The Effect of Nb Doping on the Properties of Ti-Al Intermetallic Compounds Using First-Principles Calculations.

The crystal structures, stability, mechanical properties and electronic structures of Nb-free and Nb-doped Ti-Al intermetallic compounds were investigated via first-principles calculations. Seven components and eleven crystal configurations were considered based on the phase diagram. The calculated results demonstrate that hP8-Ti3Al, tP4-TiAl, tP32-Ti3Al5, tI24-TiAl2, tI16-Ti5Al11, tI24-Ti2Al5, and tI32-TiAl3 are the most stable phases. Mechanical properties were estimated with the calculated elastic constants, as well as the bulk modulus, shear modulus, Young's modulus, Poisson's ratio and Pugh's ratio following the Voigt-Reuss-Hill scheme. As the Al content increases, the mechanical strength increases but the ductility decreases in the Ti-Al compounds. This results from the enhanced covalent bond formed by the continuously enhanced Al-sp hybrid orbitals and Ti-3d orbitals. Nb doping (~5 at.% in this study) keeps the thermodynamical and mechanical stability for the Ti-Al compounds, which exhibit slightly higher bulk modulus and better ductility. This is attributed to the fact that the Nb 4d orbitals locate near the Fermi level and interact with the Ti-3d and Al-3p orbitals, improving the metallic bonds based on the electronic structures.

Microstructure and Electrochemical Behavior of a 3D-Printed Ti-6Al-4V Alloy.

3D printing (or more formally called additive manufacturing) has the potential to revolutionize the way objects are manufactured, ranging from critical applications such as aerospace components to medical devices, making the materials stronger, lighter and more durable than those manufactured via conventional methods. While the mechanical properties of Ti-6Al-4V parts manufactured with two major 3D printing techniques: selective laser melting (SLM) and electron beam melting (EBM), have been reported, it is unknown if the corrosion resistance of the 3D-printed parts is comparable to that of the alloy made with isothermal forging (ISF). The aim of this study was to identify the corrosion resistance and mechanisms of Ti-6Al-4V alloy manufactured by SLM, EBM and ISF via electrochemical corrosion tests in 3.5% NaCl solution, focusing on the effect of microstructures. It was observed that the equiaxed α + ß microstructure in the ISF-manufactured Ti-6Al-4V alloy had a superior corrosion resistance to the acicular martensitic α' + ß and lamellar α + ß microstructures of the 3D-printed samples via SLM and EBM, respectively. This was mainly due to the fact that (1) a higher amount of ß phase was present in the ISF-manufactured sample, and (2) the fraction of phase interfaces was lower in the equiaxed α + ß microstructure than in the acicular α' + ß and lamellar α + ß microstructures, leading to fewer microgalvanic cells. The lower corrosion resistance of SLM-manufactured sample was also related to the higher strain energy and lower electrochemical potential induced by the presence of martensitic twins, resulting in faster anodic dissolution and higher corrosion rate.

Stretch Formability of an AZ61 Alloy Plate Prepared by Multi-Pass Friction Stir Processing.

The stretch formability behavior of an AZ61 magnesium alloy plate produced by multi-pass friction stir processing (M-FSP) was investigated, with the applied load vs. displacement curves recorded during Erichsen cupping tests at different punching speeds at room temperature. The stretch formability of M-FSP AZ61 magnesium alloy was significantly enhanced, compared with that of its cast counterpart. The highest Erichsen index of 3.7 mm was obtained at a punching speed of 0.1 mm/min. The improved stretch formability was mainly attributed to the grain refinement stemming from the M-FSP and the presence of extension twinning to accommodate deformation during Erichsen cupping testing.

Cyclic Deformation Behavior of A Heat-Treated Die-Cast Al-Mg-Si-Based Aluminum Alloy.

The purpose of this investigation was to study the low-cycle fatigue (LCF) behavior of a newly developed high-pressure die-cast (HPDC) Al-5.5Mg-2.5Si-0.6Mn-0.2Fe (AlMgSiMnFe) alloy. The effect of heat-treatment in comparison with its as-cast counterpart was also identified. The layered (α-Al + Mg2Si) eutectic structure plus a small amount of Al8(Fe,Mn)2Si phase in the as-cast condition became an in-situ Mg2Si particulate-reinforced aluminum composite with spherical Mg2Si particles uniformly distributed in the α-Al matrix after heat treatment. Due to the spheroidization of intermetallic phases including both Mg2Si and Al8(Fe,Mn)2Si, the ductility and hardening capacity increased while the yield stress (YS) and ultimate tensile strength (UTS) decreased. Portevin-Le Chatelier effect (or serrated flow) was observed in both tensile stress-strain curves and initial hysteresis loops during cyclic deformation because of dynamic strain aging caused by strong dislocation-precipitate interactions. The alloy exhibited cyclic hardening in both as-cast and heat-treated conditions when the applied total strain amplitude was above 0.4%, below which cyclic stabilization was sustained. The heat-treated alloy displayed a larger plastic strain amplitude and a lower stress amplitude at a given total strain amplitude, demonstrating a superior fatigue resistance in the LCF regime. A simple equation based on the stress amplitude of the first and mid-life cycles ((Δσ/2)first, (Δσ/2)mid) was proposed to characterize the degree of cyclic hardening/softening (D): D=±(Δσ/2)mid - (Δσ/2)first(Δσ/2)first, where the positive sign "+" represents cyclic hardening and the negative sign "-" reflects cyclic softening.

Reducing Yield Asymmetry between Tension and Compression by Fabricating ZK60/WE43 Bimetal Composites.

