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Additive manufacturing produces net-shaped components layer by layer for engineering applications

Lithium-ion batteries are yet to realize their full promise because of challenges in the design and construction of electrode architectures that allow for their entire interior volumes to be reversibly accessible for ion storage. Electrodes constructed from the same material and with the same specifications, which differ only in terms of dimensions and geometries of the constituent particles, can show surprising differences in polarization, stress accumulation and capacity fade. Here, using operando synchrotron X-ray diffraction and energy dispersive X-ray diffraction (EDXRD), we probe the mechanistic origins of the remarkable particle geometry-dependent modification of lithiation-induced phase transformations in V2O5 as a model phase-transforming cathode. A pronounced modulation of phase coexistence regimes is observed as a function of particle geometry. Specifically, a metastable phase is stabilized for nanometre-sized spherical V2O5 particles, to circumvent the formation of large misfit strains. Spatially resolved EDXRD measurements demonstrate that particle geometries strongly modify the tortuosity of the porous cathode architecture. Greater ion-transport limitations in electrode architectures comprising micrometre-sized platelets result in considerable lithiation heterogeneities across the thickness of the electrode. These insights establish particle geometry-dependent modification of metastable phase regimes and electrode tortuosity as key design principles for realizing the promise of intercalation cathodes. Designing electrode architectures for Li-ion batteries that can be reversibly accessible for ion storage can be challenging. Using operando techniques the mechanistic origin of lithiation-induced phase transformations in a V2O5 model cathode is now clarified.

Synthesizing bulk nanocrystalline materials is challenging since grain growth should be suppressed whereas densification promoted. Here, we demonstrate a novel route to synthesize superhard bulk nanocrystalline cubic boron nitride (cBN), which combines the use of emulsion detonation and high-pressure high-temperature transformation-assisted consolidation. The emulsion detonation process activates BN to possess unique structure and chemistry, i.e. wurtzitic BN nanograins in hexagonal BN matrix with enhanced structural disordering and oxygen impurity, a combination that enhances the nucleation rate of cBN and its densification leading to the formation of bulk nanocrystalline cBN at reduced conditions. The cBN, synthesized at 7.5 GPa and 1800 °C, displayed Vickers hardness values of 50−62 GPa for 5−20 N loads. The findings in the study suggest a feasible solution to synthesize bulk nanocrystalline cBN in a more scalable way, while also providing design insights on how to refine grain growth while enhancing densification to synthesize bulk nanocrystalline materials.

Graphitic carbon materials are commonly used for storing Li ions owing to their outstanding electrochemical stability and electrical conductivity, and their 3D porous structures are promising for achieving high capacity anodes by depositing Li metal beyond lithiation. However, lithiophobicity and high conductivity of the graphitic surface engender dendrite formation on the outer surface of the electrode rather than inserting Li metal into the pores. Here, we grafted mossy MnO2 uniformly on the entire surface of carbon nanotubes (CNTs), concurrently providing lithiophilic and dendrite-less surfaces. Our MnO2-decorated CNTs can deliver an outstanding performance parameter, which considers both areal capacity and lifetime, over 10 000 mA h2 cm−2, which is the highest to the best of our knowledge, due to a super-long lifetime over 1800 hours for repeated Li plating/stripping at a high areal capacity of 6 mA h cm−2. The striking improvement can be attributed to low overpotential due to superior lithiophilicity and electrolyte wetting characteristics of MnO2, large surface areas of the mossy structures (low local current density), distributed Li insertion into MnO2/CNTs for suppressing dendrite formation, and porous CNT frameworks with high conductivity according to our electrochemical impedance spectroscopy and density functional theory calculation results. We anticipate that our results will give rise to subsequent research about mossy structure coatings on porous structures with various metal oxides and Li attracting groups for further improving the energy density of Li batteries.

