Mechanical Microstructure Evolution Research Articles

Microstructural evolution in 12% Cr heat-resistant steel during compression deformation at 650°C

Microstructural evolution in 12% Cr heat-resistant steel during compression deformation at 650°C

Molecular Dynamics Simulation on Solidification Microstructure and Tensile Properties of Cu/SiC Composites.

The shape of ceramic particles is one of the factors affecting the properties of metal matrix composites. Exploring the mechanism of ceramic particles affecting the cooling mechanical behavior and microstructure of composites provides a simulation basis for the design of high-performance composites. In this study, molecular dynamics methods are used for investigating the microstructure evolution mechanism in Cu/SiC composites containing SiC particles of different shapes during the rapid solidification process and evaluating the mechanical properties after cooling. The results show that the spherical SiC composites demonstrate the highest degree of local ordering after cooling. The more ordered the formation is of face-centered-cubic and hexagonal-close-packed structures, the better the crystallization is of the final composite and the less the number of stacking faults. Finally, the results of uniaxial tensile in three different directions after solidification showed that the composite containing spherical SiC particles demonstrated the best mechanical properties. The findings of this study provide a reference for understanding the preparation of Cu/SiC composites with different shapes of SiC particles as well as their microstructure and mechanical properties and provide a new idea for the experimental and theoretical research of Cu/SiC metal matrix composites.

Microstructural evolution and spheroidization mechanism of powder metallurgy Ti-6Al-4 V alloys after high-temperature forging

After high-temperature forging and rapidly cooling, the microstructure evolution and spheroidization mechanism of powder metallurgy Ti-6Al-4 V alloy have been clarified. The spheroidization process is divided into two asynchronous stages. The initial stage is primarily characterized by the initial shearing and twisting of GBα grain boundaries, as well as the deformation of lamellar structure. Subsequently, the fragmentation of original GBα grain boundaries and the fracture of intra-granular α lamellae are observed. This process is accompanied by grain twisting and substructure formation, especially the division of lamellae through interface splitting and the segregation of local chemical elements. The differential accumulation of elements around the fractured and twisted grains suggests that element segregation and interfacial energy play a significant role in microstructure evolution. Therefore, the static spheroidization process largely depends on the formation and evolution of dislocation substructures, and the reduction of interfacial energy may be a key factor driving this process. These findings provide a theoretical basis for manufacturing metals with specific anisotropic properties by controlling microstructure evolution.

Evolution mechanism of the core-shell to homogeneous microstructure in immiscible alloy by semi-solid treatment under a high magnetic field

Immiscible alloys possess broad industrial applications, but the presence of immiscible gaps makes them highly susceptible to the formation of segregated microstructures, thus, a new method for obtaining a uniform distribution of fine minor separated phases needs to be explored. The present work focuses on the evolution mechanism of a CuCo immiscible alloy with a core-shell microstructure during semi-solid isothermal processing under a high magnetic field. The results showed that the microstructure changes from the core-shell structure of the initial sample to homogeneous microstructure after semi-solid treatment, regardless of whether a magnetic field is applied. The mechanism of microstructure evolution of the alloy during semi-solid treatment was revealed through in-situ experiment, in which Ostwald ripening and coalescence mechanisms led to grain coarsening, grain boundary remelting caused grain dissociation, and ultimately the grains underwent spheroidization. However, as a high magnetic field was applied, the average radius of the Co-rich particles decreased, and the particles were aligned in the direction of the magnetic field, forming a chain-like microstructure due to dipole-dipole interactions between the grains. The CuCo immiscible alloy with a uniform microstructure after semi-solid treatment exhibited a higher microhardness and saturation magnetization. This study offers a novel perspective for designing immiscible alloys with homogeneous microstructures as well as chain-like microstructures by utilizing semi-solid treatment combined with a magnetic field.

