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Deformation-induced grain-growth in nanocrystalline materials is a widely-reported phenomenon that has been attributed to grain boundary (GB) processes. In this paper, we report on the opposite phenomenon, wherein a stable nanocrystalline (NC) Cu-Ta alloy undergoes a further refinement of the nano-grains during severe plastic deformation (SPD). SPD up to 250% results in a significant grain-size reduction despite the 350°C increase in temperature caused by the deformation process. Experiments and atomistic-simulations show that this unexpected grain-refinement is a direct result of well-dispersed Ta-nanoclusters throughout grain centers and along GBs acting as kinetic-pinning agents and suppressing GB processes that occur during recrystallization.

Non-metallic contamination is a practically unavoidable byproduct of commercial synthesis processes; however, non-metallic impurities are often overlooked when considering material design and performance of nanostructured materials. Importantly, there is disputing evidence as to whether non-metallic contamination stabilize or destabilize nanocrystalline materials against grain growth. Furthermore, it is unclear if non-metallic contamination has a significant impact on hardness of nanocrystalline systems. In this work, two nanocrystalline Ni-28at%W alloys with different impurity concentrations were produced via mechanical alloying to directly evaluate the effect of contamination on thermal stability and hardness of nanostructured materials. The alloys were isothermally annealed at several temperatures, and the microstructures were compared by applying atom probe tomography and aberration-corrected scanning transmission electron microscopy. It was determined that impurity concentrations can be substantially reduced by using specific milling media and pre-milling reduction processes. Furthermore, the clean and contaminated alloys exhibited similar thermal stabilities against grain growth, but the clean alloy displayed a 100% improvement in hardness despite a similar grain size and distribution of second phases. Impurity phases including CrOx, Ni6W6C, and trapped Ar pores were also identified and likely contributed to the thermal stability and mechanical properties observed in this study. Overall, this work suggests that impurities my not always be detrimental to thermomechanical behavior of nanocrystalline systems.

Nanocrystalline Cu-Ta is among the most successfully developed nanostructured alloys involving microstructural design, synthesis, characterization, and testing. However, the interplay of direct and indirect thermal stability mechanisms is still unclear. In this work, mechanically alloyed Cu-10at.%Ta was characterized with atomic-resolution electron microscopy to identify thermal stability mechanisms. A new mechanism involving athermal core-shell particles that were coarsening resistant was discovered after annealing between 100–800 °C up to 1000 h. Evidence suggests that oxide amorphous shells decreased the phase boundary energy thereby reducing the thermodynamic driving force for particle growth and indirectly maximizing thermal stability of Cu(Ta) grains.

Thermomechanical behavior of an ultrafine-grained nickel-yttrium alloy has been investigated through quasi-static (10−4 s−1) and high temperature creep experiments under uniaxial compression along with post-deformed transmission electron microscopy (TEM) characterization. While the alloy possesses a quasi-static flow stress of ~1255 MPa at room temperature, the flow stress drops by about 80% at 873 K. TEM analysis showed negligible average grain growth over the entire temperature range tested. Furthermore, the alloy showed exceptional steady–state creep behavior owing to the relative stability of the grain size and interactions between dislocations/grain boundary and inclusions/dispersoids.

Nanocrystalline (NC) materials possess excellent room temperature properties, such as high strength, wear resistance, and toughness as compared to their coarse-grained counterparts. However, due to the excess free energy, NC microstructures are unstable at higher temperatures. Significant grain growth is observed already at moderately low temperatures, limiting the broader applicability of NC materials. Here, we present a design approach that leads to a significant improvement in the high temperature tensile creep resistance (up to 0.64 of the melting temperature) of a NC Cu-Ta alloy. The design approach involves alloying of pure elements to create a distribution of nanometer sized solute clusters within the grains and along the grain boundaries. We demonstrate that the addition of Ta nanoclusters inhibits the migration of grain boundaries at high temperatures and reduces the dislocation motion. This leads to a highly unusual tensile creep behavior, including the absence of any appreciable steady-state creep deformation normally observed in almost all materials. This design strategy can be readily scaled-up for bulk manufacturing of creep-resistant NC parts and transferred to other multicomponent systems such as Ni-based alloys.

This paper examines the residual stresses generated by laser-assisted cold spray deposition of an iron-based oxide dispersion strengthened alloy (Fe91Ni8Zr1 at.%) on an AISI 1018 mild steel substrate, as well as studies of the effect of the laser heating on the substrate alone. The in-plane residual stress values were determined by X-ray diffraction-based measurements. In the top section of the layers, established at a raster deposition rate of 25 mm/s and simultaneous surface heating temperatures of 650 and 950 °C, stresses were compressive ranging from − 170 to − 440 MPa. For the substrate only study, a larger span of surface temperatures from 350 to 950 °C and scan rates of 5 and 25 mm/s were investigated. Here, the stresses in the laser tracks were tensile, of the order of + 400 MPa, with both “W''- and “M”- shaped profiles about the laser centerline. It was found that the stress profile shape was influenced by the Gaussian power distribution across the laser spot diameter which correlated with microstructural changes (martensite formation) in the substrate.