The corrosion susceptibility of recrystallized and un-recrystallized grains in equal channel angular pressed (ECAPed) Mg–9Al–1Zn (AZ91) alloys immersed in chloride containing media was investigated through immersion testing and an electrochemical microcell technique coupled with high resolution techniques such as scanning Kelvin probe force microscopy (SKPFM), transmission electron microscopy (TEM), and electron backscatter diffraction (EBSD). During ECAP, dynamic recrystallization (DRX) and strain-induced dynamic precipitation (SIDP) simultaneously occurred, resulting in a bimodal grain structure of original elongated coarse grains and newly formed equiaxed fine grains with a large volume fraction of β-Mg17Al12 precipitates. Corrosion preferentially initiates and propagates in the DRXed grains, owing to the greater microchemistry difference between the β-Mg17Al12 precipitates formed at the DRXed grain boundaries and the adjacent α-Mg matrix, which induces a strong microgalvanic coupling between these phases. Additionally, the weaker basal texture of the DRXed grains also makes these grains more susceptible to electrochemical reactions than the highly textured un-DRXed grains. The influence of dynamic recrystallization and dynamic precipitation was also studied in ECAPed alloys with different levels of deformation strain through corrosion and electrochemical techniques. Increasing the strain level led to a more uniform corrosion with a shallow penetration depth, lower corrosion rate values, and higher protective ability of the oxide film. Furthermore, higher levels of strain resulted in greater hardness values of the ECAPed alloys. The superior corrosion resistance and strength of the ECAPed alloys with increasing strain level was attributed to the combination of smaller DRXed grain size, higher DRX ratio, and higher volume fraction of uniformly distributed fine β-Mg17Al12 precipitates.

We investigated the indentation response of Ta/Ti nanocomposite thin films with widely differing morphologies of the constituent phases, ranging from particulate to bicontinuously interpenetrating, but comparable characteristic dimensions of microstructure features. We find no influence of microstructure morphology on stiffness or hardness. However, we see a systematic dependence of indentation pileup height on microstructure morphology, with the largest pileups observed in composites with connected, Ta-rich networks and lowest for highly connected, Ti-rich networks. We attribute this dependence to an influence of microstructure morphology on strain hardening rates and propose mechanisms to explain it.

Inconel alloy 718 is a high-strength and corrosion resistant alloy that is commonly used as a beamline vacuum window. The accumulation of irradiation-induced damage substantially decreases the window’s service lifetime, and replacing it engenders significant beamline downtime. With this application in mind, herein we examine whether post-irradiation annealing can alleviate irradiation-induced damage of Inconel alloy 718. Inconel alloy 718 was received in a solution annealed state. We then irradiated samples using two different modalities (1.5 MeV H+ and 5 MeV Ni2+) at three representative temperatures for beamline windows (room temperature, 100 °C, and 200 °C), followed by annealing at temperatures viable for in-situ annealing processes (no anneal, 300 °C, and 500 °C). Using nanoindentation, we determined that irradiation-induced hardening occurs but is largely mitigated by post-irradiation annealing. Overall, our results suggest that in-situ annealing of radiation damage in Inconel alloy 718 vacuum windows appears feasible, which could potentially decrease beam downtime and maintenance costs.

Shear banding is an important deformation and failure mechanism in metallic systems, especially at high-rate straining. Dynamic recrystallization was often reported to account for the refined microstructure of shear bands but rarely confirmed using direct quantitative measurement. Here, we employ quantitative precession electron diffraction analysis to uncover shear band microstructure in pure titanium. The results reveal that the microstructure is dominated by early stages of grain subdivision process. Dynamic recrystallization is not as prevalent as perceived conventionally. Our results offer key insights into understanding shear banding and highlight the need for quantitative analyses of shear band microstructure. A critical quantitative assessment of shear band microstructures is made using precession beam diffraction imaging. Specifically, grain subdivision, as opposed to dynamic recrystallization, drives the shear band microstructure evolution.

The size, density, and distribution of helium (He) bubbles in a Ti-Ta single-phase alloy and a Ti/Ta dual-phase nanocomposite have been investigated using transmission electron microscopy. The Ti/T...

