Mechanistic understanding of speciated oxide growth in high entropy alloys.

Complex multi-element alloys are gaining prominence for structural applications, supplementing steels, and superalloys. Understanding the impact of each element on alloy surfaces due to oxidation is vital in maintaining material integrity. This study investigates oxidation mechanisms in these alloys using a model five-element equiatomic CoCrFeNiMn alloy, in a controlled oxygen environment. The oxidation-induced surface changes correlate with each element's interactive tendencies with the environment, guided by thermodynamics. Initial oxidation stages follow atomic size and redox potential, with the latter becoming dominant over time, causing composition inversion. The study employs in-situ atom probe tomography, transmission electron microscopy, and X-ray absorption near-edge structure techniques to elucidate the oxidation process and surface oxide structure evolution. Our findings deconvolute the mechanism for compositional and structural changes in the oxide film and will pave the way for a predictive design of complex alloys with improved resistance to oxidation under extreme conditions.

Impact of environmental oxygen on nanoparticle formation and agglomeration in aluminum laser ablation plumes.

The role of ambient oxygen gas (O2) on molecular and nanoparticle formation and agglomeration was studied in laser ablation plumes. As a lab-scale surrogate to a high explosion detonation event, nanosecond laser ablation of an aluminum alloy (AA6061) target was performed in atmospheric pressure conditions. Optical emission spectroscopy and two mass spectrometry techniques were used to monitor the early to late stages of plasma generation to track the evolution of atoms, molecules, clusters, nanoparticles, and agglomerates. The experiments were performed under atmospheric pressure air, atmospheric pressure nitrogen, and 20% and 5% O2 (balance N2), the latter specifically with in situ mass spectrometry. Electron microscopy was performed ex situ to identify crystal structure and elemental distributions in individual nanoparticles. We find that the presence of ≈20% O2 leads to strong AlO emission, whereas in a flowing N2 environment (with trace O2), AlN and strong, unreacted Al emissions are present. In situ mass spectrometry reveals that as O2 availability increases, Al oxide cluster size increases. Nanoparticle agglomerates formed in air are found to be larger than those formed under N2 gas. High-resolution transmission electron microscopy demonstrates that Al2O3 and AlN nanoparticle agglomerates are formed in both environments; indicating that the presence of trace O2 can lead to Al2O3 nanoparticle formation. The present results highlight that the availability of O2 in the ambient gas significantly impacts spectral signatures, cluster size, and nanoparticle agglomeration behavior. These results are relevant to understanding debris formation in an explosion event, and interpreting data from forensic investigations.

Exceptional enhancement of mechanical properties in high-entropy alloys via thermodynamically guided local chemical ordering.

Understanding the local chemical ordering propensity in random solid solutions, and tailoring its strength, can guide the design and discovery of complex, paradigm-shifting multicomponent alloys. First, we present a simple thermodynamic framework, based solely on binary enthalpies of mixing, to select optimal alloying elements to control the nature and extent of chemical ordering in high-entropy alloys (HEAs). Next, we couple high-resolution electron microscopy, atom probe tomography, hybrid Monte-Carlo, special quasirandom structures, and density functional theory calculations to demonstrate how controlled additions of Al and Ti and subsequent annealing drive chemical ordering in nearly random equiatomic face-centered cubic CoFeNi solid solution. We establish that short-range ordered domains, the precursors of long-range ordered precipitates, inform mechanical properties. Specifically, a progressively increasing local order boosts the tensile yield strengths of the parent CoFeNi alloy by a factor of four while also substantially improving ductility, which breaks the so-called strength-ductility paradox. Finally, we validate the generality of our approach by predicting and demonstrating that controlled additions of Al, which has large negative enthalpies of mixing with the constituent elements of another nearly random body-centered cubic refractory NbTaTi HEA, also introduces chemical ordering and enhances mechanical properties.

Non-polar ether-based electrolyte solutions for stable high-voltage non-aqueous lithium metal batteries.

