High Dislocation Density Research Articles

Achieving enhanced thermal conductivity and mechanical properties in Mg-Zn-Gd-Zr alloys via regulation microstructure characteristics

It is well known that the microstructure of metallic materials determines the mechanical properties. However, the effect of microstructure on thermal conductivity lacks an accurate quantitative description of this relationship. In this work, the mechanism of variation in mechanical and thermal conductivities with microstructure was revealed by the characterization of cast, heat-treated, and extruded Mg-xZn-yGd-0.6Zr (wt%) alloys: ZV66, ZV62, and ZV26. The contributions of solution atoms, second phases, grain size, and dislocations to the yield strength and thermal conductivity were quantitatively calculated, and their effects on the plasticity and work-hardening behavior were qualitatively analyzed. The results show that hot extrusion promotes the precipitation of nanoprecipitates, such as MgZn2, Mg4Zn7, and Mg5Gd, resulting in the reduction of Zn and Gd solute atoms and the introduction of high-density dislocations and grain boundaries. The extruded ZV66 alloy exhibits excellent mechanical properties and thermal conductivity (a tensile yield strength of 232 MPa, an elongation of 22 %, and a thermal conductivity of 127.6 W/(m·k)); these values are better than those reported for similar products. The achievement of high strength and thermal conductivity is attributed to the precipitation of solute atoms to improve thermal conductivity in addition to grain boundary strengthening and work-hardening strengthening to improve strength. These findings provide new insights into achieving excellent strength–thermal conductivity property amalgamations in magnesium alloys by tailoring their microstructure.

Texture Evolution and Plastic Deformation Mechanism of Cold-Drawn Co-Cr-Ni-Mo Alloy

The plastic deformation behavior and mechanisms of Co-Cr-Ni-Mo alloy were investigated. The wires were subjected to different reductions using a multi-pass drawing approach and the resulting microstructures were characterized by EBSD and TEM. It was found that the alloy cold-drawn from surface to center exhibited non-uniform radial strain, with decreasing strain from surface to center. As the strain increased, the transverse texture of the alloy evolved from the initial bimodal texture consisting of strong {100}<110> and weak {110}<001> components to bimodal texture with {110}<233> and {112}<111> components, with significant twinning and mirror orientation between twin and matrix. The longitudinal texture evolution of the alloy mainly occurred on the α-fiber line, and ultimately did not form a significant texture due to grain elongation and crystal rotation. The plastic deformation mechanism of the Co-Cr-Ni-Mo alloy was dominated by dislocation slip at lower strain levels, which gradually transitioned to a combination of dislocation slip and twinning at higher strain levels. The deformation twins were typically distributed in high-density dislocation regions, and the twin boundaries transformed into high-angle sub-grain boundaries, hindering the extension of dislocation slip and deformation twin. With the increase in strain, work hardening results in a significant increase in strength and microhardness.

Step-edge-guided nucleation and growth mode transition of α-Ga2O3 heteroepitaxy on vicinal sapphire

Abstract Controlling the epitaxial growth mode of semiconductor layers is crucial for optimizing material properties and device performance. In this work, the growth mode of α-Ga2O3 heteroepitaxial layers was modulated by tuning miscut angles (θ) from 0° to 7° off the (10-10) direction of sapphire (0002) substrate. On flat sapphire surfaces, the growth undergoes a typical three-dimensional (3D) growth mode due to the random nucleation on wide substrate terraces, as evidenced by the hillock morphology and high dislocation densities. As the miscut angle increases to θ=5°, the terrace width of sapphire substrate is comparable to the distance between neighboring nuclei, and consequently, the nucleation is guided by terrace edges, which energetically facilitates the growth mode transition into the desirable two-dimensional coherent growth. Consequently, the mean surface roughness decreases to only 0.62 nm, accompanied by a significant reduction in screw and edge dislocations to 0.16×107 cm-2 and 3.58×109 cm-2, respectively. However, the further increment of miscut angles to θ=7° shrink the terrace width less than nucleation distance, and the step-bunching growth mode is dominant. In this circumstance, the misfit strain is released in the initial growth stage, resulting in surface morphology degradation and increased dislocation densities.

