Dual heterogeneous structures lead to ultrahigh strength and uniform ductility in a Co-Cr-Ni medium-entropy alloy

Nanostructured High Entropy Alloys as Structural and Functional Materials

Since their introduction in 2004, high entropy alloys (HEAs) have attracted significant attention due to their exceptional mechanical and functional properties. Advances in our understanding of atomic-scale ordering and phase formation in HEAs have facilitated the development of fabrication techniques for synthesizing nanostructured HEAs. These materials hold immense potential for applications in various fields including automobile industries, aerospace engineering, microelectronics, and clean energy, where they serve as either structural or functional materials. In this comprehensive Review, we conduct an in-depth analysis of the mechanical and functional properties of nanostructured HEAs, with a particular emphasis on the roles of different nanostructures in modulating these properties. To begin, we explore the intrinsic and extrinsic factors that influence the formation and stability of nanostructures in HEAs. Subsequently, we delve into an examination of the mechanical and electrocatalytic properties exhibited by bulk or three-dimensional (3D) nanostructured HEAs, as well as nanosized HEAs in the form of zero-dimensional (0D) nanoparticles, one-dimensional (1D) nanowires, or two-dimensional (2D) nanosheets. Finally, we present an outlook on the current research landscape, highlighting the challenges and opportunities associated with nanostructure design and the understanding of structure-property relationships in nanostructured HEAs.

Harnessing instability for work hardening in multi-principal element alloys

The strength-ductility trade-off has long been a Gordian knot in conventional metallic structural materials and it is no exception in multi-principal element alloys. In particular, at ultrahigh yield strengths, plastic instability, that is, necking, happens prematurely, because of which ductility almost entirely disappears. This is due to the growing difficulty in the production and accumulation of dislocations from the very beginning of tensile deformation that renders the conventional dislocation hardening insufficient. Here we propose that premature necking can be harnessed for work hardening in a VCoNi multi-principal element alloy. Lüders banding as an initial tensile response induces the ongoing localized necking at the band front to produce both triaxial stress and strain gradient, which enables the rapid multiplication of dislocations. This leads to forest dislocation hardening, plus extra work hardening due to the interaction of dislocations with the local-chemical-order regions. The dual work hardening combines to restrain and stabilize the premature necking in reverse as well as to facilitate uniform deformation. Consequently, a superior strength-and-ductility synergy is achieved with a ductility of ~20% and yield strength of 2 GPa during room-temperature and cryogenic deformation. These findings offer an instability-control paradigm for synergistic work hardening to conquer the strength-ductility paradox at ultrahigh yield strengths.

Multiscale Heterogeneities-Based Piezoresistive Interfaces with Ultralow Detection Limitation and Adaptively Switchable Pressure Detectability

Mechanical compliance and electrical enhancement are crucial for pressure sensors to promote performances when perceiving external stimuli. Here we propose a bioinspired multiscale heterogeneity-based interface to adaptively regulate its structure layout and switch to desirable piezoresistive behaviors with ultralow detection limitation. In such a multiscale heterogeneities system, the micro-/nanoscale spiny Ag-MnO2 heterostructure contributes to an ultralow detection limitation of 0.008 Pa and can perceive minor pressure increments under preloads with high resolution (0.0083%). The macroscale heterogeneous orientation of the cellular backbone enables anisotropic deformation, allowing the sensor to switch to rational sensitivity and working range (e.g., 580 kPa-1 for 0-20 kPa/54 kPa-1 for 60-140 kPa) as required. The sensor's stepwise activation progresses from the micro-/nanoscale heterostructure to the macroscale heterogeneous orientation, which can adaptively match diverse sensing tasks in complex applications scenarios. This multiscale heterogeneous and switchable design holds immense potential in the development of intelligent electromechanical devices, including wearable sensors, soft robotics, and smart actuators.

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.

General synthesis and atomic arrangement identification of ordered Bi-Pd intermetallics with tunable electrocatalytic CO2 reduction selectivity

Intermetallic compounds (IMCs) with fixed chemical composition and ordered crystallographic arrangement are highly desirable platforms for elucidating the precise correlation between structures and performances in catalysis. However, diffusing a metal atom into a lattice of another metal to form a controllably regular metal occupancy remains a huge challenge. Herein, we develop a general and tractable solvothermal method to synthesize the Bi-Pd IMCs family, including Bi2Pd, BiPd, Bi3Pd5, Bi2Pd5, Bi3Pd8 and BiPd3. By employing electrocatalytic CO2 reduction as a model reaction, we deeply elucidated the interplay between Bi-Pd IMCs and key intermediates. Specific surface atomic arrangements endow Bi-Pd IMCs different relative surface binding affinities and adsorption configuration for *OCHO, *COOH and *H intermediate, thus exhibiting substantially selective generation of formate (Bi2Pd), CO (BiPd3) and H2 (Bi2Pd5). This work provides a comprehensive understanding of the specific structure-performance correlation of IMCs, which serves as a valuable paradigm for precisely modulating catalyst material structures.

