Electron Backscatter Diffraction Research Articles

Influence of post-weld rolling and artificial aging on microstructure and mechanical properties of friction stir welded 2195-T4 Al-Li alloy joints

Fiction stir welding (FSW) of a naturally aged (T4) 2195 Al-Li alloy was conducted to study the effect of post-weld artificial aging (AA) and rolling+artificial aging (R+AA) on microstructure and mechanical properties of the FSW joints. Grain features were analyzed by electron back scattered diffraction (EBSD) technology, and precipitates were characterized using transmission electron microscopy (TEM) along [011]Al and [001]Al zone axes. Mechanical properties of the joints were evaluated through micro-hardness and tensile testing. The results indicate that grain development, including grain orientation, grain boundary components and dislocation density, varies within different regions of the As-welded joints due to complicated thermal-mechanical history. The alloying elements mostly exist as Guinier-Preston zones in the base material (BM) with a few formations of δ'/β', and slightly precipitate into T1 in the heat affected zone (HAZ), form σ in the thermal-mechanical affected zone (TMAZ), as well as develop T1 and S' in the nugget zone (NZ) after FSW. The lowest hardness zone (LHZ) exhibits elevated precipitation levels, generating coarse T1 and grain boundary precipitates with evident σ and precipitate free zone. The overall precipitation level of the As-welded joints remains minor, resulting in a slight decrease in hardness at the LHZ. Post-weld AA promotes many T1 formations, enhancing the joint strength and hardness. As a result, the ultimate tensile strength (UTS) of the joints increases from 440 MPa to 506.5 MPa, while the elongation decreases from 13.5% to 3.4%. Furthermore, hardness profiles transform from a low-amplitude wave curve to a high-amplitude W-shaped curve, generating a significant LHZ due to the minimal precipitation of T1. Pre-rolling deformation can enhance dislocation density and low angle grain boundaries (LAGBs), promoting the nucleation of high-density, fine T1 during artificial aging, and especially improves precipitation ability of the LHZ, leading to an elevated hardness increment in the region after AA. Compared to the Joint-AA, both strength and elongation of the Joint-R+AA increase, obtaining 530.5 MPa and 3.9%, respectively.

An innovative thermal simulation study of microstructure improvement by delay forging during solidification

The solid fraction at the beginning of the forging process is an important factor affecting the performance of the casting-forging integrated forming, which is an innovative and efficient process. The solid fraction depends on the delayed forging time during the casting-forging integrated forming. This paper investigates the effect of delayed forging time on the microstructure of aluminum alloy forged during solidification using an innovative physical simulation method. In this work, a solidification-forging device compatible with the Gleeble system has been developed. Then, experiments were conducted at various delayed forging time. Temperature and force data were collected using the Gleeble system for analysis. Microstructural evolution was investigated using methods including Optical Microscopy (OM), Scanning Electron Microscopy (SEM), Electron Backscattered Diffraction (EBSD), and Three Dimensional Computed Tomography (3D-CT). The results demonstrate that with the extension of the delayed forging time, the grain size of the alloy decreases gradually, and the coarse dendrite structure changes to the rose-shaped grains, and the local misorientation in the grain increases. Moreover, the effect of forging under different forging time on the casting defects of the alloy is studied. When the forging delay is extended to 8 s, the forging promotes the porosity caused by the liquid phase convection. However, with further extension of forging delay, the reduction of the liquid phase and the fracture of dendrites lead to the complexity of liquid phase channels, resulting in the increase of porosity. Additionally, forging near solidification can close shrinkage porosity.