In this work, we statistically studied the activation and suppression of 〈c + a〉 dislocations in a textured Mg–3Al–1Zn alloy after compression. Our results revealed that the activation and suppression of 〈c + a〉 dislocations in polycrystals are primarily governed by the overall texture, regardless of the crystallographic orientation of each grain. This observation is explained by the requirement of five independent slip systems, reduced anisotropy, and twin-induced strain localization. These direct observations of 〈c + a〉 dislocation activities offer a key insight into understanding the deformation mechanism of polycrystalline Mg alloys.

dislocations in pure Mg have been reported to dissociate on basal planes, resulting in a sessile configuration that limits the ductility and formability of Mg. In this study, careful tilting experiments and weak-beam dark-field electron microscopy observations elucidated that dislocations in the commercial alloy AZ31 remain compact without apparent dissociation. The stabilization of the dislocation core structure with Al and Zn alloying may explain the improved strain to failure in the AZ31 alloy as compared to pure Mg samples.

The utilization of metallic anodes holds promise for unlocking high gravimetric and volumetric energy densities and is pivotal to the adoption of ‘beyond Li’ battery chemistries. Much of the promise of magnesium batteries stems from claims regarding their lower predilection for dendrite growth. Whilst considerable effort has been invested in the design of novel electrolytes and cathodes, detailed studies of Mg plating are scarce. Using galvanostatic electrodeposition of metallic Mg from Grignard reagents in symmetric Mg–Mg cells, we establish a phase map characterized by disparate morphologies spanning the range from fractal aggregates of 2D nanoplatelets to highly anisotropic dendrites with singular growth fronts and nanowires entangled in the form of mats. The effects of electrolyte concentration, applied current density, and coordinating ligands have been explored. The study demonstrates a complex range of electrodeposited morphologies including canonical dendrites with shear moduli conducive to penetration through typical polymeric separators. We further demonstrate a strategy for mitigating Mg dendrite formation based on the addition of molecular Lewis bases that promote nanowire growth through selective surface coordination.

The orientation dependence of tensile deformation in Fe40Mn40Co10Cr10 high entropy alloy (HEA) was investigated in [111], [001] and [123] oriented single crystals. Transmission electron microscopy investigations revealed three major mechanisms controlling the deformation stages, depending on the orientation: (i) deformation twinning, (ii) planar slip and (iii) dislocation wall/network formation. While twinning and planar slip were strongly orientation dependent, dislocation walls were observed in all orientations. Twinning was the dominant deformation mode in [111] crystals, while only multi-slip was observed in [001]. Both twins and planar slip were activated in [123] crystals. [111] crystals exhibited the highest strain hardening coefficients and ultimate tensile strength due to the strong twin-twin and twin-slip interactions where twin boundaries reduce the mean free path of dislocations, leading to dynamic Hall–Petch hardening. The decent ductility levels (∼45%) were attained in [111] due to nanoscale internal twins and tertiary twin system forming at the later stages of deformation and suppressing necking. In contrast, no twins or stacking faults were observed in [001] crystals, which is consistent with the Copley–Kear effect. [123] crystals had outstanding tensile ductility (∼65%), due to the activation of planar slip and twinning. Overall, in this off-stoichiometric HEA, we have determined the stacking faculty energy and critical resolved shear stresses for both twinning and slip, and demonstrated the formation of high dislocation density walls and wavy slip in [001], while the hardening stages of [123] and [111] are primarily governed by planar slip and twinning, which can be rationalized by the Copley–Kear effect.

Printing defects are known to degrade the performance of additively manufactured (AM) alloys. Thus, a thorough understanding of their formation mechanisms and effects on the mechanical properties of AM materials is critically needed. Here, we take CoCrFeNi high-entropy alloy as a model material and print this alloy by laser powder bed fusion over a wide range of printing conditions. We reveal the processing windows for the formation of different printing defects including lack of fusion (LOF), keyhole, and solidification cracking. LOF and keyholes can be well correlated with insufficient and excessive laser energy density inputs, respectively. Of particular interest, we observe that solidification cracks only emerge at the medium laser energy density region, where the porosity is minimal yet the grain size and misorientation are relatively large. Such observation is rationalized within the framework of Rappaz–Drezet–Gremaud solidification theory. Among the above printing defects, solidification cracks in AM CoCrFeNi result in less degradation of mechanical properties compared with LOF and keyholes due to their different defect densities and resultant capabilities of coalescence. Our work provides fundamental insight into understanding the physical origins underlying the formation of printing defects and their impacts on the mechanical properties of AM metals and alloys.

