Microstructural Evolution Research Articles

Effect of Extrusion Temperature on Microstructure and Mechanical Properties of Mg–Al–Zn Alloy Prepared by Solid‐State Recycling of Mixed Waste Chips

The recycled Mg–Al–Zn alloys are successfully fabricated through solid‐state recycling of mixed waste chips, including cold pressing and hot extrusion. The effects of extrusion temperature on the microstructure evolution, slip mode, tensile properties, and hardness are studied. The homogeneous fine dynamic recrystallization (DRXed) grains with an average grain size of less than 13.1 μm can be obtained at four different extrusion temperatures (250, 300, 350, and 400 °C). The average grain size of the DRXed grains continuously increases with the rising extrusion temperature. However, the yield strength (YS), ultimate tensile strength (UTS), and elongation to failure (EL) of the recycled alloys increase first and then decrease. The recycled Mg–Al–Zn alloys at 350 °C demonstrate excellent mechanical properties with the YS of 134.6 MPa, UTS of 286.2 MPa, EL of 7.4%, and Vickers hardness of 75.2 HV, respectively. In addition, the slip mode is transformed from the previous basal slip to the coactivation of multiple slips composed of the basal slip, prismatic slip, and pyramidal slip with the rising extrusion temperature.

Microstructural Modifications and Failure Mechanisms of an Aluminum‐Based Abradable Coating System during Isothermal and Cyclic Aging

Abradable systems are used in the aeronautical industry to improve the efficiency of gas turbine. Those materials are exposed in service to temperature up to 450 °C. The increase in gas turbine efficiency requires to increase the operating temperature and therefore the service temperature of abradable coating. The present study focuses on the isothermal and cyclic thermal aging of the Al–Si abradable coating system in a laboratory air at high temperature up to 500 °C. The investigation encompasses the microstructural evolution, phase transformation, and the formation of cracks, along with their interrelated effects. During aging, silicon particles precipitate in the abradable top coat. In addition, coarsening of those particles is observed and the coarsening kinetics appears to be faster in cyclic thermal aging conditions compared to isothermal aging. During cyclic and isothermal aging, brittle aluminides develope at the abradable top–coat/bond–coat interface, due to the interdiffusion of Al and Ni species. During cyclic aging, thermal cycles create thermomechanical stress at the top‐coat/bont‐coat interface due to coefficient of thermal expansion mismatch between the Al‐Si deposit and intermetallic phases. The stress generated results in the formation of cracks and porosities at the top–coat/bond–coat interface resulting in a dramatic failure of the system.

Investigation on the microstructure and mechanical properties of large-tube forging manufactured by additive forging

Abstract Large-tube forgings were formed using nine layers of continuous-casting billet made from 15CrNi3MoV alloy steel via additive forging. The interfacial microstructural evolution under different hot-compression bonding temperatures and strains was investigated using optical microscopy, scanning electron microscopy, and electron backscatter diffraction. The tensile properties of the hot-compression-bonded and tube-forged samples were also evaluated. The results showed that as the hot-compression bonding temperature and strain increased, the bonding interface gradually disappeared and the voids at the bonding interface closed. Finally, the interface was replaced with recrystallised grains. The tensile properties of the hot-compression-bonded samples at different temperatures and strains were identical. The tensile properties of the interface and base samples of the tube forging were comparable, and the fracture morphologies were consistent. The fracture position of the large tensile sample with a length of 1000 mm containing three original interfaces is the base, indicating the complete metallurgical bonding of the forging

Creep Phenomena, Mechanisms, and Modeling of Complex Engineering Alloys

Metal creep has been a subject of extensive study for more than 110 years because it affects the useful life of engineering components operating at high temperatures. This is even more true with ever-increasing operating temperatures of propulsion/power-generation systems and the environmental regulations to reduce greenhouse emissions. This review summarizes the recent development in creep modeling with regards to creep strain evolution, creep rate, creep ductility, creep life, and fracture mode, attempting to provide a comprehensive mechanism-based framework to address all the important creep phenomena and the long-standing issue of long-term creep life prediction with microstructural evolution and environmental effects.

