Ultrahigh-Strength Porous Ceramic Composites via a Simple Directional Solidification Process.

Porous ceramics possess great application potential in various fields. However, the contradiction between their pores and their strength have significantly hampered their applications. In this study, we present a simple directional solidification process that relies on its in situ pore forming mechanism to fabricate Al2O3/Y3Al5O12/ZrO2 porous eutectic ceramic composites with a highly dense and nanostructured eutectic skeleton matrix and a lotus-type porous structure. The flexural strength of this porous ceramic composite with a porosity of 34% is 497 MPa at ambient temperature, which is a new record of the strength of all current porous ceramics. This strength can remain at 324 MPa when the temperature increases up to 1773 K because of its refined lamellar structure and strong bonding interface. We demonstrate an interesting application of the directional solidification in efficiently preparing the ultrahigh-strength porous ceramic with high purity. The findings will open a window to the strength of porous ceramics.

Effects of Melt Hydrogenation on the Microstructure Evolution and Hot Deformation Behavior of TiBw/Ti-6Al-4V Composites.

In this study, Ti-6Al-4V matrix composites reinforced with TiB ceramic whiskers were in situ synthesized and hydrogenated using the melt hydrogenation technique (MHT). The effects of MHT on the microstructure evolution and hot compression behavior of the composites were investigated by optical microscopy (OM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). Hot compression tests were performed at strain rates of 0.1/s, 0.01/s, and 0.001/s and temperatures of 800 °C, 850 °C, and 900 °C; the hot workability of composites significantly improved after hydrogenation, for example, the 900 °C peak flow stress of hydrogenated composites (43 MPa) decreased by 53.76% compared with that of unhydrogenated ones (93 MPa) at a strain rate of 0.01/s. Microstructural observations show that MHT can effectively facilitate the dispersion of TiB whiskers and induce the α/ß lath refinement of the matrix in our as-cast hydrogenated composite. During hot compression, MHT effectively promoted the as-cast composite microstructure refinement, accelerated the dynamic recrystallization (DRX) generation, and reduced the stress concentration at the interface between the reinforcement and matrix; in turn, the hydrogenated composites presented low peak stress during hot compression.

Microstructure Evolution and Toughening Mechanism of a Nb-18Si-5HfC Eutectic Alloy Created by Selective Laser Melting.

Because of their superior mechanical performance at ultra-high temperatures, refractory niobium-silicon-based alloys are attractive high-temperature structural alloys, particularly as structural components in gas turbine engines. However, the development of niobium-silicon-based alloys for applications is limited because of the trade-off between room temperature fracture toughness and high-temperature strength. Here, we report on the fabrication of a Nb-18Si alloy with dispersion of hafnium carbide (HfC) particles through selective laser melting (SLM). XRD and SEM-BSE were used to examine the effects of scanning speed on the microstructure and the phase structure of the deposited Nb-18Si-5HfC alloy. The results show that when the scanning speed rises, the solid solubility of the solid solution improves, the interlamellar spacing of eutectics slowly decrease into nano-scale magnitude, and the corresponding hafnium carbide distribution becomes more uniform. We also discover the hafnium carbide particles dispersion in the inter-lamella structure, which contributes to its high fracture toughness property of 20.7 MPa∙m1/2 at room temperature. Hardness and fracture toughness are simultaneously improved because of the control of microstructure morphology and carbide distribution.

An innovation for microstructural modification and mechanical improvement of TiAl alloy via electric current application.

In this article, microstructural evolution during the solidification of Ti-48Al-2Cr-2Nb with current density, as well as the formation mechanisms, are discussed, along with the impacts on microhardness and hot compression properties. The applied electric current promotes the solidification from the α primary phase to a largely ß solidification in Ti-48Al-2Cr-2Nb. With an increase in supercooling, the solidification process have a tendency to change from an α-led primary phase to (α + ß)-led primary phase. The primary dendrites, grain size, and lamellar spacing show a tendency to decrease first before increasing with increasing current density. Microhardness and high-temperature yield strength increase with a decrease in primary dendrite spacing, grain size, and lamellar spacing. Correlations between primary dendrite spacing, lamellar spacing, microhardness, yield strength, and current density are described by a fitting formula. An increase of α2 phase, due to the application of electric current, results in improved microhardness. The yield strength of Ti-48Al-2Cr-2Nb alloy increases linearly with microhardness. Yield stress increases with a decrease in microstructure parameters, in accordance with the Hall-Petch equation. The predominant modification mechanism with electric current application for TiAl solidification is the variation of supercooling and temperature gradients ahead of the mush zone due to Joule heating.

High-density deformation nanotwin induced significant improvement in the plasticity of polycrystalline γ-TiAl-based intermetallic alloys.

Intermetallic alloys with high melting point can mostly serve as promising high-temperature structural materials, but their intrinsic brittleness limits their further application. Herein, we developed a strategy to realize high strength and high plasticity simultaneously in Cr-rich γ-TiAl-based intermetallic alloys via introducing high-density deformation nanotwins. Non-equilibrium continuous casting followed by annealing in the (α + γ) phase region generated numerous Shockley partial dislocations and stacking faults as well as a number of α2 nanoparticles in the γ-TiAl phase. The substantial Shockley partial dislocations and stacking faults acting as effective heterogeneous nucleation sites favored the generation of high-density nanotwins in the as-annealed alloys during deformation, especially within the γ lamellae. This strategy can also be applied to other brittle alloys with a favorable twinning deformation mechanism and paves the way for the development of high-strength and high-ductility materials.

