Showing papers on "Alloy published in 2022"

Additive manufacturing of metals: Microstructure evolution and multistage control

Abstract: As a revolutionary industrial technology, additive manufacturing creates objects by adding materials layer by layer and hence can fabricate customized components with an unprecedented degree of freedom. For metallic materials, unique hierarchical microstructures are constructed during additive manufacturing, which endow them with numerous excellent properties. To take full advantage of additive manufacturing, an in-depth understanding of the microstructure evolution mechanism is required. To this end, this review explores the fundamental procedures of additive manufacturing, that is, the formation and binding of melt pools. A comprehensive processing map is proposed that integrates melt pool energy- and geometry-related process parameters together. Based on it, additively manufactured microstructures are developed during and after the solidification of constituent melt pool. The solidification structures are composed of primary columnar grains and fine secondary phases that form along the grain boundaries. The post-solidification structures include submicron scale dislocation cells stemming from internal residual stress and nanoscale precipitates induced by intrinsic heat treatment during cyclic heating of adjacent melt pool. Based on solidification and dislocation theories, the formation mechanisms of the multistage microstructures are thoroughly analyzed, and accordingly, multistage control methods are proposed. In addition, the underlying atomic scale structural features are briefly discussed. Furthermore, microstructure design for additive manufacturing through adjustment of process parameters and alloy composition is addressed to fulfill the great potential of the technique. This review not only builds a solid microstructural framework for metallic materials produced by additive manufacturing but also provides a promising guideline to adjust their mechanical properties.

Realizing Negatively Charged Metal Atoms through Controllable d‐Electron Transfer in Ternary Ir1−xRhxSb Intermetallic Alloy for Hydrogen Evolution Reaction

Abstract: Alloying noble metals with non‐noble metals is a promising method to fabricate catalysts, with the advantages of reduced noble metal usage and excellent activity. In this work, electron‐abundant Ir/Rh sites, as highly active centers for the hydrogen evolution reaction (HER), are realized by fabricating Ir1−xRhxSb alloys through the arc‐melting method. The electron transfer from Sb to Ir/Rh makes the latter negatively charged, leading to considerably optimized adsorption for active H species during HER. As a result, the Ir1−xRhxSb alloy exhibits outstanding activity for HER, with an optimized overpotential of 22 mV at 10 mA cm–2 and a Tafel slope of 47.6 mV dec–1. This work provides insights into highly active alloys and sheds light on the utilization of electron‐abundant metal atoms.

Unraveling the electronegativity-dominated intermediate adsorption on high-entropy alloy electrocatalysts

Abstract: High-entropy alloys have received considerable attention in the field of catalysis due to their exceptional properties. However, few studies hitherto focus on the origin of their outstanding performance and the accurate identification of active centers. Herein, we report a conceptual and experimental approach to overcome the limitations of single-element catalysts by designing a FeCoNiXRu (X: Cu, Cr, and Mn) High-entropy alloys system with various active sites that have different adsorption capacities for multiple intermediates. The electronegativity differences between mixed elements in HEA induce significant charge redistribution and create highly active Co and Ru sites with optimized energy barriers for simultaneously stabilizing OH* and H* intermediates, which greatly enhances the efficiency of water dissociation in alkaline conditions. This work provides an in-depth understanding of the interactions between specific active sites and intermediates, which opens up a fascinating direction for breaking scaling relation issues for multistep reactions.

