findings provide valuable insights that can guide future alloy design and heat treatment strategies to optimize the high-temperature structural performance of L12-precipitate CCAs.

Phase transformation behavior and mechanical properties of NiTi shape memory alloys fabricated by directed laser deposition

Directed laser deposition shows promise as a method for fabricating complex structure NiTi shape memory alloy parts in engineering, aerospace, automobile, and biomedical fields. The dislocation density has an impact on phase transformation behavior and mechanical properties of NiTi manufactured by directed laser deposition. In this work, NiTi samples were produced by directed laser deposition, and the mechanism of martensitic phase transformation and its interactions with dislocation density were revealed through molecular dynamics. Laser power and scanning speed are the main factors affecting dislocation density, the phase compositions of the samples are B2, B19′, and Ti2Ni phase, and the samples with dislocation density below 2 × 1015 m−2 show single-step B2–B19′ martensitic transformation, stress plateau and improved elongation, the samples with dislocation density above the value exhibit no significant transformation peak and no stress plateau. The movement of (100) twin planes and the growth of advantageous variants are observed in the simulation which can explain stress-induced martensitic reorientation and the stress plateau phenomenon. The bending test suggested that the sample under the optimal parameters has an 85 % recovery ratio within 8 % pre-strain.

Synthesis and Characterization of WNiFeCo, WNiFeMo, and WNiFeCoMo Compositional Complex Alloys Manufactured by Powder Metallurgy Technique

AbstractThe WNiFeCo, WNiFeMo, and WNiFeCoMo compositional complex alloys (CCAs) were prepared by powder metallurgy technique. The thermodynamic investigations of the CCAs proved that WNiFeCo, and WNiFeMo, are medium entropy alloys (MEAs), whereas WNiFeCoMo is a high entropy alloy (HEA). The density of the prepared specimens was estimated. The sintered CCAs were characterized by investigating their microstructures and elemental distribution using SEM and EDX analysis. The crystal structure of the different phases was identified utilizing X-ray diffraction (XRD). From XRD results, W, Fe7W6, and FeNi were observed in all CCAs, whereas Co7W6, MoNi4, and Co7Mo6 phases were found in WNiFeCoMo HEA. WNiFeCo MEA contained a Co7W6 phase, while the MoNi4 phase was observed in WNiFeCo MEA. The A7B6 phases are formed in the CCAs which have good characteristics. The hardness, Young’s modulus, and corrosion behavior were evaluated. Among the investigated CCAs, WNiFeMo MEA showed the highest relative density percentage (95%), Young’s modulus (190 GPa), hardness (451 HV), and lowest corrosion rate in 3.5% NaCl (0.22 mm/y). The surface morphology of the WNiFeCo, WNiFeMo, and WNiFeCoMo alloys displayed uniform corrosion, galvanic corrosion, and localized corrosion.

New strategy in light-weight and ultrastrong Ti40Nb15Mo30(NbC)15 refractory complex concentrated alloy

Traditional refractory high-entropy alloys (RHEAs) generally exhibit a trade-off between high-temperature strength and light weight. In present work, a novel design strategy based on tailoring element distribution is proposed to achieve excellent high-temperature strength at a density lower than 7 g·cm-3. Specifically, a Ti40Nb15Mo30(NbC)15 composite was designed and prepared by powder metallurgy. The composite is found to be composed of two ultrafine-grained (UFG) phases including a body-centered cubic (bcc) solid-solution phase and a face-centered cubic (fcc) ceramic reinforcement phase (Ti, Nb)C. The as-sintered composite shows a uniform and UFG microstructure where two phases are interconnected. Due to this unique microstructure, the Ti40Nb15Mo30(NbC)15 composite displays superb specific yield strengths among surveyed RHEAs, complex concentrated alloys, and metal-matrix composites from 800°C (243 MPa·g-1·cm3) to 1000°C (127 MPa·g-1·cm3). The outstanding high-temperature compressive strength was found to be associated with high resistance to dislocation motion and strong dislocation interactions in both the bcc and fcc phases. The phase interface after hot compression remained semi-coherent, vindicating its high stability. The high-density of stable phase interfaces not only retards the dislocation motion due to the large image force near the phase boundary but also induces a high value of activation energy for diffusion. The high activation energy can further achieve significant microstructure stability even after a long-term annealing (36 h) at 1000°C. This work provides new perspectives for the design and application of light and ultrastrong refractory complex concentrated alloys (RCCAs) by comparison to the insufficient strength of many traditional and light RCCAs.

