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Formation mechanisms of Sn-rich δ phase and its role in strengthening Cu-10Sn manufactured by laser powder bed fusion

Cu-Sn alloys produced via laser powder bed fusion (L-PBF) additive manufacturing (AM) have gained significant attention because they combine the advantages of AM relevant to intricate component design with outstanding combinations of strength, ductility, and resistance to wear and corrosion. However, a detailed understanding of the microstructure that contributes to the enhancement of the mechanical properties of L-PBF Cu-10Sn alloys remains unclear. In particular, there is a lack of understanding of the formation mechanisms of the Sn-rich δ phase commonly observed in Cu-10Sn. This study reveals two distinct variants of the δ phase possessing unique morphological characteristics. These characteristics are attributed to the local solidification conditions inherent to the melt pool boundaries versus those at the interiors of melt pools. A phase transformation pathway that elucidates the origin of the morphological variants of the δ phase from the Sn-rich metastable phases during the cyclic heating of the AM process is proposed. We report superior mechanical properties in L-PBF Cu-10Sn compared to those of conventionally manufactured counterparts due to the synergistic contributions from grain boundaries, dislocations, and the δ phase. Notably, the δ phase alone contributes approximately 22 % to the overall strength observed in the L-PBF Cu-10Sn alloy. The discovery of two types of distinct Sn-rich δ phase offers key insights into precise microstructural control in AM Cu-Sn alloys to enhance mechanical properties, providing practical strategies for improving material performance for diverse applications in automotive, aerospace, and machinery industries.

36 MATERIALS SCIENCE↗

Materials Data on CuSn by Materials Project

CuSn crystallizes in the hexagonal P6_3/mmc space group. The structure is three-dimensional. Cu is bonded in a body-centered cubic geometry to two equivalent Cu and six equivalent Sn atoms. Both Cu–Cu bond lengths are 2.55 Å. All Cu–Sn bond lengths are 2.73 Å. Sn is bonded in a 6-coordinate geometry to six equivalent Cu atoms.

36 MATERIALS SCIENCE↗

Materials Data on Cu6Sn5 by Materials Project

Cu6Sn5 crystallizes in the monoclinic C2/c space group. The structure is three-dimensional. there are four inequivalent Cu sites. In the first Cu site, Cu is bonded in a distorted q6 geometry to three Cu and six Sn atoms. There are a spread of Cu–Cu bond distances ranging from 2.56–2.65 Å. There are a spread of Cu–Sn bond distances ranging from 2.70–2.85 Å. In the second Cu site, Cu is bonded in a distorted q6 geometry to three Cu and six Sn atoms. There are one shorter (2.55 Å) and one longer (2.66 Å) Cu–Cu bond lengths. There are a spread of Cu–Sn bond distances ranging from 2.70–2.86 Å. In the third Cu site, Cu is bonded in a distorted q6 geometry to four Cu and six Sn atoms. Both Cu–Cu bond lengths are 2.74 Å. There are a spread of Cu–Sn bond distances ranging from 2.81–2.88 Å. In the fourth Cu site, Cu is bonded in a 11-coordinate geometry to six Cu and five Sn atoms. There are a spread of Cu–Sn bond distances ranging from 2.67–2.74 Å. There are three inequivalent Sn sites. In the first Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms. In the second Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms. In the third Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms.

