Synthesis of Discontinously Reinforced Metal matrix Composites Using Spray Atomisation and Co injection

A variety of processing techniques have evolved over the last two decades to optimize the structure and properties of particulate reinforced metal-matrix composites (MMCs). Among these, spray processes offer a unique opportunity to combine the benefits associated with fine particulate technology with in situ processing, and in some cases, near-net shape manufacturing. Spray processing generally involves mixing reinforcements and matrix under highly non-equilibrium conditions, and as a result, these processes offer the opportunity to modify the properties of existing alloy systems, and develop novel alloy compositions. In principle, such an approach will inherently avoid the extreme thermal excursions, with concomitant macrosegregation, normally associated with casting processes. Furthermore, this approach also eliminates the need to handle fine reactive particulates, normally associated with powder metallurgical processes. The present paper discusses recent developments in the area of spray atomisation and deposition processing of discontinuously reinforced MMCs, with particular emphasis on the synergism between microstructure, mechanical properties and processing

Development and Demonstration of Adanced Tooling Alloys for Molds and Dies

This report summarizes research results in the project Development and Demonstration of Advanced Tooling Alloys for Molds and Dies. Molds, dies and related tooling are used to manufacture most of the plastic and metal products we use every day. Conventional fabrication of molds and dies involves a multiplicity of machining, benching and heat treatment unit operations. This approach is very expensive and time consuming. Rapid Solidifcation Process (RSP) Tooling is a spray-forming technology tailored for producing molds and dies. The appraoch combines rapid solidifcation processing and net-shape materials processing in a single step. An atomized spray of a tool-forming alloy, typically a tool steel, is deposited onto an easy-to-form tool pattern to replicate the pattern's shape and surface features. By so doing, the approach eliminates many machining operations in conventional mold making, significantly reducing cost, lead time and energy. Moreover, rapid solidification creates unique microstructural features by suppressing carbide precipitation and growth, and creating metastable phases. This can result in unique material properties following heat treatment. Spray-formed and aged tool steel dies have exhibited extended life compared to conventional dies in many forming operations such as forging, extrusion and die casting. RSP Tooling technolocy was commercialized with the formation of RSP Tooling, LLC in Solon, Oh

Aluminum with dispersed nanoparticles by laser additive manufacturing.

While laser-printed metals do not tend to match the mechanical properties and thermal stability of conventionally-processed metals, incorporating and dispersing nanoparticles in them should enhance their performance. However, this remains difficult to do during laser additive manufacturing. Here, we show that aluminum reinforced by nanoparticles can be deposited layer-by-layer via laser melting of nanocomposite powders, which enhance the laser absorption by almost one order of magnitude compared to pure aluminum powders. The laser printed nanocomposite delivers a yield strength of up to 1000 MPa, plasticity over 10%, and Young's modulus of approximately 200 GPa, offering one of the highest specific Young's modulus and specific yield strengths among structural metals, as well as an improved specific strength and thermal stability up to 400 °C compared to other aluminum-based materials. The improved performance is attributed to a high density of well-dispersed nanoparticles, strong interfacial bonding between nanoparticles and Al matrix, and ultrafine grain sizes

Influence of chemistry and structure on interfacial segregation in NbMoTaW with high-throughput atomistic simulations

Refractory multi-principal element alloys exhibiting promising mechanical properties such as excellent strength retention at elevated temperatures have been attracting increasing attention. Although their inherent chemical complexity is considered a defining feature, a challenge arises in predicting local chemical ordering, particularly in grain boundary regions with enhanced structural disorder. In this study, we use atomistic simulations of a large group of bicrystal models to sample a wide variety of interfacial sites (grain boundary) in NbMoTaW and explore emergent trends in interfacial segregation and the underlying structural and chemical driving factors. Sampling hundreds of bicrystals along the [001] symmetric tilt axis and analyzing more than one hundred and thirty thousand grain boundary sites with a variety of local atomic environments, we uncover segregation trends in NbMoTaW. While Nb is the dominant segregant, more notable are the segregation patterns that deviate from expected behavior and mark situations where local structural and chemical driving forces lead to interesting segregation events. For example, incomplete depletion of Ta in low-angle boundaries results from chemical pinning due to favorable local compositional environments associated with chemical short-range ordering. Finally, machine learning models capturing and comparing the structural and chemical features of interfacial sites are developed to weigh their relative importance and contributions to segregation tendency, revealing a significant increase in predictive capability when including local chemical information. Overall, this work, highlighting the complex interplay between local grain boundary structure and chemical short-range ordering, suggest tunable segregation and chemical ordering by tailoring grain boundary structure in multi-principal element alloys