Nanocrystalline materials are known to possess excellent radiation resistance due to high fraction of grain boundaries that act as defect sinks, provided they are microstructurally stable at such extreme conditions. In this work, radiation response of a stable nanocrystalline Cu-Ta alloy is studied by irradiating with 4 MeV copper ions to doses (close to the surface) of 1 displacements per atom (dpa) at room temperature (RT); 10 dpa at RT, 573 and 723 K; 100 and 200 dpa at RT and 573 K. Nanoindentation results carried out for samples irradiated till 100 dpa at RT and 573 K show exceptionally low radiation hardening behavior compared to various candidate materials from literature. Results from microstructural characterization, using atom probe analysis and transmission electron microscopy, show a stable nanocrystalline microstructure with minimal grain growth and a meagre swelling in samples irradiated to 100 dpa (~0.2%) and 200 dpa at RT, while no voids in those at 573 K. This radiation tolerance is partly attributed to the stability of Ta nanoclusters due to phase separating nature of the alloy. Additionally, the larger tantalum particles are observed to undergo ballistic dissolution at doses greater than 100 dpa and are eventually precipitated as nanoclusters, replenishing the sink strength, which enhanced material's radiation tolerance when exposed to high irradiation doses and elevated temperatures.

The microstructures of materials typically undergo significant changes during shock loading, causing failure when higher shock pressures are reached. However, preservation of microstructural and mechanical integrity during shock loading are essential in situations such as space travel, nuclear energy, protection systems, extreme geological events, and transportation. Here, we report ex situ shock behavior of a chemically optimized and microstructurally stable, bulk nanocrystalline copper–tantalum alloy that shows a relatively unchanged microstructure or properties when shock compressed up to 15 GPa. The absence of shock-hardening indicates that the grains and grain boundaries that make up the stabilized nanocrystalline microstructure act as stable sinks, thereby annihilating deformation-induced defects during shock loading. This study helps to advance the possibility of developing advanced structural materials for extreme applications where shock loading occurs. Shock loading of materials alters the microstructure and considerably degrades mechanical performance. Here, shock loading of a nanocrystalline Cu–Ta alloy is found to induce minor changes to microstructure and mechanical performance, attributed to the annihilation of defects during deformation.

Cryogenic mechanical alloying is a viable method to synthesize nanostructured alloys that exhibit improved mechanical properties without using highly contaminating, process control agents. However, cryogenically milled alloys still contain impurities introduced from the milling media and cryogenic fluid, and it is unclear how these milling parameters can be tailored to optimize alloy design. Here, milling media and cryogenic fluid were systematically varied and studied to quantify differences in impurity concentrations, microstructural evolution, and microhardness. Four derivatives of a Mo25Nb25Ta25W25 high entropy alloy were mechanically alloyed using tool steel or tungsten carbide milling media with either liquid N2 or Ar. Alloys were annealed for 100 h at 1000 °C or 1200 °C. Aberration-corrected scanning transmission electron microscopy (STEM) was primarily used to characterize as-milled and annealed specimens, and Vicker’s microindentation was used to compare hardness. Depending on the milling parameters, total impurity concentrations varied between 12 and 44 at.%, different impurity nitrides or carbides were identified in annealed specimens, and differences in hardness of up to 5 GPa were measured amongst the alloys. Overall, milling with LN2 led to the precipitation of ultrahard nitride phases that when combined with optimized heat treatments, improved the hardness beyond 17 GPa.

The potential benefits of nanocrystalline (NC) alloys for use in various structural applications stem from their enhanced mechanical strengths. However, deformation-induced grain growth in NC materials reduces the strength and is a widely reported phenomenon occurring even at low-temperatures. Controlling such behavior is critical for the maturation of bulk nanocrystalline metals in various advanced engineering applications. Here, we disclose the mechanism by which grain boundary sliding and rotation are suppressed when a NC material is truly thermo-mechanically stabilized against grain growth. Unlike in any other known nanocrystalline metals, the absence of sliding and rotation during loading, at extreme temperatures, is related to short-circuit solute diffusion along the grain boundaries causing the formation of solute clusters and thus a significant change of the grain boundary structures. The departure of this unusual behavior from the well-established norm leads to a strong enhancement of many mutually exclusive properties, such as thermo-mechanical strength, creep resistance, and exceptionally high electrical/thermal conductivity. This work demonstrates that Cu-based nanocrystalline alloys can be used in applications where conventional Cu-based polycrystalline materials are not viable.

