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Effect of hafnium micro-addition on precipitate microstructure and creep properties of a Fe-Ni-Al-Cr-Ti ferritic superalloy
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Cantor-derived medium-entropy alloys: bridging the gap between traditional metallic and high-entropy alloys
The year 2004 marked the beginning of a new era in the design of metallic materials, as the concept of multiple principal component alloys, commonly known as High-Entropy Alloys (HEAs), was proposed by Cantor and Yeh. The unexpected single-phase microstructure, instead of the expected brittle intermetallic compounds, was attributed to the large entropy of mixing and immediately caught the attention of the scientific community. Today, HEAs are considered important advanced materials and a broad range of alloys using nominally the same design principle have been investigated. Despite that, the CrMnFeCoNi (Cantor) alloy stands out as the most successful HEA due to its outstanding mechanical properties and microstructure. In this scenario, variants of the Cantor alloy, named medium-entropy alloys (MEAs), are gaining significant interest as they display a better industrial potential than both HEAs and traditional alloys. These variants of the Cantor alloy with only three or four main elements result in 15 possible combinations. The microstructure of these alloys is discussed in terms of advanced characterization as well as thermodynamic parameters and computational simulation. Their phase stability is addressed over a wide range of temperatures and strain rates. The mechanical properties, especially the fracture toughness, of the CrFeCoNi and CrCoNi alloys have been reported to be even superior to those of the Cantor alloy and most modern engineering alloys. This is associated with the formation of a continuous sequence of strengthening mechanisms, including hierarchical twin networks, which serve to prolong the strain hardening. The present article reviews and critically assesses, for the first time, recent advances in these Cantor-derived MEAs.
Thermally Grown Oxide Stress in PS-PVD and EB-PVD Thermal Barrier Coatings Observed at Various Lifetimes Via Synchrotron X-ray Diffraction
The current standard application method for thermal barrier coatings (TBCs) on turbine blades for jet engines is electron-beam physical vapor deposition (EB-PVD) due to its high strain tolerance and low thermal conductivity. An emerging deposition method, plasma-spray physical vapor deposition (PS-PVD), presents an opportunity for a tailorable microstructure, and non-line-of-sight deposition that is faster and less expensive. To compare the lifetime behavior of both PS-PVD and EB-PVD coatings, samples subjected to 300 and 600 thermal cycles were measured during a 1 h thermal cycle to determine the strains, which were converted to stress, in the thermally grown oxide (TGO) layer of the TBCs using synchrotron X-ray diffraction (XRD). Room temperature XRD measurements indicated among samples that PS-PVD coatings experienced greater variation in in-plane room temperature strain in the TGO after cycling than the EB-PVD coatings. In-situ XRD measurements indicated similar high-temperature strain and no spallation after 600 thermal cycles for both coatings. Further, microscopy imaging after cycling showed greater rumpling in PS-PVD coatings that led to different failure modes between the two coatings’ TGO layers. The tailorability of PS-PVD coatings allows for adjustments in the processing parameters to improve their overall performance after aging and bridge the differences between the two deposition methods.
Thermomechanical Processing of Metal Feedstock for Semisolid Forming: A Review
Thermomechanical processing of cast structures is an effective solid working route of generating thixotropic morphologies after subsequent partial melting and is in use for decades to manufacture the bulk billet feedstock for thixoforming from a variety of alloys. The solid-state deformation is also critical for coarse particulate feedstock, utilized for semisolid forming either directly or after compaction into billets. Although the original concept, called strain-induced melt activation (SIMA), defined the specific procedure, the term became generally recognized synonym for a variety of thermomechanical treatments offering an opportunity of controlling the solidification microstructure. This review covers transformations during solid-state deformation, reheating to semisolid state and isothermal holding within solidus–liquidus range, and solidification of thixotropic slurries. Essentials of semisolid metal processing, necessary to understand the subject, are supported by details related to specific implementation techniques and alloys. Application examples at laboratory and commercial levels and properties achieved with conventional and severe plastic deformation techniques, for different alloys along with present limitations, are described. The link between solid-state deformation-enhanced melting and liquid metal engineering is emphasized throughout the paper in terms of the common goal of controlling the solidification outcome in order to develop technology for mass-scale production of net-shape components having performance characteristics superior to conventional castings.