Nanostructuring of an additively manufactured CoCrFeNi multi-principal element alloy using severe plastic deformation: Comparison of two materials processed by different laser scan speeds

Experiments were conducted to reveal the refinement of the microstructure and the evolution of the hardness of an additively manufactured (AM) CoCrFeNi multi-principal element alloy (MPEA) processed by severe plastic deformation (SPD) using high pressure torsion (HPT) technique. AM was carried out by laser powder bed fusion (L-PBF) technique at two different laser scan speeds. The as-built alloys for both laser scan speeds have a single-phase face-centered cubic (fcc) structure with <110> fiber texture parallel to the building direction. X-ray line profile analysis (XLPA) revealed that the dislocation density was considerably high even in the AM-processed state before HPT (3 × 1014 m−2) which increased by two orders of magnitude during HPT. The saturation of the lattice defects (dislocation density and twin fault probability) as well as the crystallite size occurred at a shear strain of about 10 during HPT. In both AM-processed alloys, <111> fiber texture developed parallel to the normal of the HPT-processed disks. For both laser scan speeds, the initial grain size in the AM-processed samples was refined from 70 to 90 μm to the nanocrystalline regime after 10 turns of HPT. Additionally, nanotwins formed with a probability of about 3 %. The initial hardness of the AM-processed MPEA samples for both laser scan speeds was 2700–2800 MPa, which is superior to that of CoCrFeNi produced by casting (about 1380 MPa). This can be explained by the high dislocation density in the AM-processed specimens. The formation of nanostructure with high lattice defect density during HPT resulted in a very high hardness value of about 5500 MPa in the AM-processed CoCrFeNi MPEA samples for both laser scan speeds.

A model for physical dislocation transmission through grain boundaries and its implementation in a discrete dislocation dynamics tool

The mechanical behavior of most metals in engineering applications is dominated by the grain size. Physics-based models of the interaction between dislocations and the grain boundary are important to correctly predict the plastic deformation behavior of polycrystalline materials. Dislocation-grain boundary interaction is complex and a challenge to model. We present a model for simulating the physical transmission of dislocations through grain boundaries within Discrete Dislocation Dynamics tools. The properties (glide plane, Burgers vector, initial length) of the transmitted dislocation are chosen based on geometric criteria as well as a maximization of the resolved shear stress of the transmitted dislocation. Additionally, stress and displacement transparency as well as the discontinuity are ensured via a grain boundary dislocation – a butterfly-like geometry in the general case – whose properties are selected to minimize the residual Burgers vector at the interface. This additional ‘grain boundary dislocation’ allows a direct comparison as well as a calibration of the model with experiments on the macroscale particularly for neighboring grains with a high dislocation density contrast. Two basic examples illustrate the model and an application to a 40-grain polycrystal demonstrates the scalability of the approach.

Accelerated improvement in tensile superelasticity of electron beam directed energy deposition manufactured NiTi alloys by artificial thermal cycling combined with low temperature aging treatment

ABSTRACT The low-temperature aging treatment at 250°C can significantly improve the tensile superelasticity of NiTi alloys fabricated by electron beam directed energy deposition (EB-DED). However, it requires a very long aging duration (up to 200 h) to achieve excellent tensile superelasticity due to inherent coarse grain size. To accelerate the aging process, the high-density dislocations are introduced by artificial thermal cycling treatment prior to the aging treatment (the original dislocation content in EB-DED processed NiTi alloys is very low), which will promote the subsequent uniform precipitation of nanoscale Ni4Ti3 particles during low-temperature aging treatment. The phase transformation behaviour always maintains a stable two-stage martensitic phase transformation. Under a cyclic tensile test at 6% strain, 24 h aged sample with thermal cycling maintains a recovery rate exceeding 90% even after 10 cycles, comparable to the performance of the sample aged for 200 h without thermal cycling, indicating a substantial improvement in aging efficiency.

