Electron Backscatter Diffraction Research Articles

Microstructure and mechanical properties of additively manufactured Ti–6Al–4V alloy based on large area, high-resolution EBSD mapping

The laser direct energy deposition (L-DED) is well-suited for metal manufacturing, offering advantages of excellent performance, high precision, intricate structures and material flexibility, etc. In this study, the microstructure and mechanical property of Ti–6Al–4V alloy were investigated using L-DED under various printing parameters. A large-area, high-resolution Electron Backscatter Diffraction (EBSD) mapping technique, enabling to characterize the coarse columnar β-grains with individual crystals up to a centimeter along the building direction, and the sub-grain acicular α′ phase down to 50 nm in the same image, was utilized to analyze the crystalline phases and their lattice orientations in additively manufactured Ti–6Al–4V parts. The microstructure evolution, involving the high temperature β grain structures, β+α phase transformation, as well as acicular α′ martensitic phases, were studied during the periodically attenuated thermal cycles of L-DED. The formation of the “fish-scale” morphology results primarily from the radically different α phase in size between the interior and edges of the “fish-scale” morphology. Additionally, the effect of processing parameters, i.e., scanning speed and laser power, on microstructures and mechanical properties is discussed in detail.

Effect of austenitizing temperature on variant selection of martensite transformation in a 2 GPa grade steel

The correlation of prior austenite grain (PAG) size, mechanical properties, and the variant selection in martensite transformation of a 2 GPa grade automobile steel has been systematically investigated by using a combination of scaning electron microscopy (SEM), electron backscatter diffraction (EBSD), and uniaxial tesile tests. As the austenitizing temperature decreases from 970 °C to 870 °C, the as-quenched microstructure of the studied steel is fully lath martensite. Meanwhile, the average size of PAG is refined from 7.2 ± 3.9 μm to 2.1 ± 1.2 μm, and the volume fraction of high angle grain boundaries (HAGB) is increased from 59.8% to 72.3%, accompanied with an increased number fraction of grains belonging to closely spaced planes (CP) group. With the refinement of the PAGs, the martensitic variant selectivity becomes strong, and the Bain group variant selection discretely transites to the CP group, resulting in a dominate CP group. Consequently, a tensile strength of 2014 ± 33 MPa, a tensile elongtation of 12.9 ± 0.5% and a maximum strength × ductility production of 26.0 ± 1.4 GPa·%, are obtained when the austenitization temperature is at 920 °C.

Fatigue mechanisms at 450°C of a highly twined (>70%) and HIP-densified IN718 superalloy additively manufactured by laser beam powder bed fusion

Fatigue resistance at elevated temperatures is crucial for certifying aerospace structures additively manufactured by the laser beam powder bed fusion (PBF-LB) method with IN718 superalloy. This study employed a multi-step, supersolvus heat treatment process with hot isostatic pressing (HIP), called RHSA, to minimize pores and brittle phases. Stress intensity factor (△K) calculations using data from X-ray computed tomography and shape factors referencing finite element analysis (FEA) studies confirmed the suppression of △K below the threshold of conventional IN718 (∼5 MPa√m), shifting fatigue behavior to grain-structure-dominated. Despite a very high twin boundary (TB) fraction (>70%), fatigue tests at 450°C and R = 0.1 demonstrated low scatter. Slip trace analysis and high-resolution electron backscatter diffraction (EBSD) revealed that TB-induced strain concentration became prominent only at high △K, causing cracking at 45⁰ to the loading direction. The randomly oriented TBs with higher angles (60⁰) compared to high-angle grain boundaries (HAGBs) (30–40⁰) likely enhanced slip resistance and provided a net strengthening effect, which can explain the lower-than-average TB% along fracture paths. These insights suggest that a high TB fraction is not detrimental if fatigue stress is not excessive, alleviating concerns about annealing twins during defect minimization in AM IN718, allowing novel processes to improve fatigue resistance in PBF-LB IN718.

