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

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

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

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

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

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

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

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

Evidence of in-situ Cu clustering as a function of laser power during laser powder bed fusion of 17–4 PH stainless steel

The use of intrinsic heat treatments to control the microstructural evolution during additive manufacturing could eliminate the need for costly post-build processing. Using atom probe microscopy and cluster search algorithms, this study investigates the degree of Cu clustering and precipitation in 17–4 precipitate hardening (PH) stainless steel fabricated by laser powder bed fusion (LPBF). It was found that LPBF samples exhibit a greater than random degree of Cu clustering, irrespective of the laser power during fabrication. It is further shown that using a higher laser power (161.5 W rather than 127.5 W) led to a higher number density of Cu clusters, Cu precipitates, and higher hardness due to the greater heat input. The observations of Cu-rich clusters and precipitates within as-printed LPBF samples and its laser power dependence are novel and show potential for inducing desired strengthening phases directly during LPBF, mitigating the need for post-fabrication heat treatments

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

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

EDP2PDF: a computer program for extracting a pair distribution function from an electron diffraction pattern for the structural analysis of materials

Pair distribution function (PDF) analysis is a powerful technique to understand atomic scale structure in materials science. Unlike X-ray diffraction (XRD)based PDF analysis, the PDF calculated from electron diffraction patterns (EDPs) using transmission electron microscopy can provide structural information from specific locations with high spatial resolution. The present work describes a new software tool for both periodic and amorphous structures that addresses several practical challenges in calculating the PDF from EDPs. The key features of this program include accurate background subtraction using a nonlinear iterative peak-clipping algorithm and automatic conversion of various types of diffraction intensity profiles into a PDF without requiring external software. The present study also evaluates the effect of background subtraction and the elliptical distortion of EDPs on PDF profiles. The EDP2PDF software is offered as a reliable tool to analyse the atomic structure of crystalline and non-crystalline materials

On the fcc to hcp transformation in a Co-Ru alloy: Variant selection and intervariant boundary character

Ru is a common addition to the Co-binder in WC[sbnd]Co hardmetals for advanced cutting tool applications. Internal Co-Co interfaces control many properties such as hot-hardness, toughness, and creep resistance. Hence, phase transformations determining the internal interface character can be harnessed to achieve superior properties. We investigate the γ (face-centred cubic) to α (hexagonally closed packed) martensitic phase transformation of a model Co-Ru binder alloy. We describe the crystallography of γ to α phase transformations and the resulting α/γ and α/α interface character distributions. The stabilisation of the γ-phase results in the formation of low energy (0 0 0 1) α/γ interphase boundary planes. Preferred formation of α/α intervariant and twin-related boundaries with symmetrical tilt configurations are also observed. We discuss how crystallographic constraints of the transformation promote the formation of grain boundary planes other than those of the lowest energy configurations

Grain boundary crystallography and segregation in Ni-based superalloy INC738 manufactured by electron-beam powder bed fusion in as-built and annealed conditions

The excellent high-temperature properties of Ni-based superalloy INC738 are due to its hierarchical microstructure, making it an ideal engineering material for high-temperature applications. Engineering parts are now increasingly made via electron beam powder bed fusion (EPBF), an additive manufacturing technique suitable for such hard-to-weld Ni-based superalloys, due to lower thermal gradients and unmatched scan path control. The thermal cycles induced by EPBF impact characteristics of the γ-matrix, γ’ precipitates, secondary phases such as carbides, grain boundary (GB) solute segregation and, in turn, properties including GB cohesion and strength. However, a more thorough understanding of the GB microstructure evolution with focus on GB chemistry and character is required to optimise properties. We systematically investigate texture, grain structure, GB habit planes, and GB segregation in INC738 fabricated with linear versus random EPBF scanning strategies. We show that random scanning is a suitable strategy to inhibit cracking, refine grains, and decrease segregation of Cr, Mo, C, and B at GBs. For both scanning strategies, γ/γ GBs predominantly terminate on {100} planes and are decorated with C, B, Mo, and W. Upon 2 h annealing at 1180 °C and 1250 °C, the GB character and texture are shown to remain stable despite a reduction in GB interfacial excess. After 24 h annealing at 1250 °C, GB segregation and depletion are nearly eradicated, while static recrystallisation is observed with a predominant formation of annealing twins and GBs terminating on {111} planes. These findings are critical for defect-free additive manufacturing of INC738 and similar grades for superior high-temperature performance

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

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