The electrochemical instability of ether-based electrolyte solutions hinders their practical applications in high-voltage Li metal batteries. To circumvent this issue, here, we propose a dilution strategy to lose the Li+/solvent interaction and use the dilute non-aqueous electrolyte solution in high-voltage lithium metal batteries. We demonstrate that in a non-polar dipropyl ether (DPE)-based electrolyte solution with lithium bis(fluorosulfonyl) imide salt, the decomposition order of solvated species can be adjusted to promote the Li+/salt-derived anion clusters decomposition over free ether solvent molecules. This selective mechanism favors the formation of a robust cathode electrolyte interphase (CEI) and a solvent-deficient electric double-layer structure at the positive electrode interface. When the DPE-based electrolyte is tested in combination with a Li metal negative electrode (50 µm thick) and a LiNi0.8Co0.1Mn0.1O2-based positive electrode (3.3 mAh/cm2) in pouch cell configuration at 25 °C, a specific discharge capacity retention of about 74% after 150 cycles (0.33 and 1 mA/cm2 charge and discharge, respectively) is obtained.

Oxygen-Vacancy Abundant Nanoporous Ni/NiMnO3/MnO2@NiMn Electrodes with Ultrahigh Capacitance and Energy Density for Supercapacitors.

High-performance energy storage devices (HPEDs) play a critical role in the realization of clean energy and thus enable the overarching pursuit of nonpolluting, green technologies. Supercapacitors are one class of such lucrative HPEDs; however, a serious limiting factor of supercapacitor technology is its sub-par energy density. This report presents hitherto unchartered pathway of physical deformation, chemical dealloying, and microstructure engineering to produce ultrahigh-capacitance, energy-dense NiMn alloy electrodes. The activated electrode delivered an ultrahigh specific-capacitance of 2700 F/cm3 at 0.5 A/cm3. The symmetric device showcased an excellent energy density of 96.94 Wh/L and a remarkable cycle life of 95% retention after 10,000 cycles. Transmission electron microscopy and atom probe tomography studies revealed the evolution of a unique hierarchical microstructure comprising fine Ni/NiMnO3 nanoligaments within MnO2-rich nanoflakes. Theoretical analysis using density functional theory showed semimetallic nature of the nanoscaled oxygen-vacancy-rich NiMnO3 structure, highlighting enhanced carrier concentration and electronic conductivity of the active region. Furthermore, the geometrical model of NiMnO3 crystals revealed relatively large voids, likely providing channels for the ion intercalation/de-intercalation. The current processing approach is highly adaptable and can be applied to a wide range of material systems for designing highly efficient electrodes for energy-storage devices.

Gas-phase oxidation and nanoparticle formation in multi-element laser ablation plumes.

The evolution from gas-phase oxidation to nanoparticle and agglomerate formation was studied in nanosecond laser-produced plasmas of a multi-principal element alloy target in air. Gas-phase oxidation of plasma species was monitored in situ via optical emission spectroscopy, while a custom-built single particle mass spectrometer was used to measure size and compositions of agglomerated nanoparticles formed in laser ablation plumes. Ex situ analysis employing transmission electron microscopy was used to study nanoparticle morphology, crystal structure, and element distribution at the nanoscale. Emission spectra indicate that gas-phase oxidation of elements in the alloy target are formed at varying times during plume evolution, and mass spectrometry results indicate fractal agglomerates contain all principal alloying elements and their oxides. Finally, electron microscopy characterization illustrates that these agglomerates consist of multiple material types: sub-10 nm diameter amorphous, multi-element nanoparticles, ≈10-30 nm diameter Ti-rich crystalline oxide nanoparticles, and ejected base material. Results highlight that the multi-component target composition impacts molecular formation in the gas phase and the morphology, composition, and structure of nanoparticles and agglomerates formed.

Extended Shear Deformation of the Immiscible Cu-Nb Alloy Resulting in Nanostructuring and Oxygen Ingress with Enhancement in Mechanical Properties.

