Engineering topics

Clarke, Kester Diederik

Publications and source records attributed to Clarke, Kester Diederik.

3 records

DOE OSTI2024

Clarifying the formation of equiaxed grains and microstructural refinement in the additive manufacturing of Ti-Cu

Controlling microstructural evolution in metallic additive manufacturing (AM) is difficult, especially in producing refined as-built grains instead of coarse, directional grains. Traditional solutions involve adding inoculants to AM feedstocks, but titanium (Ti) alloys cannot employ this approach without producing detrimental secondary phases. Ti-Cu (Ti-copper) alloys offer a solution through constitutional supercooling and/or solid state thermal cycling under AM conditions. This work analyzes a compositionally graded directed energy deposition (DED) Ti-Cu build, single-melt laser tracks, and dilatometric heat treatments to evaluate if, when, and by what mechanism(s) microstructural refinement occurs. Refinement by inoculation of unmelted powder particles was also considered. Constitutional supercooling produced no net microstructural refinement as any equiaxed dendrites which form are remelted with new deposition. This finding agreed with solidification modeling of powder bed fusion-laser beam (PBF-LB) and DED builds. Solid state thermal cycling refined microstructures only during ex-situ dilatometric heat treatments, suggesting build parameter optimization is needed to achieve refinement in-situ. Accidental heterogeneous nucleation on unmelted Ti powder, originating from the different thermophysical properties of Ti and Cu, provided the most significant microstructural refinement. This work systematically assesses the microstructural refinement mechanisms of Ti-Cu in AM builds and offers insights into microstructural control in eutectoid alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Computational thermodynamics-guided alloy design and phase stability in CoCrFeMnNi-based medium-and high-entropy alloys: An experimental-theoretical study

A computational thermodynamics approach has been employed to design CoCrFeMnNi-based medium- and high-entropy alloys (M/HEAs) with systematically varied compositions (Co(( 80-X )/ 2 )Cr(( 80-X )/ 2 )Fe X Mn 10 Ni 10 with x = 30, 40, and 50 at.%) and phase stability. Since the formation of sigma phase, usually brittle and undesirable, is a common concern, when this class of alloys is subjected to elevated temperatures (600–1000 °C), predicting its formation becomes essential. Thus, its formation and the phase equilibria were studied using the CALPHAD method, and two empirical methods, namely, valence electron concentration (VEC) and paired sigma-forming element (PSFE). Isothermal aging treatments at 900–1100 °C for 20 h were performed, since CALPHAD and VEC/PSFE predictions diverged. Both prediction methods were compared with experimental characterization by a combination of scanning electron microscopy and high-energy synchrotron X-ray diffraction. In conclusion, the predictions from the VEC/PSFE and CALPHAD calculations (depending on the database used) were shown to be quite accurate.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Tuning austenite stability through prior microstructure control in a low-alloy Q&P steel

Quenching and partitioning (Q&P) processing is a widely accepted heat treatment methodology for creating high strength steels consisting of ferrite, martensite, and austenite, while maintaining relatively low manufacturing costs. Though the research on effects of prior microstructure is limited, an understanding of the heat treatment response of different starting microstructures is critical to processing and creating steels with complex microstructures that contain retained austenite and may afford opportunities to further optimize properties. This study investigates the influence of starting microstructure (ferrite/pearlite versus martensite) and prior levels of cold work (38 verses 58 %) on the microstructural development and mechanical properties of a 0.2 C-2.0 Mn-1.5 Si (wt.%) steel exposed to Q&P processing. Samples with a starting martensitic microstructure resulted in higher retained austenite fractions and a more homogeneous microstructure after Q&P processing compared to a starting microstructure of ferrite-pearlite. Starting martensitic microstructures also displayed higher work hardening rates and higher uniform elongations. Larger cold reductions saw accelerated dissolution kinetics and austenite formation during intercritical annealing, resulting in more similar final microstructures from the ferrite-pearlite and martensitic starting microstructures. Finally, the results presented here indicate that varying prior processing can be a route to manipulate and control austenite stability in a Q&P processed steel.

36 MATERIALS SCIENCE↗