Effects and mechanism of ultrasonic irradiation on solidification microstructure and mechanical properties of binary TiAl alloys.

In spite of their high temperature and reactivity, the binary TiAl alloys are successfully imposed by the ultrasonic irradiation and the microstructure evolution, solidification behaviors and mechanical properties are elaborately investigated. After ultrasonic irradiation, a high quality ingot without shrinkage defects and element segregation is obtained and the coarse dendrite structure is well modified into fine non-dendrite globular grains. The coarse lamellar colony and lamellar space of Ti44Al alloy is refined from 685µm to 52µm and 1185nm to 312nm, respectively (similarly, 819µm to 102µm and 2085nm to 565nm for Ti48Al alloy). For Ti48Al alloy, the α peritectic phase is simultaneously precipitated from the melt as well as the ß primary phase before the peritectic reaction and the solidification is transformed into the mixed α-solidifying and ß-solidifying. Ultrasonic irradiation promotes the peritectic reaction and phase transformation completely and the phase constituent becomes more close to the equilibrium level. The compressive strength of Ti44Al and Ti48Al alloys are increased from 623MPa to 1250MPa and 980MPa to 1295MPa, respectively. The grain refinement and dendrite transformation enhance the grain boundary sliding improving the plastic deformation ability. Ultrasonic irradiation significantly accelerates the melt flow and solute redistribution and the main grain refinement mechanism is the cavitation-enhanced nucleation by inclusion activation and heightened supercooling.

Design of (Nb, Mo)40Ti30Ni30 alloy membranes for combined enhancement of hydrogen permeability and embrittlement resistance.

The effect of substitution of Nb by Mo in Nb40Ti30Ni30 was investigated with respect to microstructural features and hydrogen dissolution, diffusion and permeation. As-cast Nb40-xMoxTi30Ni30 (x = 0, 5, 10) alloys consist of primary bcc-Nb phase and binary eutectic (bcc-Nb + B2-TiNi). The substitution of Nb by Mo reduces the hydrogen solubility in alloys, but may increase (x = 5) or decrease (x = 10) the apparent hydrogen diffusivity and permeability. As-cast Nb35Mo5Ti30Ni30 exhibits a combined enhancement of hydrogen permeability and embrittlement resistance as compared to Nb40Ti30Ni30. This work confirms that Mo is a desirable alloying element in Nb that can contribute to a reduction in hydrogen absorption and an increase in intrinsic hydrogen diffusion, thus improving embrittlement resistance with minimal permeability penalty.

Detachment of secondary dendrite arm in a directionally solidified Sn-Ni peritectic alloy under deceleration growth condition.

In order to better understand the detachment mechanism of secondary dendrite arm during peritectic solidification, the detachment of secondary dendrite arm from the primary dendrite arms in directionally solidified Sn-36at.%Ni peritectic alloys is investigated at different deceleration rates. Extensive detachment of secondary dendrite arms from primary stem is observed below peritectic reaction temperature TP. And an analytical model is established to characterize the detachment process in terms of the secondary dendrite arm spacing λ2, the root radius of detached arms and the specific surface area (SV) of dendrites. It is found that the detachment mechanism is caused by not only curvature difference between the tips and roots of secondary branches, but also that between the thicker secondary branches and the thinner ones. Besides, this detachment process is significantly accelerated by the temperature gradient zone melting (TGZM) effect during peritectic solidification. It is demonstrated that the reaction constant (f) which is used to characterize the kinetics of peritectic reaction is crucial for the determination of the detachment process. The value of f not only changes with growth rate but also with solidification time at a given deceleration rate. In conclusion, these findings help the better understanding of the detachment mechanism.

On migration of primary/peritectic interface during interrupted directional solidification of Sn-Ni peritectic alloy.

The migration of the primary/peritectic interface in local isothermal condition is observed in dendritic structure of Sn-Ni peritectic alloy after experiencing interrupted directional solidification. It was observed that this migration of primary Ni3Sn2/peritectic Ni3Sn4 interface towards the primary Ni3Sn2 phase was accompanied by migration of liquid film located at this interface. The migration velocity of this interface was confirmed to be much faster than that of peritectic transformation, so this migration was mostly caused by superheating of primary Ni3Sn2 phase below TP, leading to nucleation and migration of liquid film at this interface. This migration can be classified as a kind of liquid film migration (LFM), and the migration velocity at the horizontal direction has been confirmed to be much faster than that along the direction of temperature gradient. Analytical prediction has shown that the migration of liquid film could be divided into two stages depending on whether primary phase exists below TP. If the isothermal annealing time is not long enough, both the liquid film and the primary/peritectic interface migrate towards the primary phase until the superheated primary phase has all been dissolved. Then, this migration process towards higher temperature is controlled by temperature gradient zone melting (TGZM).