Damage-tolerant oxides by imprint of an ultra-high dislocation density

Dislocations in ductile ceramics offer the potential for robust mechanical performance while unlocking versatile functional properties. Previous studies have been limited by small volumes with dislocations and/or low dislocation densities in ceramics. Here, we use Brinell ball scratching to create crack-free, large plastic zones, offering a simple and effective method for dislocation engineering at room temperature. Using MgO, we tailor high dislocation densities up to ∼1015 m−2. We characterise the plastic zones by chemical etching, electron channelling contrast imaging, and scanning transmission electron microscopy, and further demonstrate that crack initiation and propagation in the plastic zones with high-density dislocations can be completely suppressed. The residual stresses in the plastic zones were analysed using high-resolution electron backscatter diffraction. With the residual stress being subsequently relieved via thermal annealing while retaining the high-density dislocations, we observe the cracks are no longer completely suppressed, but the pure toughening effect of the dislocations remains evident.

Optimization of high-temperature mechanical properties of aluminum alloys through exclusive precipitation of T-phase

An aluminum alloy with an actual composition of Al - 5.4 wt%Cu- 1 wt%Mn was cast and subjected to solution heat treatment for 1 h, 2 h, 4 h, 8 h, and 16 h to make the T-phase the sole strengthening phase. The microstructural evolution of the samples, especially the T-phase microstructure, was studied using transmission electron microscope (TEM) and scanning electron microscope (SEM) with electron backscatter diffraction (EBSD) attachment. The ImageJ software was utilized to statistically analyze T-phase content. Tensile tests were conducted to obtain mechanical property data, and high-temperature tensile tests were performed at 200 °C, 300 °C, and 400 °C to assess the high-temperature performance. Subsequently, the strengthening effect of the T-phase on the room-temperature and high-temperature mechanical properties of the aluminum alloy was quantitatively evaluated. The sample subjected to an 8 h solution treatment exhibited optimal strength and toughness. The yield strength was 147 MPa, and the tensile strength was 300 MPa. The yield strength contributed by the T-phase was 73 MPa. The tensile strength of the sample at 400 °C remained at 91 MPa. The T-phase contributes significantly to the mechanical properties of the aluminum alloy both at room temperature and at high temperatures.

Tectonic evolution of the early Paleozoic intraplate orogen in the South China Block: Insights from Ductile Shear Zones in North Wuyishan

The ductile shear zones within the North Wuyishan domain are key to understand the tectonic evolution of the South China Block (SCB). This study integrates a multifaceted approach, including field observations, thin section analysis, quartz electron backscatter diffraction (EBSD), zircon U-Pb dating, and mica 40Ar/39Ar dating, to elucidate the deformation history of these shear zones in North Wuyishan. The research identifies a two-stage deformation process of early Paleozoic. The initial D1 phase is marked by a top-to-SW thrusting shear, with associated felsic veins dated to the Ordovician period (447 ± 10 Ma to 459 ± 4 Ma), correlating with high-grade metamorphism and partial melting. The later D2 phase is characterized by NE-striking foliation and lineation, indicative of sinistral strike-slip shear, dated to the early Devonian (412 Ma) and early Carboniferous (∼354 Ma). The D1 phase suggests early crustal thickening and melting within the Cathaysia block, while D2 indicates a transpressional regime during post-orogenic adjustment. The geological features of the SCB, notably the absence of arc magmatism, ophiolitic mélange, and high-pressure metamorphism, comply with an intracontinental rift closure model as previously proposed. This model supports the hypothesis that the Early Paleozoic intracontinental orogeny in the SCB was likely a far-field consequence of a continental collision between the SCB-North Vietnam and South Vietnam blocks near the east Gondwana supercontinent.

Microstructure evolution after hot working and heat treatment in 6082 aluminum alloy manufactured by horizontal continuous casting

In this paper, 6082 aluminum alloy manufactured by horizontal continuous casting was subjected to high-temperature plastic deformation under 20–70 % deformation levels with following T6 heat treatment process. Microstructural and phase changes were investigated by light and scanning electron microscopy together with energy dispersive spectroscopy, while grain, grain boundary, dislocation and texture evolution was studied by electron-backscattered diffraction. The results are showing that continuous dynamic recrystallization processes are active during the hot working while influence of static recrystallization is significant only for highest deformation degrees. The abnormally coarse-grained microstructure does locally occur in the subsurface layer after the 70 % deformation and T6 heat treatment. Crystallographic texture components are gradually evolving from the various types (Goss, Brass, D) for the low deformations (up to 40 %) into fiber-type textures (α-fiber, γ-fiber or C2-fiber) for high deformations due to the inhomogeneity of plastic deformation. The formation of AlMnSi dispersoids, CSL-boundaries Σ25b and an increase in fraction of GND, MgSi and Fe-based intermetallic particles was observed during the phase transformation which promotes ongoing nucleation of recrystallization processes.