36 MATERIALS SCIENCE↗

Materials Data on Cu3Sn by Materials Project

Cu3Sn crystallizes in the hexagonal P6_3/mmc space group. The structure is three-dimensional. there are two inequivalent Cu sites. In the first Cu site, Cu is bonded to eight Cu and four equivalent Sn atoms to form CuCu8Sn4 cuboctahedra that share corners with four equivalent SnCu12 cuboctahedra, corners with fourteen equivalent CuCu8Sn4 cuboctahedra, edges with six equivalent SnCu12 cuboctahedra, edges with twelve CuCu8Sn4 cuboctahedra, faces with four equivalent SnCu12 cuboctahedra, and faces with sixteen CuCu8Sn4 cuboctahedra. There are a spread of Cu–Cu bond distances ranging from 2.59–2.95 Å. There are two shorter (2.76 Å) and two longer (2.77 Å) Cu–Sn bond lengths. In the second Cu site, Cu is bonded to eight equivalent Cu and four equivalent Sn atoms to form CuCu8Sn4 cuboctahedra that share corners with four equivalent SnCu12 cuboctahedra, corners with fourteen CuCu8Sn4 cuboctahedra, edges with six equivalent SnCu12 cuboctahedra, edges with twelve equivalent CuCu8Sn4 cuboctahedra, faces with four equivalent SnCu12 cuboctahedra, and faces with sixteen CuCu8Sn4 cuboctahedra. There are two shorter (2.76 Å) and two longer (2.77 Å) Cu–Sn bond lengths. Sn is bonded to twelve Cu atoms to form SnCu12 cuboctahedra that share corners with six equivalent SnCu12 cuboctahedra, corners with twelve CuCu8Sn4 cuboctahedra, edges with eighteen CuCu8Sn4 cuboctahedra, faces with eight equivalent SnCu12 cuboctahedra, and faces with twelve CuCu8Sn4 cuboctahedra.

36 MATERIALS SCIENCE↗

Materials Data on Cu10Sn3 by Materials Project

Cu10Sn3 is Bergman Structure: Mg32(Al,Zn)49 Bergman-derived structured and crystallizes in the hexagonal P6_3 space group. The structure is three-dimensional. there are six inequivalent Cu sites. In the first Cu site, Cu is bonded to six Cu and six equivalent Sn atoms to form CuCu6Sn6 cuboctahedra that share corners with twelve CuCu8Sn4 cuboctahedra, edges with six CuCu8Sn4 cuboctahedra, and faces with fourteen CuCu6Sn6 cuboctahedra. There are three shorter (2.61 Å) and three longer (2.62 Å) Cu–Cu bond lengths. There are three shorter (2.96 Å) and three longer (2.99 Å) Cu–Sn bond lengths. In the second Cu site, Cu is bonded in a distorted q6 geometry to eight Cu and three equivalent Sn atoms. There are a spread of Cu–Cu bond distances ranging from 2.57–2.72 Å. All Cu–Sn bond lengths are 2.79 Å. In the third Cu site, Cu is bonded in a distorted q6 geometry to eight Cu and three equivalent Sn atoms. There are three shorter (2.57 Å) and four longer (2.58 Å) Cu–Cu bond lengths. All Cu–Sn bond lengths are 2.80 Å. In the fourth Cu site, Cu is bonded in a 11-coordinate geometry to eight Cu and three equivalent Sn atoms. All Cu–Cu bond lengths are 2.60 Å. All Cu–Sn bond lengths are 2.69 Å. In the fifth Cu site, Cu is bonded to eight Cu and four equivalent Sn atoms to form a mixture of distorted edge, corner, and face-sharing CuCu8Sn4 cuboctahedra. There are a spread of Cu–Cu bond distances ranging from 2.62–2.86 Å. There are a spread of Cu–Sn bond distances ranging from 2.64–2.92 Å. In the sixth Cu site, Cu is bonded to eight Cu and four equivalent Sn atoms to form a mixture of distorted edge, corner, and face-sharing CuCu8Sn4 cuboctahedra. There are a spread of Cu–Sn bond distances ranging from 2.64–2.92 Å. Sn is bonded in a 9-coordinate geometry to thirteen Cu atoms.

