Density, excess volume, and structure of Fe-Cr-Ni melts.

The relationship between the excess volume and the structure of Fe-Cr-Ni melts is investigated using containerless levitation and in situ high-energy synchrotron x-ray diffraction techniques. The density of six hypoeutectic Fe-Cr-Ni alloys along the 72 wt. % Fe isopleth was measured in the stable and undercooled regions, and the excess volume was evaluated as a function of Cr concentration. It is found that the 72Fe-Cr-Ni alloys exhibit a positive sign of excess volume and the amount increases with increasing Cr concentration. Analysis of the structure factor and pair distribution function of the alloy family reveals that the short-range order in the melt becomes more pronounced with decreasing Cr concentration; this demonstrates a direct correlation between the excess volume and local liquid structure. A characteristic signature of the icosahedral structure is observed in the structure factor of the melts, and the potential origin of the positive excess volume of the 72Fe-Cr-Ni alloys is qualitatively discussed in relation to the icosahedral structure.

Circumventing Solidification Cracking Susceptibility in Al-Cu Alloys Prepared by Laser Powder Bed Fusion.

Laser powder bed fusion (LPBF) of Al-Cu alloys shows high susceptibility to cracking due to a wide solidification temperature range. In this work, 2024 alloys were manufactured by LPBF at different laser processing parameters. The effect of processing parameters on the densification behavior and mechanical properties of the LPBF-processed 2024 alloys was investigated. The results show that the porosity increases significantly with increasing laser power, while the number of cracks and lack-of-fusion defects increase distinctly with increasing scan speed. The solidification cracking susceptibility of the LPBF-processed 2024 alloys prepared at different processing parameters was analyzed based on a finite element model, which was accurately predicted by theoretical calculations. Dense and crack-free 2024 samples with a high densification of over 98.1% were manufactured at a low laser power of 200 W combined with a low laser scan speed of 100 mm/s. The LPBF-processed 2024 alloys show a high hardness of 110 ± 4 HV0.2, an ultimate tensile strength of 300 ± 15 MPa, and an elongation of ∼3%. This work can serve as reference for obtaining crack-free and high-performance Al-Cu alloys by LPBF.

In Situ Mapping of Phase Evolutions in Rapidly Heated Zr-Based Bulk Metallic Glass with Oxygen Impurities.

Metallic glasses exhibit unique mechanical properties. For metallic glass composites (MGC), composed of dispersed nanocrystalline phases in an amorphous matrix, these properties can be enhanced or deteriorated depending on the volume fraction and size distribution of the crystalline phases. Understanding the evolution of crystalline phases during devitrification of bulk metallic glasses upon heating is key to realizing the production of these composites. Here, results are presented from a combination of in situ small- and wide-angle X-ray scattering (SAXS and WAXS) measurements during heating of Zr-based metallic glass samples at rates ranging from 102 to 104 Ks-1 with a time resolution of 4ms. By combining a detailed analysis of scattering experiments with numerical simulations, for the first time, it is shown how the amount of oxygen impurities in the samples influences the early stages of devitrification and changes the dominant nucleation mechanism from homogeneous to heterogeneous. During melting, the oxygen rich phase becomes the dominant crystalline phase whereas the main phases dissolve. The approach used in this study is well suited for investigation of rapid phase evolution during devitrification, which is important for the development of MGC.

Programming Crystallographic Orientation in Additive-Manufactured Beta-Type Titanium Alloy.

Additively manufactured metallic materials typically exhibit preferential <001> or <110> crystallographic orientations along the build direction. Nowadays, the challenge is to program crystallographic orientation along arbitrary 3D direction in additive-manufactured materials. In this work, it is established a technique of multitrack coupled directional solidification (MTCDS) to program the <001> crystallographic orientation along an arbitrary 3D direction in biomedical beta-type Ti-Nb-Zr-Ta alloys via laser powder bed fusion (LPBF). MTCDS can be achieved via directional solidification of coupled multi-track melt pools with a specific temperature gradient direction. This results in continuous epitaxial growth of the ß-Ti phase and consequently sets the <001> crystallographic orientation along an arbitrary 3D direction. This way, relatively low elastic modulus values of approximately 60 ± 1.2 GPa are customized along an arbitrary 3D direction. It is expected that MTCDS can be generalized to a wide range of applications for programming specific crystallographic orientations and, respectively, tailoring desired properties of different metallic materials.

