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At least 1,099 records · Page 61

Molecular dynamics simulation of phase competition in terbium

The competition among multiple solid phases determines the final microstructures of a material. Such competition can originate at the very beginning of the solidification process. We report the results of molecular dynamics simulation of the phase competition between the hexagonal close-packed (hcp), face-centered cubic (fcc), and body-centered cubic (bcc) phases during the solidification of pure Tb. We found that the liquid supercooled below the hcp melting temperature has both bcc and hcp/fcc nuclei, but only the bcc nuclei grow such that the liquid always solidifies into the bcc phase, even at temperatures where the hcp phase is more stable. The hcp phase can only form in the last liquid droplet or at the bcc grain boundaries. Depending on the bcc grain orientations, the hcp phase jammed between the bcc grains either completely disappears or slowly grows via a solid-state massive transformation mechanism. Once the hcp phase becomes large enough, the stresses associated with its appearance can trigger a martensitic transformation. Yet, not the entire bcc phase is consumed by the martensitic transformation and the remaining bcc phase is transformed into the hcp phase via the solid-state massive transformation mechanism. If the supercooling is too large, the nucleation becomes almost barrier free and the liquid solidifies into a structure consisting of ultra-fine hcp and bcc grains after which the bcc phase quickly disappears.

36 MATERIALS SCIENCE↗

Interpreting dynamic-compression experiments to uncover the time dependence of freezing: Application to gallium

Using pulsed-power magnetic field sources to compress gallium to gigapascal pressures on nanosecond timescales, we report here experiments on shockless dynamic compression of a liquid metal. Time-resolved velocimetry data reveal signatures of rapid freezing from a metastable liquid state, and we demonstrate that the kinetics of this nonequilibrium solidification can be accurately simulated with a computational modeling framework we have developed in previous studies, where classical nucleation theory is coupled with hydrodynamics. Notably, velocity traces in some of our experiments show evidence of a phase transition, while others do not, even though other types of evidence suggest that solidification may be occurring in all of them. We explain how predictions made by our models regarding the presence or absence of these phase-transition signatures motivated additional experiments that later confirmed the theoretical predictions. Our analysis shows that due to the rapid, quasi-isentropic nature of the loading path, our experiments were able to compress liquid gallium to metastable states that are undercooled below the equilibrium melt temperature by more than 300 K and exhibit pressures that approach five times the equilibrium melt pressure. The understanding gained in this study should form the basis for future dynamic-compression experiments aimed at interrogating melt curves at high pressures.

gallium↗

Sparse thermal data for cellular automata modeling of grain structure in additive manufacturing

Grain growth in the wake of the melt pool formed during alloy-based additive manufacturing (AM) is complex and multifaceted, depending on parameters governing heat transport, fluid flow, and solidification itself. Cellular automata (CA) models have proven effective in providing computationally efficient and physically sound predictions of grain structure for several AM problems, but their efficiency is tied to the performance of heat transport models. CA models use only a small portion of the problem's temperature data (near the moving melt pool boundary), and much of the CA calculations do not affect the final result due to re-melting of material. Coupling of and communication between heat transport and solidification models, and eliminating operations irrelevant towards final grain structure prediction, will be necessary for using these methods for efficient simulation of large parts. In this work, we introduce a procedure of decoupling the CA from temperature field simulation, using files of relevant temperature data written by the heat transport model. This approach is validated against the standard coupling approach using data obtained through the computational fluid dynamics software OpenFOAM. Negligible differences are seen in grain size, volume, and texture distributions for multilayer simulation of test problems, while the quantity of temperature data for these test problems was reduced by four orders of magnitude (from 100s of GB to 10s of MB) and the code performance sped up by a factor of around 50. Furthermore, variability in microstructure as a function of cell size, substrate, time step, and nucleation parameters is studied, and it is found that cell sizes less than or equal to 1.67 μm and sufficiently small time steps yield Αstatistically equivalent microstructures. Finally, a potential use case for this CA approach—the layer-wise convergence in grain structure starting from extremes in initial grain size—is examined. This approach's ability to simulate expected trends in nucleation and epitaxial grain growth for large regions of microstructure, simulated independently of heat transport models themselves, should prove useful for investigation of various microstructure uncertainties and prediction of part-scale experimental results.

