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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effects of Silicon Content on the Microstructures and Mechanical Properties of (AlCrTiZrV)-Si x -N High-Entropy Alloy Films

A series of (AlCrTiZrV)-Si x -N films with different silicon contents were deposited on monocrystalline silicon substrates by direct-current (DC) magnetron sputtering. The films were characterized by the X-ray diffractometry (XRD), scanning electron microscopy (SEM), high-resolution transmission electron microscopy (HRTEM), and nano-indentation techniques. The effects of the silicon content on the microstructures and mechanical properties of the films were investigated. The experimental results show that the (AlCrTiZrV)N films grow in columnar grains and present a (200) preferential growth orientation. The addition of the silicon element leads to the disappearance of the (200) peak, and the grain refinement of the (AlCrTiZrV)-Si x -N films. Meanwhile, the reticular amorphous phase is formed, thus developing the nanocomposite structure with the nanocrystalline structures encapsulated by the amorphous phase. With the increase of the silicon content, the mechanical properties first increase and then decrease. The maximal hardness and modulus of the film reach 34.3 GPa and 301.5 GPa, respectively, with the silicon content (x) of 8% (volume percent). The strengthening effect of the (AlCrTiZrV)-S ix -N film can be mainly attributed to the formation of the nanocomposite structure.

(AlCrTiZrV)-Six-N films↗
DOE OSTI2019

Effect of Heat Treatment on Microstructure and Mechanical Properties of Extruded Mg-4Zn-1.5Al-2Sn Alloy

The microstructure and mechanical properties of extruded Mg-4Zn-1.5Al-2Sn (ZAT422) alloy under different heat treatments were investigated by optical microscopy, scanning electron microscopy, x-ray diffraction, transmission electron microscopy, micro-hardness tests, and tensile tests. The results show that the as-extruded and heat-treated ZAT422 alloys mainly consisted of α-Mg and Mg{sub 2}Sn, and no ternary phase was detected. After aging, the amount of secondary phase precipitates increased significantly and the mechanical properties were improved. Among all the heat treatments, T5 heat treatment at 150 °C for 25 h resulted in the best combination of strength and ductility for ZAT422 alloy. The ultimate tensile strength, yield strength, and elongation (ε{sub f}) were found to be 290, 182 MPa, and 20%, respectively. Based on microstructural characterization, the variations in mechanical properties of the alloy subjected to heat treatment were analyzed in detail.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Mechanical Properties of W-ZrC Composites Synthesized by Reactive Melt Infiltration of Zr{sub 2}Cu into Porous Preforms from Partially Carburized W Powders

W-ZrC composites with different W contents from 48 to 73 vol.% have been synthesized by reactive melt infiltration of Zr{sub 2}Cu melt into porous preforms from partially carburized W powders at 1300 °C for 1 h in vacuum. The influences of carbon content and porosity in the preforms on microstructure and mechanical properties of W-ZrC composites are investigated. Cold isostatic pressing followed by pre-sintering process is used to produce porous preforms with suitable porosities of 53.6-47% under a pressure of 100 MPa to allow sufficient penetration of Zr{sub 2}Cu melt into the preforms. Small amounts of Cu-rich phases form in the synthesized W-ZrC composites after a complete reaction of y/2xZr{sub 2}Cu(l) + WC{sub y}(s) = y/xZrC{sub x}(s) + W(s) + y/2xCu(l). These Cu-rich phases are distributed not only at the phase boundaries of W matrix and ZrC grains, but also in the interior of ZrC{sub x} grains. With decreasing W content from 73 to 48 vol.% in the W-ZrC composites, the flexural strength and fracture toughness increase from 519 to 657 MPa and from 9.1 to 10.6 MPa m{sup 1/2}, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The annealing temperature dependences of microstructures and magnetic properties in electro-chemical deposited CoNiFe thin films