Formation mechanism of surface gradient microstructure and mechanical properties evolution of Mg–Y-Nd-Gd-Zr alloy by ultrasonic rolling

The evolution mechanism of the microstructure and mechanical properties of a Mg–Y-Nd-Gd-Zr alloy subjected to different numbers of passes of the ultrasonic surface rolling process (USRP) was investigated. The results demonstrated an initial decrease followed by an increase in the surface roughness of the alloy. The optimal surface roughness was achieved after four passes, with a contour mean deviation of 0.06 μm and micro-roughness 10-point height of 0.55 μm. After the USRP, the alloy exhibited a composite gradient structure characterized by increased grain size and decreased dislocation, lamination, and twin densities. The depth of the gradient layer increased with each additional USRP pass, ranging from 650 μm (1 pass) to 910 μm (8 passes). Furthermore, the USRP treatment effectively enhanced the alloy strength; compared with the untreated samples; the yield strength increased by 34.2% in the gradient sample after one pass. No significant change was observed in the YS with an increasing number of rolling passes for Mg alloys, whereas both the tensile strength and elongation showed improvements. High-density twinning played a crucial role in enhancing the YS of the gradient samples without significant variation across different numbers of rolling passes, thus following a consistent pattern. The formation of more nanocrystals on the surface of Mg alloys after multiple rolling cycles is key to preventing premature fracture failure and improving the work-hardening rate.

Non-uniform microstructure evolution rules and mechanisms of Ti55 alloy with initial basket-weave structure during electrically-assisted V bending

Electrically assisted V-bending (EAVB) experiments of Ti55 alloy sheets with initial basketweave structure were carried out at effective current densities of 3-5A/mm2. The history of temperature field, microstructure patterns and mechanical properties were characterized by IR imaging, OM, EBSD and hardness tests. The results show that α lamellae continuously decrease in thickness (from 2.38μm to 0.64μm) with increasing current density. The microstructure patterns of the three deformation zones are significantly different due to different deformation mode and electro-thermo-mechanical routes. Due to limited plastic strain, the orientation rotation and shear fracture of the α lamellae are restricted in the neutral layer, while the ones in the inner and outer layers are refined and become more uniform at mild current density. With increasing current density, the main deformation mode of α grains in the inner layer is {1010} prismatic slip and dynamic spheroidization/recrystallization tends to occur at α lamellae with <0110>α//TD orientation. In the neural and outer layer, intense local Joule heat effect induces α→β→α’ phase transformation in “hot spots”, leading to massive growth of 3 variant needle-like α’, intensified heterogeneous micro-deformation and significant strengthening effect. The combined effects of local Joule heat, residual α phase and deformation-induced defect nucleation break the strict Burgers orientation relationship between α/α’ lamellae and β matrix during EAVB and subsequent cooling process.

Microstructure evolution and multi-reinforcement mechanisms in Al-Cu-Ag alloys

As one of the most commonly used binary alloys, the effect of intermetallic compounds (IMCs) of Al-Cu alloys in powder metallurgy on their structure and properties is instructive for tailoring Al-Cu alloys for different applications. In this investigation, a series of Al-Cu-Ag alloys with varying Cu compositions were fabricated via hot pressing. TEM analysis identified CuAl2 as the primary intermetallic compounds, with Ag existing in forms including Ag2Al, elemental Ag, and an Ag-(Cu) solid solution. The modulation of Cu content influenced the state of Ag and the mechanical behaviors of the Al-Cu-Ag alloy. Particularly, the high Al/Cu alloy, benefiting from a synergistic effect comprising stacking faults, nanoscale precipitates, and solid solutions, exhibited outstanding mechanical properties. Conversely, the Al-50Cu-3Ag alloys displayed significant brittleness, attributed to the adverse impact of large-scale intermetallic compounds and increased grain size due to the formation of CuAl2. The incorporation of nanoparticles effectively mitigated the grain size in high Al/Cu alloys. This study elucidates the correlation between the evolution of intermetallic compounds and composition in Al-Cu alloys, offering novel insights into the reinforcement of both Al-based and Cu-based alloys.