Corrosion resistance and wear behavior of CoCrFeNiMn@Gr high entropy alloy-based composite coatings prepared by laser cladding

In this study, we utilize laser cladding to apply a CoCrFeNiMn HEA with 2 wt.% few-layer graphene (Gr) coating onto the surface of Q235B mild steel. Alcohol stirring method was used for HEA and Gr preparation of composite powder. Raman spectroscopy and energy dispersion spectroscope (EDS) indicate the successful mixing of HEA and Gr powders, with Gr adhering to the surface of the HEA powder in a lamellar structure. The X-ray diffraction (XRD), scanning electron microscope (SEM), EDS, and Electron backscatter diffraction (EBSD) analyses revealed that grain refinement and the formation of fine carbide-hard phases in the HEA/Gr coating improve microhardness and wear resistance. The average Schmidt factors of the coating decreased from 0.47 to 0.45 with the addition of Gr, indicating enhanced resistance to plastic deformation and anisotropy. Nanoindentation experiments demonstrated that the HEA/Gr coatings exhibit superior resistance to plastic deformation, effectively enhancing the coating’s durability against spalling under stress and wear conditions. The microhardness of the HEA/Gr coating increased by 99.25%, and the wear rate decreased by 86.31% compared to the HEA coating alone. The open circuit potential (OCP), linear polarization curve, Tafel curves, electrochemical impedance spectroscopy (EIS), and Mott-Schottky tests all indicated that the HEA/Gr coating possesses superior corrosion resistance. X-ray Photoelectron Spectroscopy (XPS) results suggest that the passivation film of the HEA/Gr coating, which contains more oxides and less hydroxide, is more protective and denser, thereby slowing the corrosion rate.

In-situ EBSD study of the active slip systems and substructure evolution in a medium-entropy alloy during tensile deformation

Electron backscatter diffraction (EBSD) coupled with in-situ tensile loading is powerful for investigating the microstructural evolution of alloys. Thermo-mechanically treated f.c.c. medium-entropy alloys (MEAs) typically have high densities of annealing twin boundaries (ATBs), which can not only strengthen but also toughen the MEA via interacting with dislocations. However, the evolution of ATBs and other substructures in plastically-deformed MEA has not yet been revealed. Plastic deformation involving dislocation evolution, active slip systems, lattice rotation, boundary transformation, and grain subdivision in a polycrystalline MEA Ni41.4Co23.3Cr23.3Al3Ti3V6 was studied using in-situ EBSD. The slip was accompanied by heterogeneous lattice rotation among grains and within grains, where inhomogeneous plasticity was accommodated by geometrically-necessary dislocations (GNDs). Both GND and low-angled boundaries (LABs) densities substantially increased with progressive strain, which was mainly concentrated in sites approaching ATBs or grain boundaries (GBs). Located stress, lattice rotation, or curvature caused a loss in the coherence of ATBs, which resulted in integrity loss with increasing strain and promoted a decrease in density by 60 %. Further, lattice rotation incompatibility due to constraints from neighboring grains leads to grain fragmentation into various misorientated volumes, which were separated by LABs or high-angle boundaries (HABs). The grain orientation angle increased with progressive strain and crystallographic 〈111〉 orientation gradually spread toward a tensile direction. Slip systems with maximum Schmid factor were activated first at ε ≥ 3.9 %, which is almost the same with experimental slip traces. Both single slip and double slip occurred during plasticity, where straight slip traces tend to curve due to lattice curvature. Slip transfers are not only controlled by geometric compatibility factor, which can occur between some neighboring grains with low geometric compatibility factor but high Schmid factor.

Studies on the retarded recrystallization of tungsten in CIMPLE-PSI exposed under very-high target temperature and long He+-fluence

Abstract Experiments are carried out in CIMPLE-PSI, to understand the recrystallization behavior of tungsten (W) exposed under very-high target temperature and ITER relevant long He+-fluence. The effect of helium bubbles on possible retardation of the recrystallization process is also studied. W samples are simultaneously exposed under He plasma and annealed by the plasma heat-load, in contrast to previously reported experiments in literature, which were carried out sequentially. Exposed samples are characterized by field emission scanning electron microscopy (FESEM), Vickers surface micro-hardness, nano-hardness and electron backscattered diffraction (EBSD). It is observed that the sample exposed to plasma under the highest temperature (1866 K) suffered acute retarded grain growth. This also contained small, unrecovered grains on the exposed surface. FESEM imaging of the cross-sections confirm relatively smaller helium bubbles still form even at the very high temperature conditions, which can impede the grain growth locally, whenever they are forming right on the grain boundaries. This results in an inhomogeneous mixture of surface grains with sizes from few micrometer to few tens of micrometer. EBSD estimates that the plasma exposed surface was only 34% recrystallized. The second sample exposed at a lower temperature (1699 K) but for three times higher fluence (ion fluence: 1.19×1027 m-2) was almost fully recrystallized, which shows retardation diminishes very fast with the duration of the exposure. Hardness measurements were undertaken to understand the variation with plasma exposure/annealing temperature and the extent of recrystallization, with three different probing length scales, spanning from few hundreds of nanometer to several micrometers. Both helium plasma exposed W samples are observed to undergo retarded softening up to a depth of few hundred nanometers from the surface, compared to when the metal may be recrystallized by simple heating, without any plasma exposure.