CoNiFe thin films with various compositions had been successfully fabricated using electro-chemical deposition method. The crystal structure of Co{sub 65}Ni{sub 15}Fe{sub 20}, Co{sub 62}Ni{sub 15}Fe{sub 23}, and Co{sub 55}Ni{sub 15}Fe{sub 30} thin films was fcc, bcc-fcc mix, and bcc, respectively. The difference crystal structure results the difference in magnetic properties. The saturation magnetic flux density (Bs) of Co{sub 65}Ni{sub 15}Fe{sub 20}, Co{sub 62}Ni{sub 15}Fe{sub 23}, and Co{sub 55}Ni{sub 15}Fe{sub 30} thin films was 1.89 T, 1.93 T, and 2.05 T, respectively. An optimal annealing temperature was determined for controlling the microstructure and magnetic properties of CoNiFe thin films. Depending on annealing temperature, the ratio of bcc and fcc structure varied without changing the film composition. By annealing at temperature of T ≥ 350°C, the intensity ratio of X-ray diffraction peaks for bcc(110) to fcc(111) increased. The increase of phase ratio of bcc(110) to fcc(111) caused the increase of Bs, from 1.89 T to 1.95 T. Coercivity (Hc) also increased after annealing, from 2.6 Oe to 18.6 Oe for fcc phase thin films, from 2.0 Oe to 12.0 Oe for fcc-bcc mix phase thin films, and 7.8 Oe to 8 Oe for bcc phase thin films. The changing crystal structures during annealing process indicated that the thermal treatment at high temperature cause the changing crystallinity and atomic displacement. The TEM bright-field images with corresponding selected-area electron diffraction (SAED) patterns showed that there are strongly effects of thermal annealing on the size of fcc and bcc phase crystalline grain as described by size of individual spot and discontinuous rings. The size of crystalline grains increased by thermal annealing. The evolution of bcc and fcc structures of CoNiFe during annealing is though to be responsible for the change of magnetic properties.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2013

Effect of oxygen partial pressure on microstructural and optical properties of titanium oxide thin films prepared by pulsed laser deposition

Graphical abstract: - Highlights: • Microstructural and optical properties are studied systematically. • The optical properties are studied by UV–visible and photoluminescence. • The PL spectra shows two peaks correspond to bandgap of anatase and rutile. • The maximum refractive index of 2.73 is obtained for rutile phase of titania. - Abstract: Nanocrystalline titanium oxide (TiO{sub 2}) thin films were deposited on silicon (1 0 0) and quartz substrates at various oxygen partial pressures (1 × 10{sup −5} to 3.5 × 10{sup −1} mbar) with a substrate temperature of 973 K by pulsed laser deposition. The microstructural and optical properties were characterized using Grazing incidence X-ray diffraction, atomic force microscopy, UV–visible spectroscopy and photoluminescence. The X-ray diffraction studies indicated the formation of mixed phases (anatase and rutile) at higher oxygen partial pressures (3.5 × 10{sup −2} to 3.5 × 10{sup −1} mbar) and strong rutile phase at lower oxygen partial pressures (1 × 10{sup −5} to 3.5 × 10{sup −3} mbar). The atomic force microscopy studies showed the dense and uniform distribution of nanocrystallites. The root mean square surface roughness of the films increased with increasing oxygen partial pressures. The UV–visible studies showed that the bandgap of the films increased from 3.20 eV to 3.60 eV with the increase of oxygen partial pressures. The refractive index was found to decrease from 2.73 to 2.06 (at 550 nm) as the oxygen partial pressure increased from 1.5 × 10{sup −4} mbar to 3.5 × 10{sup −1} mbar. The photoluminescence peaks were fitted to Gaussian function and the bandgap was found to be in the range ∼3.28–3.40 eV for anatase and 2.98–3.13 eV for rutile phases with increasing oxygen partial pressure from 1 × 10{sup −5} to 3.5 × 10{sup −1} mbar.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Optical properties of large-area ultrathin MoS{sub 2} films: Evolution from a single layer to multilayers