Description, Twin boundary migration transitions from atomic shear to atomic shuffle at high stresses and strain rates., Twinning is a prominent deformation mode that accommodates plasticity in many materials. This study elucidates the role of deformation rate on the atomic-scale mechanisms that govern twin boundary migration. Examination of Mg single crystals deformed under quasi-static compression was compared with crystals deformed via plate impact. Evidence of two mechanisms was uncovered. Atomic-level observations using high-resolution transmission electron microscopy revealed that twin boundaries in the -axis quasi-statically compressed single crystals are relatively smooth. At these modest stresses and rates, the twin boundaries were found to migrate predominantly via shear (i.e., disconnection nucleation and propagation). By contrast, in the plate-impacted crystals, which are subjected to higher stresses and rates, twin boundary migration was facilitated by local atomic shuffling and rearrangement, resulting in rumpled twin boundaries. This rate dependency also leads to marked variations in twin variant, size, and number density in Mg. Analogous effects are anticipated in other hexagonal closed-packed crystals.

The origin of the indentation size effect has been extensively researched over the last three decades, following the establishment of nanoindentation as a broadly used small-scale mechanical testing technique that enables hardness measurements at submicrometer scales. However, a mechanistic understanding of the indentation size effect based on direct experimental observations at the dislocation level remains limited due to difficulties in observing and quantifying the dislocation structures that form underneath indents using conventional microscopy techniques. Here, we employ precession electron beam diffraction microscopy to “look beneath the surface,” revealing the dislocation characteristics (e.g., distribution and total length) as a function of indentation depth for a single crystal of nickel. At smaller depths, individual dislocation lines can be resolved, and the dislocation distribution is quite diffuse. The indentation size effect deviates from the Nix–Gao model and is controlled by dislocation source starvation, as the dislocations are very mobile and glide away from the indented zone, leaving behind a relatively low dislocation density in the plastically deformed volume. At larger depths, dislocations become highly entangled and self-arrange to form subgrain boundaries. In this depth range, the Nix–Gao model provides a rational description because the entanglements and subgrain boundaries effectively confine dislocation movement to a small hemispherical volume beneath the contact impression, leading to dislocation interaction hardening. The work highlights the critical role of dislocation structural development in the small-scale mechanistic transition in indentation size effect and its importance in understanding the plastic deformation of materials at the submicron scale.

Here, an experimental study utilizing in-situ scanning electron microscopy (SEM) micro-compression testing and post-mortem transmission electron microscopy (TEM) imaging is presented to quantify the effect of temperature on the transition in deformation modes in twin-oriented Mg single crystals. Single crystal micropillars were fabricated using FIB milling, then tested by in-situ SEM micro-compression from 20 °C to 225 °C. It is observed that plasticity in the deformed Mg microcrystals at temperatures at and below 100 °C is governed by { 10 1 ¯ 2 } extension twinning. However, an anomalous increase of the flow stresses is observed at 100 °C, which is likely due to paucity of dislocation sources that are required to promote twin boundary migration. At 150 °C and above, extension twinning is suppressed and a continuous plastic flow and strain softening induced by prismatic dislocation mediated plasticity is observed. By comparing the current results with those from bulk scale studies for other hexagonal-closed-pack single crystals (e.g. titanium (Ti) and zirconium (Zr)), a general trend for the effect of temperature on the transition in deformation modes in HCP materials is proposed.