Several miniature Kolsky bars are used to obtain stress–strain curves for nanocrystalline Cu–10Ta over a range of high strain-rates. The smallest bar (steel) has a 305 μm diameter, and achieved rates up to 700 × 103/s. Different sample sizes are needed to obtain different strain-rates, and it is shown that there is no appreciable sample size effect when different sizes are tested at similar strain-rates, even though the sample sizes vary by over an order of magnitude. No significant increase in strain-rate sensitivity is noted over the strain-rate range studied, i.e., the strength increases linearly with the logarithm of strain-rate from 0.001/s to 700 × 103/s.

A ternary immiscible nanostructured Cu-Al-Nb alloy was fabricated by friction stir processing of mechanically compacted pellets. Subsequently, aging was carried out at 563 K for various times. The material exhibited hardness of ~4.3 ± 0.1 GPa in the peak-aged condition (aging for 6 h), which is remarkable among Cu-based ternary immiscible alloys. The excellent strength of the material is attributed to Hall-Petch strengthening due to the extremely refined nanocrystalline structure, coupled with precipitation strengthening due to a uniform distribution of nano-scale Al- and Nb-rich precipitates or clusters, as confirmed by X-ray diffraction and microstructural characterization.

Isoconcentration surfaces are commonly used to delineate phases in atom probe datasets. These surfaces then provide the spatial and compositional reference for proximity histograms, the number density of particles, and the volume fraction of particles within a multiphase system. This paper discusses the influence of the isoconcentration surface selection value on these quantitative outputs, using a simple oxide dispersive strengthened alloy, Fe91Ni8Zr1, as the case system. Zirconium reacted with intrinsic oxygen impurities in a consolidated ball-milled powder to precipitate nanoscale zirconia particles. The zirconia particles were identified by varying the Zr-isoconcentration values as well as by the maximum separation data mining method. The associated outputs mentioned above are elaborated upon in reference to the variation in this Zr isosurface value. Considering the dataset as a whole, a 10.5 at.% Zr isosurface provided a compositional inflection point for Zr between the particles and matrix on the proximity histogram; however, this value was unable to delineate all of the secondary oxide particles identified using the maximum separation method. Consequently, variations in the number density and volume fraction were observed as the Zr isovalue was changed to capture these particles resulting in a loss of the compositional accuracy. This highlighted the need for particle-by-particle analysis.

Here, the Cottrell–Stokes ratio in a microstructurally-stable Cu-3Ta (at.%) nanocrystalline alloy is examined from the standpoint of changes in deformation mechanisms. Toward this, uniaxial compression experiments were performed in the temperature range of 113 K – 273 K. The Cottrell-Stokes ratio at the lowest temperature tested was ~1.3, and the material exhibited a very low strain-rate sensitivity at cryogenic-temperatures. Transmission electron microscopy (TEM) characterization showed negligible average grain size coarsening and a transition in the deformation mechanism toward athermal activation processes such as twinning with the reduction in the testing temperature.

This work details the additive friction stir-deposition (AFS-D) of copper and evaluation of its microstructure evolution and hardness. During deposition, a surface oxide is formed on the deposit exterior. A very fine porosity is formed at the substrate&ndash, deposit interface. The deposit (four layers of 1 mm nominal height) is otherwise fully dense. The grains appear to have recrystallized throughout the deposit with varying levels of refinement. The prevalence of twinning was found to be dependent upon the grain size, with larger local grain sizes having a higher number of twins. Vickers hardness measurements reveal that the deposit is softer than the starting feedstock. This result indicates that grain refinement and/or higher twin densities do not replace work hardening contributions to strengthen Cu processed by additive friction stir-deposition.

In this work, a nanocrystalline (NC) Cu-10at.%Ta alloy is irradiated with helium at different temperatures to assess the stability and effectiveness of Ta nanoclusters in trapping helium and suppressing swelling. Advanced microstructural characterization of the room-temperature irradiated specimens indicated the presence of small He-bubbles (∼1-2 nm) at the peak damage depth mainly at the core and along the interface of Ta nanoclusters with Cu matrix. Few bubbles were found along grain boundaries, with much smaller bubbles homogenously distributed within the copper lattice. High-temperature irradiation exhibited bubbles of ∼3-5 nm, which were primarily associated with nanoclusters as compared to other locations, with no observed faceting of the bubbles. Atom probe analysis confirmed helium partitioning to the Ta nanoclusters indicating the effective entrapment of these He atoms.