Steel-copper functionally graded material produced by twin-wire and arc additive manufacturing (T-WAAM)

Abstract: In this work, a functionally graded material (FGM) part was fabricated by depositing a Cu-based alloy on top of a high strength low alloy (HSLA) steel by twin-wire and arc additive manufacturing (T-WAAM). Copper and steel parts are of interest in many industries since they can combine high thermal/electrical conductivity, wear resistance with excellent mechanical properties. However, mixing copper with steel is difficult due to mismatches in the coefficient of thermal expansion, in the melting temperature, and crystal structure. Moreover, the existence of a miscibility gap during solidification, when the melt is undercooled, causes serious phase separation and segregation during solidification which greatly affects the mechanical properties. Copper and steel control samples and the functionally graded material specimen were fabricated and investigated using optical microscopy, scanning electron microscopy, and high energy synchrotron X-ray diffraction. Retained δ-ferrite was found in a Cu matrix at the interface region due to regions with mixed composition. A smooth gradient of hardness and electric conductivity along the FGM sample height was obtained. An ultimate tensile strength of 690 MPa and an elongation at fracture of 16.6% were measured in the FGM part.

Gradient fluorinated alloy to enable highly reversible Zn-metal anode chemistry

Abstract: Unsatisfying reversibility of zinc (Zn) metal anode seriously hinders its further practical applications. It corresponds to two major issues including the notorious dendrite growth and the exacerbated hydrogen evolution, resulting...

Additive manufacturing of Ti-6Al-4V alloy- A review

Abstract: The most popular additive manufacturing (AM) technologies to produce titanium alloy parts are electron beam melting (EBM), selective laser melting (SLM) and directed energy deposition (DED). This investigation explores mainly these three techniques and compares these three methods comprehensively in terms of microstructure, tensile properties, porosity, surface roughness and residual stress based on the information available in the literature. It was found that the microstructure is affected by the highest temperature generated and the cooling rate which can be tailored by the input variables of the AM processes. The parts produced from EBM have strength comparable to that of conventionally fabricated counterparts. SLM and DED yield superior strength, which can be up to 25% higher than traditionally manufactured products. Due to the presence of larger tensile residual stress, surface roughness and porosity, AM fabricated parts have lower fatigue life compared to those of from traditional methods. EBM parts have slightly lower fracture toughness (i.e., lower fatigue life) than conventionally produced parts while SLM and DED have significantly lower fracture toughness. Annealing, hot isostatic pressing, stress relief and additional machining processes improve the characteristics of parts produced from AM. Ti–6Al–4V alloy parts fabricated via AM may have limited applications despite the high demands in aerospace or biomedical engineering. Since rapid product development using 3D printers leads to significant cost reductions more recently, it is expected that more opportunities may soon be available for the AM of titanium alloys with newer AM processes such as cold spray additive manufacturing (CSAM) and additive friction stir deposition (AFSD).

Electrostatic Shielding Regulation of Magnetron Sputtered Al-Based Alloy Protective Coatings Enables Highly Reversible Zinc Anodes.

Abstract: The uncontrolled zinc dendrite growth during plating leads to quick battery failure, which hinders the widespread applications of aqueous zinc-ion batteries. The growth of Zn dendrites is often promoted by the "tip effect". In this work, we propose a generate strategy to eliminate the "tip effect" by utilizing the electrostatic shielding effect, which is achieved by coating Zn anodes with magnetron sputtered Al-based alloy protective layers. The Al can form a surface insulating Al2O3 layer and by manipulating the Al content of Zn-Al alloy films, we are able to control the strength of the electrostatic shield, therefore realizing a long lifespan of Zn anodes up to 3000 h at a practical operating condition of 1.0 mA cm-2 and 1.0 mAh cm-2. In addition, the concept can be extended to other Al-based systems such as Ti-Al alloy and achieve enhanced stability of Zn anodes, demonstrating the generality and efficacy of our strategy.

