Search Results (1,446)

This study systematically investigates the hot deformation behavior and microstructure evolution of Ti-3Al-2.5V-0.5Ni alloy under compression at temperatures ranging from 800 °C to 1010 °C and strain rates ranging from 0.1 s⁻¹ to 10 s⁻¹, with a maximum deformation of 75% (with a corresponding true strain of 1.4). An Arrhenius-type constitutive equation was developed, and a hot processing map was established using a dynamic material model (DMM). Microstructural evolution was characterized using electron backscatter diffraction (EBSD). A hot processing map delineated stable and unstable regions. Regions with high power dissipation efficiency (η) were identified at deformation temperatures of 850–880 °C with strain rates of 0.1–10 s⁻¹, and at 940–960 °C with strain rates of 1.5–10 s⁻¹. These regions show high recrystallization fraction and good processing performance. The instability zone was observed at about 900 °C and high strain rate, which should be avoided during processing. The microstructure analysis of different power dissipation efficiency regions was carried out in detail. The results show that the power dissipation efficiency is about 0.38 at the deformation temperature of 950 °C and the strain rate of 0.1 s⁻¹, accompanied by high dynamic recrystallization. However, when the deformation condition is 800 °C and 10 s⁻¹, the power dissipation efficiency is lower than 0.18, the degree of recrystallization is limited, and a large number of dislocations accumulate. In summary, the large strain rolling of Ti-3Al-2.5V-0.5Ni alloy should be processed in the high-temperature α + β phase region (850–900 °C) and low-to-medium strain rate range of 0.1–5 s⁻¹. The process conditions can promote high recrystallization fraction, good processability, and weakened crystallographic texture, thereby minimizing the anisotropy of the final sheet. This study provides theoretical guidance for the optimization of industrial hot processing parameters of the alloy. Full article

The limited ductility of conventional titanium alloys significantly limits their application in critical load-bearing components. To overcome this limitation, a Ti-6Al-2Mo-2Nb-2Zr-2Sn titanium alloy (TC21) was subjected to warm rolling at 500 and 600 °C and aging treatment. Subsequently, microstructural characterization was conducted using scanning electron microscopy, electron backscatter diffraction and transmission electron microscopy, while the mechanical properties were tested by uniaxial tensile tests and nanoindentation tests. The sample warm rolled at 600 °C exhibited an optimal combination of strength and ductility, with an ultrahigh yield strength of 1138 MPa and an elongation-to-fracture of 7.3%. Aging treatment further enhanced the yield strength to 1263 MPa, while retaining a good ductility of 9.6%. The improved mechanical properties are mainly associated with the formation of nanoscale secondary α phase (α_s) lamellae caused by the aging treatment. Interface strengthening is identified as the primary strengthening mechanism. In particular, the optimal volume fraction and decreasing texture intensity of the soft phase contribute to the enhanced ductility. This work provides a method for viable thermo-mechanical processing for achieving an excellent strength–ductility combination in titanium alloys. Full article

The selection of deformation mechanisms in hexagonal close-packed (HCP) metals is strongly influenced by both crystallographic orientation and macroscopic deformation constraints. In commercially pure titanium, plastic deformation under constrained loading conditions involves a complex interplay between dislocation slip and deformation twinning, whose respective activation cannot be fully described by classical stress-based criteria. In this study, the mechanical origin of slip and twinning variant selection in commercially pure titanium subjected to plane strain compression is investigated experimentally. Plane strain compression is used as a canonical loading condition representative of constrained deformation paths encountered in sheet metal forming. Interrupted in-situ electron backscatter diffraction is combined with slip trace and twin variant analyses to identify the active deformation mechanisms at the grain scale. Resolved shear stress calculations show that stress-based criteria provide a necessary first-order condition for the activation of both slip and twinning systems. While the Schmid factor reasonably predicts part of the observed slip activity, it fails to uniquely determine the selection of active twinning variants. A kinematic analysis reveals that twinning variant selection is governed by the compatibility between the deformation induced by twinning and the macroscopic strain constraints imposed by plane strain compression. Only variants whose deformation accommodates compression along the loading axis, extension along the free in-plane direction, and minimal strain along the constrained in-plane direction are preferentially activated. These results demonstrate that deformation mechanism selection in HCP titanium under constrained loading conditions results from a combined effect of resolved shear stress and kinematic compatibility. The proposed framework provides a physically grounded basis for interpreting deformation-induced texture evolution and offers clear perspectives for the development of crystal plasticity models incorporating twinning under complex strain paths. Full article