B4C-SiC composites were fabricated via the preceramic polymer (PCP) route combined with pressure-assisted sintering. Fully dense bodies were achieved by controlling surface oxide on B4C powder and pyrolysis conditions for PCP coated powder. We elucidate i) the microstructure and phase developments observed in the process of fabricating dense B4C-PCP derived SiC composites and ii) the mechanical properties and crack deflection behavior of dense bodies. The incorporation of PCP derived SiC to B4C decreases hardness due to the lower hardness value of SiC compared to B4C and the residual carbon accompanied by SiC formation. Instead, the PCP derived SiC improved indentation fracture toughness. The main toughening mechanism supposed is a combination of crack impeding by SiC grains and crack deflection within SiC grains, likely due to the presence of subgrains or layered microstructure in the PCP derived SiC grains.

Hexagonal boron nitride (h-BN) is a well-known ceramic that has wide application areas ranging from electronics to metallurgy. However, highly ordered h-BN is conventionally synthesized at high temperatures above 1800 °C. In this work, we investigated the formation of BN from boric acid (H3BO3)-ammonium chloride (NH4Cl) mixture in the sodium chloride (NaCl)-potassium chloride (KCl) eutectic salt. We report the synthesis of highly ordered and nanostructured h-BN at 1000 °C using molten salt synthesis. The effect of starting composition, synthesis temperature, and dwell time on BN formation and its structural ordering were systematically investigated. It is concluded that the molten salt plays important roles in the formation of BN and its structural ordering, which is achieved by i) decomposing the boron (B)-nitrogen (N) bearing reactants that lead to the formation of BN layers, and ii) increasing the mobility of BN layers formed. Furthermore, we propose a possible reaction mechanism that governs the BN formation from the reactant mixture in molten salts and explain the observations based on thermodynamic and kinetic considerations.

We have investigated the effect of synthesis conditions of BCNO compounds on BN formation and its structural ordering. BCNO compounds were synthesized from boric acid (H3BO3)-melamine (C3H6N6) mixtures with various molar ratios (H3BO3:C3H6N6 = 1:1 to 6:1) at 400 °C. The BCNO compounds were then subjected to post heating between 1400 °C and 1800 °C under argon flow. The final products were crystalline BN with hexagonal symmetry exhibiting varying degrees of structural ordering. As the H3BO3 to C3H6N6 ratio in the starting composition is increased, BN formation temperature decreases and the structural ordering of BN increases. Post heating at higher temperature also promotes BN formation and structural ordering. The findings indicate that synthesis and structural ordering of BN can be tailored by controlling starting composition and post heating temperature. These observations may provide a guideline to synthesize high or low-density polymorphs of BN at reduced pressure, temperature, or both.

In this work, we investigated the fundamental plastic deformation mechanisms that can contribute to the improved ductility of a newly developed Mg-2Zn-0.3Ca-0.2Ce-0.1Mn1 (ZXEM2000) wrought alloy. Scanning electron microscopy and transmission electron microscopy were carried out at selected strain levels of the ZXEM2000 alloy under tension along the rolling direction to uncover the microstructural evolution. Our results revealed that the improved ductility could be attributed to three key factors: weaker texture, suppression of twinning, and the increased cross-slip frequency of dislocation. These direct observations offer a key insight into understanding the improved ductility of the ZXEM2000 alloy. The aforementioned three key factors can also guide future Mg alloy design.

We investigated the effect of twin Schmid factor on the tension twinning of individual grains in deformed textured Mg-3Al-1Zn samples. The samples were deformed to ~3% strain (normal-direction compression and tension, rolling-direction compression and tension, and 45 o compression). Statistical analyses on the electron backscatter diffraction results revealed tension twinning generally obeys the Schmid law for individual grains, regardless of whether the global stress state favors tension twinning or not. The strong dependence of tension twinning on Schmid factor is in contrast to the reported weak correlation of dislocations and Schmid factor in the same material system. Such observations are anticipated to advance the understanding of the Schmid factor effect on the deformation behavior of polycrystalline Mg alloys.