Solving Ambiguity in EBSD Indexing of Long-Period Stacking Ordered (LPSO) Phase in Mg with Template Matching Approach

Magnesium (Mg) alloys with long-period stacking ordered (LPSO) phases are receiving increasing interest because of their excellent mechanical performance. The close similarity in atomic stacking sequences between different LPSO polytypes and Mg lattice often leads to ambiguous indexing in electron backscatter diffraction (EBSD), a commonly used material characterization technique. Instead of the Hough transformation approach used in commercial software, an alternative indexing approach, which can catch subtle differences by matching experimental patterns with simulated ones, is explored in this study. Our results, showing ~94% of mapping data being correctly indexed as the target phase, 14H LPSO, demonstrate the capability of not only resolving the LPSO phases but also distinguishing different LPSO polytypes. This approach offers a valuable, if not unique, solution for the microscale characterization of LPSO phases, enabling precise microstructure tuning to further promote the mechanical properties of Mg alloys.

Research on the Heterogeneous Deformation Behavior of Nickel Base Alloy Based on CPFEM

AbstractIn this paper, a crystal plasticity finite element method (CPFEM), considering the grain morphology and orientation, as well as the dislocation density, is used to research the tensile deformation behavior of GH4169 based on Electron Backscatter Diffraction (EBSD). The stress, plastic strain, and dislocation density distributions are obtained for different levels of deformation. Results show that the stress, plastic strain, and dislocation density exhibit obvious heterogeneous plastic deformation, and stress concentration and dislocation pileup mainly occurs near grain boundaries. The initial dislocation density mainly affects the stress–strain curve of the material, and it can obviously effect the yield strength but cannot influence the hardening ability of the material. The total dislocation density increases with plastic strain. However, the texture evolution has no evident change with increasing plastic strain, except for the increase of texture content in Cube (001)[100].

Investigation of Mechanical Properties and Microstructural Evolution in Pure Copper with Dual Heterostructures Produced by Surface Mechanical Attrition Treatment

Heterostructured materials consist of heterogeneous zones with dramatic variations in mechanical properties, and have attracted extensive attention due to their superior performance. Various heterostructured materials have been widely investigated in recent years. In the present study, a combination of two different types of heterogeneous structures, a surface bimodal structure and gradient structure, was designed using the traditional surface mechanical attrition treatment (SMAT) method in pure copper, and the mechanical properties and microstructural evolution of dual-heterostructure Cu were studied in depth. In total, 100 stainless steel balls with a diameter of 6 mm were utilized to impact the specimen surface at room temperature for a short period of time. In this work, the sample surface was divided into hard areas and soft areas, along with a roughly 90 μm gradient structure in the cross-sectional direction after 30 s of SMAT processing. After the partial SMAT processing, lasting 30 s, the strength increased to 158.0 MPa and a considerable ductility of 25.7% was sustained, which overcomes the strength–ductility trade-off. The loading–unloading–reloading (LUR) test was utilized to measure the HDI stress, and the result showed that the HDI stress of the partial SMAT sample was much higher than the annealed one, especially for the Cu-SMAT-30S specimen, the strength of which increased from 80.4 MPa to 153.8 MPa during the tensile test. An in situ digital image correlation (DIC) investigation demonstrated that the strain developed stably in the Cu-SMAT-10S specimen. Furthermore, electron backscatter diffraction (EBSD) was carried out to study the microstructural evolution after partial SMAT processing; the KAM value increased to 0.34 for the Cu-SMAT-10S specimen. This research provides insights for the effective combination of superior strength and good ductility in dual-heterostructure materials.