High-temperature hot deformation behavior and processing map of Ti-22Al-25Nb alloy

The high-temperature deformation behavior of the Ti-22Al-25Nb alloy was investigated by conducting hot compression experiments. A constitutive equation predicting the flow behavior of the Ti-22Al-25Nb alloy was established by analyzing its stress–strain curves. The strain-compensated constitutive equation effectively predicted the flow stress of the alloy with a correlation coefficient of 0.992 between the measured and predicted values and an average absolute relative error of 6.548 %. A hot processing map was obtained based on a dynamic material model. It demonstrated that the optimal processing region corresponded to the deformation temperatures of 1273–1353 K and strain rates of 0.001–0.01 s−1. Using electron backscatter diffraction data, thermal deformation mechanisms were elucidated under different deformation conditions within the safe region. The obtained results revealed that under the low temperature (T ≤ 1323 K) and low strain rate (ε̇ ≤ 1 s−1) conditions, continuous dynamic recrystallization and dynamic recovery (DRV) were the main thermal deformation mechanisms. Under the medium-to-high temperature (T ≥ 1323 K) and low strain rate (ε̇ ≤ 1 s−1) conditions, the main thermal deformation mechanisms were discontinuous dynamic recrystallization and DRV. At high strain rates (ε̇ ≥ 1 s−1), the primary thermaldeformation mechanism was DRV. The occurrence of discontinuous yielding in the alloy at high strain rates was related to the proliferation of mobile dislocations at grain boundaries.

Solidification and crystallographic texture modeling of laser powder bed fusion Ti-6Al-4V using finite difference-monte carlo method

Laser powder bed fusion (LPBF) additive manufacturing makes near-net-shaped parts with reduced material cost and time, rising as a promising technology to fabricate Ti-6Al-4 V, a widely used titanium alloy in aerospace and medical industries. However, LPBF Ti-6Al-4 V parts produced with 67° rotation between layers, a scan strategy commonly used to reduce microstructure and property inhomogeneity, have varying grain morphologies and weak crystallographic textures that change depending on processing parameters. This study predicts LPBF Ti-6Al-4 V solidification at three energy levels using a finite difference-Monte Carlo method and validates the simulations with large-area electron backscatter diffraction (EBSD) scans. The developed model accurately shows that a 〈001〉 texture forms at low energy and a 〈111〉 texture occurs at higher energies parallel to the build direction but with a lower strength than the textures observed from EBSD. A validated and well-established method of combining spatial correlation and general spherical harmonics representation of texture is developed to calculate a difference score between simulations and experiments. The quantitative comparison enables effective fine-tuning of nucleation density (N0) input, which shows a nonlinear relationship with increasing energy level. Future improvements in texture prediction code and a more comprehensive study of N0 with different energy levels will further advance the optimization of LPBF Ti-6Al-4 V components. These developments contribute a novel understanding of crystallographic texture formation in LPBF Ti-6Al-4 V, the development of robust model validation and calibration pipeline methodologies, and provide a platform for mechanical property prediction and process parameter optimization.

Link between b.c.c.-f.c.c. orientation relationship and austenite morphology in CF8M stainless steel.