Deformation processing of immiscible systems is observed to disrupt thermodynamic equilibrium, often resulting in nonequilibrium microstructures. The microstructural changes including nanostructuring, hierarchical distribution of phases, localized solute supersaturation, and oxygen ingress result from high-strain extended deformation, causing a significant change in mechanical properties. Because of the dynamic evolution of the material under large strain shear load, a detailed understanding of the transformation pathway has not been established. Additionally, the influence of these microstructural changes on mechanical properties is also not well characterized. Here, an immiscible Cu-4 at. % Nb alloy is subjected to a high-strain shear deformation (∼200); the deformation-induced changes in the morphology, crystal structure, and composition of Cu and Nb phases as a function of total strain are characterized using transmission electron microscopy and atom probe tomography. Furthermore, a multimodal experiment-guided computational approach is used to depict the initiation of deformation by an increase in misorientation boundaries by crystal plasticity-based grain misorientation modeling (strain ∼0.6). Then, co-deformation and nanolamination of Cu and Nb are envisaged by a finite element method-based computational fluid dynamic model with strain ranging from 10 to 200. Finally, the experimentally observed amorphization of the severely sheared supersaturated Cu-Nb-O phase was validated using the first principle-based simulation using density functional theory while highlighting the influence of oxygen ingress during deformation. Furthermore, the nanocrystalline microstructure shows a >2-fold increase in hardness and compressive yield strength of the alloy, elucidating the potential of deformation processing to obtain high-strength low-alloyed metals. Our approach presents a step-by-step evolution of a microstructure in an immiscible alloy undergoing severe shear deformation, which is broadly applicable to materials processing based on friction stir, extrusion, rolling, and surface shear deformation under wear and can be directly applied to understanding material behavior during these processes.

Highly complex magnetic behavior resulting from hierarchical phase separation in AlCo(Cr)FeNi high-entropy alloys.

Magnetic high-entropy alloys (HEAs) are a new category of high-performance magnetic materials, with multicomponent concentrated compositions and complex multi-phase structures. Although there have been numerous reports of their interesting magnetic properties, there is very limited understanding about the interplay between their hierarchical multi-phase structures and the resulting magnetic behavior. We reveal for the first time the influence of a hierarchically decomposed B2 + A2 structure in an AlCo0.5Cr0.5FeNi HEA on the formation of magnetic vortex states within individual A2 (disordered BCC) precipitates, which are distributed in an ordered B2 matrix that is weakly ferromagnetic. Non-magnetic or weakly ferromagnetic B2 precipitates in large magnetic domains of the A2 phase, and strongly magnetic Fe-Co-rich interphase A2 regions, are also observed. These results provide important insight into the origin of coercivity in this HEA, which can be attributed to a complex magnetization process that includes the successive reversal of magnetic vortices.

Excellent ballistic impact resistance of Al0.3CoCrFeNi multi-principal element alloy with unique bimodal microstructure.

Multi-principal element alloys represent a new paradigm in structural alloy design with superior mechanical properties and promising ballistic performance. Here, the mechanical response of Al0.3CoCrFeNi alloy, with unique bimodal microstructure, was evaluated at quasistatic, dynamic, and ballistic strain rates. The microstructure after quasistatic deformation was dominated by highly deformed grains. High density of deformation bands was observed at dynamic strain rates but there was no indication of adiabatic shear bands, cracks, or twinning. The ballistic response was evaluated by impacting a 12 mm thick plate with 6.35 mm WC projectiles at velocities ranging from 1066 to 1465 m/s. The deformed microstructure after ballistic impact was dominated by adiabatic shear bands, shear band induced cracks, microbands, and dynamic recrystallization. The superior ballistic response of this alloy compared with similar AlxCoCrFeNi alloys was attributed to its bimodal microstructure, nano-scale L12 precipitation, and grain boundary B2 precipitates. Deformation mechanisms at quasistatic and dynamic strain rates were primarily characterized by extensive dislocation slip and low density of stacking faults. Deformation mechanisms at ballistic strain rates were characterized by grain rotation, disordering of the L12 phase, and high density of stacking faults.

In Situ Probing Potassium-Ion Intercalation-Induced Amorphization in Crystalline Iron Phosphate Cathode Materials.