Morphological-informed Thermal Property Prediction in the Engineering Domain
Using first-principle, atomic scale methods to predict thermal carrier (electron and phonon) behavior at nanoscale yields highly resolved thermal properties. Density functional theory simulations can model myriad effects on the transport of phonons and electrons (e.g., phonon and electron coupling, electron correlation, defect presence, carrier scattering), and yield thermal properties for small geometric domains such as thermal and electrical conductivity, or heat capacity. While these thermal properties are accurate in atomistic and nanoscopic systems, they must be scaled up to the microstructural domain to be a useful predictor for experimental basis, as the microscale is where myriad changes and physical phenomenon occur within a material (e.g., grain boundaries, precipitate aggregations, interfaces, defect clusters). My talk will discuss the necessity of thermal property predictions for nuclear fuels applications and more. Additionally I will discuss the necessity in developing multi-physics, multi-scale methods for future applications in predictions for not only nuclear fuels, but other materials applications.
Thermoelectric performance in disordered Cu 2 ZnSnSe 4 nanostructures driven by ultra-low thermal conductivity
Here, high-energy reactive mechanical alloying (ball milling) was used to synthesize tetragonal and cubic polymorphs of Cu 2 ZnSnSe 4 . The ordered tetragonal (I-4) polymorph undergoes a phase transition above 400 K into a Cu-Zn disordered tetragonal (I-42 m) polymorph, while the cubic (F-43 m) polymorph with full cation disorder is stabilized at room temperature. Both polymorphs show ultra-low thermal conductivities, 0.42 W m -1 K -1 at 722 K and 0.21 W m -1 K -1 at 523 K for the disordered tetragonal and cubic phases respectively. The cubic polymorph has a higher zT in the low-temperature range, peaking at 0.26 (523 K), while the disordered tetragonal has a maximum zT of 0.46 at 712 K. The latter is the highest reported zT for stoichiometric Cu 2 ZnSnSe 4 , comparable to the best-performing doped materials in the literature. A combination of experimental results and ab-initio calculations point to a coupling between structural disorder and microstructure as the mechanism behind the reported performance.
Excellent high cyclic fatigue properties of a novel ultrafine-grained medium entropy alloy
Fatigue is a major cause of failure and requires dedicated investigation to validate the integrity of potential structural materials. As high and medium entropy alloys (HEAs and MEAs) are garnering significant attention from scientific communities, it is important to test the structural integrity of these novel alloys in cyclic loading environment. This study analyzed both monotonic and cyclic loading properties of a novel medium entropy alloy (MEA) CoCr 1.3 Ni in the ultrafine-grained (UFG) and fine grain (FG) conditions. The UFG MEA performs better than the FG MEA during cyclic loading. Microstructural evolution after cyclic loading via electron back-scattered diffraction shows microstructural stability of both FG and UFG microstructures. Transmission electron microscopy suggests formation of stacking faults and fine-scale HCP transformation during cyclic loading.
Stability of a model Fe-14Cr nanostructured ferritic alloy after long-term thermal creep
The successful development of advanced materials such as nanostructured ferritic alloys (NFA) for next generation nuclear reactor concepts and ultra-supercritical steam power plants requires information on long term thermal creep. To support this initiative, we examine the NFA MA957 (Fe-14Cr-1.0Ti-0.3Mo + 0.3Y 2 O 3 in wt%) crept to 61,251 h at 825 °C and 70 MPa, the longest creep test available to date for this material. Using atom probe tomography and electron microscopy, it is demonstrated that the grain size and nanoprecipitate size/composition are unaffected following this 7 yr creep test, although significant porosity is noted throughout the microstructure attributed to microvoid coalescence and growth.
