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The highly tunable properties of multi-principal element alloys, commonly known as high-entropy alloys (HEAs), provide a remarkable potential for the development of superior materials for critical structural applications that involve extreme conditions. However, the optimization of the properties of HEAs has been primarily limited to behavior at either low or high temperatures. Here, we report on a non-equiatomic, heterostructured, high-entropy alloy FeNiCoAlTaB which possesses remarkable combinations of mechanical properties across a wide range of temperatures from 77 K to 1073 K. The current metastable alloy presents good ductility and superior engineering tensile strengths of 2.2 GPa, 1.4 GPa, 800 MPa, and 500 MPa at 77 K, 298 K, 873 K, and 1073 K, respectively. This behavior is achieved by a synergic sequence of individual mechanisms that are activated at different temperatures. The alloy even displays pseudoelasticity at 77 K with an applied load up to 2 GPa. This work provides a methodology for tailoring structural heterogeneity and metastability in the design and fabrication of multifunctional HEAs that will outperform known metals and alloys over a wide range of temperatures.

Batteries are important for promoting renewable energy, but, like most engineered products, they contain multiple hazardous materials. The purpose of this study is to evaluate industrial-scale batteries using GreenScreen® for Safer Chemicals, an established chemical hazard assessment (CHA) framework, and to develop a systematic, transparent methodology to quantify the CHA results, harmonize them, and aggregate them into single-value hazard scores, which can facilitate quantitative comparison and a robust evaluation of data gaps, inconsistencies, and uncertainty through the implementation of carefully selected scenarios and stochastic multicriteria acceptability analysis (SMAA). Using multiple authoritative toxicity data sources, six battery products are evaluated: three lithium-ion batteries (lithium iron phosphate, lithium nickel cobalt manganese hydroxide, and lithium manganese oxide), and three redox flow batteries (vanadium redox, zinc-bromine, and all-iron). The CHA results indicate that many materials in these batteries, including reagents and intermediates, inherently exhibit high hazard; therefore, safer materials should be identified and considered in future designs. The scenario analysis and SMAA, combined, provide a quantitative evaluation framework to support the decision-making needed to compare alternative technologies. Thus, this study highlights specific strategies to reduce the use of hazardous materials in complex engineered products before they are widely used in this rapidly-expanding industry sector.

The abrupt occurrence of twinning when Mg is deformed leads to a highly anisotropic response, making it too unreliable for structural use and too unpredictable for observation. Here, we describe an in-situ transmission electron microscopy experiment on Mg crystals with strategically designed geometries for visualization of a long-proposed but unverified twinning mechanism. Combining with atomistic simulations and topological analysis, we conclude that twin nucleation occurs through a pure-shuffle mechanism that requires prismatic-basal transformations. Also, we verified a crystal geometry dependent twin growth mechanism, that is the early-stage growth associated with instability of plasticity flow, which can be dominated either by slower movement of prismatic-basal boundary steps, or by faster glide-shuffle along the twinning plane. The fundamental understanding of twinning provides a pathway to understand deformation from a scientific standpoint and the microstructure design principles to engineer metals with enhanced behavior from a technological standpoint.

Energy storage systems are critical for enabling the environmental benefits associated with capturing renewable energy to displace fossil fuel-based generation, yet producing these systems also contributes to environmental impacts through their materials use and manufacturing. As energy storage capacity is scaled up to support increasingly renewable grids, the environmental benefits from their use may scale at different rates than the environmental impacts from their production. This implies the existence of capacity thresholds beyond which installing additional storage capacity may be environmentally detrimental. Identifying such thresholds are important for ensuring that energy storage capacity selection in future grids are consistent with net emissions reduction goals, but such thresholds have not been studied in the present literature. To identify such thresholds, here we combine electric grid dispatch modeling with life cycle analysis to compare how the emissions reductions from deploying three different flow battery energy storage types on a future California grid (>80% wind and solar) compare with emissions contributions from producing such batteries as total battery capacity installed on the grid increases. Depending on the type of battery and environmental impact indicator (greenhouse gas or particulate matter emissions), we find that the marginal environmental benefits of storage begin to diminish at deployed capacities of 38–76% of the mean daily renewable generation (256–512 GWh in our California scenarios) and reach zero at 105–284% of mean daily renewable generation (700–1810 GWh). Such storage capacities are conceivable, but upstream impacts of storage must be assessed in evaluating the environmental benefits of large-scale storage deployment, or they could negate the environmental benefits of regional electricity system decarbonization.

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

Cooling, nucleation, and phase growth are ubiquitous processes in nature. Effective control of nucleation and phase growth is of significance to yield refined microstructures with enhanced performance for materials. Recent studies reveal that ultrafine grained (UFG)/nanocrystalline metals exhibit extraordinary properties. However, conventional microstructure refinement methods, such as fast cooling and inoculation, have reached certain fundamental limits. It has been considered impossible to fabricate bulk UFG/nanocrystalline metals via slow cooling. Here, we report a new discovery that nanoparticles can refine metal grains to ultrafine/nanoscale by instilling a continuous nucleation and growth control mechanism during slow cooling. The bulk UFG/nanocrystalline metal with nanoparticles also reveals an unprecedented thermal stability. This method overcomes the grain refinement limits and may be extended to any other processes that involve cooling, nucleation, and phase growth for widespread applications.

Bulk, polycrystalline (Co, Cu, Mg, Ni, Zn)O was synthesized using solid-state sintering. Micropillars were prepared and mechanically deformed along three crystallographic orientations: (001), (101), and (111). Pillars (001) and (111) cracked, while Pillar (101) remained intact. Pillars (001) and (101) exhibited activated slip systems, confirmed by a large stress drop, and the presence of slip bands, respectively. Schmid factor (SF) analysis was performed to examine the effect of grain orientations on dislocation activity and slip behavior. SF values range from 0 to 0.5, with non-zero values indicating potential for slip. Six slip systems exist in the (Co, Cu, Mg, Ni, Zn)O rock salt crystal structure: 1 / 2 ⟨ 110 ⟩ 1 1 ¯ 0. For the (001) orientation, four slip systems are potentially active (SF = 0.5). For the (101) orientation, there are four potentially active slip systems (SF = 0.25). For the (111) orientation, no potentially active slips systems exist (SF = 0). Dislocation structures, which were observed post-compression via transmission electron microscopy, demonstrated variations in size, number, and distribution across the pillar, depending on micropillar orientation. Entangled dislocations created misorientation in Pillar (001), which led to the possible formation of subgrains, while singular dislocations were observed in Pillar (101), and a lack of dislocations was observed in Pillar (111). Zener–Stroh type dislocation entanglement-mediated cracking is the proposed cause of the transgranular-type cracks in Pillar (001). The possible subgrain formation, or lack of formation, respectively, caused intergranular-type cracks to additionally form in Pillar (001), while Pillar (111) only exhibited transgranular-type brittle fracture. In combination, these findings highlight the importance of dislocation activity, without the need for elevated temperature, and grain orientation in controlling the mechanical deformation response in single-phase (Co, Cu, Mg, Ni, Zn)O. [ABSTRACT FROM AUTHOR]