We investigated the optical properties of ultrathin MoS{sub 2} films (number of layers: N = 1, 2, 4, and 12) using Raman spectroscopy, photoluminescence (PL) spectroscopy, and spectroscopic ellipsometry. We estimated the layer thicknesses based on Raman spectra. We characterized the microstructural properties of a single-layer MoS{sub 2} film using atomic force microscopy. We measured the lowest-energy A and B excitons using PL spectroscopy. We measured the ellipsometric angles (Ψ and Δ) of MoS{sub 2} thin films using spectroscopic ellipsometry, and obtained the dielectric functions as the films' thickness changed from a single layer to multi-layers. We determined the films' optical gap energies from the absorption coefficients. Applying the standard critical point model to the second derivative of the dielectric function (d{sup 2}ε(E)/dE{sup 2}), we determined several critical point energies. The d{sup 2}ε(E)/dE{sup 2} spectra showed doublet peaks around 3 eV corresponding to the C and D transitions, as well as doublet peaks around 2 eV corresponding to the A and B transitions. These doublet structures at 3 eV are attributed to the transitions in the Brillouin zone between the Γ and K points.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

CHARACTERIZATION OF DIRECT ADDITIVE MANUFACTURED U3Si2 SURROGATE TO PREDICT U3Si2 MICROSTRUCTURES

The purpose of this research is to perform characterization exclusively on U3Si2 surrogate materials to predict the process envelope for future work with uranium compounds, considering potential microstructural properties. The surrogate material will be synthesized using a laser energy source. This characterization work will provide new property data to aid the concept development stages of fabricating U3Si2 by means of a novel INL-designed direct additive manufacturing methodology. This process not only seeks to potentially reduce production costs, but also to shorten the current silicide fuel fabrication process. U3Si2 has been downselected as a candidate for accident-tolerant fuel for commercial light-water reactors due to its improved thermal conductivity, higher atomic density, and fuel cycle economics when compared with UO2. The research efforts on this work are performed at Idaho National Laboratory (INL) in partnership with Westinghouse Electric. The initial stage of the surrogate research will include a thermodynamic study along with physical and mechanical property analyses to assist in the downselection of surrogate materials for initial experimentation. Initial characterization analyzed the microstructural effects to determine effectiveness of laser interaction on the surrogate materials. Additional characterization via scanning electron microscopy (SEM), transmission electron microscopy (TEM), and x-ray diffraction (XRD) may predict the end product morphology when working with uranium compounds. Complementary comparative studies were performed on the surrogate end products analyzing similarities in microstructural features present on the U3Si2 fuel fabricated by means of alternate methods. This stage provided novel microstructural data on surrogate silicide fuel fabrication by means of an additive manufacturing process (laser synthesis), and was crucial to confirm the formation of surrogate silicide fuels (Hf3Si2 and Zr3Si2) employing a laser synthesis.

42 ENGINEERING↗
DOE OSTI2024

Surface Finishing and Coating Parameters Impact on Additively Manufactured Binder-Jetted Steel–Bronze Composites

In this paper, electroless nickel plating is explored for the protection of binder-jetting-based additively manufactured (AM) composite materials. Electroless nickel plating was attempted on binder-jetted composites composed of stainless steel and bronze, resulting in differences in the physicochemical properties. We investigated the impact of surface finishing, plating solution chemistry, and plating parameters to attain a wide range of surface morphologies and roughness levels. We employed the Keyence microscope to quantitatively evaluate dramatically different surface properties before and after the coating of AM composites. Scanning electron microscopy revealed a wide range of microstructural properties in relation to each combination of surface finishing and coating parameters. We studied chempolishing, plasma cleaning, and organic cleaning as the surface preparation methods prior to coating. We found that surface preparation dictated the surface roughness. Taguchi statistical analysis was performed to investigate the relative strength of experimental factors and interconnectedness among process parameters to attain optimum coating qualities. The quantitative impacts of phosphorous level, temperature, surface preparation, and time factor on the roughness of the nickel-plated surface were 17.95%, 8.2%, 50.02%, and 13.21%, respectively. On the other hand, the quantitative impacts of phosphorous level, temperature, surface preparation, and time factor on the thickness of nickel plating were 35.12%, 41.40%, 3.87%, and 18.24%, respectively. The optimum combination of the factors’ level projected the lowest roughness of Ra at 7.76 µm. The optimum combination of the factors’ level projected the maximum achievable thickness of ~149 µm. This paper provides insights into coating process for overcoming the sensitivity of AM composites in hazardous application spaces via robust coating.