Achieving strength-ductility synergy in Al-4.5 wt%Cu binary alloy through semisolid isothermal treatment coupled with ECAP

Bulk nanostructured (NS) aluminum alloys typically have high strength but with extremely limited ductility. An advanced two-step thermomechanical processing, i.e. semisolid isothermal treatment coupled with equal-channel angular pressing (ECAP), was adopted to achieve high strength (413±2.5 MPa) and high elongation (12.0±0.6 %) in bulk NS Al-4.5 wt%Cu binary alloy. The broken nanoscale Al2Cu particles (∼50–80 nm) from lamellar eutectic, dynamic precipitations Al2Cu (∼30–60 nm), refined grains, and high-density dislocations are believed to be key contributors for the high strength. The bimodal grain structure, which caused a well-balanced work hardening and a good deformation compatibility, is critical for the enhanced strength-ductility synergy. This work demonstrates a new approach for improving strength-ductility synergy in interdendritic-eutectic type aluminum alloys.

Promoting nanoprecipitates via prefabricated defects to pin dislocations and grain boundaries for trading off high-strength and low-thermal-expansion of invar alloys

Invar alloys that combine high strength with a low coefficient of thermal expansion (CTE) are urgently required for industrial applications. Based on the lower coarsening rate during aging and the CTE values of carbonitrides, a novel strategy is proposed to prepare carbonitrides by reducing carbon and increasing nitrogen to design high-strength and low-thermal-expansion invar alloys. The V(C, N) nanoprecipitate was introduced into the invar alloy, and its effects on the microstructure, thermal expansion behavior, and mechanical properties were investigated. The direct-aged alloy exhibited an enhanced tensile strength of 525 MPa and a ductility of 47.6%. The cold-deformation aging alloy achieved an enhanced tensile strength of 815 MPa while retaining 7.4% ductility and a low CTE value of 1.23×10−6 /°C. The V(C, N) nanoprecipitates effectively immobilized dislocations and grain boundaries, leading to a high dislocation density and small grain size in the alloy. The contributions of each strengthening mechanism were calculated, and the precipitation and dislocation strengthening were found to be the main mechanisms of strength enhancement. These results provide a novel approach for preparing high-strength and low-CTE invar alloys.

Hydrogen-enhanced densified deformation twins in 304L austenitic stainless steel fabricated by selective laser melting

Twin boundaries are the preferred site for crack nucleation and propagation in a hydrogen-rich environment. The relationship among hydrogen, cellular structure, and deformation twins is significant in further enhancing the resistance to hydrogen embrittlement of austenitic stainless steels produced by SLM. It has been demonstrated that cellular structures with high dislocation densities play a positive role in increasing stress above a critical level for deformation twin formation. The cellular structure affects the distribution of hydrogen, with hydrogen presence at cellular boundaries reducing its accumulation at grain boundaries. Hydrogen increases the density of deformation twins and reduces the thickness of individual deformation twins. This phenomenon can be attributed to an increase in nucleation sites for the deformation twin, which is closely related to the decrease in stacking fault energy and the increase in dislocation density caused by hydrogen. Both cellular structure and deformation twins play a positive role in improving the hydrogen embrittlement resistance of austenitic stainless steels.

Constructing high-density dislocations by primary (Nb,Ti)(C,N) to induce massive secondary precipitations in austenitic heat-resistant cast steel

The microstructural evolution and the high-temperature tensile properties of a novel Nb-Ti-N alloyed austenitic heat-resistant cast steel were investigated during the isothermal aging at 900 °C for up to 1000 h. The mechanisms of enhancing strength-ductility synergy and the high-temperature tensile fracture behaviors after the aging process were analyzed in detail through tensile tests at 900 °C. Obtained results show that the high-density dislocation regions and the Cr segregation, formed around the intragranular primary (Nb,Ti)(C,N), provided numerous nucleation sites for submicron-sized secondary M23C6 precipitates. The density of secondary M23C6 significantly increased, while the coarsening rate was notably reduced during the aging process. Simultaneously, the uniform dispersed precipitation of nano-sized secondary (Nb,Ti)C was promoted by massive dislocations, which exhibited high resistance to coarsening during long-term aging. The improvement of high-temperature strength was attributed to the precipitation strengthening effects induced by the submicron-sized M23C6 and nano-sized (Nb,Ti)C particles. Additionally, the enhancement of ductility during aging was mainly due to the more effective stress transmission and the ameliorated interface relationship between primary (Nb,Ti)(C,N) and austenitic matrix, which was facilitated by the abundant precipitation of secondary phases. The current findings indicate that high-density dislocations constructed by the intragranular primary (Nb,Ti)(C,N) induce the extensive dispersion of secondary strengthening phases, which enhanced both ultimate tensile strength of 158 MPa and elongation of 45.3% at 900 °C after isothermal aging for 1000 h.