In this study ZK60/WE43 bimetal composite rods were manufactured by a special method of hot diffusion and co-extrusion. Interface microstructure, deformation mechanism, and yield asymmetry between tension and compression for the composite rods were systematically investigated. It was observed that the salient deformation mechanism of the ZK60 constituent was {10-12}<-1011> extension twinning in compression and prismatic slip in tension, and different deformation modes resulted in yield asymmetry between tension and compression. In contrast, the WE43 constituent tends to be more isotropic due to grain refinement, texture weakening, solid-solution and precipitation strengthening, which were deformed via basal slip, prismatic slip, and {10-12}<-1011> extension twinning in both tension and compression. Surprisingly, it was found that yield asymmetry between tension and compression for the ZK60/WE43 composite rods along the extrusion direction was effectively reduced with a compression-to-tension ratio of ~0.9. The strongly bonded interface acting as a stress transfer medium for the ZK60 sleeve and WE43 core exhibited the coordinated deformation behavior. This finding provides an effective method to decrease the yield asymmetry between tension and compression in the extruded magnesium alloys.

Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding.

The aim of this study was to identify and analyze the fatigue fracture characteristics of dissimilar Al 6061 to Cu (UNS C11000) lap joints made with ultrafast electromagnetic pulse welding (EMPW) via fractography, stress analysis and finite element simulation. It was observed that EMPW generated an annular (or ring-shaped) bonding area, with weld zones and a central non-weld zone when viewed from the cross section. Two types of failure modes occurred in relation to the cyclic loading levels: base metal fracture or transverse through-thickness (TTT) crack growth at a higher loading level, and joint interfacial failure at a lower loading level. In the interfacial failure, fatigue crack initiated from the outer edge of annular welding area, and propagated to form an approximate elliptical boundary. Fatigue crack propagation was characterized by fatigue striations existing in discrete areas on the fracture surface. This was attributed to a coupled role of shear and normal stresses present in a tensile lap shear sample due to the bending moment caused by the inherent misalignment. The final rapid fracture started from elliptical boundary with elongated shear dimples. Both theoretical stress analysis and finite element model revealed the maximum stress and stress concentration along the outer edge, where fatigue crack initiation occurred.

A New Mechanism of Dynamic Phase Transformations in An Isothermal Forged Beta-Gamma Intermetallic Alloy.

A new mechanism of dynamic phase transformations of α2 ↔ γ in an isothermally forged γ-TiAl-based alloy that occur simultaneously during a short-term exposure at 1000 °C is identified in this study. In the heating process, γ phase significantly decreases through a phase transformation of γ → α2, while new γ lamellae are precipitated in the interior of equiaxed grains of α2 phase through a phase transformation of α2 → γ. The reasons for the presence of these two inverse phase transformations α2 ↔ γ occurring simultaneously are discussed.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy.

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique-ultrasonic spot welding (USW)-at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with "river-flow" patterns and characteristic fatigue striations.

Cymbiola nobilis shell: Toughening mechanisms in a crossed-lamellar structure.

Natural structural materials with intricate hierarchical architectures over several length scales exhibit excellent combinations of strength and toughness. Here we report the mechanical response of a crossed-lamellar structure in Cymbiola nobilis shell via stepwise compression tests, focusing on toughening mechanisms. At the lower loads microcracking is developed in the stacked direction, and channel cracking along with uncracked-ligament bridging and aragonite fiber bridging occurs in the tiled direction. At the higher loads the main mechanisms involve cracking deflection in the bridging lamellae in the tiled direction alongside step-like cracking in the stacked direction. A distinctive crack deflection in the form of "convex" paths occurs in alternative lamellae with respect to the channel cracks in the tiled direction. Furthermore, a barb-like interlocking mechanism along with the uneven interfaces in the 1st-order aragonite lamellae is also observed. The unique arrangement of the crossed-lamellar structure provides multiple interfaces which result in a complicated stress field ahead of the crack tip, hence increasing the toughness of shell.

Flat-cladding fiber Bragg grating sensors for large strain amplitude fatigue tests.

We have successfully developed a flat-cladding fiber Bragg grating sensor for large cyclic strain amplitude tests of up to ± 8,000 µÎµ. The increased contact area between the flat-cladding fiber and substrate, together with the application of a new bonding process, has significantly increased the bonding strength. In the push-pull fatigue tests of an aluminum alloy, the plastic strain amplitudes measured by three optical fiber sensors differ only by 0.43% at a cyclic strain amplitude of ± 7,000 µÎµ and 1.9% at a cyclic strain amplitude of ± 8,000 µÎµ. We also applied the sensor on an extruded magnesium alloy for evaluating the peculiar asymmetric hysteresis loops. The results obtained were in good agreement with those measured from the extensometer, a further validation of the sensor.

Modeling the dependence of strength on grain sizes in nanocrystalline materials.

A model was developed to describe the grain size dependence of hardness (or strength) in nanocrystalline materials by combining the Hall-Petch relationship for larger grains with a coherent polycrystal model for nanoscale grains and introducing a log-normal distribution of grain sizes. The transition from the Hall-Petch relationship to the coherent polycrystal mechanism was shown to be a gradual process. The hardness in the nanoscale regime was observed to increase with decreasing grain boundary affected zone (or effective grain boundary thickness, Δ) in the form of Δ-1/2. The critical grain size increased linearly with increasing Δ. The variation of the calculated hardness value with the grain size was observed to be in agreement with the experimental data reported in the literature.