Friction stir welding (FSW) of dissimilar aluminium alloys often results in non-uniform microstructure and hardness distributions due to asymmetric temperature fields and material flow. The objective of this study is to establish a quantitative relationship between thermal history, microstructural evolution, and hardness distribution in dissimilar AA5052-H32/AA6061-T6 FSW joints by combining experimental characterisation with validated thermal modelling. AA5052-H32 and AA6061-T6 plates were welded under five different parameter sets. A thermal finite element model was developed in COMSOL Multiphysics to simulate temperature evolution during welding and was validated using embedded thermocouple measurements, with predicted peak temperatures ranging from 455 °C to 641 °C. Optical microscopy, scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to characterise grain structure and dynamic recrystallisation (DRX) behaviour, while Vickers microhardness mapping was used to evaluate the local mechanical response. The results show that DRX occurred in the nugget zone (NZ), leading to significant grain refinement, with a minimum grain diameter of 6.07 µm, representing an approximately eightfold reduction compared with the base material AA5052-H32. In contrast, the thermo-mechanically affected zone (TMAZ) experienced limited recrystallisation due to insufficient plastic deformation and temperature. The lowest hardness was observed in the TMAZ on the AA5052-H32 side, with the hardness reduction of 22% primarily caused by work hardening loss. Hardness was also reduced by 34% on the AA6061-T6 side due to decreased precipitation strengthening caused by high temperatures. This combined experimental–numerical study provides a systematic thermal–microstructure–hardness framework for understanding and predicting local property variations in dissimilar FSW joints. Full article

FeCrMnNi-based alloys, derived from the well-known Cantor high-entropy alloy, have attracted increasing attention due to their excellent strength–ductility balance. Additively manufactured FeCrMnNi variants are characterized by superior hardness compared to their conventionally processed counterparts. In the present study an optimized composition of the FeCrMnNi medium-entropy alloy was additively manufactured via laser-based powder bed fusion and subsequently subjected to systematic heat treatments. CALPHAD simulations were applied to select the specific composition and post-processing heat treatment conditions, where the latter aimed at promoting the evolution of a dual-phase microstructure. Experimental characterization included X-ray diffraction, scanning electron microscopy, energy-dispersive X-ray spectroscopy, and electron backscatter diffraction, as well as Vickers hardness and tensile testing. A microstructure could be established dominated by a face-centered cubic (FCC) phase with minor fractions of a secondary phase in the non-treated condition. The evolution of an additional body-centered cubic (BCC) phase upon heat treatment at and above 700 °C was observed. The emerging BCC phase as well as increasing fractions of the secondary phase were accompanied by significantly increased hardness and strength, surpassing the literature values of similar compositions. However, a heat treatment at 1000 °C resulted in recrystallization and an increase in grain size, while the decreasing fraction of the secondary phase eventually led to a reduction in strength. These findings underscore the combined potential of composition optimization and targeted post-processing to enhance the mechanical performance of additively manufactured FeCrMnNi alloys. Full article

Aluminum alloy composites are widely used in various high-end fields due to their ability to give full play to the advantages of each layer. However, the traditional three-layer aluminum alloy composite sheet cannot meet the current demand. In this study, composite rolling technology is adopted to combine three different alloys (4045, 3003, and 6061) for fabricating a 2.0 mm thick four-layer aluminum alloy composite sheet (4045/3003/6061/3003). The microstructure and properties of the composite sheet were analyzed by simulating the vacuum brazing process (595 °C/10 min) and artificial aging treatment (175 °C for 12 h), combined with characterization techniques including scanning electron microscopy (SEM), electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). The results show that the four-layer composite sheet exhibits lower Si diffusion after brazing, where the intermediate 3003 aluminum alloy layers effectively prevent the combination of magnesium (Mg) and the 4045 alloy. Compared with the brazed three-layer composite sheet the ultimate tensile strength and yield strength of the four-layer composite sheet after aging are increased by 139.7% and 326.6%, respectively, indicating significant improvement in its mechanical properties. This study provides a reference for the production of four-layer aluminum alloy composite sheet and contributes to the development of rail transit. Full article