Hydrogen trapping and embrittlement in high-strength Al alloys

Abstract: Ever more stringent regulations on greenhouse gas emissions from transportation motivate efforts to revisit materials used for vehicles. High-strength Al-alloys often used in aircrafts could help reduce the weight of automobiles, but are susceptible to environmental degradation. Hydrogen (H) "embrittlement" is often pointed as the main culprit, however, the mechanisms underpinning failure are elusive: atomic-scale analysis of H inside an alloy remains a challenge, and this prevents deploying alloy design strategies to enhance the materials' durability. Here we successfully performed near-atomic scale analysis of H trapped in second-phase particles and at grain boundaries in a high-strength 7xxx Al-alloy. We used these observations to guide atomistic ab-initio calculations which show that the co-segregation of alloying elements and H favours grain boundary decohesion, while the strong partitioning of H into the second-phases removes solute H from the matrix, hence preventing H-embrittlement. Our insights further advance the mechanistic understanding of H-assisted embrittlement in Al-alloys, emphasizing the role of H-traps in retarding cracking and guiding new alloy design.

Achievement of giant cryogenic refrigerant capacity in quinary rare-earths based high-entropy amorphous alloy

Abstract: Magnetic refrigeration (MR) by utilizing the magnetocaloric (MC) effect is recognized as one of the most potential promising solid state environmentally friendly and high efficiency alternative method to the well-used state-of-the-art gas compression cooling technique. In this work, a systematic investigation of quinary equi-atomic rare-earths (RE) based Er20Ho20Gd20Ni20Co20 high-entropy (HE) amorphous alloy in terms of the microstructure, magnetic and magnetocaloric (MC) properties have been reported. The Er20Ho20Gd20Ni20Co20 exhibits promising glass forming ability with an undercooled liquid region of 72 K. Excellent cryogenic MC performances can be found in wide temperature from ∼25 and ∼75 K, close to H2 and N2 liquefaction, respectively. Apart from the largest magnetic entropy change (-ΔSM) reaches 17.84 J/(kg K) with 0-7 T magnetic field change, corresponding refrigerant capacity (RC) attains a giant value of 1030 J/kg. The promising cryogenic MC performances together with the unique HE amorphous characterizations make the quinary Er20Ho20Gd20Ni20Co20 HE amorphous alloy attractive for cryogenic MR applications.

Computational Contact Pressure Prediction of CoCrMo, SS 316L and Ti6Al4V Femoral Head against UHMWPE Acetabular Cup under Gait Cycle

Abstract: Due to various concerns about the use of metal-on-metal that is detrimental to users, the use of metal as acetabular cup material was later changed to ultra high molecular weight polyethylene (UHMWPE). However, the wear on UHMWPE releases polyethylene wear particles, which can trigger a negative body response and contribute to osteolysis. For reducing the wear of polyethylene, one of the efforts is to investigate the selection of metal materials. Cobalt chromium molybdenum (CoCrMo), stainless steel 316L (SS 316L), and titanium alloy (Ti6Al4V) are the frequently employed materials. The computational evaluation of contact pressure was carried out using a two-dimensional axisymmetric model for UHMWPE acetabular cup paired with metal femoral head under gait cycle in this study. The results show Ti6Al4V-on-UHMWPE is able to reduce cumulative contact pressure compared to SS 316L-on-UHMWPE and CoCrMo-on-UHMWPE. Compared to Ti6Al4V-on-UHMWPE at peak loading, the difference in cumulative contact pressure to respective maximum contact pressure is 9.740% for SS 316L-on-UHMWPE and 11.038% for CoCrMo-on-UHMWPE.

Multi-scale defects in powder-based additively manufactured metals and alloys

Abstract: Defect formation is a critical challenge for powder-based metal additive manufacturing (AM). Current understanding on the three important issues including formation mechanism, influence and control method of metal AM defects should be updated. In this review paper, multi-scale defects in AMed metals and alloys are identified and for the first time classified into three categories, including geometry related, surface integrity related and microstructural defects. In particular, the microstructural defects are further divided into internal cracks and pores, textured columnar grains, compositional defects and dislocation cells. The root causes of the multi-scale defects are discussed. The key factors that affect the defect formation are identified and analyzed. The detection methods and modeling of the multi-scale defects are briefly introduced. The effects of the multi-scale defects on the mechanical properties especially for tensile properties and fatigue performance of AMed metallic components are reviewed. Various control and mitigation methods for the corresponding defects, include process parameter control, post processing, alloy design and hybrid AM techniques, are summarized and discussed. From research aspect, current research gaps and future prospects from three important aspects of the multi-scale AM defects are identified and delineated.