Slow-cooled CF8M duplex stainless steel is used for critical parts of the primary coolant pipes of nuclear reactors. This steel can endure severe service conditions, but it tends to become more brittle upon very long-term aging (tens of years). Therefore, it is essential to understand its specific microstructure and temporal evolution. As revealed by electron backscatter diffraction (EBSD) analyses, the microstructure consists of millimetre-scale ferritic grains within which austenite lath packets have grown with preferred crystallographic orientations concerning the parent ferritic phase far from the ferrite grain boundaries. In these lath packets where the austenite phase is nucleated, the lath morphology and crystal orientation accommodate the two ferrite orientations. Globally, the Pitsch orientation relationship appears to display the best agreement with the experimental data compared with other classical relationships. The austenite lath packets are parallel plate-shaped laths, characterized by their normal n. A novel methodology is introduced to elucidate the expected relationship between n and the crystallographic orientation given the coarse interfaces, even though n is only partly known from the observation surface, in contrast to the 3D crystal orientations measured by EBSD. The distribution of retrieved normals n is shown to be concentrated over a set of discrete orientations. Assuming that the ferrite and austenite obey the Pitsch orientation relationship, the determined lath normals are close to an invariant direction of the parent phase given by the same orientation relationship.

Microstructure evolution and springback behavior in single-pass roll bending of magnesium alloy plates

Using magnesium alloy plates instead of high-strength steel and titanium alloys in roll-formed parts significantly improves the lightweight, damping, and heat dissipation properties of automotive components. This paper employs finite element simulation combined with experimental methods to perform single-pass roll bending of AZ31B magnesium alloy plates at angles of 0°-15°, 0°-25°, and 0°-35°. Measured the springback angle and microhardness at the bends, and used optical microscopy (OM) and electron back scatter diffraction (EBSD) to analyze the microstructural characteristics, texture, and orientation evolution at the bend during the roll bending process. The results indicate that during roll bending, the inner bend area has significantly more twins than the outer area, with more pronounced grain refinement on the inner side. {10-12} tensile twins mainly coordinate plastic deformation, with some {10-12}-{10-12} tensile twin variants present. The inner bend area's texture shifts from ND to TD direction, strengthening the TD direction texture, while the outer area retains typical rolling texture. The prismatic slip in the inner region of the bend changes from hard to soft orientation. The inner region is mainly coordinated plastic deformation by prismatic slip, while the outer region is mainly coordinated by basal slip. As single-pass roll bending angles increase, the increase in twin boundaries and low-angle grain boundaries (LAGBs) significantly reduces the springback angle. Additionally, grain refinement and increased geometric necessary dislocation density lead to higher microhardness.

Effects of heat input on microstructure evolution and corrosion resistance of underwater laser cladding high-strength low-alloy steel coating

The effects of heat input on the microstructure evolution and corrosion resistance of the high-strength low-alloy (HSLA) steel coating obtained by wire-feed underwater laser cladding were studied. Optical digital microscope, scanning electron microscope (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), transmission electron microscope (TEM), electron back-scattered diffraction (EBSD), electrochemical tests, laser microscope and other characterization methods were used. As the heat input increased, the smoothness of the underwater cladding coating improved, with little changes in elemental distribution and phase composition. However, the content of acicular ferrite increased, while the amounts of lath bainite, lath martensite, and granular bainite decreased. As the heat input increased from 0.4 to 0.55 kJ/mm, the grain size increased from 25.3 to 55.9 μm, the proportion of low-angle grain boundaries rose from 61.3 % to 69.1 %, and the texture intensity of the (110) crystal plane increased from 16.22 to 23.83. Meanwhile, the dislocation density decreased from 4.9 × 1014 to 4.1 × 1014 m−2. These changes enhanced the corrosion resistance of underwater coating. As the heat input increased from 0.4 to 0.55 kJ/mm, the corrosion current density decreased from 2.13 × 10−5 to 3.35 × 10−6 A/cm2, and the corrosion potential increased from −0.823 to −0.529 V. Additionally, the depth-to-width ratio of the corrosion pits decreased from 0.255 to 0.053. This study laid the foundation for high-quality in-situ underwater repairs of ships and submarines made of high-strength steel.