In fundamental physics, sensors operating below liquid helium temperatures are highly vulnerable to vibrations, which can affect the sensitivity, for example, of high-performance particle detectors. Pulse-tube refrigerators, while generating vibrations lower than those of conventional systems, may still introduce several disturbances. Hence, flexible thermal connections are a commonly used mechanical solution to mitigate these undesirable effects. Among the materials that can be used, ultra-high-purity aluminum (UHP-Al) has attracted the attention for low-amplitude-vibration cryogenic applications, including gravitational wave interferometry, quantum information systems, precision space instrumentation, and cryogenic resonators. Thus, the aim of the paper is the characterization of the mechanical and microstructure properties of three UHP-Als (i.e., 5N—99.999 wt%, 5N5—99.9995 wt% and 6N—99.9999 wt%) intended for the production of thermal flexible connections with low stiffness, specifically designed to reduce vibration transmission in cryogenic environments. Mechanical properties were evaluated through standard tensile tests from room (+25 °C) to low temperature (i.e., −150 °C), providing insights into yield strength, ultimate tensile strength, elongation and elastic modulus. In addition, the dynamic elastic modulus of material loads, at cryogenic conditions (i.e., about −180 °C), was determined by measuring the natural resonance frequency, thereby assessing the material’s response to vibrational. Moreover, an extensive microstructural analysis was conducted using electron backscatter diffraction and x-ray diffraction. The correlation between the observed microstructure and the elastic properties was systematically examined. The results underscore the pivotal role of microstructural characteristics in dictating the elastic behavior of UHP Als. Eventually, the analysis provides valuable guidelines for the materials employment inside cryogenic systems, where severe vibration control is critical to maintain high operational performance. Full article

A Cu-containing FeCrMnNiAl multi-principal element alloy was processed by laser-based and electron beam-based powder bed fusion (PBF-LB/M and PBF-EB/M) to investigate processing–microstructure–property relationships. In focus were alloy variants with a relatively high Cu content. Two PBF-LB/M scan strategies, employing a Gaussian beam with and without a re-scan with a laser featuring a flat-top profile, were compared to PBF-EB/M processing, followed by heat-treatments between 300 °C and 1000 °C. The phase constitution, elemental partitioning and grain boundary characteristics were analyzed by X-ray diffraction, electron backscatter diffraction and energy-dispersive X-ray spectroscopy. Mechanical behavior was assessed by hardness and tensile testing. Both manufacturing routes promoted the evolution of stable multi-phase microstructures composed of face-centered-cubic (FCC)- and body-centered-cubic (BCC)-type phases across all heat-treatment conditions. PBF-LB/M processing resulted in finer, dendritic microstructures and suppressed formation of a Cu-rich FCC phase due to higher cooling rates, whereas PBF-EB/M promoted the evolution of Cu-rich FCC segregates and equiaxed grain morphologies. Heat-treatment above 700 °C led to recrystallization, accompanied by an increase of the FCC phase fraction, grain coarsening, and recovery. At lower heat-treatment temperatures, the changes in microstructure are different. Here, it is assumed that small, non-clustered Cu-rich precipitates formed at the grain and sub-grain boundaries, although this assumption is only based on the assessment of the mechanical properties. The size of these precipitates is below the resolution limit of the techniques applied for analysis in the present work. Additional structures seen within the Cu-rich areas of PBF-EB/M-manufactured samples treated at lower temperatures also seem to have an influence on the hardness and yield strength. All of the conditions investigated exhibited pronounced brittleness, limiting reliable tensile property evaluation and indicating the need for further optimization of processing strategies and microstructural control for high-Cu-fraction-containing multi-principal element alloys. Full article