Laboratory investigation on static and dynamic properties, durability, and microscopic structure of Nano-SiO2 and polypropylene fiber cemented soil under coupled seawater corrosion and cyclic loading

Cemented soils in coastal harbors are susceptible to adverse factors such as seawater corrosion and cyclic dynamic loading, which may consequently reduce their stability and durability. In recent years, Nano-SiO2(NS) has been widely used to enhance the mechanical properties of cemented soil. However, this enhancement may potentially lead to a reduction in ductility. Conversely, polypropylene fibers (PP) have attracted widespread attention for their potential to enhance the ductility of cemented soils, but their ability to improve the strength of cemented soils is limited. To address these issues, this study focused on utilizing five different nano-dosages combined with four different fiber dosages to enhance cemented soils. These enhanced soils were then subjected to curing periods of 7, 28, and 60 days in seawater environments. The study employed various tests including unconfined compressive strength tests (UCS), uniaxial cyclic loading tests, scanning electron microscopy tests (SEM), X-ray diffraction (XRD), and nuclear magnetic resonance (NMR) to investigate the potential impacts of these additives on durability, strength, corrosion resistance, and microstructure evolution. The results of the study indicate that seawater corrosion and cyclic loading contribute to a reduction in the stability of cemented soils. However, the addition of NS and PP effectively enhances the compressive strength and durability of these soils. The optimal combination ratio is achieved when the dosages of NS and PP are 3.6 % and 0.8 %, respectively. In this case, the growth rate of unconfined compressive strength of cemented soils surpasses the sum of each individual dosage, increasing by 137.7 %, 245.6 %, and 235.3 % after 7, 28, and 60 days of curing, respectively. Furthermore, the growth rate of PP on the compressive strength of cemented soils remains largely unaffected by seawater corrosion. The optimal composite dosage of cemented soils effectively mitigates the increase in porosity caused by seawater corrosion. C-S-H enhances the mechanical interlocking between hydration products and PP by encapsulating PP, reducing energy transfer losses in cemented soils, and increasing their dynamic modulus. The volcanic ash reaction and nucleation effect of NS further enhance this effect, and their combined use significantly improves the seawater corrosion resistance of cemented soils.

Superior comprehensive performance CaO‐based core achieved by optimizing particle gradation via orthogonal experiments

AbstractThe effect of CaCO3 particle size on the viscosity of slurry, phase formation, microstructural evolution, and performances of the water‐soluble CaO‐based ceramic core sintered at different temperatures was systematically investigated and discussed, and the particle gradation orthogonal experiments were used to adjust flexural strength, water‐soluble rate, shrinkage rate, apparent porosity, and hygroscopicity rate. The results showed that the finer particle size increased the effective contact area between CaO and SiO2, which promoted the generation of CaO–SiO2 system phase and the dense microstructure in the sintered CaO‐based cores. The higher sintering resulted in dense microstructure. The optimal gradation scheme included 28 wt.%, 56 wt.%, and 16 wt.% CaCO3 powder with D50 = 11.0 µm, 6.17 µm, and 4.62 µm, respectively, and the resulting flexural strength was 9.57 MPa, water‐soluble rate was 65.37 g/h in 60°C water, shrinkage rate was 8.62%, porosity rate was 38.85%, presenting a well‐balanced comprehensive performance, which is significant for the complex internal castings.

Study of Aging Temperature on the Thermal Compression Behaviors and Microstructure of a Novel Ni-Cr-Co-Based Superalloy

Nickel-based superalloys have been widely used in the aerospace industry, and regulating the reinforcing phases is the key to improving the high-temperature strength of the alloy. In this study, a series of aging treatments (650 °C, 750 °C, 850 °C and 950 °C for 8 h) were designed to study different thermal deformation behaviors and microstructure evolutions for a novel nickel-based superalloy. Among the aged samples, the 950 °C aged sample achieved the peak stress of ~323 MPa during the thermal deformation and the highest microhardness of ~315 HV after thermal compression, which were the greatest differences compared to before deformation. In addition, the grains of the 950 °C sample exhibit deformed fibrous shapes, and the grain orientation is isotropic, while the other samples exhibited isotropy. In the 850 °C and 950 °C high-temperature aging samples, the γ′ precipitate (about 20 nm in size) is gradually precipitated, which inhibits the movement of dislocation in the grain during compression, thus inhibiting the occurrence of dynamic recrystallization and improving the high-temperature mechanical properties of the alloy.