Hydrogen diffusion mechanisms in the 4130X steel: An integrated study with electrochemical experiments and molecular dynamics simulations

In this work, hydrogen diffusion behavior and mechanisms in the 4130X steel influenced by temperature, locally high concentration, and grain boundary were studied by leveraging both electrochemical hydrogen permeation experiments and molecular dynamics simulations. It was revealed that the hydrogen diffusion coefficient of the 4130X steel was increased with increasing temperature and decreasing locally high hydrogen concentration. The grain boundaries with misorientation below 15° characterized by an electron backscatter diffraction map were identified as hydrogen trapping sites, thus rendering a lower mean square displacement of hydrogen atoms and localized hydrogen diffusion trajectories. Furthermore, at a high hydrogen concentration of 4 at. %, these grain boundaries were saturated by hydrogen atoms, and platelet-like hydrogen clusters were formed within the lattice, which further inhibited the diffusive motion of hydrogen atoms. These findings would deepen our understanding of hydrogen embrittlement mechanisms by establishing the connections between macroscopic permeation behavior and atomic-scale hydrogen diffusion in structural materials.

High-Pressure Synthesis of Te-Ge Double-Substituted Skutterudite with Enhanced Thermoelectric Properties.

We synthesized Co4Sb11TexGe1-x (x = 0.5-0.8) using high-pressure, high-temperature conditions at ∼2 GPa and ∼900 K. The microstructure, morphology, and components were characterized via X-ray diffraction, scanning electron microscopy, and electron backscatter diffraction (EBSD). EBSD indicated that the average grain size of Co4Sb11Te0.8Ge0.2 was 1 μm. Electrical conductivity, Seebeck coefficient, and thermal conductivity were measured from 300 to 800 K. The minimum lattice thermal conductivity of Co4Sb11Te0.8Ge0.2 was 0.72 W m-1 K-1, 74% lower than that at 300 K. The introduction of Te and Ge effectively enhanced point effects scattering and location scattering, notably decreasing lattice thermal conductivity. Therefore, the maximum zT value of Co4Sb11Te0.8Ge0.2 was 1.13 at 800 K. These results indicate that high pressure combined with multielement substitution optimized the thermoelectric transport properties of skutterudites.

Production and Characterization of Hybrid Al6061 Nanocomposites

Aluminum-based hybrid nanocomposites, namely the Al6061 alloy, have gained prominence in the scientific community due to their unique properties, such as high strength, low density, and good corrosion resistance. The production of these nanocomposites involves incorporating reinforcing nanoparticles into the matrix to improve its mechanical and thermal properties. The Al6061 hybrid nanocomposites were manufactured by conventional powder metallurgy (cold pressing and sintering). Ceramic silicon carbide (SiC) nanoparticles and carbon nanotubes (CNTs) were used as reinforcements. The nanocomposites were produced using different reinforcement amounts (0.50, 0.75, 1.00, and 1.50 wt.%) and sintered from 540 to 620 °C for 120 min. The characterization of the Al6061 hybrid nanocomposites involved the analysis of their mechanical properties, such as hardness and tensile strength, as well as their micro- and nanometric structures. Techniques such as optical microscopy (OM) and scanning electron microscopy (SEM) with electron backscatter diffraction (EBSD) were used to study the distribution of nanoparticles, the grain size of the microstructure, and the presence of defects in the matrix. The microstructural evaluation revealed significant grain refinement and greater homogeneity in the hybrid nanocomposites reinforced with 0.75 wt.% of SiC and CNTs, resulting in better mechanical performance. Tensile tests showed that the Al6061/CNT/SiC hybrid composite had the highest tensile strength of 104 MPa, compared to 63 MPa for the unreinforced Al6061 matrix. The results showed that adding 0.75% SiC nanoparticles and CNTs can significantly improve the properties of Al6061 (65% in the tensile strength). However, some nanoparticle agglomeration remains one of the challenges in manufacturing these nanocomposites; therefore, the expected increase in mechanical properties is not observed.