36 MATERIALS SCIENCE↗

Materials Data on Cu10Sn3 by Materials Project

Cu10Sn3 is Bergman Structure: Mg32(Al,Zn)49 Bergman-derived structured and crystallizes in the hexagonal P6_3 space group. The structure is three-dimensional. there are six inequivalent Cu sites. In the first Cu site, Cu is bonded in a distorted q6 geometry to eight Cu and three Sn atoms. There are a spread of Cu–Cu bond distances ranging from 2.58–2.74 Å. All Cu–Sn bond lengths are 2.80 Å. In the second Cu site, Cu is bonded to eight Cu and four Sn atoms to form distorted CuCu8Sn4 cuboctahedra that share corners with ten CuCu6Sn6 cuboctahedra, edges with nine CuCu8Sn4 cuboctahedra, and faces with twelve CuCu8Sn4 cuboctahedra. There are a spread of Cu–Cu bond distances ranging from 2.57–2.86 Å. There are a spread of Cu–Sn bond distances ranging from 2.66–2.92 Å. In the third Cu site, Cu is bonded to six Cu and six Sn atoms to form a mixture of edge, face, and corner-sharing CuCu6Sn6 cuboctahedra. All Cu–Cu bond lengths are 2.63 Å. There are three shorter (2.95 Å) and three longer (3.04 Å) Cu–Sn bond lengths. In the fourth Cu site, Cu is bonded in a 11-coordinate geometry to eight Cu and three Sn atoms. There are one shorter (2.59 Å) and three longer (2.62 Å) Cu–Cu bond lengths. All Cu–Sn bond lengths are 2.69 Å. In the fifth Cu site, Cu is bonded to eight Cu and four Sn atoms to form a mixture of distorted edge, face, and corner-sharing CuCu8Sn4 cuboctahedra. The Cu–Cu bond length is 2.60 Å. There are a spread of Cu–Sn bond distances ranging from 2.66–2.93 Å. In the sixth Cu site, Cu is bonded in a distorted q6 geometry to eight Cu and three Sn atoms. All Cu–Sn bond lengths are 2.80 Å. There are two inequivalent Sn sites. In the first Sn site, Sn is bonded in a 9-coordinate geometry to thirteen Cu atoms. In the second Sn site, Sn is bonded in a 9-coordinate geometry to thirteen Cu atoms.

36 MATERIALS SCIENCE↗

Materials Data on Cu3Sn by Materials Project

Cu3Sn is beta Cu3Ti structured and crystallizes in the orthorhombic Pmmn space group. The structure is three-dimensional. there are two inequivalent Cu sites. In the first Cu site, Cu is bonded to eight equivalent Cu and four equivalent Sn atoms to form distorted CuCu8Sn4 cuboctahedra that share corners with eight equivalent SnCu12 cuboctahedra, corners with ten CuCu8Sn4 cuboctahedra, edges with eighteen CuCu8Sn4 cuboctahedra, faces with six equivalent SnCu12 cuboctahedra, and faces with fourteen CuCu8Sn4 cuboctahedra. There are a spread of Cu–Cu bond distances ranging from 2.62–2.96 Å. There are two shorter (2.73 Å) and two longer (2.77 Å) Cu–Sn bond lengths. In the second Cu site, Cu is bonded to eight Cu and four equivalent Sn atoms to form distorted CuCu8Sn4 cuboctahedra that share corners with four equivalent SnCu12 cuboctahedra, corners with fourteen CuCu8Sn4 cuboctahedra, edges with six equivalent SnCu12 cuboctahedra, edges with twelve CuCu8Sn4 cuboctahedra, faces with four equivalent SnCu12 cuboctahedra, and faces with sixteen CuCu8Sn4 cuboctahedra. There are a spread of Cu–Cu bond distances ranging from 2.65–2.74 Å. There are a spread of Cu–Sn bond distances ranging from 2.73–2.80 Å. Sn is bonded to twelve Cu atoms to form SnCu12 cuboctahedra that share corners with two equivalent SnCu12 cuboctahedra, corners with sixteen CuCu8Sn4 cuboctahedra, edges with six equivalent SnCu12 cuboctahedra, edges with twelve equivalent CuCu8Sn4 cuboctahedra, faces with six equivalent SnCu12 cuboctahedra, and faces with fourteen CuCu8Sn4 cuboctahedra.

