Effect of the Addition of Re on the Microstructure and Phase Composition of Haynes 282: Ab Initio Modelling and Experimental Investigation of Additively Manufactured Specimens.

Interactions in a multicomponent Ni-Cr-Mo-Al-Re model alloy were determined by ab initio calculations in order to investigate the Re doping effect on Haynes 282 alloys. Simulation results provided an understanding of short-range interactions in the alloy and successfully predicted the formation of a Cr and Re-rich phase. The Haynes 282 + 3 wt% Re alloy was manufactured using the additive manufacturing direct metal laser sintering (DMLS) technique, in which the presence of the (Cr17Re6)C6 carbide was confirmed by an XRD study. The results provide useful information about the interactions between Ni, Cr, Mo, Al, and Re as a function of temperature. The designed five-element model can lead to a better understanding of phenomena that occur during the manufacture or heat treatment of modern, complex, multicomponent Ni-based superalloys.

Novel Cold Crucible Ultrasonic Atomization Powder Production Method for 3D Printing.

A new powder production method has been developed to speed up the search for novel alloys for additive manufacturing. The technique involves an ultrasonically agitated cold crucible installed at the top of a 20 kHz ultrasonic sonotrode. The material is melted with an electric arc and undergoes pulverization with standing wave vibrations. Several different alloys in various forms, including noble and metallic glass alloys, were chosen to test the process. The atomized particles showed exceptional sphericity, while powder output suitable for additive manufacturing reached up to 60%. The AMZ4 metallic glass powder remained amorphous below the 50 µm fraction, while tungsten addition led to crystallization in each fraction. Minor contamination and high Mn and Zn evaporation, especially in the finest particles, was observed in atomized powders. The innovative ultrasonic atomization method appears as a promising tool for material scientists to develop powders with tailored chemical composition, size and structure.

Chemical short-range order in derivative Cr-Ta-Ti-V-W high entropy alloys from the first-principles thermodynamic study.

The development of high-entropy alloys (HEAs) focuses on exploring compositional regions in multi-component systems with all alloy elements in equal or near-equal atomic concentrations. Initially it was based on the main idea that high mixing configurational entropy contributions to the alloy free energy could promote the formation of a single solid solution phase. By using the ab-initio based Cluster Expansion (CE) Hamiltonian model constructed for the quinary bcc Cr-Ta-Ti-V-W system in combination with Monte Carlo (MC) simulations, we show that the phase stability and chemical short-range order (SRO) of the equiatomic quinary and five sub-quaternary systems, as well as their derivative alloys, can dramatically change the order-disorder transition temperatures (ODTT) as a function of alloy compositions. In particular, it has been found, that the equiatomic quaternary Ta-Ti-V-W and Cr-Ta-Ti-W alloys had the lowest order-disorder transition temperature (500 K) among all the analysed equiatomic compositions. In all investigated alloy systems, the strongest chemical ordering has been observed between Cr and V, which led to the conclusion that decreasing the concentration of either Cr or V might be beneficial in terms of decreasing the ODTT. It also predicts that increasing concentration of Ti significantly decreases the ODTT. Our analysis of chemical SRO as a function of alloy composition allows to understand the microstructure evolution of HEAs as a function of temperature in excellent agreement with available experimental observations. Importantly, our free energy of mixing and SRO calculations predict that the origin of precipitates formed by Cr- and V-rich in the sub-quaternary Cr-Ta-V-W system is driven by the thermodynamics. The modelling results are in an excellent agreement with experimental observation of Cr and V segregation in the W0.38Ta0.36Cr0.15V0.11 alloy which in turns shows an exceptional radiation resistance.

Configurational Entropy in Multicomponent Alloys: Matrix Formulation from Ab Initio Based Hamiltonian and Application to the FCC Cr-Fe-Mn-Ni System.

Configuration entropy is believed to stabilize disordered solid solution phases in multicomponent systems at elevated temperatures over intermetallic compounds by lowering the Gibbs free energy. Traditionally, the increment of configuration entropy with temperature was computed by time-consuming thermodynamic integration methods. In this work, a new formalism based on a hybrid combination of the Cluster Expansion (CE) Hamiltonian and Monte Carlo simulations is developed to predict the configuration entropy as a function of temperature from multi-body cluster probability in a multi-component system with arbitrary average composition. The multi-body probabilities are worked out by explicit inversion and direct product of a matrix formulation within orthonomal sets of point functions in the clusters obtained from symmetry independent correlation functions. The matrix quantities are determined from semi canonical Monte Carlo simulations with Effective Cluster Interactions (ECIs) derived from Density Functional Theory (DFT) calculations. The formalism is applied to analyze the 4-body cluster probabilities for the quaternary system Cr-Fe-Mn-Ni as a function of temperature and alloy concentration. It is shown that, for two specific compositions (Cr 25Fe 25Mn 25Ni 25 and Cr 18Fe 27Mn 27Ni 28), the high value of probabilities for Cr-Fe-Fe-Fe and Mn-Mn-Ni-Ni are strongly correlated with the presence of the ordered phases L1 2 -CrFe 3 and L1 0-MnNi, respectively. These results are in an excellent agreement with predictions of these ground state structures by ab initio calculations. The general formalism is used to investigate the configuration entropy as a function of temperature and for 285 different alloy compositions. It is found that our matrix formulation of cluster probabilities provides an efficient tool to compute configuration entropy in multi-component alloys in a comparison with the result obtained by the thermodynamic integration method. At high temperatures, it is shown that many-body cluster correlations still play an important role in understanding the configuration entropy before reaching the solid solution limit of high-entroy alloys (HEAs).

The Effect of Electronic Structure on the Phases Present in High Entropy Alloys.

Multicomponent systems, termed High Entropy Alloys (HEAs), with predominantly single solid solution phases are a current area of focus in alloy development. Although different empirical rules have been introduced to understand phase formation and determine what the dominant phases may be in these systems, experimental investigation has revealed that in many cases their structure is not a single solid solution phase, and that the rules may not accurately distinguish the stability of the phase boundaries. Here, a combined modelling and experimental approach that looks into the electronic structure is proposed to improve accuracy of the predictions of the majority phase. To do this, the Rigid Band model is generalised for magnetic systems in prediction of the majority phase most likely to be found. Good agreement is found when the predictions are confronted with data from experiments, including a new magnetic HEA system (CoFeNiV). This also includes predicting the structural transition with varying levels of constituent elements, as a function of the valence electron concentration, n, obtained from the integrated spin-polarised density of states. This method is suitable as a new predictive technique to identify compositions for further screening, in particular for magnetic HEAs.