Grain boundary segregation is an important phenomenon for nanocrystalline materials as it influences thermal stability and mechanical properties. While several studies have considered effects of single, intentional segregants, co-segregation of intentional and unintentional segregants to general grain boundaries is not commonly investigated using experimental techniques on the atomic scale. This study utilized aberration-corrected scanning transmission electron microscopy and atom probe tomography to evaluate the grain boundary structure and chemistry of an electroplated and annealed electrodeposited Ni–W alloy. Several phases were observed in the annealed microstructure including elongated nanoscale oxide particles and relatively large impurity carbide phases. Furthermore, grain boundaries regularly exhibited ordered structures, minimal elemental tungsten segregation (intended solute) and impurity carbon segregation (unintentional solute), but moderately high-impurity oxygen segregation (unintentional solute). The unintentional segregated impurities (oxygen and carbon) resulted in a total average grain boundary composition of ~ 10 at.%. The consequence of impurity segregation is discussed in terms of thermal stability and potential mechanical properties.

Cemented tungsten carbide materials are traditionally bonded using a cobalt matrix, resulting in a material that possesses a unique combination of exceptional properties. However, cobalt has been recently classified as “reasonably anticipated to be a human carcinogen,” and thus, removal of this hazardous phase is desired for many applications. This research focuses on the production of tungsten carbide bodies cemented with a non-hazardous iron-based alloy binder phase. This binder has roots in the previous transition metal binders and additives for tungsten carbide and is based on the principles of high-entropy alloys; however, it relies on a novel means of carbide formation and dispersion from prior investigations. Sintering studies were conducted through uniaxial hot pressing, field-assisted sintering techniques, and pressureless sintering techniques. While some of the results of hot pressing and field-assisted sintering technique were positive, the resultant mesostructure exhibited an undesired, graded, heterogeneous form. Pressureless sintering, on the other hand, was capable of producing a homogeneous microstructure with high theoretical density along with promising hardness and indentation toughness values.

This letter demonstrates the use of laser assisted cold spray for consolidation of oxide dispersion strengthened steel. Cold spray with and without the use of an in situ laser for heating of the substrate was used to deposit coatings of a Fe–Ni–Zr based oxide dispersion strengthened steel powder. Nanoscale zirconium oxide dispersants were found to be present in deposits produced with and without use of the heating laser. Higher substrate temperatures increased deposition efficiency, but also produced samples with lower hardness, larger grain size, and coarser oxide dispersants.

Long periodic stacking ordered (LPSO) phases have been reported to enhance the strength and ductility of Mg alloys due to their high elastic properties. In the present work, the effects of atomic arrangements in terms of Gd-Al L12-type clusters on LPSOs' elastic properties in the Mg-Gd-Al system were studied using first-principles calculations. Four types of LPSO phases (10H, 18R, 14H, and 24R) were investigated with and without an interstitial atom in the center of the L12-type clusters. It was observed that the elastic stiffness components of the LPSO phases such as C11, C33 and C66 are closely related to the bonding distances of L12 cluster. Furthermore, the interstitial atom within the L12 cluster plays an important role in affecting the elastic stiffness constants of LPSOs, resulting in an increase of C11 and C33 due to the bonding distances of L12 cluster.

Fundamentally, material flow stress increases exponentially at deformation rates exceeding, typically, ~103 s−1, resulting in brittle failure. The origin of such behavior derives from the dislocation motion causing non-Arrhenius deformation at higher strain rates due to drag forces from phonon interactions. Here, we discover that this assumption is prevented from manifesting when microstructural length is stabilized at an extremely fine size (nanoscale regime). This divergent strain-rate-insensitive behavior is attributed to a unique microstructure that alters the average dislocation velocity, and distance traveled, preventing/delaying dislocation interaction with phonons until higher strain rates than observed in known systems; thus enabling constant flow-stress response even at extreme conditions. Previously, these extreme loading conditions were unattainable in nanocrystalline materials due to thermal and mechanical instability of their microstructures; thus, these anomalies have never been observed in any other material. Finally, the unique stability leads to high-temperature strength maintained up to 80% of the melting point (~1356 K)., Metals deformed at very high rates experience a rapid increase in flow stress due to dislocation drag. Here, the authors stabilise a nanocrystalline microstructure to suppress dislocation velocity and limit drag effects, conserving low strain-rate deformation mechanisms up to higher strain rates and temperatures.