36 MATERIALS SCIENCE↗
DOE OSTI2016

On the evolution of secondary hardening carbides during continuous versus isothermal heat treatment of high speed steel HS 6-5-2

The continuous heat treatment of high speed steels reduces the process times from several hours to a few minutes. The resulting cost savings as well as lower decarburisation and distortion make the continuous heat treatment favourable over an isothermal heat treatment. However, the microstructure-property relationship during continuous heat treatments is far from being well understood. In order to identify the key microstructural features for the future optimisation of continuous heat treatments of high speed steels this study compares a current industrial continuous and an isothermal heat treatment of steel HS 6-5-2 by means of light optical microscopy, scanning electron microscopy, X-ray diffraction, atom probe tomography, and red hardness. After continuous hardening the content of primary carbides is higher and the amount of retained austenite is lower compared to isothermal hardening. Due to the reduced time for dissolution of primary carbides a lower content of alloying elements is present in the martensitic matrix for subsequent tempering. Therefore, the chemical composition of the secondary hardening carbides after tempering is different for a continuous heat treatment. Although the difference in chemistry is quite pronounced, the deterioration of the hardness at elevated temperatures, which strongly influences the performance characteristics of the finished parts, is not altered. - Highlights: •We studied the continuous and isothermal heat treatment of the steel HS 6-5-2. •The amount of primary carbides is higher in a continuously heat treated steel. •The chemistry of secondary hardening carbides changes during tempering. •Continuously heat treated steels exhibit the same performance characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Clustering Algorithm for AM Parts using GSH and EDT with Autoencoder

SAND2025-10103O The Clustering Algorithm for AM Parts Using GSH and (EDT With Autoencoder is a software tool. It uses a clustering algorithm for additive manufacturing (AM) parts using generalized spherical harmonics (GSH) and Euclidean distance transform (EDT) with an autoencoder to quantify material microstructure. The tool offers improved sensitivity to microstructural changes compared to traditional approaches. The tool integrates multiple microstructural properties, such as grain morphology, crystallographic orientation, and material phase information, to provide a comprehensive analysis of material microstructures. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Rodgers, Theron [Sandia National Lab. (SNL-CA), Li↗
DOE OSTI2012

Enhanced visible light activity of nano-titanium dioxide doped with multiple ions: Effect of crystal defects

Titanium dioxide photocatalysts co-doped with iron(III) and lanthanum(III) have been prepared through a modified sol-gel method. Doping with Fe{sup 3+} resulted in a relatively lower anatase to rutile phase transformation temperature, while La{sup 3+} addition reduced the crystal growth and thus retarded the phase transformation of titania nanoparticles. The presence of Fe{sup 3+} ions shifted the absorption profile of titania to the longer wavelength side of the spectrum and enhanced the visible light activity. On the other hand, La{sup 3+} addition improved the optical absorption of titania nanoparticles. Both the dopants improved the life time of excitons by proper transferring and trapping of photoexcited charges. In the present work, considerable enhancement in photocatalytic activity under visible light was achieved through synergistic effect of optimum concentrations of the two dopants and associated crystal defects. - Graphical abstract: Photocatalytic activity studies indicate a synergistic effect of dopants and crystal defects leading to an enhanced photochemical activity. Highlights: Black-Right-Pointing-Pointer An aqueous sol-gel synthesis of Fe{sup 3+} and La{sup 3+} co-doped TiO{sub 2} is being reported. Black-Right-Pointing-Pointer Optical and microstructural properties of titania were modified by co-doping. Black-Right-Pointing-Pointer Enhanced activity of titania by the crystal defects is being reported.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure and mechanical properties of a Ti-microalloyed low-carbon stainless steel treated by quenching-partitioning-tempering process