Microstructural Characterization of AlCrCuFeMnNi Complex Concentrated Alloy Prepared by Pressureless Sintering.

A significant and increasing number of studies have been dedicated to complex concentrated alloys (CCAs) due to the improved properties that these metallic materials can exhibit. However, while most of these studies employ melting techniques, only a few explore powder metallurgy and pressureless sintering as production methods. In this work, a microstructural characterization of AlCrCuFeMnNi CCA samples obtained by powder metallurgy and pressureless sintering using mixtures of powders with different compositions was carried out. One batch of samples (B1) was prepared using commercial powders of Al, Cr, Cu, Fe, Mn, and Ni. Another batch (B2) used mixtures of CrFeMn, AlNi, and Cu powders. A third set of samples (B3) was obtained by adding 1% at. of Mg to the B2 powder. The samples were characterized by X-ray diffraction, scanning and transmission electron microscopy, energy dispersive spectroscopy, density measurements, and hardness tests. Thermodynamic calculations were also used to complement the microstructural characterization. All the obtained samples exhibited high relative density and hardness values. However, B3 samples showed a higher hardness, attributed to the finer distribution of oxide particles, which was promoted by the presence of Mg during sintering. These last samples presented a hardness/density ratio of 62 HV/(g cm-3), surpassing that of some martensitic stainless steels and nickel-titanium alloys.

The effect of grain boundaries and precipitates on the mechanical behavior of the refractory compositionally complex alloy NbMoCrTiAl

Refractory compositionally complex alloys (CCAs) have been found to exhibit promising high-temperature properties. However, the brittleness of most CCAs at room temperature limits their application. To understand the influence of microstructure on the deformation behavior of these alloys, we conducted micromechanical experiments, including nanoindentation and micropillar compression tests, on a representative NbMoCrTiAl alloy at room temperature. The indentation at the grain boundaries showed increased shear stress and hardness compared to the matrix (ordered B2 crystal structure) due to the presence of local intermetallic precipitates (C14 and A15 phases). Although the NbMoCrTiAl alloy exhibits no ductility at the millimeter scale as shown in previous studies, the micropillars at the grain boundaries, which were decorated with precipitates, demonstrated higher yield strength and significant plastic strain >30% at room temperature. Numerous slip lines were observed, while cracks and fracture occurred at higher levels of deformation. The grain boundaries with precipitates increased the probability of crack initiation and propagation, but they did not necessarily lead to catastrophic failure of the pillars.

Fabrication of Cu-Ni Alloy Microcomponents using Localized Electrochemical Deposition

With the rapid development of electronics, additive manufacturing of complex three-dimensional microscale metal and alloy structures has emerged as one of the future directions for advanced technologies. In this study, a localized electrochemical deposition technique was developed which enables the fabrication of microscale three-dimensional metal structures in an ambient environment. Notably, we investigated the effects of voltage, initial electrode gap, and electrolyte composition on the deposition of Cu-Ni alloy. Furthermore, we successfully fabricated Cu-Ni equiatomic micro-columns, providing possibilities for the micro/nanoscale fabrication of commercial K-Monel copper. Finally, based on these foundations, we successfully shaped overhanging structures with various angles as well as an “H” structure using a rotating cathode substrate, demonstrating their potential in the fabrication of Cu-Ni alloy micro components.

Strengthening complex concentrated alloy without ductility loss by 3D printed high-density coherent nanoparticles

Metallic 3D printing enables fast fabrication of net-shaped components for broad engineering applications, yet it restrains the use of most mechanical processing methods for strengthening alloys, e.g. forging, rolling, etc. Here, we proposed a new strategy for enhancing the strength of 3D printed complex concentrated alloys without losing ductility. This strategy relies on the rapid cooling of 3D printing to achieve a supersaturation state that is beyond conventional casting. Then, spinodal decomposition via aging is exploited to introduce high-density coherent nanoparticles for strengthening. The proposed strategy is demonstrated in a 3D printed Cu-based complex concentrated alloy. The rapid solidification during printing strongly inhibits elemental diffusion, leading to a high supersaturation state. High-density nanoparticles with coherent interface and size of ∼7 nm are introduced into the 3D printed samples through spinodal decomposition via simple aging treatment. The strength of the 3D printed alloy is increased by 30 % after aging with no ductility loss, leading to a strength-ductility combination superior to other Cu alloys. This strategy is readily applicable to other spinodal alloys fabricated by 3D printing for circumventing the strength-ductility trade-off dilemma.