Mathematical models in process engineering are becoming an essential part of accelerated materials by design, drastically shortening time to discovery by minimizing the vast experimental matrix. In this paper a combination of thermodynamic and analytical models have been used to develop an algorithm for visually guiding the rapid design of a nontoxic (cobalt free) liquid metal binder for WC based cermets. A method based on rapid screening method of key processing parameters is developed that significantly reduces the design space (here, to 27% of the initial alloy composition space). The parameters included represent heretofore unexamined considerations such as chemistry effects on capillary flow, viscosity, surface tension, and melting point which are less computationally intensive than the traditional thermodynamic modeling used in this problem to date. The results are presented in a series of easy to interpret atlases that enable quick identification of systems of interest for further study. Keywords: Cermet, Capillary, Materials by design

Mechanically alloyed 91Fe-8Ni-1Zr (at%) powders were fabricated through high energy ball milling of elemental powder and subsequently consolidated via equal channel angular extrusion (ECAE) at 800 °C and 1000 °C. The resulting microstructure was fine grain with a nano-dispersion of Zr-oxide within the matrix, which was spherical for the 800 °C. ECAE and plate-like (and volumetrically larger) for the 1000 °C ECAE conditions. Atom probe tomography confirmed trace levels of C, N, and Cr impurities within the alloy making it similar to a low-carbon steel. By performing mechanical testing at a quasi-static strain rate (10−3 s−1) and at high strain rate (103 s−1) at room temperature and 473 K, a load drop was noted after yielding. In general, this load drop became more pronounced with increasing strain rate and temperature and has been shown to be a result of dynamic strain aging in the ODS alloy.

The mechanical properties of the weld regions of a 6061-T6 resistance spot welded lap joint are determined. The change in mechanical properties resulting from RSW are linked to the changes observed in the microstructure. Processing currents and strain rates are varied to probe the effects of processing temperature at strain rates from 10−3 to 103 s−1. Results show that material strength decreases within the heat affected zone (HAZ) and fusion zone due to precipitate dispersion. Further, decreased ductility results at quasi-static strain rates from accelerated crack growth arising near voids formed during weld formation, but the short time scale at higher strain rates limits the ability for crack growth from these voids allowing the material to exhibit higher ductility. Overall, significant changes in the mechanical behavior across the weld resulting from a change in microstructure congruent with precipitate dispersion are apparent for all processing conditions.

An Al-5 at. pct Cr alloy was produced by high-energy ball milling at liquid nitrogen temperature followed by consolidation using equal-channel axial extrusion at 200 °C, 300 °C and 450 °C. The microstructure and corrosion response were compared with a cast alloy of the same composition. Rather than the intermetallics expected by the phase diagram and seen in the cast alloy, consolidated HEBM alloys exhibited extended solid solubility of Cr in the aluminum matrix in addition to a finely dispersed Cr-rich phase. This led to improvement in the corrosion behavior as investigated via potentiodynamic polarization and constant immersion tests in NaCl solution. Hardness and tensile tests were performed to evaluate the mechanical properties. The highest consolidation temperature (450 °C) contributed to significant grain growth and Cr diffusion, lessening the beneficial effects of processing with HEBM.

Nanocrystalline Cu-Ta alloys are emerging as a new class of structural materials preserving the nano-scale grain size up to the melting point of Cu. This extraordinary structural stability is caused by the strong pinning of grain boundaries (GBs) by Ta nano-clusters precipitating from the unstable solid solution after mechanical alloying. Many aspects of the Ta stabilization effect remain elusive and call for further experimental and simulation work. In previous atomistic computer simulations of stress-driven GB migration [JOM 68, 1596 (2016)], the GB–cluster interactions in Cu-Ta alloys have been studied for several different compositions and GB velocities. The results have pointed to the Zener pinning as the main mechanism responsible for the grain stabilization. This paper extends the previous work to the motion of individual GBs driven by capillary forces whose magnitude is similar to that in real nanocrystalline materials. Both the impingement of a moving GB on a set of Ta clusters and the GB unpinning from the clusters are studied as a function of temperature and alloy composition. The results demonstrate a quantitative agreement with the Zener pinning model and confirm the “unzip” mechanism of unpinning found in the previous work. In the random Cu-Ta solid solution, short-circuit Ta diffusion along stationary and moving GBs leads to the nucleation and growth of new GB clusters, which eventually stop the GB motion.

The crystallographic and electronic structures of (010) APB of L12 Co3Al0.75TM0.25 are studied by high-resolution transmission electron microscopy and first-principles calculations. Effects of solute atoms (TM = Cr, Hf, Mo, Ni, Re, Ru, Ta, Ti, W and Y) on the formation energy, lattice parameters/distortion, magnetism, and bonding strength of the (010) APB in Co3Al0.75TM0.25 are obtained from first-principles calculations. Comparing to the equilibrium volume of Co3Al, it is found that the volume change of the Co3Al0.75TM0.25 with and without the presence of APB increases linearly with the volume of the corresponding FCC elements, indicating the contribution of the solute atoms on lattice distortion of bulk and (010) APB. Particularly, the strong dependence of the APB energy on the composition is comprehensively discussed together with the available experimental and theoretical data in the literature. The negative (010) APB energy indicates that the formation of (010) APB could stabilize the ordered L12 (or the FCC-lattice) Co3Al, and the local L12 → D022 phase transformation can occur. The physical natures of lattice distortions caused by the fault layers of APB and the solute atoms are characterized by bonding charge density. It is found that the solute atoms, occupying Al site of L12 phase and its (010) APB, increase the local bonding strength along (010) through the electron redistribution during forming the chemical bonds with Co, revealing an intrinsic solid-solution strengthening mechanism. This work provides an insight into the atomic and electronic basis for solid-solution strengthening mechanism of L12 Co3Al0.75TM0.25.