Quenching-partitioning-tempering (Q-P-T) process was used to treat a Ti-microalloyed low-carbon stainless steel after cold rolling. In addition to martensite, ferrite and retained austenite, TiN, coarse TiC, fine TiC, (Fe,Cr){sub 3}C and ultra-fine TiC precipitates were formed after the Q-P-T treatment. Based on field emission-scanning electron microscope (FESEM) and transmission electron microscope (TEM) observations, thermodynamic, crystallographic and statistical analyses were used to reveal the precipitation behaviors of these particles. The effects of partitioning-tempering (P-T) temperature and time on the microstructure and mechanical properties of Q-P-T treated specimens were specially studied. The coarsening and spheroidization of (Fe,Cr){sub 3}C particles during P-T stage were obviously retarded by large Cr addition. The retained austenite was obtained significantly with appropriate P-T parameters. The precipitation of ultra-fine TiC particles in the martensite during the P-T stage at 500 °C induced a secondary hardening. - Highlights: • Some fine TiC with 30–70 nm precipitated in austenite during partial austenization. • A part of fine TiC had K-S OR with martensite after Q-P-T treatment. • A part of fine TiC had a OR specially deviating from K-S OR with martensite. • Coarsening and spheroidization of (Fe,Cr){sub 3}C were retarded during P-T stage. • Ultra-fine TiC with < 10 nm precipitated in martensite during P-T stage at 500 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2015

The effect of scandium addition on microstructure and mechanical properties of Al–Si–Mg alloy: A multi-refinement modifier

Effect of scandium (Sc) additions on the microstructure, mechanical properties and fracture behavior of Al–Si–Mg casting alloy (F357) were systematically investigated. It was found that Sc addition caused a multi-refining efficiency on the microstructure of as-cast F357 alloy, including refinement of grains and secondary dendrite arm spacing (SDAS), modification of eutectic Si and harmless disposal of β-Al{sub 5}FeSi phase. Subsequent T6 heat treatment had further induced the complete spheroidization of eutectic Si and precipitation of fine secondary Al{sub 3}Sc dispersoids in the Sc modified alloys. Thus the mechanical properties, especially the ductility, were significantly enhanced by the addition of Sc combined with the heat treatment. The highest ultimate tensile strength, yield strength and elongation were achieved in 0.8 wt.% Sc modified F357 alloy combined with T6 heat treatment. Furthermore, fractographic examinations indicated that the ductile fracture mechanism served as a dominate role in the modified alloys due to the formation of fine, deep and uniformly distributed dimples. - Highlights: • Detailed characterization of the multi-refining microstructure of Sc modified F357 alloy was performed. • The multi-refinement was proposed to refine grain and SDAS, modify eutectic Si and β-phase. • Sc modifier combined with T6 treatment is effective in improving tensile properties. • Modification of eutectic Si in F357 alloy with Sc is consistent with the IIT mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Heat Treatment on Microstructure and Mechanical Properties of Ti-6Al-4V-1.5Mn Fabricated by Powder Metallurgy

Ti-6Al-4V-1.5Mn alloy was prepared by powder metallurgy and solid solution aging treatment. Effect of composition segregation on properties of the titanium alloy was eliminated, and microstructure and the mechanical properties of the alloy were studied. Results show that the microstructure of Ti-6Al-4V-1.5Mn is composed of homogeneous α + β phase, and the optimal mechanical properties of the alloy are obtained when the solution temperature is 950 °C and the aging temperature is 460 °C. Analysis of the fracture illustrates that a small amount of dimple was found in the section and the fracture of the material was quasi-cleavage fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Measurement and Simulation of Thermal Conductivity of Hafnium-Aluminum Thermal Neutron Absorber Material