One-Dimensional Magnetic FeCoNi Alloy Toward Low-Frequency Electromagnetic Wave Absorption

Abstract: Rational designing of one-dimensional (1D) magnetic alloy to facilitate electromagnetic (EM) wave attenuation capability in low-frequency (2-6 GHz) microwave absorption field is highly desired but remains a significant challenge. In this study, a composite EM wave absorber made of a FeCoNi medium-entropy alloy embedded in a 1D carbon matrix framework is rationally designed through an improved electrospinning method. The 1D-shaped FeCoNi alloy embedded composite demonstrates the high-density and continuous magnetic network using off-axis electronic holography technique, indicating the excellent magnetic loss ability under an external EM field. Then, the in-depth analysis shows that many factors, including 1D anisotropy and intrinsic physical features of the magnetic medium-entropy alloy, primarily contribute to the enhanced EM wave absorption performance. Therefore, the fabricated EM wave absorber shows an increasing effective absorption band of 1.3 GHz in the low-frequency electromagnetic field at an ultrathin thickness of 2 mm. Thus, this study opens up a new method for the design and preparation of high-performance 1D magnetic EM absorbers.

A review on dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel for electric vehicle battery manufacturing

Abstract: The electric vehicle (EV) battery systems are complex assemblies of dissimilar materials in which battery cells are connected using several thousand interconnect joints. Every single joint influences the functionality and efficiency of the whole battery system, making the joining process crucial. Laser welding is considered a desirable choice for EV battery manufacturing due to its non-contact nature, high energy density, precise control over the heat input, and ease of automation. However, incompatible thermos-physical properties of dissimilar materials used in battery tabs and interconnectors pose a significant challenge for achieving complete metallurgical bond. Furthermore, the formation of undesirable weld microstructures such as hard and brittle intermetallic compounds (IMCs) substantially undermines the structural, electrical, and thermal characteristics of battery joints. This paper reviews the fundamental difficulties and latest developments in dissimilar laser welding of steel-copper, steel-aluminum, aluminum-copper, and steel-nickel, some of the potential joint combinations in EV battery pack manufacturing. The weld microstructure and common metallurgical defects, as well as mechanical and electrical properties of joints are discussed. In addition, the effects of laser welding process parameters on the joint properties and the applicability of various interlayers and coatings in laser welding of battery materials are assessed.

Lignin fractionation from lignocellulosic biomass using deep eutectic solvents and its valorization

Abstract: Lignin, the most abundant natural aromatic feedstock, is one of the most renewable resources for many biofuels, chemicals, and smart materials. Recent progress in deep eutectic solvents (DESs), a class of green solvents exhibiting appealing properties, suggests promising pathways for lignin fractionation and further valorization. Despite considerable efforts that have been devoted to their development, the fractionation and valorization of lignin using DESs are still in their nascent stage. This review presents a comprehensive summary of recent progress in lignin fractionation and valorization using DESs. The introduction of emerging type V DESs, and the relationship between Kamlet–Taft solvatochromic parameters and lignin fractionation and solubility are emphasized. Key factors that affect the lignin fractionation yield and lignin structure have been identified. Particularly, recent growth in computation-based studies to determine which DESs are appropriate for lignin biorefinery and the investigation of underlying mechanisms are also highlighted. Furthermore, the properties of DESs-fractionated lignin and its further valorization routes are systematically summarized. Finally, future perspectives on the development of more efficient and sustainable lignin fractionation and valorization are provided. The present work will provide valuable guidance on the fractionation and valorization of lignin by using renewable DESs.