Twinning-dominated microstructure evolution and deformation mechanism during cold rolling in pure rhenium

The extremely high work hardening rate and the high cracking propensity were the main challenges that limit the successful deformation processing of rhenium. Rolling tests to 82% thickness reduction were conducted at room temperature, and three-stage twining evolution behavior was revealed. At 10% rolling reduction, primary {112¯1} tension twins were activated and dislocation accumulation appeared near the twin boundary. As the rolling reduction increases to 45%, twin-twin interactions prevailed and abundant GNDs accumulated around {112¯1} twin boundaries and {112¯1} twin- {112¯1} twin interactions. More importantly, A new twinning sequence behavior in rhenium, secondary {112¯1} twins within primary {112¯1} twins, was investigated. After twinning saturation, shear bands were formed due to the promoted local plastic deformation by the twin lamellar structure and submicron-scale isolated twins, which brought pronounced strengthening of rhenium. The extremely high work hardening rate of rhenium was found to mainly originate from the twin lamellar structure and twin-twin interactions. High temperature annealing released the stored strain energy, achieving a synergistic effect of high tensile strength and ductility. This study provides a systematic investigation into the deformation structure during the large reduction cold rolling in rhenium and provides insights into unique twinning evolution and shear bands.

A novel high-strength Al–Li alloy printed by laser powder bed fusion: Microstructural evolution and strengthenin mechanism

This paper obtained an additively manufactured high-strength Al–Li alloy by laser powder bed fusion (LPBF) based on a third generation AA2195 alloy powder raw material. The relationship between the process optimization, microstructure evolution, and mechanical properties of the as-printed (AP) and heat-treated (HT) specimens was established for the first time to explain the intergranular fracture sensibility during LPBF and reveal the dominant precipitation strengthening mechanism induced by the subsequent heat treatment. The precipitation order of AP Al–Li alloy at the last stage of the solidification process was: L (Liquid phase) →T2 (Al6CuLi3) + θ′(Al2Cu) + δ′/β' (Al3(Li,Zr)) + T (LiAlSi) + Ω (AlCuMgAg). The micro-cracks caused by a relatively high grain boundary coverage of interconnected film-like eutectic phases, as well as micro-voids caused by the localized slip between the coarse T2-phases and soft precipitate-free zones, resulted in the high intergranular fracture sensibility. The well-designed T6 heat treatment of 515 °C/60 min solution treatment and 170 °C/6 h aging treatment was conducted to maximize the precipitation strengthening by T1-phases. The precipitation order of HT Al–Li alloy was supersaturated solid solution → GP zone + δ′/β' → θ′ + T1 (Al2CuLi) + ω (Al7Cu2Fe) + β′. The presence of continuously distributed T1-cells along the grain boundaries was not only capable of providing a pinning effect on dislocations movement and boundary migration, but also able to shorten the pile-up distance on the slip plane. Such phenomena improved the resistance ability of Al–Li alloys to mechanical damage and permitted a significant strength enhancement.

Ion-irradiation effect on swelling and microstructure of BN particle dispersed liquid phase sintering SiC

The boron nitride (BN) particle dispersed silicon carbide (SiC) materials were fabricated by liquid phase sintering (LPS) with Al2O3 and Y2O3 sintering additives as the reference matrix material for SiC composites. They were irradiated to 0.1/1/3/10 dpa by 5.1 MeV Si2+ ions at 800 °C. Raman spectra indicated that the pure h-BN structure was partially destroyed following irradiation, while yttrium aluminum garnet (YAG) structure at grain boundaries formed from the sintering additives wasn’t destroyed. TEM images and diffraction patterns indicated that the mechanism of microstructure evolution of SiC after irradiation up to high fluence at 800 °C was defect clusters induced by irradiation.

Unleashing the potential of nano-bainite bearing steels: Controllable selection of microstructure evolution enables concurrent improvement of toughness and hardness by pre-cold deformation

In the face of increasingly demanding service conditions for high-end bearings, the need for bearing steels that demonstrate superior mechanical properties, specifically a robust balance of strength and toughness, is growing. The adoption of near-net-shaped cold rolling methods has emerged as a leading international technology to enhance bearing performance. In this study, the effect mechanisms of pre-cold deformation on the phase transformation kinetics, microstructure evolution and mechanical properties of nano-bainite bearing steels are systematically studied. Results reveal that pre-cold deformation treatment effectively reduces the Ac1 temperature of the experimental steel, expedites nano-bainite transformation and promotes strong variant selection during bainite phase transformation. With the increase in pre-cold deformation from 0 % to 50 %, the size of the prior austenite grains decreases from 6.7 μm to 3.3 μm, and the size of carbides in specimens becomes more uniform, whilst the refinement of austenite grains can considerably reduce the thickness of bainitic ferrite plates. The decrease in grain size and the increase in V1–V2 variant pairs lead to an improvement in the toughness of the nano-bainite bearing steel from 64.9 J/cm2 to 114.3 J/cm2. A marginal increase in the hardness of the bearing steel is observed with the increase in pre-cold deformation. Furthermore, this study discusses the evolution mechanism of microstructure in the subsequent phase transformation by different microstructures in the early stage. Results show that pre-cold deformation leads to the transition of the martensite twin substructure in the specimens from {112} <111> twins to twinned variants. These insights offer critical understanding into the microstructural underpinning the enhanced performance of nano-bainite bearing steels subjected to pre-cold deformation treatment.