Study on the Microstructure, Mechanical Properties, and Corrosion Behavior of 900 °C-Annealed CoCrFeMnNiSix (X = 0, 0.3, 0.6, 0.9) High-Entropy Alloys

In this study, a series of CoCrFeMnNiSix (x = 0, 0.3, 0.6, 0.9) high-entropy alloys (HEAs) were prepared by suspension melting of cold crucible, annealed at 1000 °C, and then quenched at 900 °C. The changes in the microstructure of the HEAs after the addition of Si were analyzed using X-ray diffraction (XRD), metallographic microscope, scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), and electron backscatter diffraction (EBSD). The hardness, room-temperature friction, and wear behavior, room-temperature compressive properties, and corrosion resistance of the annealed CoCrFeMnNiSix HEAs were also studied. The results show that when the Si content is 0 and 0.3, the annealed CoCrFeMnNiSix HEA exhibits a single face-centered cubic (FCC) structure. As the silicon content increases, a face-centered orthorhombic (FCO) phase appears. At a Si content of 0.9, a hexagonal close-packed (HCP) phase is observed. After heat treatment, the hardness of the CoCrFeMnNiSix HEAs increases continuously with the addition of Si. The HEA with a Si content of 0.9 achieves the highest hardness of 974.8 ± 30.2 HV. The HEA with a Si content of 0.6 reaches the highest compressive strength and yield strength, which are 1990.3 MPa and 1327.5 MPa. When the Si content is 0.9, the HEA shows the smoothest surface after wear, with the best wear resistance, achieving a value of 0.21 mm−1. In the CoCrFeMnNiSix HEAs after 900 °C heat treatment, the HEA with a Si content of 0.6 exhibits the lowest self-corrosion current density of 0.23 µA/cm2 and the highest pitting potential of 157.65 mV, indicating the best corrosion resistance.

Grain refinement of Inconel 625 during wire-based directed energy deposition additive manufacturing by in-situ added TiB2 particles: Process development, microstructure evolution and mechanical characterization

In this study, a novel method for enhancing the quality of components fabricated by wire and arc additive manufacturing (WAAM) was developed. This approach employs an innovative mechanism featuring an actuator that dispenses a solution containing refinement particles (TiB2 inoculants), in conjunction with a soldering flux that vaporizes prior to reaching the electric arc. This leaves the particles to adhere to the welding wire or be carried by the shielding gas. By implementing this device, TiB2 particles were successfully incorporated into the molten pool during the WAAM process of Inconel 625 at levels of 0.31 and 0.56 wt%. Microstructural analysis reveals a significant reduction in the size of interdendritic segregation regions when TiB2 particles are introduced. Electron backscatter diffraction analysis further reveals the transformation of columnar grains into equiaxed grains. The average grain area decreased from 1823 μm2 in the as-built sample to 583 μm2 in the sample with a TiB2 content of 0.56 wt%. In addition, an improvement in the Inconel 625 fabricated by WAAM mechanical strength was observed due to the use of TiB2 inoculants, which was primarily attributed to the effect of the grain size refinement.

Growth kinetics and microstructure transition of undercooled Fe7(CoNi)75B18 eutectic muti-principal element alloy

The mechanism of rapid solidification behavior of eutectic muti-principal element alloys (EMPEAs) is an eye-catching field. In this study, the novel Fe7(CoNi)75B18 EMPEA was undercooled via rapid solidification and B2O3 glass purification method and the maximum undercooling up to 190 K was achieved. A clear microstructure evolution path was identified with the undercooling: fully regular eutectic → primary dendrite and regular eutectic → primary dendrite and divorced eutectic. The orientation relationship (OR) between the primary (Fe, Co, Ni) phase and secondary B-rich phase was revealed both at low and medium undercoolings by electron backscatter diffraction (EBSD) analysis. The results show that the OR disappears at high undercooling (190 K) owing to the microstructure fragment and rotation during the post-recalescence. Furthermore, the growth velocity exponentially raised with the increase of undercooling. The maximum growth velocity of the primary phase was 1.152×10−1 m/s, which is significantly lower than binary alloys due to the sluggish kinetics effect of EMPEAs. This study helps to understand the solidification kinetics and microstructure transition of the novel EMPEA and has important implications for controlling the solidification process of more complex alloys.