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Materials Data on Cu3Sn by Materials Project

Cu3Sn is alpha bismuth trifluoride structured and crystallizes in the cubic Fm-3m space group. The structure is three-dimensional. there are two inequivalent Cu sites. In the first Cu site, Cu is bonded in a distorted body-centered cubic geometry to eight equivalent Cu and six equivalent Sn atoms. All Cu–Cu bond lengths are 2.67 Å. All Cu–Sn bond lengths are 3.08 Å. In the second Cu site, Cu is bonded in a distorted body-centered cubic geometry to four equivalent Cu and four equivalent Sn atoms. All Cu–Sn bond lengths are 2.67 Å. Sn is bonded in a distorted body-centered cubic geometry to fourteen Cu atoms.

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Materials Data on Cu5Sn4 by Materials Project

Cu5Sn4 crystallizes in the monoclinic P2_1/c space group. The structure is three-dimensional. there are five inequivalent Cu sites. In the first Cu site, Cu is bonded in a 10-coordinate geometry to four Cu and six Sn atoms. There are two shorter (2.59 Å) and two longer (2.64 Å) Cu–Cu bond lengths. There are a spread of Cu–Sn bond distances ranging from 2.68–2.96 Å. In the second Cu site, Cu is bonded in a distorted q6 geometry to four Cu and six Sn atoms. There are one shorter (2.55 Å) and two longer (2.76 Å) Cu–Cu bond lengths. There are a spread of Cu–Sn bond distances ranging from 2.74–2.91 Å. In the third Cu site, Cu is bonded in a distorted q6 geometry to three Cu and six Sn atoms. There are one shorter (2.59 Å) and one longer (2.62 Å) Cu–Cu bond lengths. There are a spread of Cu–Sn bond distances ranging from 2.70–2.82 Å. In the fourth Cu site, Cu is bonded in a distorted q6 geometry to three Cu and six Sn atoms. The Cu–Cu bond length is 2.66 Å. There are a spread of Cu–Sn bond distances ranging from 2.72–2.85 Å. In the fifth Cu site, Cu is bonded in a 11-coordinate geometry to six Cu and five Sn atoms. There are a spread of Cu–Sn bond distances ranging from 2.63–2.79 Å. There are four inequivalent Sn sites. In the first Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms. In the second Sn site, Sn is bonded in a 10-coordinate geometry to eight Cu atoms. In the third Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms. In the fourth Sn site, Sn is bonded in a 7-coordinate geometry to seven Cu atoms.

36 MATERIALS SCIENCE↗

Materials Data on CuSn3 by Materials Project

Sn3.0Cu is beta Cu3Ti-like structured and crystallizes in the tetragonal I4/mmm space group. The structure is three-dimensional. Cu is bonded to twelve Sn atoms to form CuSn12 cuboctahedra that share corners with four equivalent CuSn12 cuboctahedra, corners with eight equivalent SnCu4Sn8 cuboctahedra, edges with eight equivalent CuSn12 cuboctahedra, edges with sixteen equivalent SnCu4Sn8 cuboctahedra, faces with four equivalent CuSn12 cuboctahedra, and faces with fourteen SnCu4Sn8 cuboctahedra. There are four shorter (3.17 Å) and eight longer (3.31 Å) Cu–Sn bond lengths. There are two inequivalent Sn sites. In the first Sn site, Sn is bonded to four equivalent Cu and eight Sn atoms to form SnCu4Sn8 cuboctahedra that share corners with twelve equivalent SnCu4Sn8 cuboctahedra, edges with eight equivalent CuSn12 cuboctahedra, edges with sixteen SnCu4Sn8 cuboctahedra, faces with four equivalent CuSn12 cuboctahedra, and faces with fourteen SnCu4Sn8 cuboctahedra. There are four shorter (3.17 Å) and four longer (3.31 Å) Sn–Sn bond lengths. In the second Sn site, Sn is bonded to four equivalent Cu and eight equivalent Sn atoms to form SnCu4Sn8 cuboctahedra that share corners with four equivalent SnCu4Sn8 cuboctahedra, corners with eight equivalent CuSn12 cuboctahedra, edges with twenty-four SnCu4Sn8 cuboctahedra, faces with six equivalent CuSn12 cuboctahedra, and faces with twelve SnCu4Sn8 cuboctahedra.

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