Insights into the North Patagonian Massif Lower Crust: Petrology and Microstructure of Granulite Xenoliths

Abstract The continental lower crust constitutes a key zone for understanding the mantle–crust magmatic and mechanical transfers, but its study is hampered by the paucity of lower crust samples. Here, we characterise the petrological, geochemical and petrophysical processes structuring the lower crust of the North Patagonian Massif (NPM; Argentina) using a suite of representative mafic granulite and websterite xenoliths. These xenoliths were entrained by alkaline lavas from five volcanic centres that erupted between the Oligocene and Pleistocene. Electron microprobe and Laser Ablation Inductively Coupled Plasma Mass Spectrometer (LA-ICPMS) were used to obtain in situ geochemical data on the minerals, while microstructural data were obtained by Electron BackScatter Diffraction (EBSD). Both granulites and websterites display a granoblastic texture and sometimes a weak inherited magmatic layering. Mafic granulite xenoliths show a plagioclase + clinopyroxene ± orthopyroxene assemblage commonly associated with spinel or titanomagnetite. Websterite xenoliths show an association of clinopyroxene + orthopyroxene + spinel, along with accessory plagioclase. Mafic granulites and websterites have SiO2 contents ranging from 44 to 53 wt %, while their Mg# varies from 53 to 79. Clinopyroxenes are characterised by weak convex upward chondrite-normalised Rare Earth Elements - REE patterns (Light-REE </<< Mid-REE > Heavy-REE) which are similar to clinopyroxene phenocrysts and megacrysts from intra-plate basalts. Calculated liquid in equilibrium with clinopyroxene have similar REE patterns to those found in Cenozoic basalts from the NPM, suggesting that the xenolith suite represents evidence for underplating processes, possibly related to one of the magmatic events that have occurred in the NPM since the Permo-Trias. Mafic granulites and websterites show a weak mineral shape preferred orientation and an associated weak Crystal Preferred Orientation (CPO) related to the magmatic layering. Recorded plastic deformation is associated with the activation of both (100)[001] and (001)[100] slip systems in clinopyroxene, (100)[001] in orthopyroxene and (010)[001] in plagioclase. However, the activation of slip systems is generally not correlated with CPO in granulites, suggesting that the lower crust underwent subsolidus equilibration and weak plastic deformation in an inactive tectonic context, thereby preserving an inherited magmatic layering. Two-pyroxene (Fe–Mg) thermometer and pseudosection calculations define P–T conditions of the main paragenesis at 760°C to 1120°C and 7.2 to 10.3 kbar, which allows to define the Cenozoic geotherm of the NPM crust at 30°C/km and to reconsider the petrologic Moho depth at ca. 40 km.

Understanding the deformation creep and role of intermetallic compound-microstructure in Sn-Ag-Cu solders

Tin-based alloys are commonly used in lead-free solder joints in electronic interconnection applications, where creep can limit joint reliability. In this work, directionally solidified bulk solder alloys of different compositions (pure tin, SAC105 and SAC305) are mechanically tested under a constant load for each composition at room temperature to understand mechanical creep performance and quantify the role of different content of Ag3Sn and Cu6Sn5 intermetallic compounds (IMCs) in terms of secondary creep strain rate, microstructural evolution, and total amount of accumulated strain. In this work, microstructures are fabricated using directional solidification to promote a systematic variation in IMC sizes, shapes, and distributions within similar crystal orientations of the primary β-Sn matrix. Analysis of creep data indicates that secondary creep is dominated by obstacle-controlled dislocation motion. This is further confirmed by electron backscatter diffraction (EBSD) analysis, which reveals that the formation of subgrains and internal structure, correlating to the initial microstructure of the sample, i.e. changes in secondary dendrite arm spacing (λ2) and eutectic intermetallic spacing (λe). The experimental observations are supported further by crystal plasticity simulations that explicitly model the presence of IMCs within the Sn-based samples and show the dependence of the secondary creep rate upon the IMC content, and therefore be beneficial for the possible future composition design in solders.

Microstructural evolution and dynamic recrystallization mechanisms of additively manufactured TiAl alloy with heterogeneous microstructure during hot compression

Microstructural evolution and dynamic recrystallization (DRX) mechanisms of a Ti−48Al−2Cr−2Nb (at.%) alloy prepared by selective electron beam melting (SEBM) during hot deformation at 1150 °C and 0.1 s−1 were investigated by hot compression tests, optical microscope (OM), scanning electron microscope (SEM), electron back-scattered diffraction (EBSD) and transmission electron microscope (TEM). The results show that the initial microstructure of the as-SEBMed alloy exhibits layers of coarse γ grains and fine γ+α2+(α2/γ) lamellar mixture grains alternately along the building direction. During the early stage of hot deformation, deformation twins tend to form within the coarse grains, facilitating subsequent deformation, and a small number of DRX grains appear in the fine-grained regions. With the increase of strain, extensive DRX grains are formed through different DRX mechanisms in both coarse and fine-grained regions, involving discontinuous dynamic recrystallization mechanism (DDRX) in the fine-grained regions and a coexistence of DDRX and continuous dynamic recrystallization (CDRX) in the coarse- grained regions.