The presence of complex states-of-stress and strain-rates directly influence the dominant deformation mechanisms operating in a given material under load. Mg alloys have shown limited ambient temperature formability due to the paucity of active slip-mechanisms, however, studies have focused on quasi-static strain-rates and/or simple loading conditions (primarily uniaxial or biaxial). For the first time, the influence of strain-rate and stress-triaxiality is utilized to unravel the active deformation mechanisms operating along the rolling, transverse- and normal-directions in wrought AZ31-alloy. It is discovered that the activation of various twin-mechanisms in the presence of multiaxial loading is governed by the energetics of the applied strain-rates. IMPACT STATEMENT It is shown for the first time that the higher deformation energy associated with dynamic strain-rates, coupled with high-triaxiality, promotes detwinning and texture evolution in HCP alloys with high c/a ratio.

In this work, various alloy compositions of immiscible copper-tantalum (Cu–Ta) are systematically studied to understand the interplay between cluster stability, precipitation hardening, and the overall stability of the matrix's average grain size. An alloy composition of Cu-3at.%Ta is found to exhibit dramatic improvements relative to other neighboring Ta contents (both higher and lower) only after exposures of more than 300 h at 800 °C. An extremely low steady-state growth rate, i.e., 3.1 nm per 100 h exposure, speaks to the extreme kinetics which allow this composition to retain its high mechanical strength. The key attribute responsible for the NC Cu-3at.%Ta alloy exhibiting such behavior is a high cluster density tailored through the Ta solute content to achieve the best combination of stability without sacrificing strength by limiting Orowan coarsening of the clusters compared to other Ta concentrations. In general, the growth kinetics of this Cu-3at.%Ta alloy are so sluggish that it places it among the most thermally resistant alloys ever produced. The work demonstrates that, if designed properly, bulk nanocrystalline alloys can withstand the prolonged high-temperature exposure required for high-temperature applications, while grain growth is stagnated or halted.

The solute-induced softening and hardening effects in bcc W for twenty-one substitutional alloying elements (Al, Co, Cr, Fe, Hf, Ir, Mn, Mo, Nb, Ni, Os, Pd, Pt, Re, Rh, Ru, Ta, Tc, Ti, V and Zr) are examined to search for a similar softening effect as that observed with Re. The changes in energy barriers of dislocation motion caused by solute-dislocation interactions are directly computed via a first-principles approach with flexible boundary conditions. The effect of solutes on the critical resolved shear stress of the ½ screw dislocation in bcc W at room temperature is quantitatively predicted, as a function of alloy concentration, via a mesoscopic solid-solution model using the first-principles results as input. Al and Mn are proposed to be promising substitutes for Re as these two elements introduce similar softening effects as Re in bcc W. In addition, the trends of the solute-dislocation interactions, and their correlations to the dislocation core structure geometries are discussed.

Stability of nanocrystalline microstructural features allows structural materials to be synthesized and tested in ways that have heretofore been pursued only on a limited basis. Here, we demonstrate using quasi-static compression and three point bend tests that, in a stabilized nanocrystalline metal with tailored solute concentrations, i.e., NC-Cu-3 at.%Ta, extraordinary properties such as ultrahigh hardness along with anomalus modulus of resilience and springback effects can be manifested. Such effects influence a wide range of materials response including elastic energy absorption, damping, fatigue and wear. The present study, therefore, represents a pathway for designing highly resilient materials for everyday applications.

Here, we show the strategies to strengthen Mg alloys through modifying the matrix by planar faults and optimizing the local lattice strain by solute atoms. The anomalous shifts of the local phonon density of state of stacking faults (SFs) and long periodic stacking-ordered structures (LPSOs) toward the high-frequency mode are revealed by HCP-FCC transformation, resulting in the increase of vibrational entropy and the decrease of free energy to stabilize the SFs and LPSOs. Through integrating bonding charge density and electronic density of states, electronic redistributions are applied to reveal the electronic basis for the ‘strengthening’ of Mg alloys. IMPACT STATEMENT Through integrating the bonding charge density, the phonon and electronic density of states, this work provides an atomic and electronic insight into the strengthening mechanism of Mg alloys.