In situ neutron diffraction study and electron microscopy analysis of microstructure and texture evolution during annealing of rolled CoCrFeNi alloy doped with 1 at.%C

In situ neutron diffraction studies of changes in the dislocation density, volume fraction of carbides, and crystallographic texture have been performed during annealing of a cold-rolled multi-principal element CoCrFeNi alloy doped with 1 at.%C. In addition, microstructures of the as-rolled and several annealed samples of this alloy have been investigated using electron microscopy-based techniques. It is found that cold rolling to a thickness reduction of 74% results in a brass-type rolling texture with a spread of orientations between the Goss and brass components and with a pronounced 〈111〉//ND fiber. The deformed microstructure is characterized by a high density of dislocations and shows large variations in deformation structures in regions of different crystallographic orientations. In particular, bundles of deformation twins and high frequencies of shear bands are observed in regions having orientations along the 〈111〉//ND fiber. Annealing at 700 °C–1000 °C leads to recovery and recrystallization, during which shear bands and regions of mixed orientations act as preferential nucleation sites for recrystallized grains. Precipitation of M23C6 particles also takes place during annealing. The particles retard boundary migration, thus slowing down recrystallization and restricting grain growth. The average size of recrystallized grains does not exceed 5 μm even after annealing at 1000 °C for 60 min. While rolling textures are retained in some annealed samples, other samples demonstrate distinct recrystallization textures with new texture components. The results obtained in this work are compared with the literature data for several carbon-doped face-centered cubic multi-principal element alloys and for a carbon-free CoCrFeNi alloy.

Hybrid interlayer hot rolling and wire arc additive manufacturing of Al-Mg alloy: Microstructure, mechanical properties and strengthening mechanism

Considering the deformation-strengthening benefits of Al-Mg alloy and the high forming efficiency offered by wire and arc additive manufacturing (WAAM), the microstructure evolution and strengthening mechanism of hybrid interlayer hot rolling and wire arc additive manufacturing (HR-WAAM) samples have been systematically investigated in this study. The results indicate that interlayer hot rolling can effectively reduce the size and number of pores, which diminishes the stress concentration areas. Additionally, rolling deformation significantly enhances the effect of dislocation strengthening. Furthermore, a high density of dislocations can promote recrystallization to refine grain size, while also improving grain orientation, all of which contribute to better stress distribution. Due to these reasons, the strength and toughness of the alloy are notably improved. The average ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) values achieved by HR-WAAM samples were 338 MPa, 276 MPa, and 20.9%, respectively. These values represent increases of 28.5%, 41.5%, and 38.4% compared to conventional WAAM samples. These findings are expected to provide an efficient and cost-effective method for additive manufacturing (AM) of deformation-strengthened aluminum alloys.

Rapid-thermal-process pre-treatment promoted precipitation towards strengthening hard magnetism of Sm2Co17-type magnets

Dislocations can act as heterogeneous nucleation sites but their annihilations upon heating sacrifice point defects nearby, weakening the driving force for precipitate nucleation. In order to keep a high density of dislocations and point defects together, here rapid-thermal-process (RTP) pre-treatment was carried out to promote the precipitate nucleation in Sm2Co17-type permanent magnets that evolve gradual formation and dissociation of dislocations during concurrent precipitation and recrystallization. As exhibited in a model magnet Sm25Co49.3Fe17.1Cu5.6Zr3.0 (wt.%) with high-density dislocations at solution-treated state, the RTP pre-treatment can induce excess point defects owing to the migration of solute atoms towards equilibrium state and the quenching of point defects, and suppress the early-stage diffusion-controlled dissociation of dislocations. After whole-process isothermal aging and slow cooling, the RTP pre-treated magnet possesses much higher fraction of hexagonal SmCo5 (1:5H) nanoprecipitates than the non-pre-treated one, giving rise to effective enhancements in coercivity Hcj from 26.20 to 30.34 kOe and in knee-point field Hk from 14.43 to 19.20 kOe. These findings add insight into controlling precipitation in dislocation-bearing supersaturated solid solutions, which are feasible for strengthening the Sm-Co-based magnets.