Predicting mechanical properties of low-alloy steels using features extracted from Electron Backscatter Diffraction characterization

Machine learning (ML) approaches have recently been increasingly employed to establish quantitative relationships between material composition, processing, microstructure, and properties. However, the complexities of microstructure pose challenges for straightforward modeling, thereby complicating research efforts. This study introduces a series of multi-parametric quantification methods based on Electron Backscatter Diffraction (EBSD) data tailored to the microstructural characteristics of low-alloy steels. These methods include quantification of boundary densities across various misorientation angles, distinct types of boundaries, and geometrically necessary dislocation densities. Through thermomechanical simulation and micro-tensile testing of low-alloy steels, data on yield and ultimate tensile strengths were obtained, alongside EBSD-based extraction of microstructure characteristics. Several ML methods, including Random Forest (RF), Gradient Boosting Decision Trees (GBDT), and Extreme Gradient Boosting (XGBoost), were utilized to predict yield strength (YS) and ultimate tensile strength (UTS) using the aforementioned microstructural features. The GBDT model outperformed other algorithms, demonstrating high accuracy in predicting YS, UTS, and elongation. The model achieved an Mean Squared Error (MSE) of 972.18, an Mean Absolute Error (MAE) of 24.75 and an Coefficient of Determination (R2) of 0.864 for YS, and an MSE of 812.28, an MAE of 22.87 and an R2 of 0.823 for UTS. These results confirm GBDT's effectiveness in predicting mechanical properties from microstructural data.This successful integration of ML with multi-parametric description microstructural features underscores its potential in facilitating material design and development processes.

Effect of processing parameters and carbon to metal ratio on microstructure and mechanical properties of (MoTaTiVW)Cx high entropy carbide produced by reactive spark plasma sintering

(MoTaTiVW)Cx high entropy ceramics with varying carbon to metal ratio in the range of 0.75-0.97 were synthesized by by reactive spark plasma sintering. The effect of ball milling time on particle size, phase evolution and carbon pick-up due to toluene decomposition were studied. Formation of single-phase high entropy carbide having face-centered cubic (FCC) crystal structure was confirmed by X-ray diffraction (XRD), electron backscattered diffraction (EBSD) and Selected area diffraction pattern (SAED) analysis of the sintered compacts. Transmission Kikuchi Diffraction images revealed presence of equiaxed nature of the grains. Transmission electron microscopy images revealed the presence of an intergranular phase at grain boundaries and triple junctions. 3D-Atom Probe Tomography studies showed uniform distribution of elements within the grains with some segregation of impurity elements Fe and Co to the grain boundaries indicating minor contribution of liquid phase sintering to densification. The grain size of single-phase sintered compacts ranged between 1.69 ± 0.60 μm to 4.6 ± 1.0 μm. A low sintering temperature and higher milling time resulted in finer grain size The microhardness was found to increase with milling time and C/M ratio. The microhardness, Young’s modulus and indentation fracture toughness lied between 2221 HV0.1 to 2732 HV0.1, 370 GPa to 473 GPa, 3.6 MPa.m1/2 to 4.4 MPa.m1/2, respectively. The highest microhardness and indentation fracture toughness was found to be 2732 ± 80 HV0.1 and 4.4 MPa.m1/2 on par with reported literature for other high entropy carbides.