Surface oxidation of metal powders is a common challenge in powder metallurgy processing, and the oxides must eventually be broken up to produce high-quality, structural components. Here it is proposed that surface oxidation may be beneficial in the creation of porous metals through intraparticle expansion, which creates porosity by the reduction of oxides which are distributed within a metallic matrix. Previous work utilized the addition of separate oxides to the metal as a two-component (Cu powder + CuO powder) cryogenic ball milling process. The feasibility of controlling pore formation by directly oxidizing copper powder before milling is examined, and it is then extended to room temperature processing. Both pore distribution and morphology vary greatly with oxygen content, which can be controlled during processing. The pore volume and interconnectedness are maximized at intermediate oxygen concentration, indicating competing effects of the oxide loading. When room temperature high-energy ball milling is applied, the oxidized powder was found to exhibit even greater expansion upon annealing and larger pore size, though cold welding of the copper was encountered at short milling times. Using a single-component method at room temperature may prove valuable to reduce the cost and complexity of large scale production of expandable powder feedstock, and key considerations are discussed.

Refractory high-entropy alloys present attractive mechanical properties, i.e., high yield strength and fracture toughness, making them potential candidates for structural applications. Understandings of atomic and electronic interactions are important to reveal the origins for the formation of high-entropy alloys and their structure−dominated mechanical properties, thus enabling the development of a predictive approach for rapidly designing advanced materials. Here, we report the atomic and electronic basis for the valence−electron-concentration-categorized principles and the observed serration behavior in high-entropy alloys and high-entropy metallic glass, including MoNbTaW, MoNbVW, MoTaVW, HfNbTiZr, and Vitreloy-1 MG (Zr41Ti14Cu12.5Ni10Be22.5). We find that the yield strengths of high-entropy alloys and high-entropy metallic glass are a power-law function of the electron-work function, which is dominated by local atomic arrangements. Further, a reliance on the bonding-charge density provides a groundbreaking insight into the nature of loosely bonded spots in materials. The presence of strongly bonded clusters and weakly bonded glue atoms imply a serrated deformation of high-entropy alloys, resulting in intermittent avalanches of defects movement. A cluster-and-glue model of atomic arrangements explains the yield strength and mechanical response of high entropy alloys. Inspired by metallic glass, a team led by William Yi Wang at China’s Northwestern Polytechnical University and collaborators in the United States of America used molecular dynamics to build different atomic arrangements of refractory high entropy alloys consisting of four or more elements. Depending on atomic size and the periodic table group of each atom, some atoms organized into clusters while others glued the clusters together. Chemical bonds broke and formed with plastic deformation as the alloys went from one atomic arrangement to another via the glue atoms, causing defect avalanches explaining the serrated mechanical response of high entropy alloys. Taking into account atomic arrangement may thus help us predict the properties of high entropy alloys.

Grain refinement through surface plastic deformation processes such as surface mechanical attrition treatment has shown measureable benefits for mechanical properties, but the impact on corrosion behavior has been inconsistent. Many factors obfuscate the particular corrosion mechanisms at work, including grain size, but also texture, processing contamination, and surface roughness. Many studies attempting to link corrosion and grain size have not been able to decouple these effects. Here we introduce a preprocessing step to mitigate the surface contamination effects that have been a concern in previous corrosion studies on plastically deformed surfaces; this allows comparison of corrosion behavior across grain sizes while controlling for texture and surface roughness. Potentiodynamic polarization in aqueous NaCl solution suggests that different corrosion mechanisms are responsible for samples prepared with the preprocessing step.

Nanocrystalline materials possess excellent room temperature properties, such as high strength, wear resistance, and toughness as compared to their coarse-grained counterparts. However, due to excess free energy, nanocrystalline microstructures are unstable at higher temperatures. Significant grain growth is observed already at moderately low temperatures, limiting their broader applicability. Here, we present a design approach that leads to a significant improvement in the high temperature tensile creep resistance (up to 0.64 of the melting temperature Tm) of a nanocrystalline Cu-Ta alloy. The design approach involves alloying of pure elements for engineering nanometer sized solute clusters within the solvent grains as well as along the grain boundaries. Using a chemically optimized nanocrystalline Cu-3at.%Ta alloy as a model material system, we demonstrate that the addition of Ta nanoclusters inhibits the migration of the planar defects at higher temperatures and reduces the dislocation motion, leading to extraordinary high temperature properties. For instance, the NC Cu-3Ta alloy tested under tensile creep conditions up to the temperature of 873 K (0.64Tm) displays highly unusual behavior, including the absence of any appreciable steady-state creep deformation which is normally observed in almost all materials. This approach can be readily scaled-up for bulk manufacturing of creep resistant nanocrystalline parts. Moreover, this design strategy can be transferred to other multicomponent systems such as Ni-based alloys for making nanocrystalline materials with tailored properties.