Benchmarking machine learning strategies for phase-field problems

We present a comprehensive benchmarking framework for evaluating machine-learning approaches applied to phase-field problems. This framework focuses on four key analysis areas crucial for assessing the performance of such approaches in a systematic and structured way. Firstly, interpolation tasks are examined to identify trends in prediction accuracy and accumulation of error over simulation time. Secondly, extrapolation tasks are also evaluated according to the same metrics. Thirdly, the relationship between model performance and data requirements is investigated to understand the impact on predictions and robustness of these approaches. Finally, systematic errors are analyzed to identify specific events or inadvertent rare events triggering high errors. Quantitative metrics evaluating the local and global description of the microstructure evolution, along with other scalar metrics representative of phase-field problems, are used across these four analysis areas. This benchmarking framework provides a path to evaluate the effectiveness and limitations of machine-learning strategies applied to phase-field problems, ultimately facilitating their practical application.

Effect of Cold Compression and Heat Treatment on Microstructure and Mechanical Properties of Al-Zn-Mg-Cu Alloyure and mechanical properties of Al-Zn-Mg-Cu alloy

The microstructural evolution of Al-Zn-Mg-Cu alloy under different stress and aging temperature was studied using cold compression and heat treatment. The relationship between the process parameter and the microstructure of the material was analyzed by OM, EBSD, and TEM. The results showed that the grain size decreased and the recrystallization fraction increased with the increase of compression. Textures of <111>||X (cubic), <110>//Y, Goss have higher intensity after solution treatment, but their intensity and proportion also decrease with the increase of compression. η' is the main precipitate in the alloy aged at 140 °C, while η is the main precipitate in the alloy aged at 160°C. Precipitation coarsening and grain refinement affect the microhardness of the alloy together.

Integrated Framework to Model Microstructure Evolution and Decipher the Microstructure-Property Relationship in Polymeric Porous Materials.

Unraveling the microstructure-property relationship is crucial for improving material performance and advancing the design of next-generation structural and functional materials. However, this is inherently challenging because it requires both the comprehensive quantification of microstructural features and the accurate assessment of corresponding properties. To meet these requirements, we developed an efficient and comprehensive integrated modeling framework, using polymeric porous materials as a representative model system. Our framework generates microstructures using a physics-based phase-field model, characterizes them using various average and localized microstructural features, and evaluates microstructure-aware properties, such as effective diffusivity, using an efficient Fourier-based perturbation numerical scheme. Additionally, the framework incorporates machine learning methods to decipher the intricate microstructure-property relationships. Our findings indicate that the connectivity of phase channels is the most critical microstructural descriptor for determining effective diffusivity, followed by the domain shape represented by curvature distribution, while the domain size has a minor impact. This comprehensive approach offers a novel framework for assessing microstructure-property relationships in polymer-based porous materials, paving the way for the development of advanced materials for diverse applications.

Effect of different powers on microstructure evolution and corrosion behavior of 5SiC-Ni60 coatings by directed energy deposition

The microstructural evolution and corrosion behavior of directed energy deposition (DED) additive manufactured 5SiC-Ni60 composite coatings are investigated, elucidating the impact of fluctuations in power on the coating. The experiment reveals the microstructural characteristics, eutectic evolution, phase-microhardness correlation, and corrosion resistance mechanisms, all influenced by power variation as a crucial factor. Utilizing SEM, EDS, XRD, PDP, EIS, and XPS, the mapping relationship between microstructure reinforcement mechanisms, microhardness region features, corrosion behavior formation mechanisms, and power variation is clarified. The optimal laser power is determined to be 3000 W, facilitating the formation of a dense passivation film, efficiently reducing corrosion contact area and enhancing corrosion resistance. The chemical composition of the passivation film is revealed through XPS. Furthermore, utilizing polarization characteristics, impedance analysis, and corrosion morphology as focal points of discussion, the pitting defects on the corroded surface are explained. Consequently, achieving corrosion protection for the composite coating requires intervention with appropriate power parameters, providing valuable insights for enhancing corrosion resistance based on process parameters.

Microstructure evolution and mechanical properties of Cu–9Ni–6Sn alloy during continuous cold deformation process

A Cu–9Ni–6Sn alloy bar with pronounced axial columnar grains and a diameter of 10.5 mm was fabricated by using directional solidification technology, which was directly cold-drawn into a superfine alloy wire with a diameter of 40 μm without intermediate annealing. The strength and microstructure evolutions of the Cu–9Ni–6Sn alloy during the cold drawing were studied. The results indicate that twinning is more likely to occur in fiber structures ranging from 60 to 120 nm. A dual-fiber structure consisting of <111> and <100> orientations formed after cold-drawing. Unexpectedly, a large number of deformation twins were discovered within the <111> fibrous texture and later transformed into detwinning structures, disrupting the axial fibrous texture. The generation of deformation twinning primarily results from Ni and Sn elements disrupting crystal symmetry and reducing stacking fault energy of the alloy and the formation of <111> texture. The combined effects of detwinning structures and dislocation wall induced work-softening of the alloy, enabling high-strain processing and ultimately yielding nanocrystalline grains, i.e., the Cu–9Ni–6Sn alloy underwent cold drawing with a high train of 11.23 and obtained an average grain size of ∼38 nm, which exhibited a tensile strength of 1453 MPa.