We present a new dealloying-based technique to form fully-dense and high-hardness metal composite coatings. By depositing then heat treating a TiCr alloy coating on a Ni-base superalloy, a eutectic reaction occurs at the coating/substrate interface, which drives spontaneous pattern formation in both alloys analogous to liquid metal dealloying. The coating exhibits a significantly higher hardness (15 GPa) than both the starting alloy (3.7 GPa) and precursor coating (6 GPa), measured by micro- and nanoindentation, while maintaining the ability to plastically deform during micro-indentation experiments without apparent cracking or spallation. The flexibility and scalability of the dealloying process used here demonstrates a promising route towards protective coatings for structural alloys.

The starting alloy microstructure can be tailored to achieve varying degrees of grain refinement and enhance mechanical properties through severe plastic shear deformation during solid-phase processing. Crystal plasticity-based grain misorientation modeling, coupled with systematic pin-on-disk tribometry-based subsurface shear deformation experiments on as-cast Al-xSi alloys (x = 0, 1, 4 at %), was conducted. The post-deformation microstructural analysis, through a combined computational and experimental approach, conclusively shows that the initial volume fraction of the hard Si phase enhances the evolution of local lattice misorientation, leading to efficient grain refinement during severe plastic shear deformation. The shear-deformation–induced nanostructure resulted in more than double the nanoindentation hardness in the processed alloy.

In-operando study coupled with voltage/current profiles are presented in order to unveil lithium insertion processes into 3D porous carbon nanotube (CNT) structures whose surfaces were altered to have lithiophobic, lithiophilic, and hybridized lithiophobic/philic characteristics using graphitic surfaces with/without carboxyl/hydroxyl groups. We found the lithiophobic graphitic surfaces hindered lithium insertion into the scaffold despite the high conductivity of CNT. The lithiophilic surface caused another problem of lithium deposition on the outer surface of the electrode, clogging pores and engendering dendrites. Conversely, in the hybridized CNT, lithiophilic trenches partially created on the pristine CNT allowed for uniform lithium deposition into the pores by simultaneously improved lithium attraction and charge transfer, reaching a high areal capacity of 16 mAh cm

During martensitic phase transformations in thin films, substrates impact hysteresis by introducing an additional interface, which can inhibit martensite/austenite interface motion. In order to reduce hysteresis, we examine 2.9-14.5 μm thick Ni-Mn-Sn films which in some cases have been delaminated from the substrates before or after annealing. We compare thermal hysteresis and defect densities at the interface. Delaminating films prior to annealing decreases hysteresis, whereas delaminating films after annealing does not significantly impact hysteresis. Substrate effects are attributed to the thermal expansion mismatch between the film and substrate, resulting in dislocations at the interface and consequentially, an increase in hysteresis.

Emulsion detonation synthesis (EDS) is a recently developed process to synthesize nano-sized ceramics based on detonation of two water-in-oil emulsions. The process produces high pressure and temperature along with fast cooling, thus providing ideal environment for metastable phase formation. Here we applied the process for the first time on hexagonal boron nitride (h-BN). Characterization studies demonstrated the formation of metastable explosion BN phase (e-BN) with grain sizes of 10–20 nm embedded in h-BN matrix. These findings support the potential use of EDS a novel and promising pathway for the synthesis of e-BN and other metastable BN phases.

Advanced metallic alloys are attractive in microelectromechanical systems (MEMS) applications that require high density, electrical and thermal conductivity, strength, and dimensional stability. Here we report the mechanical behavior of direct current (DC) magnetron sputter deposited Nickel (Ni)-Molybdenum (Mo)-Tungsten (W) films annealed at various temperatures. The films deposit as single-phase nanotwinned solid solutions and possess ultra-high tensile strengths of approximately 3 GPa, but negligible ductility. Subsequent heat treatments resulted in grain growth and nucleation of Mo-rich precipitates. While films annealed at 600 °C or 800 °C for 1 h still showed brittle behavior, films annealed at 1,000 °C for 1 h were found to exhibit strength greater than 1.2 GPa and near 10% tensile ductility. In addition to the excellent mechanical properties, alloy films further exhibit remarkably improved dimensional stability – a lower coefficient of thermal expansion and greater microstructural stability. An excellent balance between mechanical properties and dimensional stability make sputter deposited Ni-Mo-W alloys promising structural materials for MEMS applications.

