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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. • Electron powder bed fusion Inconel 738 builds possess thermally stable grain structures up to 1250 ℃. • Change of scanning strategy from linear to random results in texture randomization and grain refinement. • The unique thermal stability can be due to the pinning of grain boundaries by carbides. • Grain boundaries mostly terminate on {100} habit planes irrespective of the scanning strategy. [ABSTRACT FROM AUTHOR]

Additive manufacturing (AM) is well-known for its capability to produce and repair intricate parts e.g., Ni-based superalloy components used in aero-engine applications. However, a comprehensive understanding of the microstructure evolution and its link to properties remains elusive, with gaps in the through-process evolution of γ grains, γ', γ'', δ, and other phases in response to thermal cycling. The outstanding challenge here is to observe these transformations dynamically during the 3D printing process, as this usually requires complex in-situ measurements. Here we apply a different approach to systematically reveal the impact of thermal cycling on the solid-state microstructure evolution of IN718, via a combination of physical simulations and thermo-kinetic modelling. We replicate the thermal cycles IN718 experiences during laser directed energy deposition. Solid-state thermal cycles are shown to have minor effects on the grain morphology due to short holding times at critical temperatures, however, they do induce plastic strain accumulation. Significantly, we show how thermal cycling influences the evolution of γ', γ", and δ phases. While high initial peak temperatures inhibit the precipitation of γ', γ", and δ phases, prolonged thermal cycling to gradually decreasing peak temperatures promotes their precipitation. The δ phase forms along grain and twin boundaries, while both γ' and γ" predominantly precipitate in Nb-enriched regions, causing heterogeneities in hardness. Our results underpin the suitability of physical simulations for replicating superalloy AM, highlighting its potential as a tool to advance the current limited understanding of the microstructure and property evolution. [Display omitted] • Physical and thermo-kinetic simulation of solid-state thermal cycling in L-DED IN718. • Physical Gleeble experiments show excellent correlation with actual L-DED process. • Variation in γ′, γ′′, and δ precipitates correlates with hardness. • Solid-state thermal cycling affects γ′, γ′′, and δ morphology in individual layers. • Solid-state thermal cycling has negligible influence on grain morphology. [ABSTRACT FROM AUTHOR]

As-sintered multi-main-phase Nd-Ce-Fe-B permanent magnets typically exhibit a higher coercivity than as-sintered single-main-phase Nd-Ce-Fe-B magnets with identical content of Ce. To clarify the microstructural features that are relevant to the coercivity, as-sintered multi-main-phase Nd-Ce-Fe-B permanent magnets are characterised by high-resolution magnetic force microscopy and atom probe tomography down to the atomic scale. Though inhomogeneous distribution of rare earth elements (Nd, Pr, and Ce) is observed inside 2:14:1 matrix grains, Ce atoms unexpectedly show similar partitioning behaviour (∼14–27% of rare earth element) at the edge of these grains in the vicinity of rare earth-rich grain boundary compared with as-sintered single-main-phase Nd-Ce-Fe-B magnets with a 20% Ce substitute of Nd and Pr. By contrast, the observation of stripe-liked magnetic domains pinned at the grain boundaries and a thin (Nd,Pr,Ce)-rich grain boundary with a composition of Nd 9.9 Pr 2.6 Ce 19.0 Fe 65.3 Co 1.9 Balance 1.3 (at.%) jointly indicates the enrichment of Ce in grain boundaries benefit to the magnetic isolation of neighbouring matrix grains in the as-sintered state. Unusual Ce-rich clustering regions are also observed in the grain boundary, which also contribute to the coercivity enhancement. The segregation of Ce, Co, and Cu and rare-earth-Cu clusters are only observed at the interface between rare earth-Cu rich phase and matrix phase while no obvious elemental segregation and clusters are observed at the interface between the rare earth-Ga rich phase and matrix phase, suggesting the occurrence of rare earth-Cu rich phase may be one of the reasons for achieving high coercivity. These findings offer fresh insights into the as-sintered multi-main-phase Nd-Ce-Fe-B permanent magnets. Image 1 • High intrinsic coercivity is achieved in the as-sintered multi-main-phase Nd-Ce-Fe-B magnets. • The formation of thin (Nd,Pr,Ce)-rich grain boundary in the as-sintered state. • The formation of Ce-rich clustering regions at grain boundaries in the as-sintered state. • The segregation of Cu at the interfaces between the rare earth-Cu rich phase and matrix phases. • No Ga segregation at the interfaces between the rare earth-Ga rich phase and matrix phases. [ABSTRACT FROM AUTHOR]

Abstract: Positron annihilation spectroscopy in two variants (coincidence Doppler-broadening CDB and lifetime spectroscopy LT) was used for the characterisation of severely deformed nanocrystalline 7075 Al alloy, with specific attention to the distribution of solute in the proximity of grain boundaries. The 7075 samples were deformed via the high pressure torsion (HPT) technique after solution treatment and quenching. The grain size at the end of the deformation was sub 100nm. The deformed samples have undergone 3 months of natural ageing post-processing. CDB and LT measurements consistently indicate that the fraction of trapped positrons in these samples is near to 90%. The analysis of CDB data shows that the environment of the positron traps is enriched with solute up to 50at.%, nearly evenly divided between Mg and transition metals (Zn and Cu). The CDB results indicate an enhancement of solute concentration at grain boundaries associated with HPT deformation. [Copyright &y& Elsevier]