FIB/SEM serial sectioning as a versatile tool for microstructural analysis

Abstract FIB/SEM tomography is a serial sectioning method in which the cross-sectional area of the sample is stepwise removed with a focused ion beam (FIB) and the exposed cross-sectional area is imaged with a scanning electron microscope (SEM). All imaging techniques of the SEM can be used, which allows the application to a wide range of materials science questions. On the one hand, resolutions of a few nm can be achieved, and on the other hand, volumes with edge lengths of 100 μm and more can be examined. This article gives an overview of the current state of the art and the practical implementation of FIB/ SEM serial sectioning. The special aspects of the integration of energy dispersive X-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD) are also discussed.

Microstructural Evolution and High‐Temperature Tensile Properties of 15Cr‐Reduced Activation Ferritic Steel Processed by Hot Powder Forging of Mechanically Alloyed Powders

Reduced activation ferritic steels are being explored as possible cladding tube materials for nuclear reactors because of their low activation and excellent irradiation resistance. In the current investigation, reduced activation ferritic steel (Fe–15Cr–2W) is processed by mechanical alloying of elemental powders followed by hot powder forging. Mechanical alloying is carried out in a Simoloyer attritor mill (Zoz GmbH), after which the powders are placed in a mild steel can and forged at 1200 °C in H2 atmosphere. X‐ray diffraction and transmission electron microscopy (TEM) investigation reveal that 10 h of mechanical alloying is required to achieve complete dissolution of Cr and W in the Fe matrix powder. The relative density and hardness distribution of the forged slab is evaluated in longitudinal as well as transverse direction to optimize the powder forging operation. Electron backscatter diffraction analysis showed dynamic recrystallization to take place during the course of hot powder forging. Tensile tests are performed at room temperature as well as at elevated temperatures (600 and 700 °C). The yield strength and ultimate tensile strength at room temperature as well as at elevated temperatures are found to be higher than those reported in literature for reduced activation ferritic steels consolidated by other techniques.

Small fatigue crack behavior of CP-Ti in thin-walled cruciform specimens under biaxial loading

This study investigates the small fatigue crack propagation behavior of commercially pure titanium (CP-Ti) using thin-walled cruciform specimens under in-plane biaxial loading, considering the effects of biaxial ratio and phase angle. Increasing phase angle results in more secondary cracks merging with main cracks perpendicular to the rolling direction (RD) and transverse direction (TD), a phenomenon attributed to the rise in shear stress that accelerates main crack growth. Higher loading biaxiality or a lower phase angle leads to decreased crack propagation rates and increased biaxial fatigue life. Electron backscatter diffraction (EBSD) analysis reveals that when the maximum normal stress aligns with the RD, prismatic slip primarily governs crack propagation, thereby accelerating crack propagation rates. Conversely, alignment with the TD reduces prismatic slip activity and crack propagation rates. Under equi-biaxial loading, prismatic slip activity decreases further, and crack propagation is dominated by multiple slip and twinning, consequently resulting in the slowest propagation rates. Additionally, a higher proportion of prismatic slip under high phase angle also accelerates crack propagation. Finally, incorporating Findley equivalent stress into the Chapetti model, which considers the crack length-dependent threshold effect, a highly accurate biaxial small fatigue crack propagation rate model is proposed.