Microstructure evolution of ATI718 plus alloy during high-speed machining: Experiments and a combined FE-CA approach

Excellent surface integrity is an eternal pursuit in high performance manufacturing, with microstructure being a crucial component of the surface integrity dataset and a key factor controlling surface properties such as fatigue and creep. The multi-physical fields generated by thermo-mechanical loads during high-speed machining act on the processed surface layer, influencing the evolution of microstructures. To investigate the microstructural evolution mechanisms of ATI718 plus during high-speed machining, cutting experiments and techniques such as Electron back scatter diffraction (EBSD), Transmission Kikuchi diffraction (TKD), and Precession electron diffraction (PED) is conducted to quantitatively analyze the microstructures in the chip shear zone and the machined surface. Subsequently, a combined finite element (FE) and cellular automata (CA) model is developed to simulate the microstructure evolution during the cutting process. The discontinuous dynamic recrystallization (DDRX) mechanism is employed to demonstrate the nucleation and growth of grains under the influence of multiple physical fields. The simulation and experimental results show similar dynamic recrystallization (DRX) grain sizes, indicating acceptable accuracy of the CA model in terms of DRX grain size. The comparison between experimental and simulation results confirms the occurrence of both continuous dynamic recrystallization (CDRX) and DDRX during the cutting process. The synergistic competition between CDRX induced grain lamellar refinement and DDRX induced grain growth emerge as the primary mechanism driving microstructural evolution. A layer of ultrafine grains, with a thickness within 20 μm, is formed on the machined surface. Results under different parameters demonstrate that the temperature has a more significant impact on the thickness of the ultrafine grain layer and the diameter of grains within the layer compared to the strain rate.

Mechanisms of microstructural evolution in high-volume TiC reinforced steel composites: Insights into particle coarsening, morphology, and thermochemical reactions

Titanium carbides reinforced steel matrix (TiC-steel) composites exhibit a range of excellent properties, including increased strength-to-weight ratio, high-temperature strength, and outstanding wear resistance. Prior research has demonstrated that the mechanical properties of TiC-steel composites are significantly affected by particle coarsening and the associated core-rim structure. Nevertheless, the fundamental mechanisms of thermochemical reactions that govern the formation of the final microstructure in these composites, including the core-rim structure, remain incompletely explored. This study elucidates the microstructure evolution mechanism of high-volume TiC-steel composites, particularly particle coarsening, through thermodynamic calculations and chemical analysis. The investigation unveils the coarsening process, shedding light on the formation of more stable phases and associated compositional changes, including the incorporation of substitutional elements and carbon depletion (resulting in low stoichiometry, x < 1) within the newly developed (Ti,M)Cx. Additionally, the increased carbon content contributes to pearlite emergence within the steel matrix. Notably, key factors influencing the distinct morphologies observed in growing TiC particles are identified, attributed to variations in Mo, V, and W concentrations, as elucidated by rigorous thermodynamic and first-principles calculations. This study represents significant progress in understanding the intricate microstructure development of high-volume TiC-steel composites.

Atomic Insight into Multilevel Microstructure Evolution and Energy Variation Mechanisms of Polyimide under Shock Compression

Atomic Insight into Multilevel Microstructure Evolution and Energy Variation Mechanisms of Polyimide under Shock Compression

Microstructure Evolution and Recrystallization Mechanisms of a Cu-Cr-Sn Alloy during Thermal Deformation Process.

