Grain boundary network evolution in electron-beam powder bed fusion nickel-based superalloy Inconel 738

Additive manufacturing (AM) of alloys has attracted much attention in recent years for making geometrically complex engineering parts owing to its unique benefits, such as high flexibility and low waste. The in-service performance of AM parts is dependent on the microstructures and grain boundary networks formed during AM, which are often significantly different from their wrought counterparts. Characteristics such as grain size and morphology, texture, and the detailed grain boundary network are known to control various mechanical and corrosion properties. Advanced understanding on how AM parameters affect the formation of these microstructural characteristics is hence critical for optimising processing parameters to unlock superior properties. In this study, the difficult-to-weld nickel-based superalloy Inconel 738 was fabricated via electron-beam powder bed fusion (EPBF) following linear and random scanning strategies. Random scanning resulted in finer, less elongated, and crystallographically more random grains compared to the linear strategy. However, both scanning strategies achieve unique high grain structure stability up to 1250 ℃ due to the presence of carbides pinning the grain boundaries. Despite significant difference in texture and morphology, majority of grains terminated on {100} habit planes in both linear and random built samples. The results show potential for controlling grain boundary networks during EPBF by tuning scan strategies

Controlling the relaxation versus rejuvenation behavior in Zr-based bulk metallic glasses induced by elastostatic compression

Elastostatic compression (ESC) has received considerable research attention as a tool to study rejuvenation and relaxation processes for bulk metallic glasses (BMGs). However, little is understood about the conditions that control whether rejuvenation or relaxation will occur, and whether conditions exist that can give structural stability. We address these questions by applying ESC at 90% of the yield stress to both cast and laser powder bed fusion (LPBF) manufactured Zr-based BMG samples in the as-cast, as-built, and different annealed states. The structural state and mechanical properties for each material condition were characterized by differential scanning calorimetry and microhardness, respectively, and two representative groups were also used for compression testing. Initial relaxation or rejuvenation was observed for elastostatically compressed as-cast samples, and the behavior reversed over 72 h of ESC. In contrast, no ESC effect was observed for the as-built LPBF samples. It was found that the onset of either relaxation or rejuvenation by ESC could be better predicted if samples were annealed into a controlled initial state. Five different types of initial response to ESC were observed, corresponding to different initial energy state ranges. Materials in the highest and lowest initial energy states were stable against structural changes by ESC. Close to the highest energy state, rejuvenation was dominant, while relaxation took place close to the lowest energy state. At intermediate initial energy states, both relaxation and rejuvenation were observed after ESC loading, suggesting that the glass structure easily finds different local minima in the potential energy landscape. In all cases, relaxation was associated with BMG hardening and rejuvenation was associated with softening. Overall, the results of this study provide new insights into how ESC impacts the structural state and mechanical properties of BMGs

Nano-twining and deformation-induced martensitic transformation in a duplex stainless steel 2205 fabricated by laser powder bed fusion

Duplex stainless steels (DSSs) possess desirable combinations of mechanical properties and excellent corrosion resistance due to their composition and equilibrium microstructure of roughly equivalent fractions of ferrite and austenite. They are used in harsh environments such as marine infrastructures, oil & gas, and paper & pulp industries. Components with complex geometries are often required for these applications. Additive manufacturing (AM) techniques such as laser powder bed fusion (LPBF) can be harnessed to fabricate components with greatest complexity. However, AM fabrication is well-known to promote non-equilibrium microstructures with high dislocation densities and Cr2N precipitates, resulting in inferior ductility. This is generally regarded as a challenge, however, short heat treatments of such as-built microstructures have been shown to attain refined duplex equilibrium microstructures. Recently, annealed LPBF DSS 2205 has been reported to possess strength higher than wrought counterparts and ductility properties better than the as-built state. However, the microstructural phenomena and deformation mechanisms behind these attractive properties remain poorly understood. Through multi-scale microstructural characterization, we show that the improved strength results not only from the hard ferrite phase, but also fine austenite grain size and nanoscale oxide dispersion strengthening. The enhanced ductility may be attributed to a combination of deformation mechanisms including dislocation slip, stacking fault formation, deformation twinning, and a deformation-induced martensitic transformation. We discuss how the level of microstructural complexity and solid-state phase transformations during LPBF and annealing can unlock multiple strengthening mechanisms during tensile deformation. Such fundamental understanding is crucial for designing AM parts with reproducible and optimised mechanical properties

Role of stress-assisted martensite in the design of strong ultrafine-grained duplex steels