Microstructure and properties of oxide-reinforced FeCrAl matrix alloy manufactured by selective laser melting

In this work, nano-Y2O3 dispersed FeCrAl powders (NYD-Fe) were used to produce oxide dispersion strengthened (ODS) alloy by selective laser melting (SLM), and their microstructures and properties were investigated in detail by the kinds of characterization techniques. The results indicate that the Y2O3 particles adhered to the surface of FeCrAl powder absorb more laser, thus increasing the laser energy demand. High quality ODS deposits can be obtained at 600 mm/s and 180 W parameters. The ODS samples deposited by SLM exhibit coarse columnar grains with [001] texture. The Ti-rich nanoparticles and core-shell structured nanoparticles (Y- and O-rich core surrounded by a Ti-rich shell) are observed in ODS alloys. The precipitation formation of core-shell structured nanoparticles involves ball milling amorphization and dissolution reprecipitation. The ODS-180 alloy exhibits a higher ductility compared to FeCrAl-180 alloy, which is caused by the cellular structure with high density dislocations and the nano-sized precipitates inhibit the dislocation motion. The wear rate of the ODS-180 alloy is 51% lower than that of FeCrAl-180 alloy, which is mainly ascribed to the hardness and interface oxide layer resulting from its specific microstructural features.

Understanding the wear behavior and mechanism of gradient nanostructured M50 bearing steel through nanoscratching tests

A gradient nanostructured M50 bearing steel with gradient structural size, carbides, and dislocation density was successfully fabricated by ultrasonic shot peening (USP) technology at room temperature. The friction behaviour and mechanism of gradient nanostructure M50 steel were investigated by using nanoscratch technology under various normal applied loads and depths. Under low normal applied load, gradient samples at ~5 μm depth exhibited a 26.5% maximum reduction in wear rate compared to the tempered sample; under high normal applied load, wear rates for samples at ~100 μm depth exhibited a maximum reduction of 44.6%. At low normal applied load, the wear mechanism involves plowing; while at high normal applied load, the wear mechanism shifts to cutting. Under low normal applied load, wear resistance correlates positively with hardness and negatively with structural size. Under high normal applied load, the increase in hardness of the martensite matrix and the partial decomposition of coarse spherical carbides enable the carbides on the surface of the USPed sample to withstand higher shear stress and stronger stress concentration, preventing cracking of the matrix and carbide edges, and spalling of carbides. High dislocation density (resulting in residual compressive stress) will slow down or inhibit the generation and expansion of cracks during the scratching process, potentially explaining why samples at ~100 μm depths exhibit superior wear resistance.

Creep strength breakdown and the change in back stress strengthening in 10 % Cr martensitic steels during creep at 923 K

The creep strength breakdown in 10 % Cr martensitic steels appeared under creep conditions at a temperature of 923 K and the applied stresses below 120 MPa as a declination from linear regression obtained using short-term creep data. To reveal the origin of creep strength breakdown, the back stress strengthening conception was used. In the initial state, both 10 % Cr martensitic steels had a tempered martensite lath structure with a high dislocation density in the lath interiors and in the lath boundaries, which was stabilized by M23C6 carbides, NbX carbonitrides, and M6C carbides. The shear internal back stresses of 57.5–68.5 MPa and 35–37 MPa were obtained from the creep rate – stress relationship for the regions of high applied stress (above 120 MPa) and low applied stress (below 120 MPa), respectively. The transition from the high stress region to the low stress one in both steels was accompanied by a significant decrease in the dislocation density by an order of magnitude as well as a decrease in particle number density and an increase in the inter-particle spacing in the M23C6 carbide and Laves phase particles located at the low-angle boundaries of the martensitic laths/subgrains. The root mean square superposition of the dislocation and particle contributions to the shear internal back stresses gave the best coincidence with the values obtained from the creep data. The stability of the M23C6 carbide and Laves phase particles located at the low-angle boundaries was concluded to be the key factor suppressing the creep strength breakdown in the 10 % Cr martensitic steels.