Thermal deformation behavior of Cu-Cr-Sn alloy ingots under deformation temperatures ranging from 600 °C to 950 °C and strain rates from 0.01 s-1 to 10 s-1 was investigated in detail. The thermal deformation constitutive equation and thermal processing map of the alloy were established, respectively. The activation energy Q was determined as 430.61 KJ/mol. The optimal deformation system corresponding to the hot working diagram was a deformation temperature of 900 °C and strain rate of 0.1 s-1. Under these deformation conditions, twin dynamic recrystallization (TDRX), continuous dynamic recrystallization (CDRX), and discontinuous dynamic recrystallization (DDRX) occurred simultaneously, with the twinning process causing the stress-strain curve to exhibit a wavy change. The thermal deformation microstructure of the alloy is co-regulated by different recrystallization mechanisms, with DDRX occurring mainly at low deformation temperatures, and both CDRX and DDRX occurring at high deformation temperatures.

Multi-scale simulation of microstructural evolution for molten U–Zr–O ternary system

The morphological evolution of the molten corium is critical to the success of the “in-vessel retention” (IVR) strategy, which is of great significance for the safety of the nuclear industry under severe accidents. However, the direct observation of microstructural evolution by experiments is impossible in extreme conditions. Herein, a multi-scale simulation approach was employed to investigate the microstructural evolution and related mechanisms for the molten U–Zr–O ternary system. First, based on the reported calculated phase diagram, a simplified free energy formula describing a phase diagram of U–Zr–O was determined, where only liquid phases are focused. Then, the atomic diffusion coefficients were calculated by ab-initio molecular dynamics simulations. Based on such information, a homemade phase-field model was developed, which was coupled with Cahn–Hillard and Navier–Stokes equations. Accordingly, the microstructural evolution of molten U–Zr–O materials was systematically investigated. The results reveal that the evolution of the molten core was driven by both the decreasing free energy and gravity potential, accessing the final morphology of the system as a two-layer structure, including a metallic layer and an oxidized layer. Moreover, diverse intermediate morphologies could be observed from different initial component distributions, although their average compositions were identical. Finally, some intermediate simulated microstructural patterns agreed well with experimental observation, demonstrating the unstable structures captured by experiments and the validity of the simulations. The present study provides an effective approach to investigate the microstructural evolution of molten core and a guideline for optimizing the IVR strategy based on different morphologies in the corium.

Anisotropic behavior and temperature-dependent mechanical properties of AA1060 aluminum alloy: A comprehensive microstructural study

This study rigorously examines the AA1060 aluminum alloy's mechanical properties across different thermal conditions (298K–77K) and orientations (RD-ND and TD-ND). Through annealing at 350 °C for 50 min followed by extensive mechanical testing at ambient and cryogenic temperatures, the study delves into the microstructural evolution and deformation mechanisms utilizing Electron Backscatter Diffraction (EBSD) and Transmission Electron Microscopy (TEM). Findings indicate a pronounced increase in yield strength, tensile strength, and ductility with decreasing temperature. Notably, RD-ND oriented samples demonstrated enhanced mechanical strength over TD-ND oriented samples under both temperature regimes, underscoring the alloy's pronounced anisotropy. This comprehensive study illuminates the AA1060 alloy's temperature-dependent mechanical enhancements and anisotropic behavior, emphasizing the significant impact of microstructural orientation on its mechanical properties. The insights gained illuminate the AA1060 alloy's temperature-dependent and anisotropic behaviors, highlighting microstructural orientation's important role in its mechanical properties, with profound implications for aluminum alloy application across varying temperature and stress conditions.

Effects of rare earth oxides on wear resistance and corrosion resistance of 316L/TiC composite coating by laser cladding