A quasi-in-situ EBSD study on abnormal grain growth in 2219 aluminum alloy friction stir welded joints during post-weld heat treatment

Abnormal grain growth occurs in the friction stir welds of 2219 aluminum alloy during the solution treatment. To further investigate abnormal grain growth, the quasi-in-situ electron backscatter diffraction (EBSD) experiment, including the EBSD testing and heating by thermal simulation testing machine, was proposed to observe the grain growth process in the weld. The results show that the abnormal grain growth behavior in the stir zone and the thermo-mechanically affected zone is different, and different microstructures at different positions in the weld promote the growth of abnormal grains. In the stir zone, the modified Humphreys’ model is used to analyze the abnormal grain growth behavior. The grains with an advantage size and low strain are more likely to grow abnormally. The non-uniform pinning caused by the dissolution of second-phase particles further promotes abnormal grain growth. In the thermo-mechanically affected zone, the abnormal grains are formed by unstrained equiaxed grains near the stir zone or recrystallized sub-grains. The growth of abnormal grains in the thermo-mechanically affected zone is a strain-induced grain boundary migration process. The research is helpful to understand the abnormal grain growth in friction-stir welds during post-weld heat treatment.

Influence of annealing on microstructures and mechanical properties of laser powder bed fusion and wire arc directed energy deposition additively manufactured 316L

The annealing response of 316L stainless steel manufactured with both laser powder bed fusion (PBF-LB) and wire-arc directed energy deposition (DED-Arc) was investigated in the context of microstructural evolution and mechanical properties. Because additive manufacturing (AM) comprises several technologies that differ in heat source, feedstock, and scan strategy, among other build variables, the final products can experience a range of thermal histories and defect (dislocation) populations. These unique thermal histories can subsequently influence as-built properties and annealing response of AM materials, most notably those manufactured with different AM deposition processes. The PBF-LB process (with higher cooling rates) yielded finer austenite microstructures having more lattice strain, higher dislocation densities, and higher yield strength values than the DED-Arc 316L process (with lower cooling rates). Electron backscattered diffraction (EBSD) data of the kernel average misorientation (KAM), boundary density, and geometrically necessary dislocation (GND) density support the differences in lattice strain. As a result, the PBF-LB 316L exhibited more recovery and recrystallization after annealing at elevated temperatures above 873 K based on changes to yield strength, work hardening behavior, and microstructure evolution. The DED-Arc 316L exhibited a δ-ferrite/austenite microstructure with microsegregation that influenced deformation mechanisms active after annealing. Tensile data, deformed microstructures and misorientation histograms from EBSD showed a decreasing amount of deformation twinning when comparing the as-built condition to annealed conditions (up to 1473 K/1h) of PBF-LB 316L. The opposite trend was noted in DED-Arc 316L. The behavior was interpreted to be due to the differences in chemical segregation during solidification and the effects of heat treatment on chemical homogenization and local stacking fault energy.

Stress relaxation aging of 7050 aluminum alloy under elastic and plastic loadings: A perspective from the geometrically necessary dislocations

Aerospace integral panels with large curvature often experience not only elastic loading but also plastic loading during creep age forming. However, the stress relaxation aging behaviors and mechanisms under loading stresses ranging from elastic to plastic regions, especially from the perspective of geometrically necessary dislocations (GNDs), have not been fully explored. The stress relaxation aging (SRA) behavior of 7050 aluminum alloy under elastic (200/250/300 MPa) and plastic loadings (350/400 MPa) are studied by uniaxial SRA, hardness and tensile tests, and corresponding mechanisms are clarified by Electron Back Scatter Diffraction (EBSD) tests and transmission electron microscopy (TEM) observations. Regardless of the loading stress, the stress relaxation of 7050 alloy shows a typical two-stage behavior (rapid stress reduction and stable stress relaxation rate). The second stage of stress relaxation under elastic loading shows an abnormal stress rebound, while the stress continuously decreases under plastic loading, and hardness and yield strength at 350 MPa are lower than that at 200 MPa during SRA. These results are attributed to strong dislocation pinning from small and dense precipitates at elastic loading and dislocations shearing large and sparse precipitates at plastic loading, respectively. Furthermore, both the stress reduction and its ratio increase with the increase of initial stress. GNDs contribute to the formation of low-angle grain boundaries (LAGBs) and accumulate at the LAGBs intersection to coordinate grain orientation for creep deformation. Compared to elastic loading, plastic loading promotes global growth of intragranular precipitates by elastic stress field and local heterogeneous nucleation and coarsening of precipitates at subgrain boundaries by more GNDs.