Coupling CPFE-CA simulation for grain refinement in ultrasonic elliptical vibration diamond cutting of polycrystalline Cu

While microstructure evolution is commonly observed in severe plastic deformation of polycrystalline metals, modulating the cutting-induced grain refinement in subsurface of polycrystalline metals is promising for promoting the performance of machined surface. In this study, we demonstrate the effectiveness of applying ultrasonic vibration assistance (UVA) in effectively prompting grain refinement of polycrystalline Cu in ultra-precision diamond cutting by experiments and multiscale coupling simulations. Specifically, ordinary cutting (OC) and ultrasonic elliptical vibration-assisted cutting (UEVC) experiments of polycrystalline Cu are carried out, and subsequent cross-sectional characterizations of microstructure evolution in subsurface by metallurgical microscope and electron backscatter diffraction, as well as instrumented nanoindentation tests, are performed, which demonstrates significantly promoted grain refinement in subsurface and increased machined surface hardness by UVA, due to increased dislocation density that is beneficial for the nucleation and growth of dynamic recrystallization. In particular, the multi-scale coupling of crystal plasticity finite element (CPFE) simulation and Cellular Automata (CA) method is firstly established for exploring the microstructural evolution during UEVC and OC of polycrystalline Cu, which is capable of elucidating the underlying correlation of grain refinement behavior in subsurface with characteristics of stress and strain fields in cutting area. Furthermore, the influence of amplitude on the propensity of grain refinement is experimentally and theoretically evaluated, which suggests a critical amplitude of 4 μm that leads to a maximum reduction in grain size by 80.9% and a maximum increase in machined surface hardness by 55.8% in UEVC from that in OC, because of the most pronounced strain accumulation and dislocation activity. The findings reported in this study demonstrate the effectiveness of applying ultrasonic vibration assistance for modulating the grain refinement accompanying strengthening of machined surface in ultra-precision diamond cutting of polycrystalline metals.

Substrate modification for high performance CrAl/CrAlBN multilayers coated TiCN-based cermet through plasma nitriding

The plasma nitriding process was conducted on a TiCN-based cermet that had been coated with a multilayer CrAl/CrAlBN coating deposited via cathodic arc. The intensity of the plasma nitriding was modified by adjusting the anode current of the ionization source. To investigate the interface conditions, techniques such as electron probe X-ray microanalysis, electron backscatter diffraction, and transmission electron microscopy were employed. The results indicated that increasing the anode current led to the formation of a thicker nitrided layer and an increase in the texture coefficient of the (111) plane. Specifically, at an anode current of 200 A, the lattice mismatch degree at the TiCN/CrAlN interface decreased from 16.4 % to 3.7 %, resulting in the formation of a nearly coherent interface. The hardness, adhesion strength, and H/E ratio of the coating reached their peak values, and the coated cutting tool exhibited optimal cutting performance when machining the GH4149 superalloy.

Investigation of corrosion resistance offered by the Fe-based clad layer under salt spray and electrochemical workstations

The present work aims to evaluate the electrochemical characteristics of the Fe–based alloy coating formed on the 27SiMn steel substrate under neutral salt spray and 3.5 wt% NaCl environments. By adopting the high-speed laser cladding technique, the Fe-based clad layer was fabricated to perform microstructural and electrochemical characterizations. The microstructure and phase of the coating were analyzed using a scanning electron microscope (SEM), electron backscatter diffraction (EBSD) and X-ray diffraction (XRD), and its corrosion performance was also discussed using the salt spray corrosion chamber and the electrochemical workstation. The results show that the microstructure of the coating surface contains equiaxed crystals and long dendritic crystals which arise due to the higher solidification rate after the cladding process. The Fe–based coating was rich in FeCr phase throughout its microstructure without the formation of the intermetallic compounds. Compared to the substrate, the corroded surface of the coating tends to be compact containing a few corrosion pits after different corrosion times, which is attributed to the formation of Cr oxide on it. The electrochemical tests on the potentiodynamic polarization curve (PPC) and electrochemical impedance spectrum (EIS) indicate that the corrosion resistance of the coating is superior to the substrate, presenting a higher corrosion potential (−0.298 V), lower passive current density (1.36 × 10−6 A•cm2), and higher charge transfer resistance (8.23 × 106 Ω·cm2). Additionally, the corrosion mechanism of coating in salt spray and electrochemical tests is the local pitting corrosion due to the autocatalytic effect on the localized region, which facilitates Cl− ions penetrating the coating and leads to the dissolution of Fe and Cr oxides.