To study the influence of freckle defects on the hot deformation behavior and the inheritance of dynamic recrystallization (DRX) structure in GH4706 alloy, the microstructures of specimens with and without freckles and the evolution laws of hot-processing parameters were compared. Hot compression experiments were conducted on a thermal simulation testing machine at 950–1150 °C, strain rates of 0.001–1 s⁻¹, and 55% deformation. Freckle-containing specimens were tested under DRX critical conditions. The flow stresses of both specimens increase with strain rate or with decreasing temperature. The power dissipation coefficient (η) and instability value (ξ) follow complex laws. Electron back-scattering diffraction (EBSD) was used to analyze DRX microstructures and nucleation mechanisms. The DRX degree of freckle-containing specimens is lower, with a larger average grain size. The DRX mechanism initiates preferentially in freckle-containing specimens, and its volume fraction changes in a complex manner. Grain coarsening occurs in freckle-containing specimens at high temperatures and low strain rates. Freckle defects lead to significant differences in the DRX mechanism of GH4706 alloy. Freckle-containing specimens exhibit both discontinuous dynamic recrystallization (DDRX) and continuous dynamic recrystallization (CDRX), whereas freckle-free specimens primarily display DDRX and second-phase particle-stimulated nucleation (PSN). The presence of MC carbides and Laves phases within freckle defects provides nucleation sites, further supporting a typical second-phase particle-stimulated nucleation mechanism. Full article

The effects of different finishing rolling temperatures on the microstructure and mechanical properties of a 580HE hole expansion steel were systematically investigated using optical microscopy, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. The results show that the yield strength increases with decreasing finishing rolling temperature, whereas the tensile strength and total elongation exhibit relatively small variations. Significant changes in phase fraction, grain size, spatial distribution, and NbC precipitation behavior are observed under different finishing rolling temperatures. The microstructure mainly consists of polygonal ferrite and granular bainite, while acicular ferrite is formed at higher finishing rolling temperatures. With decreasing finishing rolling temperature, the ferrite and bainite grains are markedly refined and become more uniformly distributed. Meanwhile, the ferrite fraction slightly increases, the crystallographic texture is weakened, and, more importantly, the number density of precipitates increases while their size is significantly reduced. The hole expansion ratio increases noticeably with decreasing finishing rolling temperature, which is mainly attributed to grain refinement, improved microstructural and strain homogeneity, and the selective strengthening effect of fine NbC precipitates. These factors effectively reduce stress concentration and hardness mismatch between soft and hard phases, thereby delaying crack initiation during hole expansion. Full article

This study systematically investigated the static recrystallization behavior and microstructural evolution of cold-rolled Ti-2Al-2.5Zr alloy tubes subjected to isothermal annealing at 650–800 °C. Electron backscatter diffraction (EBSD), optical microscopy, and microhardness testing were used to analyze recrystallization kinetics, grain size, grain boundary character, texture evolution, and strain energy release under different annealing temperatures and times. The results show that with increasing annealing temperature, the recrystallization incubation time is significantly shortened and the recrystallization rate increases nonlinearly; the times required for full recrystallization at 650, 700, 750, and 800 °C are 480 min, 25 min, 20 min, and 15 min, respectively. Compared with the other annealing temperatures, annealing at 700 °C yields finer, more uniform equiaxed grains and lower texture intensity, while at higher temperatures, recrystallization and recovery proceed too rapidly, which is unfavorable for fine control of the microstructure. After completion of recrystallization, the alloy microhardness stabilizes at approximately 200 HV. Based on the Avrami kinetics model, the recrystallization activation energy of the Ti-2Al-2.5Zr alloy tubes was calculated to be approximately 303.9 kJ/mol, providing a theoretical basis for optimizing the annealing process. Full article

Eutectic alloys stand out for their ability to combine high strength and good ductility; a behaviour rooted in their characteristic two-phase microstructure—lamellar or globular—formed at a constant solidification temperature that minimizes segregation and suppresses brittle phases. Their low interfacial energy limits microcrack propagation, while interfacial sliding and dislocation blocking at phase boundaries enhance both strength and toughness. In this work, we investigate how controlled microstructural modifications influence the behaviour of the eutectic high-entropy alloy AlCoCrFeNi2.1, composed of B2 (Ni–Al-rich) and L12 (Co–Fe–Ni-rich) phases. Because these phases exhibit distinct mechanical responses, microconstituent morphology becomes a design parameter. Powder metallurgy is the only processing route capable of providing the level of microstructural control required in this study. It preserves the rapidly solidified eutectic architecture of gas-atomised powders while allowing its intentional transformation during consolidation. Two strategies were implemented: (i) tuning the thermal–electrical input in Spark Plasma Sintering (SPS) and Electrical Resistance Sintering (ERS), and (ii) engineering the particle size distribution, including a bimodal design that enhances surface-energy-driven morphological transitions. SPS enables a gradual lamellar-to-globular evolution, whereas ERS induces ultrafast transformations governed by current intensity. The bimodal PSD significantly accelerates globularisation at lower energy input. EBSD-KAM (Electron Backscatter Diffraction—Kernel Average Misorientation) mapping identifies the lamellar B2 phase as metastable and highly strained, while globular B2 domains show reduced dislocation density. Nanoindentation confirms that intrinsic phase properties remain unchanged, whereas microhardness scales with morphology and lamellar spacing. These results demonstrate that the macroscopic mechanical response is governed by microstructure, establishing powder metallurgy as a uniquely powerful pathway for microstructure-driven design in eutectic HEAs. Full article