In situ correlation between metastable phase-transformation mechanism and kinetics in a metallic glass.

A combination of complementary high-energy X-ray diffraction, containerless solidification during electromagnetic levitation and transmission electron microscopy is used to map in situ the phase evolution in a prototype Cu-Zr-Al glass during flash-annealing imposed at a rate ranging from 102 to 103 K s-1 and during cooling from the liquid state. Such a combination of experimental techniques provides hitherto inaccessible insight into the phase-transformation mechanism and its kinetics with high temporal resolution over the entire temperature range of the existence of the supercooled liquid. On flash-annealing, most of the formed phases represent transient (metastable) states - they crystallographically conform to their equilibrium phases but the compositions, revealed by atom probe tomography, are different. It is only the B2 CuZr phase which is represented by its equilibrium composition, and its growth is facilitated by a kinetic mechanism of Al partitioning; Al-rich precipitates of less than 10 nm in a diameter are revealed. In this work, the kinetic and chemical conditions of the high propensity of the glass for the B2 phase formation are formulated, and the multi-technique approach can be applied to map phase transformations in other metallic-glass-forming systems.

Fabrication of Metastable Crystalline Nanocomposites by Flash Annealing of Cu47.5Zr47.5Al5 Metallic Glass Using Joule Heating.

Flash Joule-heating was applied to the Cu47.5Zr47.5Al5 metallic glass for designing fully crystalline metastable nanocomposites consisting of the metastable B2 CuZr and low-temperature equilibrium Cu10Zr7 phases. The onset of crystallization was in situ controlled by monitoring resistivity changes in the samples. The effect of heating rate and annealing time on the volume fraction of the crystalline phases and mechanical properties of the nanocomposites was studied in detail. Particularly, an increase of the heating rate and a decrease of the annealing time lead to a lower number of equilibrium Cu10Zr7 precipitates and an increase of tensile ductility. Tailoring of these non-equilibrium microstructures and mechanical properties may not be possible unless one starts with a fully glassy material that opens new perspectives for designing metastable nanomaterials with unique physical properties.

Fast-current-heating devices to study in situ phase formation in metallic glasses by using high-energy synchrotron radiation.

Details of fast-resistive-heating setups, controlled heating ranging from ∼101 K s-1 to ∼103 K s-1, to study in situ phase transformations (on heating and on cooling) in metallic glasses by high-energy synchrotron x-ray diffraction are discussed. Both setups were designed and custom built at the Leibniz Institute for Solid State and Materials Research Dresden (IFW Dresden) and have been implemented at the P02.1 Powder Diffraction and Total Scattering Beamline and the P21.1 Swedish Materials Science Beamline at PETRA III storage ring, DESY, Hamburg. The devices are interchangeable at both beamlines. Joule heating is triggered automatically and is timed with the incident beam and detector. The crystallization process can be controlled via a feedback circuit by monitoring the change in the time-dependent resistivity and temperature of glasses. Different ambient atmospheres, such as vacuum and inert gases (He and Ar), can be used to control oxidation and cooling. The main focus of these devices is on understanding the crystallization mechanism and kinetics in metallic glasses, which are brittle and for which fast heating gives defined glass-crystal composites with enhanced plasticity. As an example, phase-transformation sequence(s) in a prototyped Cu-Zr-based metallic glass is described on heating, and a crystalline phase beneficial to the plasticity is identified.

Liquid-liquid hierarchical separation and metal recycling of waste printed circuit boards.