Multiscale modelling of microstructure evolution, and local solidification behaviours of the AlSi10Mg build component in laser powder bed fusion process

Laser powder bed fusion (L-PBF) process is an additive manufacturing process, in which rapid heating and cooling takes place. The microstructure and the solidification behaviour of L-PBF components have significant impacts on their mechanical properties. The solidification takes place in a very short duration which is difficult to capture experimentally, therefore the finite-element (FE) simulation is the best feasible solution. In this paper, to study the evolution of the AlSi10Mg alloy’s microstructure during the L-PBF process, a model composed of macroscopic finite element (FE) model and microscopic phase field (PF) model was built. This model is suitable to predict a more realistic thermal behaviour involving the possible physical phenomena and the thermal behaviour for various heat inputs was calculated. The PF model was then updated with these results in order to simulate the chemical compositions’ concentration field and solidified microstructure. According to the simulation’s results, the primary dendrite arm spacing (PDAS) is significantly influenced by the laser line energy. To validate the FE model along with the Phase field (PF) model, the results were compared with the analytical and experimental findings; and the FE model and PF results exhibited good agreement with the experimental results. Additionally, the solute distribution analysis demonstrated that during the solidification process, micro-segregation developed and the process parameters affected the micro-segregation. Finally, the specimens were subjected to metallographic and element distribution analyses using an energy-dispersive spectrometer (EDS) to compare the results with those from the PF simulation and establish the relationship between the process parameters.

Temperature Effect on Microstructure Evolution and Mechanical Properties of Fe–28Mn–8Al–1C Lightweight Steel via Supersonic Fine Particle Bombardment

Temperature Effect on Microstructure Evolution and Mechanical Properties of Fe–28Mn–8Al–1C Lightweight Steel via Supersonic Fine Particle Bombardment

High-efficient hybrid arc and friction stir additive manufacturing of high-performance Al-Cu-Mg-Ag-Zr alloy: Microstructural evolution and precipitation behaviors with Ω/L12 co-precipitates

Cost-effective and convenient additive manufacturing technologies are recognized as suitable alternatives for achieving lightweight aluminum alloy components with dense and defect-free parts toward high mechanical properties. Herein, a high-efficient hybrid arc and friction stir additive manufacturing (HAFS-AM) technique was employed to fabricate a high-performance Al-Cu-Mg-Ag-Zr alloy part. The AC pulsed tungsten inert gas (TIG) was utilized for the rapid pre-deposition of Al-Cu-Mg-Ag-Zr alloy with high efficiency. Friction stir processing contributed to eliminating pore defects and refining coarse microstructure in the pre-deposited arc layers, accounting for enhancing mechanical properties. During the HAFS-AM, the coarse θ phase with continuous network morphology was completely broken and gradually dissolved into the α-Al matrix. The addition of Zr element promoted the precipitation of coherent L12-Al3Zr inducing dislocation shearing behavior. The Mg and Ag additions accelerated the precipitation of semi-coherent plate-like Ω and σ phases, where a critical size (thickness and diameter) of precipitates existed for deciding the behaviors of dislocation shearing and dislocation looping. The ultimate tensile strength and elongation of the HAFS-AMed steady-state layer reached 262 MPa and 18.8 %, which were increased by 21 % and 96 % compared to that of the arc layer, respectively. The combined effect of arc and friction stir with high efficiency achieved high-performance manufactured components, expediting the future industry application of advanced additive manufacturing technology.