Microstructure and mechanical properties of Ti-Nb alloys: comparing conventional powder metallurgy, mechanical alloying, and high power impulse magnetron sputtering processes for supporting materials screening

At the interface of thin film development and powder metallurgy technologies, this study aims to characterise the mechanical properties, lattice constants and phase formation of Ti-Nb alloys (8–30 at.%) produced by different manufacturing methods, including conventional powder metallurgy (PM), mechanical alloying (MA) and high power impulse magnetron sputtering (HiPIMS). A central aspect of this research was to investigate the different energy states achievable by each synthesis method. The findings revealed that as the Nb content increased, both the hardness and Young’s modulus of the PM samples decreased (from 4 to 1.5 and 125 to 85 GPa, respectively). For the MA alloys, the hardness and Young’s modulus varied between 3.2 and 3.9 and 100 to 116 GPa, respectively, with the lowest values recorded for 20% Nb (3.2 and 96 GPa). The Young’s modulus of the HiPIMS thin film samples did not follow a specific trend and varied between 110 and 138 GPa. However, an increase in hardness (from 3.6 to 4.8 GPa) coincided with an increase in the β2 phase contribution for films with the same chemical composition (23 at.% of Nb). This study highlights the potential of using HiPIMS gradient films for high throughput analysis for PM and MA techniques. This discovery is important as it provides a way to reduce the development time for complex alloy systems in biomaterials as well as other areas of materials engineering.Graphical abstract

High-throughput approach for investigating interdiffusion in medium- and high-entropy alloys

Interdiffusion experiments are usually time-consuming and tedious since diffusion couples must be annealed at several temperatures for a long time. The efforts required to study interdiffusion in multicomponent alloys increase dramatically as multiple diffusion couples are required to cover broad composition ranges and determine the diffusivities of individual elements in different chemical environments. To circumvent this challenge, we present a high-throughput approach applicable to single-phase and compositionally complex alloys, which are assumed to approximate ideal solid solutions. Here, a simple diffusion-multiple experiment combined with a physically based kinetic model is proposed to efficiently determine the diffusion coefficients of the constituent elements in quaternary CrFeCoNi alloys. Compared with tracer diffusivities reported in the literature, the results, thus, obtained do not differ by more than a factor of 2 and were obtained from a single interdiffusion experiment. In contrast, the diffusivities simulated with commercial mobility and thermodynamic databases are strongly overestimated by a factor ranging from 1 to 16. Therefore, our approach enables high-throughput determination of diffusivities and can help in the design of alloys for high-temperature applications where diffusion plays a key role.

Contributions to Diffusion in Complex Materials Quantified with Machine Learning.

Using machine learning with a variational formula for diffusivity, we recast diffusion as a sum of individual contributions to diffusion-called "kinosons"-and compute their statistical distribution to model a complex multicomponent alloy. Calculating kinosons is orders of magnitude more efficient than computing whole trajectories, and it elucidates kinetic mechanisms for diffusion. The density of kinosons with temperature leads to new accurate analytic models for macroscale diffusivity. This combination of machine learning with diffusion theory promises insight into other complex materials.

Excellent specific strength-ductility synergy in novel complex concentrated alloy after suction casting

Lightweight alloys are known to improve the fuel efficiency of the structural components due to high strength-to-weight ratio, however, they lack formability at room temperature. This major limitation of poor formability is most of the time overcome by post-fabrication processing and treatments thereby increasing their cost exponentially. We present a novel Ti50V16Zr16Nb10Al5Mo3 (all in at. %) complex concentrated alloy (Ti-CCA) designed based on the combination of valence electron concentration theory and the high entropy approach. The optimal selection of constituent elements has led to a density of 5.63 gm/cc for Ti-CCA after suction casting (SC). SC Ti-CCA displayed exceptional room temperature strength (UTS ∼ 1.25 GPa) and ductility (ε ∼ 35 %) with a yield strength (YS) of ∼ 1.1 GPa (Specific YS = 191 MPa/gm/cc) without any post-processing treatments. The exceptional YS in Ti-CCA is attributed to hetero grain size microstructure, whereas enormous strength-ductility synergy is due to the concurrent occurrence of slip and deformation band formation in the early stages of deformation followed by prolonged necking event due to delayed void nucleation and growth. The proposed philosophy of Ti-CCA design overcomes the conventional notion of strength-ductility trade-off in such alloy systems by retaining their inherent characteristics.

Design and fabrication of lightweight AlCrFeNiTix compositionally complex alloys with exceptional specific strength

Design and fabrication of lightweight AlCrFeNiTix compositionally complex alloys with exceptional specific strength