Waste electrical and electronic equipment is rapidly increasing worldwide, resulting in a large quantity of waste printed circuit boards (WPCBs). There is a great challenge on how to efficiently separate mixed metals in WPCBs, which consists of more than 10 elements including hazardous Cr, Pb and Cd. In this work, based on atomic interactions, a method of liquid-liquid hierarchical separation is developed to separate the mixed metals dissociated from the pyrolyzed WPCBs of mobile phones. The hierarchical separation of L→LFe-rich + LCu,Pb-rich, LCu,Pb-rich→LCu-rich + LPb-rich and LPb-rich→SCu-dendritical + L'Pb-rich produces four immiscible Fe-rich, Cu-rich, Cu-dendritical and Pb-rich substances. The separation rate between these substances can reach more than 96% in a super-gravity field of G = 1000g. Other metals selectively distribute in the four substances. The Fe-rich substance collects Cr, Co, Ni and Si. Almost all of Au and Ag are trapped in the Cu-rich and Cu-dendritical substances. The low-melting-point metals, i.e. Bi, Cd, In and Sn, are located in the Pb-rich substance. This work provides a green shortcut for efficiently separating and recycling overall metals in WPCBs.

Optimizing mechanical properties of Fe26.7Co26.7Ni26.7Si8.9B11 high entropy alloy by inducing hypoeutectic to quasi-duplex microstructural transition.

High-entropy alloys (HEAs) have inspired considerable interest due to their attractive physical and mechanical properties. In this work, the microstructural evolution induced by different heat treatments on rapidly solidified hypoeutectic precursors of a Fe26.7Co26.7Ni26.7Si8.9B11 HEA is investigated and correlated with the corresponding mechanical properties. The microstructures of the rapidly solidified precursors are composed of primary fcc solid solution dendrites embedded in a eutectic matrix. When the samples are annealed at different temperatures after furnace cooling or quenching, respectively, the eutectic structure gradually decomposes into fcc, tetragonal (Fe,Co)2B, and hexagonal Ni31Si12 crystals with increasing annealing temperature, leading to a gradual increase of the content of the fcc crystals and both their aggregation and coarsening. Then the dominant structural framework gradually transforms from eutectic structures to fcc dendrites and ultimately the (Fe,Co)2B crystals become isolated as dominant reinforcement particles distributed in the interdendritic regions. This gradual microstructural transition from hypoeutectic to quasi-duplex structures leads to the change of the dominant deformation mechanism from crack-controlled to dislocation-dominated deformation, which allows to control both ductility and strength in a wide range. Hence, this study provides some guideline for how to tune the microstructure and mechanical properties of HEAs.

Local melting to design strong and plastically deformable bulk metallic glass composites.

Recently, CuZr-based bulk metallic glass (BMG) composites reinforced by the TRIP (transformation-induced plasticity) effect have been explored in attempt to accomplish an optimal of trade-off between strength and ductility. However, the design of such BMG composites with advanced mechanical properties still remains a big challenge for materials engineering. In this work, we proposed a technique of instantaneously and locally arc-melting BMG plate to artificially induce the precipitation of B2 crystals in the glassy matrix and then to tune mechanical properties. Through adjusting local melting process parameters (i.e. input powers, local melting positions, and distances between the electrode and amorphous plate), the size, volume fraction, and distribution of B2 crystals were well tailored and the corresponding formation mechanism was clearly clarified. The resultant BMG composites exhibit large compressive plasticity and high strength together with obvious work-hardening ability. This compelling approach could be of great significance for the steady development of metastable CuZr-based alloys with excellent mechanical properties.

Structural, electronic and kinetic properties of the phase-change material Ge2Sb2Te5 in the liquid state.

Phase-change materials exhibit fast and reversible transitions between an amorphous and a crystalline state at high temperature. The two states display resistivity contrast, which is exploited in phase-change memory devices. The technologically most important family of phase-change materials consists of Ge-Sb-Te alloys. In this work, we investigate the structural, electronic and kinetic properties of liquid Ge2Sb2Te5 as a function of temperature by a combined experimental and computational approach. Understanding the properties of this phase is important to clarify the amorphization and crystallization processes. We show that the structural properties of the models obtained from ab initio and reverse Monte Carlo simulations are in good agreement with neutron and X-ray diffraction experiments. We extract the kinetic coefficients from the molecular dynamics trajectories and determine the activation energy for viscosity. The obtained value is shown to be fully compatible with our viscosity measurements.