A metal matrix composite (MMC) material comprised of hafnium aluminide (Al3Hf) intermetallic particles in an aluminum matrix has been identified as a promising material for fast-flux irradiation testing applications. This material can filter thermal neutrons while simultaneously providing high rates of conductive cooling for experiment capsules. Our purpose is to investigate effects of Hf-Al material composition and neutron irradiation on thermophysical properties, which were measured before and after irradiation. When performing differential scanning calorimetry (DSC) on the irradiated specimens, a large exotherm corresponding to material annealment was observed. Thus, a test procedure was developed to perform DSC and laser flash analysis (LFA) to obtain the specific heat and thermal diffusivity of pre- and post-annealment specimens. This paper presents the thermal properties for three states of the MMC material: (1) unirradiated, (2) as-irradiated, and (3) irradiated and annealed. Microstructure-property relationships were obtained for the thermal conductivity. These relationships are useful for designing components from this material to operate in irradiation environments. Furthermore, the ability of this material to effectively conduct heat as a function of temperature, volume fraction Al 3 Hf, radiation damage and annealing is assessed using the MOOSE suite of computational tools.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Temperature-dependent mechanical properties and crystal plasticity parameters for additively manufactured Haynes-214 alloy: Experiments and numerical modeling

Our experimental mechanical testing data demonstrated that the additively manufactured (AM) laser powder bed fusion (L-PBF) Haynes-214 alloy exhibits non-linear mechanical properties as the temperature rises from ambient to 870 °C. Crystal plasticity (CP) simulations provide an effective approach to gaining deeper insights into microstructure-property linkages under thermomechanical loading. This method can reduce the need for costly high-temperature mechanical testing while accounting for the effects of crystallographic texture and grain morphology on the mechanical behavior of AM materials. However, calibrating a CP model is time-consuming because individual simulations are computationally expensive and hundreds (or more) of iterations over parameter sets may be required. To address this issue, we have designed a machine learning-differential evolution (ML-DE) CP framework that can accurately interpolate the tensile properties of AM L-PBF Haynes-214 alloy across a wide temperature range from ambient to 870 °C, with minimal reliance on experimental data. The framework uses electron backscatter diffraction (EBSD) measurements to generate statistically equivalent microstructural volume elements to serve as inputs to the CP modeling framework. Stress–strain curves were generated from 1000 CP simulations, which serve as the training data set for the three ML regression algorithms explored: linear, extra-trees, and multi-layer perceptron. These three regression models were independently evaluated to compare their efficiency and identify the most suitable algorithm for the given problem. Results revealed that the extra-trees ML regressor outperforms the other models in both qualitative and quantitative aspects with an R 2 of 0.98. Subsequently, the differential evolution optimization approach is employed to calibrate the ML-based CP material parameters with experimental results obtained at various temperatures. Finally, temperature-dependent CP material parameters are formulated. The effectiveness and efficiency of the designed framework are validated through comparison with experimental results, demonstrating a high degree of agreement. These calibrated parametric constitutive equations enable further use of the CP model to study the deformation behavior of this alloy under a wide range of thermo-mechanical loading conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparison of microstructural and mechanical properties of friction stir spot welded ultra-high strength dual phase and complex phase steels

Highlights: • The microstructure and mechanical properties of FSSW of ultra high strength DP and CP steels are compared. • The stir zone (SZ) of CP steel mainly consists of bainite and martensite; no bainite is identified in the SZ of DP steel. • The cooling was not fast enough for the CP steel to suppress the effect of chemical composition on phase transformation. - Abstract: The microstructure and mechanical properties of friction stir spot welding of ultrahigh strength dual phase (DP) and complex phase (DP) steels are compared based on the experimental results. For both DP and CP steels, FSSW joints are successfully fabricated using the same process parameter set. While the microstructure of joints are characterized in detail using scanning electron microscopy, electron back scattered diffraction, and transmission electron microscopy, the mechanical property of joints are evaluated by shear tensile tests. The result of the microstructural analysis shows that the stir zone (SZ) of CP steel mainly consists of bainite and martensite, while no bainite is identified in the SZ of DP steel. The existence of bainite in the SZ of CP steel suggests that the cooling rate, which is nearly identical for both CP and DP steels, was not fast enough to suppress the effect of the alloying composition, particularly that of Mn, on the phase transformation. The result of the present study contributes to the development of solid state joining process of the ultrahigh strength steels.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Additive manufacturing of metal matrix composites

Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

36 - MATERIALS SCIENCE↗