Na-ion and K-ion batteries are promising alternatives for large-scale energy storage due to their abundance and low cost. Intercalation of these large ions could cause irreversible structural deformation and partial to complete amorphization in the crystalline electrodes. A lack of understanding of the dynamic changes in the amorphous nanostructure during battery operation is the bottleneck for further developments. Here, we report the utilization of in-operando digital image correlation and XRD techniques to probe dynamic changes in the amorphous phase of iron phosphate during potassium ion intercalation. In-operando XRD demonstrates amorphization in the electrode's nanostructure during the first charge and discharge cycle. Additionally, ex situ HR-TEM further confirms the amorphization after potassium-ion intercalation. An in situ strain analysis detects reversible deformations associated with redox reactions in the amorphous phases. Our approach offers new insights into the mechanism of ion intercalation in the amorphous nanostructure which are highly potent for the development of next-generation batteries.

Interfacial reaction during friction stir assisted scribe welding of immiscible Fe and Mg alloy system.

We report on interfacial characteristics and chemistry of bonded Mg-Fe interfaces welded using friction stir assisted scribe technique (FaST). Two pairs of dissimilar joints: (AZ31-DP590) and (Pure Mg-DP590) were studied to shed light on joining mechanisms responsible for bonding of "immiscible" pairs of Mg and Fe. We present first direct experimental evidence of presence of oxide layer, Al segregation by atom probe tomography and nano steel grains close to interface by transmission electron microscopy study.

Co-introduction of precipitate hardening and TRIP in a TWIP high-entropy alloy using friction stir alloying.

Tuning deformation mechanisms is imperative to overcome the well-known strength-ductility paradigm. Twinning-induced plasticity (TWIP), transformation-induced plasticity (TRIP) and precipitate hardening have been investigated separately and have been altered to achieve exceptional strength or ductility in several alloy systems. In this study, we use a novel solid-state alloying method-friction stir alloying (FSA)-to tune the microstructure, and a composition of a TWIP high-entropy alloy by adding Ti, and thus activating site-specific deformation mechanisms that occur concomitantly in a single alloy. During the FSA process, grains of the as-cast face-centered cubic matrix were refined by high-temperature severe plastic deformation and, subsequently, a new alloy composition was obtained by dissolving Ti into the matrix. After annealing the FSA specimen at 900 °C, hard Ni-Ti rich precipitates formed to strengthen the alloy. An additional result was a Ni-depleted region in the vicinity of newly-formed precipitates. The reduction in Ni locally reduced the stacking fault energy, thus inducing TRIP-based deformation while the remaining matrix still deformed as a result of TWIP. Our current approach presents a novel microstructural architecture to design alloys, an approach that combines and optimizes local compositions such that multiple deformation mechanisms can be activated to enhance engineering properties.

Dynamic Shear Deformation of a Precipitation Hardened Al0.7CoCrFeNi Eutectic High-Entropy Alloy Using Hat-Shaped Specimen Geometry.

Lamellar eutectic structure in Al0.7CoCrFeNi high-entropy alloy (HEA) is emerging as a promising candidate for structural applications because of its high strength-ductility combination. The alloy consists of a fine-scale lamellar fcc + B2 microstructure with high flow stresses > 1300 MPa under quasi-static tensile deformation and >10% ductility. The response to shear loading was not investigated so far. This is the first report on the shear deformation of a eutectic structured HEA and effect of precipitation on shear deformation. A split-Hopkinson pressure bar (SHPB) was used to compress the hat-shaped specimens to study the local dynamic shear response of the alloy. The change in the width of shear bands with respect to precipitation and deformation rates was studied. The precipitation of L12 phase did not delay the formation of adiabatic shear bands (ASB) or affect the ASB width significantly, however, the deformed region around ASB, consisting of high density of twins in fcc phase, was reduced from 80 µm to 20 µm in the stronger precipitation strengthened condition. We observe dynamic recrystallization of grains within ASBs and local mechanical response of individual eutectic lamellae before and after shear deformation and within the shear bands was examined using nano-indentation.

Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion.

An aluminum (Al) matrix with various transition metal (TM) additions is an effective alloying approach for developing high-specific-strength materials for use at elevated temperatures. Conventional fabrication processes such as casting or fusion-related methods are not capable of producing Al-TM alloys in bulk form. Solid phase processing techniques, such as extrusion, have been shown to maintain the microstructure of Al-TM alloys. In this study, extrusions are fabricated from gas-atomized aluminum powders (≈100-400 µm) that contain 12.4 wt % TM additives and an Al-based matrix reinforced by various Al-Fe-Cr-Ti intermetallic compounds (IMCs). Two different extrusion techniques, conventional hot extrusion and friction extrusion, are compared using fabricating rods. During extrusion, the strengthening IMC phases were extensively refined as a result of severe plastic deformation. Furthermore, the quasicrystal approximant IMC phase (70.4 wt % Al, 20.4 wt % Fe, 8.7 wt % Cr, 0.6 wt % Ti) observed in the powder precursor is replaced by new IMC phases such as Al3.2Fe and Al45Cr7-type IMCs. The Al3Ti-type IMC phase is partially dissolved into the Al matrix during extrusion. The combination of linear and rotational shear in the friction extrusion process caused severe deformation in the powders, which allowed for a higher extrusion ratio, eliminated linear voids, and resulted in higher ductility while maintaining strength comparable to that resulting from hot extrusion. Results from equilibrium thermodynamic calculations show that the strengthening IMC phases are stable at elevated temperatures (up to ≈ 600 °C), thus enhancing the high-temperature strength of the extrudates.

Hierarchical Eutectoid Nano-lamellar Decomposition in an Al0.3CoFeNi Complex Concentrated Alloy.

This paper reports a novel eutectoid nano-lamellar (FCC + L12)/(BCC + B2) microstructure that has been discovered in a relatively simple Al0.3CoFeNi high entropy alloy (HEA) or complex concentrated alloy (CCA). This novel eutectoid nano-lamellar microstructure presumably results from the complex interplay between Al-mediated lattice distortion (due to its larger atomic radius) in a face-centered cubic (FCC) CoFeNi solid solution, and a chemical ordering tendency leading to precipitation of ordered phases such as L12 and B2. This eutectoid microstructure is a result of solid-state decomposition of the FCC matrix and therefore distinct from the commonly reported eutectic microstructure in HEAs which results from solidification. This novel nano-lamellar microstructure exhibits a tensile yield strength of 1074 MPa with a reasonable ductility of 8%. The same alloy can be tuned to form a more damage-tolerant FCC + B2 microstructure, retaining high tensile yield stress (~900 MPa) with appreciable tensile ductility (>20%), via annealing at 700 °C. Such tunability of microstructures with dramatically different mechanical properties can be effectively engineered in the same CCA, by exploiting the complex interplay between ordering tendencies and lattice distortion.

A novel nano-particle strengthened titanium alloy with exceptional specific strength.

Various ecological and economical concerns have spurred mankind's quest for materials that can provide enhanced weight savings and improved fuel efficiency. As part of this pursuit, we have microstructurally tailored an exceptionally high-strength titanium alloy, Ti-6Al-2Sn-4Zr-6Mo (Ti6246) through friction stir processing (FSP). FSP has altered the as-received bimodal microstructure into a unique modulated microstructure comprised of fine acicular α″-laths with nano precipitates within the laths. The sequence of phase transformations responsible for the modulated microstructure and consequently for the strength is discussed with the help of scanning electron microscopy, transmission electron microscopy, and synchrotron X-ray diffraction studies. The specific strength attained in one of the conditions is close to 450 MPa m3/mg, which is about 22% to 85% greater than any commercially available metallic material. Therefore, our novel nano particle strengthened Ti alloy is a potential replacement for many structural alloys, enabling significant weight reduction opportunities.

Facile Photochemical Syntheses of Conjoined Nanotwin Gold-Silver Particles within a Biologically-Benign Chitosan Polymer.