Computational Modeling of Microstructure Formation During Laser Powder Bed Fusion of Bulk Thermoelectric Materials
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Applications of CALPHAD modeling and databases in advanced lightweight metallic materials
Here this paper presents an overview on the application of CALPHAD (CALculation of Phase Diagrams) methodology in the design and development of advanced lightweight metallic materials including magnesium, aluminum, titanium, aluminum-based metal matrix composites, and high entropy alloys. In this work, CALPHAD methodology has been established and summarized from the construction of databases describing thermodynamics, atomic mobility, kinetics, thermo-physical properties (such as viscosity) to the application of computational design of lightweight materials. The examples in this paper have demonstrated the effectiveness and capability of CALPHAD methodology in accelerating the design of advanced lightweight materials by optimizing the compositions and various heat-treatment conditions, modifying the evolution of microstructures during processing, and finally predicting the mechanical properties (e.g., yield strength and hardness) of the lightweight components. Although the examples are given in lightweight alloys for structural applications, the fundamental methodology and modeling principles are applicable to all materials and engineering applications. Thus, the future of the advanced material design will be strongly based on development of CALPHAD methodology such as the construction of reliable databases coupled with CALPHAD-based models for various applications.
Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations
A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.
Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing
The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.
The evolution history of superalloy powders during hot consolidation and plastic deformation
Highlights: • Element segregations in a powder metallurgy superalloy at different states are identified. • The surface energy drives precipitation of oxides, carbides, and γ' particles on powder surface during hot consolidation. • Prior particle boundary structure is distorted and more uniformly refined grains are obtained after hot extrusion. - Abstract: Powder metallurgy superalloys are widely used to produce critical rotating parts in turbine engines. However, the issues like what is the driving force of precipitation on prior particle boundary (PPB) during consolidation and how the PPB structure evolves during plastic deformation still remain to be resolved. In this study, with the characterization of the microstructure evolution from powder, consolidation, to plastic deformation, the segregation of alloying elements on the particle boundaries at elevated temperature was analyzed by equilibrium thermodynamic calculations, and the distortion of PPB structure under large plastic deformation was quantitively simulated by finite element (FE) methods. The results indicated that surface energy serves as the main driving force of PPB precipitation and hot extrusion could distort the PPB structure and yield more uniformly refined grains.
Investigations towards incorporation of Eu 3+ and Cm 3+ during ZrO 2 crystallization in aqueous solution
Nuclear energy provides a widely applied carbon-reduced energy source. Following operation, the spent nuclear fuel (SNF), containing a mixture of radiotoxic elements such as transuranics, needs to be safely disposed of. Safe storage of SNF in a deep geological repository (DGR) relies on multiple engineered and natural retention barriers to prevent environmental contamination. In this context, zirconia (ZrO 2 ) formed on the SNF rod cladding, could be employed as an engineered barrier for immobilization of radionuclides via structural incorporation. This study investigates the incorporation of Eu 3+ and Cm 3+ , representatives for trivalent transuranics, into zirconia by co-precipitation and crystallization in aqueous solution at 80 °C. Complementary structural and microstructural characterization has been carried out by powder X-ray diffraction (PXRD), spectrum imaging analysis based on energy-dispersive X-ray spectroscopy in scanning transmission electron microscopy mode (STEM-EDXS), and luminescence spectroscopy. The results reveal the association of the dopants with the zirconia particles and elucidate the presence of distinct bulk and superficially incorporated species. Hydrothermal aging for up to 460 days in alkaline media points to great stability of these incorporated species after initial crystallization, with no indication of phase segregation or release of Eu 3+ and Cm 3+ over time. These results suggest that zirconia would be a suitable technical retention barrier for mobilized trivalent actinides in a DGR.
Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels
Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.