36 MATERIALS SCIENCE↗

Crack-Free 30% Chromium-Nickel Alloy Welding Products for Nuclear Service

We report prior research in the development of 30% chromium-nickel alloy nuclear welding wires has resulted in the resolution of primary water stress corrosion cracking (PWSCC) and ductility dip cracking (DDC) as well as improvement in solidification cracking (SC) resistance. The resolution of DDC exhibits some Laves phase, which has a negative effect on SC resistance. In this study, the use of an alternate carbide former, tantalum (Ta), in combination with niobium (Nb) was researched. Three heats of recently designed Filler Metal 52MSS-Ta (i.e., HV1648, HV1673A, and VX131WXW) were melted, fabricated, and systematically studied. DDC and SC were evaluated with thermodynamic modeling using the Scheil solidification simulation model, two types of varestraint tests, and strain-to-fracture (STF) testing. The varestraint and STF test results showed an improved SC resistance with reduced Laves phase and concurrent excellent DDC resistance. Optimized compositions with low Laves phase also exhibited high threshold strain values (TSVs) in the STF test. VX131WXW — which contains 2.81 wt-% Ta, 0.6 wt-% Nb, and 6 wt-% iron (Fe) - exhibited a TSV of 24%. Thermo-Calc computed the Laves phase to be 0.24% for VX131WXW compared to 0.06% in HV1673A. This difference in Laves phase resulted in the lower SC resistance of VX131WXW compared to HV1673A when measured with longitudinal varestraint testing. The maximum crack distance for HV1673A was about 0.6 mm while that of heat VX131WXW was about 1.0 mm. The typical diluted weld deposit made with VX131WXW was also resistant to PWSCC due to the chromium content exceeding 24%. These simultaneous results mark progress toward crack-free welds and provide direction for further optimization of Ta-containing filler metals.

30% chromium-nickel alloy↗

Immobilization of Organic Liquid Radioactive Waste (LWR) in a Sulfur Composite Matrix at the BN-350 Fast Neutron Reactor Site, Kazakhstan - 18031

The immobilization treatment and final disposition of all forms of organic radioactive liquids, such as pump oil, spent solvent, tri-butyl-phosphate (TBP) and scintillation fluids, remain a significant challenge for nuclear waste generators and national regulators. The majority of nuclear nations have instituted regulations that require some form of encapsulation of treated organic liquid, notwithstanding LLW organic liquids that can be safely incinerated. In most cases cement is the designated material for encapsulation; however, cement can pose certain problems with the containment of treated organic liquids. In 2013, with funding from the U.S. Department of Energy - National Nuclear Security Administration through its Global Initiative for Proliferation Prevention Program (GIPP), a proven U.S. technology for the treatment of radioactive organic liquids was introduced at the BN-350 fast neutron reactor facility in Aktau, Kazakhstan. As the facility was undergoing full decommissioning, one hundred and sixty cubic meters of contaminated pump oil (including Cs-137, Sr-90 and U-235/238) contained in large above ground tanks had to be treated for final disposal. As a result of the research conducted over a two-year period, a new 2-step treatment process was invented by combining the U.S. solidification technology with a newly developed inorganic filler and molecular sulfur, referred to as radiation-resistant composite (RRC) to fully encapsulate the waste oil. The outcome of extensive test program indicates that the final form can reach up to 60 wt.% with a compressive strength of about 100 kg/cm{sup 2}. Preliminary conclusions indicate that RRC outperforms cement as an encapsulation form for final waste treatment which meets U.S. Nuclear Regulatory requirements for final disposal. This paper examines the preliminary experimental work that was conducted in Kazakhstan with the U.S. polymer technology and radioactive pump oil, and the subsequent secondary process of combining the solidified material into a homogeneous final form utilizing RRC. Topics covered in the paper include: - Kazakhstan's regulatory requirements for attaining an achievable waste form for acceptance, which led to the RRC invention; - Technical objectives for the application of polymer technology and RRC materials to radioactive liquid waste; - Polymer solidification with radioactive oil and the result; step one of the RRC process; - Description of RRC materials, their origin and chemical characteristics; - Process of combining the solidified polymer mass with RRC materials into a solid, homogeneous matrix; step two of the RRC process; - Experimental results including leaching data, waste loading estimates and heat process calculations to create the matrix; - Cost advantages of the RRC process over cementation; - Limitations of the RRC process; - Next steps to verify conformance of the RRC technology to the U.S. requirements. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Hydraulic Properties of Grout Monoliths Containing Organic Ion Exchange Resin - 18369