In this paper, 316L/TiC composite coatings with different kinds of REOs (Y2O3, La2O3, CeO2, PrO2, Nd2O3) at identical contents (2%) were prepared on S355 marine steel using the laser cladding technology. The surface morphology, phase composition, microhardness, coefficient of friction curve (COF), Tafel curve and electrochemical impedance spectroscopy (EIS) impedance of the test specimens were studied with such instruments as scanning electron microscope (SEM), energy dispersive spectrometer (EDS), X-ray diffractometer, Vickers microhardness tester, friction and wear tester, and multi-channel electrochemical workstation. The results show that the coating with REO added owns increased thickness and is uniform and dense without such defects as crack, and hole. The microstructure evolution mechanism of the coating from the bottom up is as follows: Cellular crystal, planar crystal → columnar crystal → equiaxed crystal. The phase composition of the coating with REO added remains unchanged, and is still Ni–Cr–Fe austenite phase and TiC phase. Further comparison shows that the coating with Nd2O3 added owns improved hardness, with a mean hardness of 3 times that of the substrate, and has a COF decreasing to 0.69, with wear loss becoming small. The coating with Nd2O3 added has the largest Ecorr, the smallest Icorr, large Z value and phase angle, the greatest Rct, and an nct value of 1, indicating that the coating has dense passivation film and small corrosion tendency, with low corrosion rate. Therefore, this study provides reference experimental and theoretical bases for application of 316L/TiC composite coating with Nd2O3 added at 2% in surface strengthening and repair of steel for marine engineering equipment.

Evolution of microstructure and mechanical properties of aluminum matrix composites reinforced with dual-phase heterostructures

The trade-off between strength and plasticity has long been challenging in particle-reinforced aluminum matrix composites (PRAMCs). This study proposes an innovative approach for preparing aluminum matrix composites (AMCs) using a dual-phase hybrid of FeCoNiCrMn high entropy alloy (HEA) and multiscale aluminum oxide (Al2O3) particles. The microstructure evolution and strengthening mechanisms were evaluated through scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). The results demonstrated that the dual-phase particle strengthening resulted from the alternating distribution and synergistic action of HEA and Al2O3 particles within the matrix, forming a continuous strain buffer with a strength gradient. Notably, introducing HEA and nano-Al2O3 led to a higher density of dislocations. Additionally, EBSD analysis revealed a uniform strain distribution within the AMCs, with a significant concentration of kernel average misorientation (KAM) near the grain boundaries (GBs). In terms of micromechanical properties, the micro-zones of heterogeneous phases exhibit exceptionally high elastic modulus and nanohardness. In terms of macroscopic mechanical properties, the material exhibited impressive ultimate compressive strength and compression ratio values of 447.9 MPa and 37.9 %, respectively. These results represented a remarkable enhancement of 72.1 % and 6.6 % compared to the single FeCoNiCrMn HEA strengthening. Moreover, when applying the HEA + nano-Al2O3 blending mode, the ultimate compressive strength further increased to 506.7 MPa, representing an astonishing boost of 94.7 %. This significant strength improvement can be attributed to effective interfacial bonding, grain refinement, and a high dislocation density resulting from both HEA and Al2O3 particles.

Microstructural evolution and mechanisms affecting the mechanical properties of wire arc additively manufactured Al-Zn-Mg-Cu alloy reinforced with high-entropy alloy particles

The mechanical properties of Al-Zn-Mg-Cu alloys produced via wire arc additive manufacturing (WAAM) are often weakened by the presence of continuous and coarse precipitated phases, which significantly limits their practical applications. In this study, high-entropy alloy (HEA) particles were incorporated into Al-Zn-Mg-Cu alloy during the WAAM process, which inhibits the continuity of precipitated phase, and the mechanism of microstructure evolution and macroscopic mechanical properties optimization of the components are explored. The results show that HEA particles promote grain refinement, and disrupt the formation of continuous precipitated phase along the grain boundary by generating plenty of fine spot-like precipitated phases, thus inhibiting grain boundary segregation. The spot-like precipitated phases are connected via a slender second-phase-band. The primary precipitates include the metastable η', stable η, and T phases, and the diffusion of solute atoms forms the Al3Ni and Al3(Ni, Cu)2 phases. The tensile strength increases from 247.4±5.9 MPa to 326.2±19.7 MPa in the horizontal direction and from 273.0±13.7 MPa to 335.4±11.1 MPa in the vertical direction, which correspond to increases of 31.9 % and 22.9 % respectively. The enhancement of mechanical properties is mainly attributed to Hall-Petch, Orowan, load-transfer, solid-solution and dislocation strengthening mechanisms. Only slight variation occurred in the elongation, the increased number of fine spot-like precipitated phases and grain boundaries hinder the crack propagation, while the increased number of pores facilitates the crack propagation, and these effects almost balance each other out in competition. These findings are expected to provide new insights into the microstructure optimization of WAAM components, thereby meeting more practical applications.