Local microstructure evolution at shear bands in metallic glasses with nanoscale phase separation.

At room temperature, plastic flow of metallic glasses (MGs) is sharply localized in shear bands, which are a key feature of the plastic deformation in MGs. Despite their clear importance and decades of study, the conditions for formation of shear bands, their structural evolution and multiplication mechanism are still under debate. In this work, we investigate the local conditions at shear bands in new phase-separated bulk MGs containing glassy nanospheres and exhibiting exceptional plasticity under compression. It is found that the glassy nanospheres within the shear band dissolve through mechanical mixing driven by the sharp strain localization there, while those nearby in the matrix coarsen by Ostwald ripening due to the increased atomic mobility. The experimental evidence demonstrates that there exists an affected zone around the shear band. This zone may arise from low-strain plastic deformation in the matrix between the bands. These results suggest that measured property changes originate not only from the shear bands themselves, but also from the affected zones in the adjacent matrix. This work sheds light on direct visualization of deformation-related effects, in particular increased atomic mobility, in the region around shear bands.

Liquid-liquid transition in a strong bulk metallic glass-forming liquid.

Polymorphic phase transitions are common in crystalline solids. Recent studies suggest that phase transitions may also exist between two liquid forms with different entropy and structure. Such a liquid-liquid transition has been investigated in various substances including water, Al2O3-Y2O3 and network glass formers. However, the nature of liquid-liquid transition is debated due to experimental difficulties in avoiding crystallization and/or measuring at high temperatures/pressures. Here we report the thermodynamic and structural evidence of a temperature-induced weak first-order liquid-liquid transition in a bulk metallic glass-forming system Zr(41.2)Ti(13.8)Cu(12.5)Ni10Be(22.5) characterized by non- (or weak) directional bonds. Our experimental results suggest that the local structural changes during the transition induce the drastic viscosity changes without a detectable density anomaly. These changes are correlated with a heat capacity maximum in the liquid. Our findings support the hypothesis that the 'strong' kinetics (low fragility) of a liquid may arise from an underlying lambda transition above its glass transition.

Structure of Te-rich Te-Ge-X (X = I, Se, Ga) glasses.

The structure of glassy Te(78)Ge(11)Ga(11), Te(79)Ge(16)Ga(5), Te(70)Ge(20)Se(10) and Te(73)Ge(20)I(7)--promising materials for far infrared applications--was investigated by means of x-ray and neutron diffraction as well as extended x-ray absorption fine structure measurements at various edges. Experimental data sets were fitted simultaneously in the framework of the reverse Monte Carlo simulation technique. Short range order in Te(85)Ge(15) was reinvestigated by fitting a new x-ray diffraction measurement together with available neutron diffraction and extended x-ray absorption fine structure data. It was found that Te(85)Ge(15) consists mostly of GeTe(4) structural units linked together directly or via bridging Te atoms. Te is predominantly twofold coordinated in Te(85)Ge(15), Te(70)Ge(20)Se(10) and Te(73)Ge(20)I(7) while in Te(78)Ge(11)Ga(11) and Te(79)Ge(16)Ga(5) the Te coordination number is significantly higher than 2. The Te-Te bond length is 2.80 ± 0.02 Å in Te(78)Ge(11)Ga(11) while it is as short as 2.70 ± 0.02 Å and 2.73 ± 0.02 Å in Te(73)Ge(20)I(7) and Te(70)Ge(20)Se(10), respectively. Our results show that the strengths of GeTe(4) (GeTe(3)I, GeTe(3)Se) 'units' are very similar in all glasses investigated but the connection between these units depends on the third component. Differences in the Te coordination number suggest that unlike Se or I, Ga does not build into the Ge-Te covalent network. Instead, it forms a covalent bond with the non-bonding p electrons of Te, which results in an increase in the average Te coordination number.