The Waste Treatment and Immobilization Plant (WTP) at Hanford is being constructed to treat 56 million gallons of radioactive waste currently stored in underground tanks at the Hanford site. Operation of the WTP will generate several solid secondary waste (SSW) streams including spent spherical resorcinol formaldehyde cation exchange resin (IXr). The current plan for safe disposal of IXr is solidification in cementitious material (CM) typically comprised of cement, fly ash and blast furnace slag. Three CM formulations were tested to stabilize IXr for long-term land disposal. Two IXr loading rates, 0.1 and 0.3 v/v IXr:grout were used with the three CM formulations to prepare simulated waste form monoliths for hydraulic property testing. Following curing, the monoliths were removed from molds and tested to determine saturated hydraulic conductivity (K{sub sat}) and water retention properties. K{sub sat} was measured using a standard flexible permeameter method ASTM D-5084-10. A constant vapor pressure (CVP) method was used to determine van Genuchten parameters for desorption moisture retention curves for each of the SSW grout formulations. For the CVP method, vacuum saturated, intact wafers approximately 1.25 cm thick were placed above a saturated salt solution inside a sealed container for equilibration. Each saturated salt solution has an associated vapor pressure related to relative humidity in the container. Visual examination and three-dimensional x-ray micro computed tomography (μCT) indicated that the IXr was uniformly distributed in the cured waste form. Saturated hydraulic conductivity was within the range previously reported by Flach et al. in a study of the hydraulic properties of 98 pastes and grouts. The solidification of IXr in CM resulted in a waste form with water retention properties similar to cementitious pastes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Study on Application of Geopolymer to the Retrieval of Fuel Debris in Fukushima Dai-ichi NPP

In order to retrieve fuel debris in Fukushima Dai-ichi NPP, many retrieval methods are proposed. Geopolymer is the candidate material applied for an alternative retrieval method. In this concept, Geopolymer can be used to stabilize fuel debris and suppress the diffusion of radioactive materials. Objective: Evaluation of geopolymer applied for retrieving fuel debris. Slump Flow Test: Slump flow values decreased as the test temperature increased. In air condition, water molecules evaporated from geopolymer and the viscosity of geopolymer increased. In water condition, the same trends as in air condition were observed. Slump flow values of geopolymer also depended on the elapsed time after mixing. By adding water, the slump flow values of geopolymer became higher (Even at 80 deg. C). It is possible to adjust the solidification time (Setting time) of geopolymer. Solidification Process of Geopolymer: After the first layer solidified, the second layer was injected. At 300 deg. C, porous structure was observed in the first layer, while the second layer structure was intact. In the actual application, multilayered geopolymer may be used to stabilize fuel debris. Conclusion: Fluidity of geopolymer decreased with raising temperature. Setting time can be adjusted by adding water. Geopolymer may be applied by injecting multiple times on high temperature materials above 100 deg. C.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Bismuth-Based Perovskite-Inspired Solar Cells: In Situ Diagnostics Reveal Similarities and Differences in the Film Formation of Bismuth- and Lead-Based Films

Organic–inorganic lead-based halide perovskite compounds currently yield thin film solar cells with a power conversion efficiency (PCE) of >23%. However, replacing the lead with less-toxic elements while maintaining a high PCE remains a challenge. For this reason, there has been significant effort to develop Pb-free compounds, including methylammonium bismuth iodide (MA 3 Bi 2 I 9 ), but such systems severely underperform when compared with the prototypical Pb-based methylammonium lead iodide (MAPbI 3 ). For the latter, it is known that lead complexes with polar solvents, such as dimethyl sulfoxide (DMSO) and dimethylformamide (DMF), to form iodoplumbates which can co-crystallize into solvated phases. Herein, the solidification and growth behaviors of Bi- and Pb-based films is investigated using multi-probe in situ characterization methods. It is shown that the Bi-based compound crystallizes directly and rapidly into a textured polycrystalline microstructure from a precursor solution without evolving through intermediate crystalline solvated phases, in contrast to MAPbI 3 . This solidification process produces isolated crystals and challenges the growth of continuous and crystalline films required for solar cells. Further, it is revealed that solvent engineering with antisolvent dripping is crucial to enable the formation of continuous polycrystalline films of MA 3 Bi 2 I 9 and functional solar cells thereof.