This work explains the occurrence of transformation-induced plasticity via stress-assisted martensite, when designing ultrafine-grained duplex steels. It is found that, when the austenite is reduced to a fine scale of about 300 nm, the initial deformation-induced microstructure can be dominated by parallel lamellae of epsilon martensite or mechanical twinning, which cannot efficiently provide nucleation sites for strain-induced martensite. Hence, alpha martensite nucleation occurs independently by a stress-assisted process that enhances transformation-induced plasticity in ultrafine-grained austenite. This metallurgical principle was validated experimentally by using a combination of transmission Kikuchi diffraction mapping, transmission electron microscopy, and atom probe microscopy, and demonstrated theoretically by the thermodynamics model of stress-assisted martensite.The authors acknowledge the facilities, and the scientific and technical assistance of the Australian Microscopy & Microanalysis Research Facility (ammrf.org.au) node at Sydney Microscopy & Microanalysis, at the University of Sydney.This is the accepted manuscript. The final version is available from Elsevier at http://www.sciencedirect.com/science/article/pii/S1359645414006958

Effect of compositional variations on the heat treatment response in 17-4 PH stainless steel fabricated by laser powder bed fusion

17–4 precipitate hardening (PH) stainless steel is used in various applications including in the aerospace, marine, and chemical industries, largely due to its unique combination of corrosion resistance and high strength, which is achieved by the formation of nanoscale Cu-rich precipitates during aging. 17–4 PH has been widely researched for its applicability for laser powder bed fusion (LPBF). However, there are discrepancies in the literature on its heat treatment response, which seem to be linked to compositional variations. Systematic studies of the interplay between these variations and nanoscale precipitation are currently missing. Using atom probe tomography, we present a systematic study of the heat treatment responses of two variants of LPBF 17–4 PH builds fabricated from different powder feedstocks, with significant differences in N contents (High vs Low N 17–4). Both variants formed predominantly δ-ferritic as-built microstructures. The as-built High N 17–4 variant showed a higher volume fraction of austenite which further increased upon solution annealing and quenching. The consequence was no appreciable hardening effect due to the absence of Cu precipitation in either austenite or martensite after aging, degrading the alloy's desirable property profile. Conversely, Low N 17–4 showed no austenite in the as-built condition and a fully martensitic matrix after solution annealing. This variant had the desired aging response; a ∼ 140 HV 5 increase in hardness due to nanoscale Cu precipitation. Our findings describe the deleterious effects of compositional variations incurred during the LPBF process flow and how they can be overcome in 17–4 PH and similar steels

Hydrogen adsorption capacity of adatoms on double carbon vacancies of graphene: A trend study from first principles

Structural stability and hydrogen adsorption capacity are two key quantities in evaluating the potential of metal-adatom decorated graphene for hydrogen storage and related devices. We have carried out extensive density functional theory calculations for the adsorption of hydrogen molecules on 12 different adatom (Ag, Au, Ca, Li, Mg, Pd, Pt, Sc, Sr, Ti, Y, and Zr) decorated graphene surfaces where the adatoms are found to be stabilized on double carbon vacancies, thus overcoming the "clustering problem" that occurs for adatoms on pristine graphene. Ca and Sr are predicted to bind the greatest number, namely six, of H2 molecules. We find an interesting correlation between the hydrogen capacity and the change of charge distribution with increasing H2 adsorption, where Ca, Li, Mg, Sc, Ti, Y, Sr, and Zr adatoms are partial electron donors and Ag, Au, Pd, and Pt are partial electron acceptors. The "18-electron rule" for predicting maximum hydrogen capacity is found not to be a reliable indicator for these systems. © 2013 American Physical Society

A nexus between 3D atomistic data hybrids derived from atom probe microscopy and computational materials science: a new analysis of solute clustering in Al-alloys

Solute clusters affect the physical properties of alloys. Knowledge of the atomic structure of solute clusters is a prerequisite for material optimisation. In this study, solute clusters in a rapid-hardening Al-Cu-Mg alloy were characterised by a combination of atom probe tomography and density functional theory, making use of a hybrid data type that combines lattice rectification and data completion to directly input experimental data into atomistic simulations. The clusters input to the atomistic simulations are thus observed experimentally, reducing the number of possible configurations. Our results show that spheroidal, compact clusters are more energetically favourable and more abundant

Direct observation of local K variation and its correlation to electronic inhomogeneity in (Ba1-xKx)Fe2As2 Pnictide

Local fluctuations in the distribution of dopant atoms are a suspected cause of nanoscale electronic disorder or phase separation observed within the pnictide superconductors. Atom probe tomography results present the first direct observations of dopant nano-clustering in a K-doped 122-phase pnictides. First-principles calculations suggest the coexistence of static magnetism and superconductivity on a lattice parameter length scale over a large range of doping concentrations. Collectively, our results provide evidence for a mixed scenario of phase coexistence and phase separation originating from variation of dopant atom experiments distroibutions.Comment: 4 pages, 4 figures and 1 table, accepted by Physical Review Letter 201