Effects of recrystallization on interfacial microstructure evolution and shear strength of TiAl alloy joints

The effects of dynamic recrystallization (DRX) and post-bonding heat treatment (PBHT) on the interfacial microstructure evolution and mechanical properties enhancement of Ti-43Al-4Nb-1Mo-0.2B alloy joints, subjected to various bonding parameters, were thoroughly investigated through detailed microstructural characterization and shear performance tests. A strip-like DRX area was observed at the interface when bonding at 1100 °C, ≥30 MPa, for 60 min. Equiaxial- γ grains underwent discontinuous dynamic recrystallization during the bonding process, and tended to form flat grains parallel to the lamellae direction during recrystallization annealing (1000 °C/6 h) owing to the hindrance imposed by the lamellae on both sides. The orientations of lamellae on the both sides of bonding interface affects the lamellae's stress distribution and deformation behavior at the bonding interface, subsequently influencing the DRX behavior and the width of the DRX zone. Static recrystallization (SRX) during the recrystallization annealing treatment can eliminate bonding defects of joints bonding at lower pressures or temperatures. Optimal joints with fully lamellar interfacial microstructure and excellent shear properties can be obtained through single-α phase annealing treatment. Lamellae microstructure tailored through PBHT can significantly enhance the quality of joints, attributed to the homogeneity of the microstructure between the interface and matrix. The highest shear strength of 478 MPa, accounting for 82 % of the matrix strength, was obtained under the bonding parameters of 1100 °C/30 MPa/60 min-1290 °C/15 min. This work provides important DB process parameters for fabricating of complex structural parts of TiAl alloy.

Study on the Influence of Surface Roughness and Temperature on the Interface Void Closure and Microstructure Evolution of Stainless Steel Diffusion Bonding Joints

Study on the Influence of Surface Roughness and Temperature on the Interface Void Closure and Microstructure Evolution of Stainless Steel Diffusion Bonding Joints

Long-term ablation behavior of Al4SiC4-YB4 modified Cf/ZrB2-SiC composites at 2600 °C

Long-term ablation behavior of Al4SiC4-YB4 modified Cf/ZrB2-SiC composites was characterized by air plasma torch at 2600 °C for 300 s. The phase composition and the microstructure evolution of the composites were investigated. The addition of YB4 promotes the formation of nano t-Zr0.92Y0.08O1.96 crystals, decreasing the phase transition stress in the oxide layer and reducing the volatilization of the glassy phase. However, the addition of Al4SiC4 reduces the melting point of Zr-based oxides and the viscosity of the oxide layer. Therefore, the air plasma torch blows the oxide layer away, leading to the increase of linear recession rate.

Polyaluminum enhanced dehydrated cement paste activated slag: Mechanical performance and microstructural analysis

Dehydrated cement paste (DCP) activated slag offer a promising sustainable alternative to traditional Portland cement, but their inadequate mechanical strength limits practical applications. This study investigates the potential of polyaluminum chloride (PAC) to enhance the performance of DCP activated slags, utilizing multi-scale characterization methods. Results demonstrate that PAC incorporation significantly promotes strength development, enabling the binder to meet requirements for most engineering applications. PAC accelerates Ca(OH)2 consumption, and facilitates additional hydration product formation that refines the pore structure, leading to the densification of samples. These improvements in strength and microstructure are attributed to the modified slag dissolution and the enhanced polymerization of the C-A-S-H gel. Furthermore, the underlying role of PAC on the hydration, mechanical performance and microstructural development of DCP activated slags are discussed.

Microstructure evolution and recrystallization mechanisms of a fine-grained nickel-based superalloy during thermal deformation process

The thermal deformation behavior of fine-grained GH93 alloy was investigated through isothermal compression tests at deformation temperatures of 930–1020 °C, strain rates of 0.001–1 s−1 and deformation amount of 50 %. Based on the true stress-strain data, the power dissipation maps, instability maps and hot processing maps of this alloy were established at different strains. The precision of the hot processing maps was verified by deformation microstructures, and the optimal processing parameter was ascertained to be 975–1010 °C/0.001–1 s−1. The microstructure evolution, dynamic recrystallization (DRX) and twinning evolution were analyzed by means of EBSD and SEM, simultaneously the DRX mechanisms under different deformation parameters were elucidated. The results demonstrate that the degree of recrystallization increases with the increase of deformation temperatures and the decrease of strain rates. At lower deformation temperatures, γ′ phases at grain boundaries hinder grain boundaries to slip and encourage dislocation entanglement, thereby promoting recrystallization. As the deformation temperatures increase, γ′ phases gradually dissolve, and the pinning effect weakens, leading to grain coarsening. The proportion of ∑3 twin boundaries shows a continuous upward trend with increasing temperature, which is consistent with the trend of changes in recrystallization volume fraction. DRX mechanisms of the alloy under different process parameters include continuous dynamic recrystallization (CDRX) mechanism and discontinuous dynamic recrystallization (DDRX) mechanism. DDRX is the main recrystallization mechanism, and CDRX mechanism becomes more active with increasing temperatures and decreasing strain rates, while it is still only an auxiliary nucleation mechanism.