Recent progress in the CoCrNi alloy system

The exceptional mechanical properties, particularly at cryogenic temperatures, of the equiatomic CoCrNi alloy are documented in numerous published studies. Similar to the equiatomic CoCrFeMnNi (so called Cantor alloy), from which the ternary alloy was derived, the CoCrNi ternary possesses low stacking fault energy that promotes complex deformation modes, as well as the activation of deformation twinning at ambient temperatures and increased strain. In addition to outstanding deformation mechanisms, chemical short-range order and face-centered cubic (FCC)-hexagonal close packed (HCP) transitions have been verified in this alloy and prove to be key factors contributing to the alloy\u27s notable properties. The relationship between stacking fault energy and FCC→HCP phase transitions has been developed over the years through other low stacking fault materials, but the question that arises is: do well established physical metallurgical mechanisms require modification when applied to systems such as CoCrNi given their compositional complexity? Local chemical order plays an important role in that it brings the deviation from the random solid solution behavior generally expected from complex concentrated alloys. In this review, the fundamental atomistic deformation mechanisms of the CoCrNi alloy will be reviewed with a focus on deformation substructures and chemical short-range ordering. Recent studies on microstructural engineering through thermo-mechanical processing and efforts to enhance the tensile properties of the CoCrNi derived systems with minor alloying additions are discussed. Finally, future directions of research, which involve applying current understanding of the underlying mechanisms towards alloy design strategies, are discussed

Identification of material parameters based on Mohr-Coulomb failure criterion for bisphosphonate treated canine vertebral cancellous bone

Nanoindentation has been widely used to study bone tissue mechanical properties. The common method and equations for analyzing nanoindentation, developed by Oliver and Pharr, are based on the assumption that the material is linearly elastic. In the present study, we adjusted the constraint of linearly elastic behavior and use nonlinear finite element analysis to determine the change in cancellous bone material properties caused by bisphosphonate treatment, based on an isotropic form of the Mohr–Coulomb failure model. Thirty-three canine lumbar vertebrae were used in this study. The dogs were treated daily for 1 year with oral doses of alendronate, risedronate, or saline vehicle at doses consistent, on a mg/kg basis, to those used clinically for the treatment of post-menopausal osteoporosis. Two sets of elastic modulus and hardness values were calculated for each specimen using the Continuous Stiffness Measurement (CSM) method (ECSM and HCSM) from the loading segment and the Oliver–Pharr method (EO–P and HO–P) from the unloading segment, respectively. Young's modulus (EFE), cohesion (c), and friction angle (ϕ) were identified using a finite element model for each nanoindentation. The bone material properties were compared among groups and between methods for property identification. Bisphosphonate treatment had a significant effect on several of the material parameters. In particular, Oliver–Pharr hardness was larger for both the risedronate- and alendronate-treated groups compared to vehicle and the Mohr–Coulomb cohesion was larger for the risedronate-treated compared to vehicle. This result suggests that bisphosphonate treatment increases the hardness and shear strength of bone tissue. Shear strength was linearly predicted by modulus and hardness measured by the Oliver–Pharr method (r2 = 0.99). These results show that bisphosphonate-induced changes in Mohr–Coulomb material properties, including tissue shear cohesive strength, can be accurately calculated from Oliver–Pharr measurements of Young's modulus and hardness

Chemical order transitions within extended interfacial segregation zones in NbMoTaW

Interfacial segregation and chemical short-range ordering influence the behavior of grain boundaries in complex concentrated alloys. In this study, we use atomistic modeling of a NbMoTaW refractory complex concentrated alloy to provide insight into the interplay between these two phenomena. Hybrid Monte Carlo and molecular dynamics simulations are performed on columnar grain models to identify equilibrium grain boundary structures. Our results reveal extended near-boundary segregation zones that are much larger than traditional segregation regions, which also exhibit chemical patterning that bridges the interfacial and grain interior regions. Furthermore, structural transitions pertaining to an A2-to-B2 transformation are observed within these extended segregation zones. Both grain size and temperature are found to significantly alter the widths of these regions. Analysis of chemical short-range order indicates that not all pairwise elemental interactions are affected by the presence of a grain boundary equally, as only a subset of elemental clustering types are more likely to reside near certain boundaries. The results emphasize the increased chemical complexity that is associated with near-boundary segregation zones and demonstrate the unique nature of interfacial segregation in complex concentrated alloys