Significantly Promoting the Thermal Conductivity and Machinability of Negative Thermal Expansion Alloy via In Situ Precipitation of Copper Networks.

Rapid advancements in electronic devices yield an urgent demand for high-performance electronic packaging materials with high thermal conductivity, low thermal expansion, and great mechanical properties. However, it is a great challenge for current design philosophies to fulfill all the requirements simultaneously. Here, an effective strategy is proposed for significantly promoting the thermal conductivity and machinability of negative thermal expansion alloy (Zr,Nb)Fe2 through eutectic precipitation of copper networks. The eutectic dual-phase alloy exhibits an isotropic chips-matched thermal expansion coefficient and a thermal conductivity enhancement exceeding 200% compared with (Zr,Nb)Fe2, along with an ultimate compressive strength of 550 MPa. The addition of copper reorganizes the composition of (Zr,Nb)Fe2, which smooths the magnetic transition and shifts it toward higher temperature, resulting in linear low thermal expansion in a wide temperature range. The highly fine eutectic copper lamellae construct high thermal conductivity networks within (Zr,Nb)Fe2, serving as highways for heat transfer electrons and phonons. The in situ forming of eutectic copper lamellae also facilitates the mechanical properties by enhancing interfacial bonding and bearing additional stress after yielding of (Zr,Nb)Fe2. This work provides a novel strategy for promoting thermal conductivity and mechanical properties of negative thermal expansion alloys via eutectic precipitation of copper networks.

An isotropic zero thermal expansion alloy with super-high toughness.

Zero thermal expansion (ZTE) alloys with high mechanical response are crucial for their practical usage. Yet, unifying the ZTE behavior and mechanical response in one material is a grand obstacle, especially in multicomponent ZTE alloys. Herein, we report a near isotropic zero thermal expansion (αl = 1.10 × 10-6 K-1, 260-310 K) in the natural heterogeneous LaFe54Co3.5Si3.35 alloy, which exhibits a super-high toughness of 277.8 ± 14.7 J cm-3. Chemical partition, in the dual-phase structure, assumes the role of not only modulating thermal expansion through magnetic interaction but also enhancing mechanical properties via interface bonding. The comprehensive analysis reveals that the hierarchically synergistic enhancement among lattice, phase interface, and heterogeneous structure is significant for strong toughness. Our findings pave the way to tailor thermal expansion and obtain prominent mechanical properties in multicomponent alloys, which is essential to ultra-stable functional materials.

Superior zero thermal expansion dual-phase alloy via boron-migration mediated solid-state reaction.

Rapid progress in modern technologies demands zero thermal expansion (ZTE) materials with multi-property profiles to withstand harsh service conditions. Thus far, the majority of documented ZTE materials have shortcomings in different aspects that limit their practical utilization. Here, we report on a superior isotropic ZTE alloy with collective properties regarding wide operating temperature windows, high strength-stiffness, and cyclic thermal stability. A boron-migration-mediated solid-state reaction (BMSR) constructs a salient "plum pudding" structure in a dual-phase Er-Fe-B alloy, where the precursor ErFe10 phase reacts with the migrated boron and transforms into the target Er2Fe14B (pudding) and α-Fe phases (plum). The formation of such microstructure helps to eliminate apparent crystallographic texture, tailor and form isotropic ZTE, and simultaneously enhance the strength and toughness of the alloy. These findings suggest a promising design paradigm for comprehensive performance ZTE alloys.

Enhancing fatigue life by ductile-transformable multicomponent B2 precipitates in a high-entropy alloy.

Catastrophic accidents caused by fatigue failures often occur in engineering structures. Thus, a fundamental understanding of cyclic-deformation and fatigue-failure mechanisms is critical for the development of fatigue-resistant structural materials. Here we report a high-entropy alloy with enhanced fatigue life by ductile-transformable multicomponent B2 precipitates. Its cyclic-deformation mechanisms are revealed by real-time in-situ neutron diffraction, transmission-electron microscopy, crystal-plasticity modeling, and Monte-Carlo simulations. Multiple cyclic-deformation mechanisms, including dislocation slips, precipitation strengthening, deformation twinning, and reversible martensitic phase transformation, are observed in the studied high-entropy alloy. Its improved fatigue performance at low strain amplitudes, i.e., the high fatigue-crack-initiation resistance, is attributed to the high elasticity, plastic deformability, and martensitic transformation of the B2-strengthening phase. This study shows that fatigue-resistant alloys can be developed by incorporating strengthening ductile-transformable multicomponent intermetallic phases.

A tension-torsional fatigue testing apparatus for micro-scale components.

Mechanical characterization of micro-scale components under complex loading conditions is a great challenge. To meet such a challenge, a microtension-torsional fatigue testing apparatus is developed in this study that specializes in the evaluation of multiaxial fatigue behavior of thin stent wires. The actuation and measurement in two controlled directions are incorporated in the tensile and torsional load frames, respectively, and a thrust air bearing is applied for the coupling of the two frames. The axial deformation of specimens measured by a grating sensor built in the linear motor and by a non-contact displacement detect system is compared and corrected. The accuracy of the torque measurement is proved by torsion tests on thin wires of 316L stainless steel in nominal diameters of 100 µm. Multistep torsion test, multiaxial ratcheting test, and a fully strain controlled multiaxial cyclic test are performed on 100 µm and 200 µm-diameter 316L wires using this apparatus. The capability of the equipment in tension-torsional cyclic tests for micro-scale specimens is demonstrated by the experimental results.

A portable hydro-thermo-mechanical loading cell for in situ small angle neutron scattering studies of proton exchange membranes.

A portable hydro-thermo-mechanical loading cell has been designed to enable in situ small angle neutron scattering (SANS) studies of proton exchange membranes (PEMs) under immersed tensile loadings at different temperatures. The cell consists of three main parts as follows: a letter-paper-size motor-driven mechanical load frame, a SANS friendly reservoir that provides stable immersed and thermal sample conditions, and a data acquisition and control system. The ex situ tensile tests of Nafion 212 membranes demonstrated a satisfactory thermo-mechanical testing performance of the cell for either dry or immersed conditions at elevated temperatures. The in situ SANS tensile measurements on the Nafion 212 membranes immersed in D2O at 70 °C proved the feasibility and capability of the cell for small angle scattering study on deformation behaviors of PEM and other polymer materials under hydro-thermo-mechanical loading.