Effect of heat treatment on hydrogen embrittlement susceptibility of Al0.25CoCrFeNi high entropy alloy

In this study, the influences of annealing and aging treatments on the hydrogen embrittlement (HE) behavior of the cryo-rolled Al0.25CoCrFeNi high entropy alloy (HEA) were investigated through tensile tests and electrochemical hydrogen charging experiments. The results found that the aged sample showed high strength but was more susceptible to HE. A trade-off between the strength and HE resistance was achieved in the annealed + aged sample. Electron backscatter diffraction analysis and fracture characteristics were performed to clarify the HE mechanism. The high dislocation density and aggregated second phase along the grain boundaries in the aged sample were the important factors to help the initiation of HE crack, and then increasing the HE susceptibility. The annealed + aged sample with low dislocation density and aging precipitation reduced the risk of hydrogen-induced cracking and resulting in the excellent HE resistance. This work offered the method to obtain a comprehensive improvement in the strength and HE resistance of this alloy.

High dislocation density TWIP steel with an excellent combination of strength and plasticity

After undergoing 75% hot deformation and 40% cold deformation, a variant of TWIP (Twin Induced Plasticity) steel with a composition of Fe−22Mn−2.7Al−0.95C−0.75Si (wt.%) was subjected to annealing at various temperatures (850°C, 650°C, 550°C) for 20min. The recovery annealed C550 sample exhibited a yield strength of 1289.20 MPa, a tensile strength of 1442.29 MPa and an elongation of 30.78%. Characterization and comparison of the samples were conducted using XRD, SEM, EBSD, TEM and uniaxial tensile tests. The yield strength of the sample was assessed through different strengthening mechanisms to analysis the exceptional properties of the recovery annealed sample. Experimental findings indicate that the high-density dislocation and the refinement of slip bands in the recovery annealed C550 samples contribute to their superior performance compared to the partially and fully recrystallized samples.

Correlation study of self-annealing-induced recrystallization and grain growth mechanism in copper foil

Copper foils demonstrate a tendency for self-annealing, which adversely impacts the stability of the products. The self-annealing induced recrystallization of copper foil is closely related to the grain growth mode. When copper foil grows in equiaxed grain mode, resulting in a decrease in tensile strength from 780 MPa to 330 MPa. Conversely, the columnar grain copper foil exhibits excellent room-temperature stability in mechanical properties. The mechanism of copper foil room temperature self-annealing behavior was put forward. It was found that the internal stress generated in the process of preparing copper foils is the key factor driving the recrystallization of equiaxed grains. This internal stress originates from nanocrystals and high-density dislocations, with the latter arising from the doping of organic elements. The initial high stress values and the plasticity of dislocations contributed to a noteworthy decrease in residual stress. As dislocation plasticity ensues, the anchoring of interstitial atoms gives rise to dislocation loops. The interaction between dislocation loops and coincident twin boundaries induces the formation of twin steps. The quantity of twins of equiaxed copper foil increases greatly after self-annealing. Conversely, the initial dislocation density of columnar grain copper foil is an order of magnitude lower than that of equiaxed grains.

Mechanical and microstructural responses in molybdenum-rhenium alloys under hot compressions

To study temperature and rate-dependent behaviors of molybdenum-rhenium (Mo-Re) alloys, compressive tests at variable temperatures and strain rates were conducted. After the same machining and thermal annealing processes, fully recrystallization happens in Mo and Mo-Re alloys with low Re content (5 wt. %), while recovery occurs in Mo-Re alloys with high Re content (14 wt.% and 42 wt. %). The strength increases as Re content rises at all temperatures (300 °C, 600 °C and 1200 °C), meaning sufficient strengthening effect of Re. The rate-dependent behaviors, however, show different trends between Mo and Mo-Re alloys. Positive strain rate sensitivity is detected in Mo and low Re Mo-Re alloys in all temperatures, which is consistent to other research. While, near zero strain rate sensitivity is found in high Re Mo-Re alloys at 600 °C. Such an unusual phenomenon may be contributed to high stored dislocation density during mechanical processes. The stored dislocations are activated at a proper temperature to accommodate plastic flow, which weakens the influence of strain rate on strength.