Engineering topics

Zhu, Gaoming

Publications and source records attributed to Zhu, Gaoming.

6 records

DOE OSTI2023

Strengthening mechanisms, hardening/softening behavior, and microstructure evolution in an LPSO magnesium alloy at elevated temperatures

Here, rapid degradation of the mechanical properties of conventional Mg alloys with temperature precludes their wide application in industry. The LPSO (long period stacking ordered) Mg alloys, on the other hand, show considerable potential to achieve excellent high-temperature mechanical performance. In this study, a Mg-5.1Y-2.4Zn (wt.%) extrusion alloy with the microstructure comprising of α-Mg matrix and LPSO phase was prepared. It is shown that the yield strength of the alloy at 200 °C retained ~83% of the yield strength of 198 MPa at room temperature (RT). Importantly, the ductility also improved, owing to the increased non-basal slip activities at elevated temperatures. In contrast to RT and 200 °C, the alloy exhibited softening tensile behavior with an apparent loss of yield strength at 300 °C. In-situ lattice strain analysis revealed that load transfer from α-Mg to LPSO remains effective at temperatures up to 200 °C, governing the high yield strength of the alloy. The post-mortem analysis by means of electron microscopy confirmed that the LPSO phase is structurally stable at 200 °C. In particular, the high strain hardenability is rationalized by the sandwiched LPSO structures together with stacking faults serving as effective obstacles to the motion of non-basal dislocations. The load transfer effect disappears at the temperature of 300 °C, resulting in the fast deterioration of strength of the alloy. The cracking of the LPSO phase along with the recrystallizing of α-Mg grains were found to be the main causes for the softening behavior of the alloy at 300 °C.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Developing ductile and isotropic Ti alloy with tailored composition for laser powder bed fusion

Laser powder bed fusion (LPBF) is an advanced technology to create metallic components with complex geometry. Ti-6Al-4V (Ti64) is one of the most frequently used materials for LPBF. The intrinsic high cooling rates and ultra-high directional thermal gradient of melt, however, lead to a hierarchical structure composed of fine martensitic alpha' within columnar prior-beta grains in LPBF Ti64. This microstructure results in poor ductility and strong mechanical anisotropy in as-built Ti64 components, which largely limit their applications. Here, we report that the above shortcomings can be overcome by tailoring the alloy composition. Specifically, by reducing the aluminum content from 6 wt% to 4 wt%, the resultant LPBF Ti-4Al-4V (Ti44) alloy exhibits substantially improved ductility and mechanical isotropy. These improvements are attributed to grain refinement during solidification and the activation of multiple slip modes and twinning in the as-built material during deformation. This work offers a simple strategy to design new titanium alloys for LPBF with significantly improved ductility and isotropy.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Origins of high ductility exhibited by an extruded magnesium alloy Mg-1.8Zn-0.2Ca: Experiments and crystal plasticity modeling

Low ductility and strength are major bottlenecks against Mg alloys' wide applications. In this work, we systematically design the composition and fabrication process for a low-alloyed Mg-Zn-Ca alloy, showing that it can be extruded at low temperatures (~ 250 degrees C) and high speeds (~2 mm/s). After the extrusion, this alloy exhibits a substantially weakened basal texture, relatively small grain size, very high tensile elongation (~ 30%), and good strength. The origin of the considerably improved ductility was studied using a combination of three-dimensional atom probe tomography (3D-APT), transmission electron microscopy (TEM), electron backscattered diffraction (EBSD) in conjunction with surface slip trace analysis, in-situ synchrotron X-ray diffraction, and elasto-plastic self-consistent (EPSC) modeling. Co-segregation of Zn and Ca atoms at a grain boundary is observed and associated with texture weakening and grain boundary mediated plasticity, both improving the ductility. While basal slip and prismatic slip are identified as the dominant deformation systems in the alloy, the ratio between their slip resistances is substantially reduced relative to pure Mg and most other Mg alloys, significantly contributing to the improved ductility of the alloy. This Mg-Zn-Ca alloy exhibiting excellent mechanical properties and low fabrication cost is a promising candidate for industrial productions.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Evaluating the Taylor hardening model in polycrystalline Ti using high energy X-ray diffraction microscopy

High energy X-ray diffraction microscopy (HEDM) was employed to index nearly 1000 grains in a polycrystalline Ti specimen and characterize their deformation during an incremental tensile test. For each grain, the positions of its associated diffraction peaks were used for analyzing its evolving crystal orientation and stress tensor. The azimuthal breadth of each peak at different load steps was measured, allowing measurement of initial yielding and providing an estimate of the dislocation density evolution in each grain. Furthermore, the Taylor hardening model was evaluated grain by grain using the above data, indicating that it can represent hardening in most grains. The yield stress and the strain hardening coefficient for all grains were statistically analyzed with respect to grain orientation, grain size, slip systems, and the surrounding neighborhood to examine how the yield stress and hardening are correlated.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Highly deformable Mg–Al–Ca alloy with Al 2 Ca precipitates

Magnesium (Mg) is the lightest structural metal. However, the poor formability of Mg alloys to great extent limits their applications in making structural parts. Formability is strongly correlated to both high tensile elongation and large work hardening capacity. In this work, we report a new Mg-Al-Ca alloy in which a majority of deformable Al 2 Ca precipitates form while the formation of Laves phases of Mg 17 Al 12 and Mg 2 Ca seems suppressed. Al 2 Ca precipitates imped dislocation motion, leading to large work hardening. Then, Al 2 Ca precipitates deform with dislocations and stacking faults under the enhanced flow stress, which relieve local stress concentration and improve tensile elongation. In addition, solutes Al and Ca suppress twin nucleation while promoting non-basal dislocations in Mg. Our Mg-Al-Ca alloy demonstrates one of the highest combinations of tensile elongation and work hardening capacity among existing Mg alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Effect of heat treatment on the tensile behavior of selective laser melted Ti-6Al-4V by in situ X-ray characterization

Selective Laser Melted Ti-6Al-4V (as-SLMed) exhibits decreased yield strength, increased work hardening, and increased ductility after heat treatment at 730 degrees C (HT-730) or 900 degrees C (HT-900) for 2 h. To understand the change of mechanical properties, in situ high energy X-ray diffraction (HEXRD) is used to examine the phase composition, load partitioning, slip system activity, and dislocation density evolution in all three specimens. The as-SLMed specimen is dominated by martensitic α'. After heat treatment, α' partly or fully decomposes into α+β, reducing the yield strength. In HT-730, beta precipitates with confined size show much higher lattice strain than the α'/α matrix during deformation; in HT-900, the lattice strain difference is mostly eliminated. This is a key reason for the increased ductility in HT-900. From the anisotropic lattice strain development, basal slip is identified as the easiest slip system in α'/α. Using an elasto-plastic self-consistent (EPSC) model, the critical resolved shear stress ratio between prismatic slip and basal slip (CRSS prism /CRSS basal ) is estimated to be 1.31 and 1.16 in the as -SLMed and the HT-900 specimens, respectively. Further, the alpha phase in HT-900 is able to activate multiple slip systems and accumulate more dislocations during plastic deformation. This explains why HT-900 has better ductility and higher work hardening rate than the other two specimens.

36 MATERIALS SCIENCE↗