A simple photochemical method for making conjoined bi-metallic gold-silver (Au/Ag) nanotwins, a new breed of nanoparticles (NPs), is developed. To the best of our knowledge, the photochemical method resulted in distinct, conjoined, bimetallic nanotwins that are different from any well-established alloyed or core-shell nanostructures in the literature. The conjoined Au-Ag NPs possessed surface plasmon resonance (SPR) properties of both metals. The bimetallic nanostructures possessing distinctive optical properties of both metals were obtained using Au NPs as seeds in the first step, followed by the addition of a silver precursor as feed in the second step during a photochemical irradiation process. In the first step, small, isotropic or large, anisotropic Au NPs are generated by photoinduced reduction within a biocompatible chitosan (CS) polymer. In the second step, a silver precursor (AgNO3) is added as the feed to the AuNPs seed, followed by irradiation of the solution in the ice-bath. The entire photochemical irradiation process resulting in the formation of bimetallic Au-AgNPs did not involve any other reducing agents or stabilizing agents other than the CS polymer stabilizer. The small, conjoined Au-Ag bi-metallic NPs exhibited SPR with peak maxima centering at ~400 nm and ~550 nm, whereas the large conjoined nanoparticles exhibited SPR with peak maxima centering at ~400 nm, 550 nm, and 680 nm, characteristic of both gold and silver surface plasmons in solution. The tunability in the SPR and size of the bimetallic NPs were obtained by varying the reaction time and other reaction parameters, resulting in average sizes between 30 and 100 nm. The SPR, size, distribution, and elemental composition of the bi-metallic NPs were characterized using UV-Vis absorption, electron microscopy, and energy dispersive X-ray spectroscopy (EDS) studies.

Influence of ordered L12 precipitation on strain-rate dependent mechanical behavior in a eutectic high entropy alloy.

Recent studies indicate that eutectic high-entropy alloys can simultaneously possess high strength and high ductility, which have potential industrial applications. The present study focuses on Al0.7CoCrFeNi, a lamellar dual-phase (fcc + B2) precipitation-strengthenable eutectic high entropy alloy. This alloy exhibits an fcc + B2 (B2 with bcc nano-precipitates) microstructure resulting in a combination of the soft and ductile fcc phase together with hard B2 phase. Low temperature annealing leads to the precipitation of ordered L12 intermetallic precipitates within the fcc resulting in enhanced strength. The strengthening contribution due to fine scale L12 is modeled using Orowan dislocation bowing and by-pass mechanism. The alloy was tested under quasi-static (strain-rate = 10-3 s-1) tensile loading and dynamic (strain-rate = 103 s-1) compressive loading. Due to the fine lamellar microstructure with a large number of fcc-bcc interfaces, the alloy show relatively high flow-stresses, ~1400 MPa under quasi-static loading and in excess of 1800 MPa under dynamic loading. Interestingly, the coherent nano-scale L12 precipitate caused a significant rise in the yield strength, without affecting the strain rate sensitivity (SRS) significantly. These lamellar structures had higher work hardening due to their capability for easily storing higher dislocation densities. The back-stresses from the coherent L12 precipitate were insufficient to cause improvement in twin nucleation, owing to elevated twinning stress under quasi-static testing. However, under dynamic testing high density of twins were observed.

High-entropy alloy strengthened by in situ formation of entropy-stabilized nano-dispersoids.

A significant increase in compressive yield strength of the Al0.3CoCrFeMnNi high-entropy alloy (HEA) from 979 MPa to 1759 MPa was observed upon the introduction of 3 vol.% Y2O3. The HEAs were processed using spark plasma sintering of mechanically alloyed powders. Transmission electron microscopy and atom probe tomography confirmed the presence of compositionally complex nano-dispersoids in the Y2O3-added HEA. The significant increase in strength can be attributed to the nano-dispersoid strengthening coupled with grain refinement. Therefore, the in-situ formation of the compositionally complex nanoscale dispersoids during the alloy processing could be a novel approach to create entropy-stabilized oxide particles in strengthening of HEAs.