The revelation of the distribution of twin boundaries on three-dimensional (3D) grains is of critical importance for the comprehension of their influence on material properties. However, this remains a significant challenge in the field of 3D material characterization. In this study, the distribution of twin boundaries on the surfaces of 3D grains in solution-annealed 316L stainless steel was systematically and quantitatively characterized using 3D electron backscatter diffraction. The results show that the average size of twin boundaries is significantly larger than that of random boundaries (approximately 52% larger). Although the size distributions of grains, random boundaries, and twin boundaries, as well as the distributions of the total number of grain boundaries and the number of twin boundaries per grain, all conform to a lognormal distribution, the area fraction of twin boundaries on grain surfaces exhibits a typical Lorentz distribution, while their number fraction shows no clear pattern. On average, each grain possesses 9.6 boundaries, of which 1.7 are twin boundaries, and the average area coverage of twin boundaries on grain surfaces reaches 38.4%. The findings offer a 3D statistical foundation for optimizing grain boundary engineering strategies in austenitic alloys. Full article

Hybrid nanocomposites based on Aluminum 6061 (Al 6061) reinforced with carbon nanotubes (CNTs) and aluminum oxide (Al₂O₃) emerge as promising materials due to their ability to achieve simultaneous improvements in strength, thermal stability, and tribological performance. This study examines the structure–property relationships of CNT–Al₂O₃ nano-reinforced hybrid Al 6061, with particular emphasis on microstructural evolution and mechanical properties. The nanocomposites are fabricated via a powder metallurgy route, which enables optimized dispersion and homogeneous distribution of CNTs and Al₂O₃ within the aluminum matrix. Microstructural characteristics, interfacial bonding, and grain refinement are systematically analyzed using scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). Mechanical characterization demonstrates a marked enhancement in mechanical properties compared to Al 6061. The observed property improvements are attributed to synergistic strengthening mechanisms, including effective load transfer from the matrix to Al₂O₃ particles, CNT-induced grain refinement, and increased resistance to dislocation motion. These results establish a direct correlation between microstructural features and mechanical performance, highlighting the potential of CNT–Al₂O₃ reinforced Al 6061 hybrid nanocomposites for lightweight, high-strength applications in aerospace, automotive, and structural engineering industries. Full article

High residual stresses significantly impact component performance during laser powder bed fusion (L-PBF) of GH3536 alloy. This study systematically investigates the effects of five scanning strategies (X-Scan, XY-Scan, R67, CB90, CB67) on residual stresses and deformation behavior in laser powder bed fusion-formed GH3536 high-temperature alloy. This is achieved by establishing a thermomechanically coupled mesoscale finite element model and combining it with experimental validation. The model was developed on the ANSYS APDL platform using a sequential coupling algorithm. It comprehensively considered melting latent heat, material nonlinearity, and dead-body element technology. While ensuring computational accuracy, significant computational efficiency gains were achieved through geometric scaling and reasonable simplifications (e.g., neglecting evaporation effects and assuming material isotropy). Results indicate that the 67° interlayer rotational scanning (R67) significantly reduces residual stresses, attributed to the breaking of thermal accumulation symmetry by asymmetric scanning. Component deformation is primarily governed by thermal stresses, with simulation results showing less than 10% deviation from experimental measurements. Despite the model’s medium-to-small scale and omission of size effects, its predicted trends highly correlate with X-ray diffraction measurements, validating its reliability for scan strategy optimization. Electron backscatter diffraction (EBSD) analysis further examined grain size and orientation differences at the microstructural level under the R67 strategy, revealing a more refined grain structure and KAM values. This provides theoretical support for L-PBF forming of nickel-based high-temperature alloys. Full article