Modelling and Simulation of Phase Formations in Martensitic Stainless Steels

Modelling and simulation of solidification processes and solid-state phase transformation have become key instruments in the field of alloy development and heat treatment optimization. Apart from equilibrium-controlled processes, also diffusion-based effects need to be considered. This contribution presents some typical approaches at the example of martensitic stainless steels. Important aspects affecting the production and properties of these steels, such as alloying limits with nitrogen, the formation of ledeburitic structures, or the retained austenite content after heat treatment, can be predicted with reasonable accuracy.

The Temperature Dependence of Deformation Behaviors in High-Entropy Alloys: A Review

Over the past seventeen years, deformation behaviors of various types of high-entropy alloys (HEAs) have been investigated within a wide temperature range, from cryogenic to high temperatures, to demonstrate the excellent performance of HEAs under extreme conditions. It has been suggested that the dominated deformation mechanisms in HEAs would be varied with respect to the environmental temperatures, which significantly alters the mechanical properties. In this article, we systematically review the temperature-dependent mechanical behaviors, as well as the corresponding mechanisms of various types of HEAs, aiming to provide a comprehensive and up-to-date understanding of the recent progress achieved on this subject. More specifically, we summarize the deformation behaviors and microscale mechanisms of single-phase HEAs, metastable HEAs, precipitates-hardened HEAs and multiphase HEAs, at cryogenic, room and elevated temperatures. The possible strategies for strengthening and toughening HEAs at different temperatures are also discussed to provide new insights for further alloy development.

Laser additive manufacturing of metallic glasses: issues in vitrification and mechanical properties

Bulk metallic glasses (BMGs), on account of their attractive properties, have now begun to witness a few commercial applications, e.g. in coatings and micro-gears. Additive manufacturing (AM) or 3D printing, although established for crystalline alloys, has only recently been used for synthesising BMG components. The issues arising in 3D printing of BMGs are of current relevance, and this review focuses on the key scientific aspects, namely vitrification (or crystallisation) during printing, mechanical properties of printed glassy alloys and the use of AM in identifying newer BMGs. Available data on crystallisation during printing of a variety of BMGs are analysed in terms of schematic TTT diagrams and the complex interplay between thermal cycles, the presence of quenched-in nuclei in the glass and oxygen contamination in a way that is hoped to be broadly applicable to most alloy systems. Also reviewed are three key factors influencing mechanical properties of printed BMGs, i.e. porosity, crystallinity and oxygen contamination and thereby potential strategies for improvement are suggested. The review concludes with a discussion on the use of AM for combinatorial alloy development aimed at identifying better glass-forming compositions, which may in turn facilitate greater use of AM in manufacturing glassy components with desired properties.

Creep Behavior of Compact γ′-γ″ Coprecipitation Strengthened IN718-Variant Superalloy

The development of high-temperature heavy-duty turbine disk materials is critical for improving the overall efficiency of combined cycle power plants. An alloy development strategy to this end involves superalloys strengthened by ‘compact’ γ′-γ″ coprecipitates. Compact morphology of coprecipitates consists of a cuboidal γ′ precipitate such that γ″ discs coat its six {001} faces. The present work is an attempt to investigate the microstructure and creep behavior of a fully aged alloy exhibiting compact coprecipitates. We conducted heat treatments, detailed microstructural characterization, and creep testing at 1200 °F (649 °C) on an IN718-variant alloy. Our results indicate that aged IN718-27 samples exhibit a relatively uniform distribution of compact coprecipitates, irrespective of the cooling rate. However, the alloy ruptured at low strains during creep tests at 1200 °F (649 °C). At 100 ksi (689 MPa) load, the alloy fails around 0.1% strain, and 75 ksi (517 MPa) loading causes rupture at 0.3% strain. We also report extensive intergranular failure in all the tested samples, which is attributed to cracking along grain boundary precipitates. The results suggest that while the compact coprecipitates are indeed thermally stable during thermomechanical processing, the microstructure of the alloy needs to be optimized for better creep strength and rupture life.

A Novel Alloy Development Approach: Biomedical Equiatomic Ta-Nb-Ti Alloy

In the present manuscript, we report on the properties of an equiatomic Ta-Nb-Ti alloy as the basis for a novel, biomedical, multi-component alloy development. The alloy was produced using an arc melting furnace under Ar atmosphere, metallographically prepared, and investigated respectively. Furthermore, the alloy produced, as well as samples of elemental Ta, Nb, alloy Co-28Cr-6Mo, and alloy Ti-6Al-4V, were prepared with defined 1200 grit SiC grinding paper. The topography of the surfaces was evaluated using confocal microscopy and contact angle measurements subsequently. Afterwards, the biocompatibility of the novel alloy Ta-Nb-Ti was evaluated by means of cell (osteoblast) attachment as well as monocyte inflammatory response analysis. First results indicate competitive osteoblast attachment, as well as comparable expressions of fibrosis markers in comparison to conventionally used biomedical materials. In addition, the Ta-Nb-Ti alloy showed a markedly reduced inflammatory capacity, indicating a high potential for use as a prospective biomedical material.

Utilizing local phase transformation strengthening for nickel-base superalloys

Almost 75 years of research has been devoted to producing superalloys capable of higher operating temperatures in jet turbine engines, and there is an ongoing need to increase operating temperature further. Here, a new disk Nickel-base superalloy is designed to take advantage of strengthening atomic-scale dynamic complexions. This local phase transformation strengthening provides the alloy with a three times improvement in creep strength over similar disk superalloys and comparable strength to a single crystal blade alloy at 760 °C. Ultra-high-resolution chemical mapping reveals that the improvement in creep strength is a result of atomic-scale η (D024) and χ (D019) formation along superlattice stacking faults. To understand these results, the energy differences between the L12 and competing D024 and D019 stacking fault structures and their dependence on composition are computed by density functional theory. This study can help guide researchers to further optimize local phase transformation strengthening mechanisms for alloy development.

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.