We present a simplified constitutive model, based on the dominant deformation mechanisms, to capture the mechanical behavior of magnesium. This approach takes into account (1) the accumulation and annihilation of 〈 a 〉 and 〈 c + a 〉 dislocations, (2) the volume fraction of extension twins, and (3) two material domains — the parent region and the twinned region. We first show that the model successfully captures the material responses of single crystal magnesium under different loading conditions. We then extend the model for application to a polycrystalline magnesium alloy. The results provide a simple and straightforward approximate model for magnesium and its alloys under various loading conditions.

Fully dense boron carbide discs were achieved by spark plasma sintering boron carbide powders with 10 wt% silicon. The silicon did not diffuse into boron carbide grains to produce a solid solution of Si-doped boron carbide; instead the silicon reacted with impurities in the starting powder to form β-SiC and borosilicate glass. The resultant new phases facilitated densification of the multiphase ceramic through liquid phase-assisted sintering. The resultant material exhibits improved hardness (34.3 GPa Vikers hardness under 1 kg load) with toughness comparable to both Si-free and commercially available boron carbide.

The starting alloy microstructure can be tailored to achieve varying degrees of grain refinement and enhance mechanical properties through severe plastic shear deformation during solid-phase processing. Crystal plasticity-based grain misorientation modeling, coupled with systematic pin-on-disk tribometry-based subsurface shear deformation experiments on as-cast Al-xSi alloys (x = 0, 1, 4 at%), was conducted. The post-deformation microstructural analysis, through a combined computational and experimental approach, conclusively shows that the initial volume fraction of the hard Si phase enhances the evolution of local lattice misorientation, leading to efficient grain refinement during severe plastic shear deformation. The shear-deformation–induced nanostructure resulted in more than double the nanoindentation hardness in the processed alloy.

A newly developed Mg–2Zn-0.3Ca-0.2Ce-0.1Mn (in weight %, ZXEM2000) wrought alloy exhibits an exceptionally high tensile ductility (29% ± 1.4% tensile elongation) along the rolling direction at room temperature. In this work, we investigated the fundamental plastic deformation mechanisms that can contribute to the high ductility of ZXEM2000. Scanning electron microscopy and transmission electron microscopy were carried out at selected strain levels to characterize the microstructural evolution. Compared with the deformed microstructures from the hot-rolled pure Mg and Mg–3Al–1Zn alloy at similar conditions, our results revealed that the high ductility of ZXEM2000 could be attributed to four key factors: weaker texture, fine grain size, reduced twinning, and increased cross-slip frequency of dislocation. These direct observations offer a key insight into improving ductility of magnesium alloys for future alloy design and development.

Boron carbide has a wide range of solubility, but the effects of stoichiometry on its microstructure and mechanical response are not well understood. In this study, detailed microstructural characterization was carried out on three hot-pressed B-rich boron carbide samples. Lattice parameter measurements from XRD identified the compositions to be B 4.2 C, B 5.6 C and B 7.6 C. Local substitutional disorder was observed by Raman spectroscopy, particularly for more B-rich samples. Electron energy loss spectroscopy observations suggest that excess boron preferentially substitutes for carbon atoms in the B 11 C icosahedra; after which additional boron modifies the CBC chains. Moreover, the boron content has salient effects on boron carbide densification and microstructure. Improved densification was observed in the more B-rich samples (B 5.6 C and B 7.6 C), and there is a transition from few or no intragranular planar defects (B 4.2 C), to numerous stacking faults (B 5.6 C), to copious twins (B 7.6 C). Nanoindentation experiments revealed that the highest value for B 4.2 C is statistically larger than that for B 5.6 C or B 7.6 C, suggesting that the hardness of boron carbide is reduced by boron substitution.