36 MATERIALS SCIENCE↗

Microstructural development in DED stainless steels: applying welding models to elucidate the impact of processing and alloy composition

Austenitic stainless steel microstructures produced by directed energy deposition (DED)are analogous to those developed during welding, particularly high energy density welding. To better understand microstructural development during DED, theories of microstructural evolution,which have been established to contextualize weld microstructures, are applied in this study to microstructural development in DED austenitic stainless steels. Phenomenological welding models that describe the development of oxide inclusions, compositional microsegregation, ferrite,matrix austenite grains, and dislocation substructures are utilized to clarify microstructural evolution during deposition of austenitic stainless steels. Two different alloys, 304L and 316L, arecompared to demonstrate the broad applicability of this framework for understanding microstmctural development during the DED process. Despite differences in grain morphology and solidification mode for these two alloys (which can be attributed to compositional differences),similar tensile properties are achieved. It is the fine-scale compositional segregation and dislocation structures that ultimately determine the strength of these materials. The evolution of microsegregation and dislocation structures is shown to be dependent on the rapid solidification and thermomechanical history of the DED processing method and not the composition of the starting material.

36 MATERIALS SCIENCE↗

Microstructure Development of 308L Stainless Steel During Additive Manufacturing

$In$ $situ$ high-energy X-ray diffraction measurements were completed during deposition of 308L stainless steel wire onto a 304L stainless steel substrate. Attempts were made to extract microstructural features such as phase fraction and internal stress, as well as temperature evolution immediately following the deposition. The limited data that could be collected during deposition and rapid solidification are critically examined. High-energy X-rays coupled with relatively slow detectors were utilized to enable determination of orientation-dependent lattice parameters accurately enough to comment on phase strain evolution between austenite and ferrite. Here, information about the hydrostatic and deviatoric stress states of the constituent phases was determined on time scales that are relevant to their development. However, the time resolution of the technique was insufficient to monitor phase evolution during the solid–solid phase transformation and, more so, during solidification. Moreover, the accurate and absolute determination of inherently statistical parameters, such as phase fraction, depends critically on the ability to sample a statistically significant numbers of grains in the microstructure.

36 MATERIALS SCIENCE↗

Thermodynamics and Kinetics of Refractory Multi-principal Element Alloys: An Experimental and Modeling Comparison

Here, the search for structural alloys capable of ultrahigh temperature performance has led to the exploration of refractory multi-principal element alloys (RMPEAs). In this work, experimental results for solidification segregation and homogenization of two RMPEAs, NbTaTiW and MoNbTaTi, are compared to simulations using the Scheil and DICTRA modules in Thermo-Calc®. Scheil calculations accurately predict the observed solidification segregation, while DICTRA predicts general trends and can provide a minimum time to achieve homogenization at a given temperature.

36 MATERIALS SCIENCE↗

Oxygen Effects and Selective Oxidation of Group IV Alloying Additions in Group V-Based Refractory Multi-principal Element Alloys

Refractory multi-principal element alloys (RMPEAs) hold significant potential for advancing ultra-high-temperature technologies due to their remarkable strength retention under these conditions. However, the beneficial effects of alloying on microstructural evolution and mechanical properties are often obscured by the presence of interstitial alloying elements. The intricate interactions between substitutional alloying elements of Groups IV, V, and VI and interstitial content, whether intentional or incidental, remain poorly understood. In this study, we investigate the impact of dissolved oxygen on the microstructural evolution and stability of RMPEAs primarily composed of Group V elements, Nb and V, along with Group IV elements Ti, Zr, and Hf. We show that the strong affinity of oxygen for Group IV elements Zr and Hf leads to the internal precipitation of oxides during heat treatment, which competes with the homogenization of the as-cast dendritic microstructure. Here, we demonstrate that careful control and design of oxygen content and Group IV alloying additions are essential to minimize micro-segregation and prevent the detrimental precipitation of internal oxides. To address these challenges, we propose employing non-equilibrium solidification calculations to predict and optimize as-cast solidification structures, thereby reducing the reliance on homogenization processes.