The effect of mechanical loading, particularly at dynamic strain rates, on nanocrystalline (NC) materials has eluded researchers owing to the inherent instability of the NC structure. However, a recently developed NC Cu-10 at.%Ta alloy has exhibited an ability to maintain a NC structure at temperatures up to 873 K. Here, NC Cu-10 at.%Ta is tested under compressive strain rates ranging from 10−3 s−1 up to 105 s−1 and at temperatures from 298 K up to 1073 K. Typical materials show a sharp increase in flow stress occurring around 103 s−1 as deformation mechanisms shift away from thermal activation mechanisms; however, at 298 K, NC Cu-10 at.%Ta observes only a limited increase in flow stress indicating that typical thermally activated mechanisms still apply up to strain rates of 105 s−1. Post deformation analyses indicate a shift from nucleation of full dislocations to increased nucleation of partial dislocations at 298 K. However, as temperature increases, thermal activation mechanisms give way to viscous effects and the high density of nucleated full dislocations leads to a dramatic increase in flow stress.

An immiscible nanocrystalline (NC) copper-tantalum (Cu-Ta) alloy is shown to exhibit a stable microstructure under thermo-mechanical loading conditions with exceptional mechanical strength (i.e., 1200 MPa strength at 298 K) indicating anomalous deformation mechanisms as compared to microstructurally unstable nanocrystalline materials. Therefore, in this work, various aspects of strength partitioning in such NC Cu-Ta alloys are discussed and the role of tantalum nanoclusters on the dominant deformation mechanism is presented as a function of temperature. Toward this, initially, the mechanical responses of NC Cu-Ta alloy were measured under uniaxial compression experiments at various temperatures. Later, atomistic simulations were performed along with the high-resolution electron microscopy to identify and validate the rate limiting mechanism behind the plastic deformation in NC Cu-Ta alloys. In general, the observed trend through experiments and simulations identify a transition from a dislocation – nanocluster interaction mediated deformation mechanism to one controlled by grain boundary strengthening as the temperature increases. The former mechanism is shown here to have a crucial role in the observed strengthening behavior of microstructurally stable NC materials. Overall, the paper demonstrates that through effective nano-engineering techniques, it is expected to extend the scope of nanocrystalline materials to a number of engineering design applications. Keywords: Nanocrystalline, Deformation, Transmission electron microscopy, Atomistic

Most attempts to improve the properties of high entropy alloys (HEAs) involve the exploration of non-equimolar compositions, addition of alloying elements, and/or manipulation of the microstructure. Alternatively, this work reports on intentionally doping HEAs with non-metallic species to precipitate coherent, ordered phases in order to maximize hardness. A refractory MoNbTaW HEA was synthesized via cryogenic mechanical alloying and doped with nitrogen by using liquid nitrogen as the cryogen. Overall, the doping strategy was successful as multiple nitrogen-rich secondary phases were observed. In particular, a unique ordered laminar phase was developed and identified as tetragonal (Mo,W)(Nb,Ta)N nitride via aberration-corrected scanning transmission electron microscopy (STEM). Another complex (Nb,Ta)2CN carbonitride was also identified. The growth behaviors of the ceramic phases were studied using long term aging treatments of up to 100 hours at 1200°C. A second MoNbTaW alloy was also prepared via high-energy ball milling, without nitrogen, by using liquid Ar as the cryogen. A comparison of the two alloys’ microstructures and properties confirm that intentional formation of complex nitride phases greatly enhanced the hardness of mechanically alloyed MoNbTaW by up to 3-4 GPa.

Six-sequential layer deposits of an oxide dispersion strengthened (ODS) Fe91Ni8Zr1 alloy were laser assisted cold sprayed (LACS) at 650 °C and 950 °C. The nanoscale zirconia phase in this alloy precipitated from residual oxygen within the high-energy ball milled constituent elemental powders used for the spray deposition. The laser provided a local heating of the substrate (or the surface of the previous deposited layer), which thermally softens it, increasing the mass deposition efficiency (DE). At a surface temperature of 650 °C during deposition, the ODS alloy was ferrite with a DE of 7.3%. This low DE resulted in a peening/tamping effect of ricocheted powders off the surface resulting in the grains at the substrate/deposit interface being notably refined. At a surface temperature of 950 °C, the ODS alloy was in the austenitic phase field during deposition resulting in a DE increase to 32.4%. With this increase in deposition temperature, the deposited grains grew and the oxide particles coarsened. This resulted in a reduction in Vickers hardness from 598 ± 56 (650 °C) to 293 ± 38 (950 °C). Hall-Petch grain size effects, Orowan strengthening between oxide particles, and Taylor hardening contributions estimated the hierarchy in the strengthening mechanisms with these microstructural changes, with grain size being determined as the dominant mechanism. These deposits demonstrate the advantages of using a laser for relatively difficult-to-spray (high hardness and strength) materials, albeit with associated changes in microstructure with their corresponding changes in hardness.