Alloy design↗

Evaluation of the Microstructure and Performance of Fe-21Cr-15Ni-6Mn-Nb Nonmagnetic Stainless Steel Welded Joints

In the present study, double-sided gas shield welding (GSW), in a single pass, was applied to Fe-21Cr-15Ni-6Mn-Nb nonmagnetic stainless steel plate. The microstructure and performance of the welded joint were investigated via microstructural and phase analysis, mechanical testing and magnetic analysis. The results showed a satisfactory micrographic appearance with full penetration, and no solidification defects observed in the welded joint, which showed typical epitaxial growth characteristics in the welding solidification. Slight grain growth, with an average size of ~ 18.9 μm, occurred in the heat-affected zone (HAZ). The primary dendrite arms, on both sides of welding joint, grew along the direction of the temperature gradient and met at the centerline of the weld with no parting microstructure in evidence. The secondary dendrite arm spacing was stable in all parts of the weld zone (WZ). The hardness of the weld zone was higher than that of the HAZ and the base metal (BM), with the lowest hardness occurring in the HAZ. The results of tensile testing showed a higher strength of the welded metal (WM) compared to the BM, and a good strength-ductility balance of the welded joint. The impact energy of the HAZ was higher than that of the WZ, corresponding to 60.5 J at room temperature and 52.7 J at − 196 °C. Microvoid coalescence, concurrent with crack propagation along the direction of the long axis of the dendritic sub-grains, was observed during plastic deformation in the WZ. Additionally, the excellent paramagnetic characteristics of the welded specimens were revealed.

36 MATERIALS SCIENCE↗

Laser spot welding of additive manufactured 304L stainless steel

Here, the goal of this work is to understand if an additively manufactured 304L stainless steel exhibits similar spot-welding behavior as wrought 304L stainless steel. Due to the many differences between an additively manufactured component and wrought product, it is important to determine how the material interacts with the laser and how it affects the weld bead morphology. In this paper, the laser coupling efficiency, weld size, and solidification of spot welds produced in wrought and additively manufactured 304L stainless steel were investigated. The coupling efficiency of wrought and additively manufactured 304L stainless steel of similar surface condition were approximately the same over a range of applied laser energies. Laser welding of the untreated (rougher) surface of additively manufactured 304L, however, showed improved coupling efficiency ranging between 3.3 and 100%. The rougher surface traps the incoming light and increases the coupling efficiency at lower laser energies, while at higher energy, the absorption efficiency is dominated by intrinsic absorption from the keyhole formation rather than surface roughness. The resulting spot weld microstructures differed from welds made in wrought 304L and additively manufactured 304L. Welds made in wrought 304L were fully austenitic containing what is suspected to be massive austenite, which suggests that these welds solidified as primary ferrite. Welds made in additively manufactured 304L were also fully austenitic and contained both cellular austenite and what is suspected to be massive austenite. These observations mean that welds made in additively manufactured 304L solidified as primary ferrite and primary austenite. The differences in weld microstructures made in wrought and AM 304L can be attributed to differences in the composition and solidification rate.

304L stainless steel↗

Strengthening mechanisms in directed energy deposited austenitic stainless steel

Microstructures and mechanical properties are evaluated in austenitic stainless steel structures fabricated by directed energy deposition (DED) considering the effects of applied loading orientation, build geometry, and distance from the deposition baseplate. Locations within an as-deposited build with different thermomechanical history display different yield strength, while those locations with similar history have approximately the same yield strength, regardless of test specimen orientation. Thermal expansion of deposited material near the baseplate is inhibited by the mechanical constraint imposed by the baseplate, promoting plastic deformation and producing a high density of dislocations. Concurrently, high initial cooling rates decrease away from the baseplate as the build is heated, causing an increased spacing of cellular solidification features. An analysis of strengthening mechanisms quantitatively established for the first time the important strengthening contribution of high dislocation densities in the materials (166–191 MPa) to yield strength that ranged from 438 to 553 MPa in the present DED fabricated structures. A newly adopted mechanistic relationship for microsegregation strengthening from the literature indicated an additional important contribution to strengthening (123–135 MPa) due to the cellular solidification features. These findings are corroborated by the measured evolution of microstructure and hardness caused by annealing the DED material. Finally, these results suggest that the mechanical properties of deposited austenitic stainless steels can be influenced by controlling thermomechanical history during the manufacturing process to alter the character of compositional microsegregation and the amount of induced plastic deformation.

36 MATERIALS SCIENCE↗

An additively manufactured near-eutectic Al-Ce-Ni-Mn-Zr alloy with high creep resistance

A new additively manufactured (AM) Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt.%) near-eutectic alloy is reported, which shows unprecedented creep resistance up to 400 °C (a homologous temperature of 0.72). The eutectic solidification microstructure comprises ~ 27 vol% of coarsening-resistant second phase network with an ultrafine (<100 nm) inter-phase spacing. Both Mn and Zr contribute to creep resistance of the alloy. Small amount of Mn addition promotes selection of coarsening resistant phases without compromising the alloy processability. Zr not only improves hot-tearing resistance, but further enhances the second phase coarsening resistance resulting in improved creep resistance. Neutron diffraction performed during creep deformation reveals that the underlying mechanism for creep resistance in this alloy is impedance to dislocation motion stemming from the ultrafine eutectic solidification microstructure, whereas load transfer strengthening becomes less effective as the creep temperature increases. The second phase forms a continuous network in the as-fabricated condition, which is maintained during long-term creep at 300 °C. However, this network is fragmented into fine dispersoids at higher temperatures. It is proposed that the rate-limiting deformation mechanism at 300–400 °C is (i) dislocation climb for the alloy with fragmented second phase dispersoids and (ii) Orowan looping for the alloy with a continuous second phase network. In conclusion, the present design of an AM-processable multicomponent eutectic alloy with high creep resistance can be applied to other metallic systems exhibiting eutectic reactions, with expected extreme creep resistance.

36 MATERIALS SCIENCE↗

Theory-guided design of duplex-phase multi-principal-element alloys

Density-functional theory (DFT) is used to identify phase-equilibria in multi-principal-element and high-entropy alloys (MPEAs/HEAs), including duplex-phase and eutectic microstructures. Here, a combination of composition-dependent formation energy and electronic-structure-based ordering parameters were used to identify a transition from FCC to BCC favoring mixtures, and these predictions experimentally validated in the Al-Co-Cr-Cu-Fe-Ni system. A sharp crossover in lattice structure and dual-phase stability as a function of composition were predicted via DFT and validated experimentally. The impact of solidification kinetics and thermodynamic stability was explored experimentally using a range of techniques, from slow (castings) to rapid (laser remelting), which showed a decoupling of phase fraction from thermal history, i.e., phase fraction was found to be solidification rate-independent, enabling tuning of a multi-modal cell and grain size ranging from nanoscale through macroscale. Strength and ductility tradeoffs for select processing parameters were investigated via uniaxial tension and small-punch testing on specimens manufactured via powder-based additive manufacturing (directed-energy deposition). This work establishes a pathway for design and optimization of next-generation multiphase superalloys via tailoring of structural and chemical ordering in concentrated solid solutions.

36 MATERIALS SCIENCE↗

Additively-manufactured Al-0.3Zr-0.2Ce-0.2Cu alloy with high creep resistance and electrical conductivity

Here, a new, solute-lean Al-0.3Zr-0.2Ce-0.2Cu (wt.%) alloy is developed for additive manufacturing that overcomes the classical tradeoff between conductivity and creep resistance. The rapid-cooling-enabled supersaturation of Zr, and its uniform distribution in α-Al matrix, along with formation of submicron (Ce,Cu)-rich intermetallic particles on solidification lead to unusually high creep resistance at 200 °C. Near-zero secondary creep rates are achieved up to the alloy yield stress (YS) of 65 MPa at 200 °C in as-fabricated state. The Zr-solute-induced dislocation-climb suppression mechanism underlying this improvement also restricts dynamic recovery above YS, as noted from appreciable primary creep and its transitioning to near-zero secondary creep rates. A combination of relatively coarse, epitaxially-grown α-Al grains, low Zr concentration in α-Al, and the impurity-scavenging effect of Ce to purify α-Al matrix produces high electrical conductivity of ∼48 %IACS. Aging precipitation of L1 2 -Al 3 Zr nanoprecipitates doubles the YS (to ∼150 MPa) at room temperature and increases alloy conductivity to ∼58 %IACS, but loss of solid-solution Zr out of α-Al matrix leads to activation of dislocation climb, degrading the creep properties as compared to the supersaturated Al-Zr solid solution in the as-fabricated state. Compared to L1 2 -Al 3 Zr nanoprecipitates, submicron (Ce,Cu)-rich particles formed on solidification are more effective at impeding dislocation climb, producing a threshold stress for dislocation creep of ∼ 50 MPa at 200 °C. The new alloy design concepts, especially solute-induced dislocation-climb suppression for creep resistance, explored here may pave way for the design of new metallic alloys for thermal/electrical conductors and other high-temperature applications.

Additive Manufacturing↗