Phase Engineering of Nanostructural Metallic Materials: Classification, Structures, and Applications

Metallic materials are usually composed of single phase or multiple phases, which refers to homogeneous regions with distinct types of the atom arrangement. The recent studies on nanostructured metallic materials provide a variety of promising approaches to engineer the phases at the nanoscale. Tailoring phase size, phase distribution, and introducing new structures via phase transformation contribute to the precise modification in deformation behaviors and electronic structures of nanostructural metallic materials. Therefore, phase engineering of nanostructured metallic materials is expected to pave an innovative way to develop materials with advanced mechanical and functional properties. In this review, we present a comprehensive overview of the engineering of heterogeneous nanophases and the fundamental understanding of nanophase formation for nanostructured metallic materials, including supra-nano-dual-phase materials, nanoprecipitation- and nanotwin-strengthened materials. We first review the thermodynamics and kinetics principles for the formation of the supra-nano-dual-phase structure, followed by a discussion on the deformation mechanism for structural metallic materials as well as the optimization in the electronic structure for electrocatalysis. Then, we demonstrate the origin, classification, and mechanical and functional properties of the metallic materials with the structural characteristics of dense nanoprecipitations or nanotwins. Finally, we summarize some potential research challenges in this field and provide a short perspective on the scientific implications of phase engineering for the design of next-generation advanced metallic materials.

The Microstructure Evolution and Formation Mechanism of Gradient Nanostructure Prepared on CrCoNi Medium-Entropy Alloy

An equiatomic CrCoNi medium-entropy alloy was subjected to high-energy shot peening (HESP) to fabricate a gradient nanostructure (GNS) in this work. The microstructures of the GNS samples at different depths within the deformed layer were thoroughly investigated. The microstructure exhibited a transformation from unstressed coarse grains to deformed coarse grains, followed by the formation of ultrafine grains, and ultimately reaching a final nanocrystalline structure with a uniform size of approximately 50 nm. Detailed structural analysis indicated that the deformation process was primarily influenced by the interaction between dislocations and deformation twins, which was attributed to the low stacking fault energy (SFE) of the alloy. The nanocrystalline mechanism was divided into three stages. In the coarse-grained deformation stage, the dislocation band divided twin/matrix lamellae into sub-segments, and the cross twin divided coarse grains into ultrafine grains simultaneously. In the ultrafine grain deformation stage, dislocations were arranged around the deformation twins in order to break the twins to form incoherent boundaries, destroying the coherent relationship between the twin and matrix. Finally, in the nanocrystalline deformation stage, the nanocrystalline structure was further divided into smaller segments to accommodate additional strains through the interaction between dislocations and twins.

Ultra-strong tungsten refractory high-entropy alloy via stepwise controllable coherent nanoprecipitations

High-performance refractory alloys with ultrahigh strength and ductility are in demand for a wide range of critical applications, such as plasma-facing components. However, it remains challenging to increase the strength of these alloys without seriously compromising their tensile ductility. Here, we put forward a strategy to "defeat" this trade-off in tungsten refractory high-entropy alloys by stepwise controllable coherent nanoprecipitations (SCCPs). The coherent interfaces of SCCPs facilitate the dislocation transmission and relieve the stress concentrations that can lead to premature crack initiation. As a consequence, our alloy displays an ultrahigh strength of 2.15 GPa with a tensile ductility of 15% at ambient temperature, with a high yield strength of 1.05 GPa at 800 °C. The SCCPs design concept may afford a means to develop a wide range of ultrahigh-strength metallic materials by providing a pathway for alloy design.

Corrosion Resistance of Amorphous-Nanocrystalline Composite Structure Materials

The purpose of this paper is to investigate the corrosion resistance of different nanoscale microstructures in the same material system and propose a novel method to obtain high-performance materials. During the last 2 decades, microstructure refinement and microalloying have become the main methods to prepare high-performance materials. The tensile strength of nanocrystalline solid solutions can reach 2.3 gigapascal, which is more than 1 fold the strength of traditional steel. However, there are few studies about the corrosion resistance of different nanoscale microstructures. In this paper, coatings with different microstructures (nanocrystalline, amorphous, and amorphous-nanocrystalline composite) have been successfully prepared by electrodeposition in the same material system (nickel-phosphorus alloy). Electrochemical test and high-pressure corrosion immersion test were carried out. The results show that the material loss of amorphous-nanocrystalline coating (P = 9.2 wt %) is about 1/4 that of crystalline coating at 8 MPa. In the range of 0.1 and 8 MPa, the average acceleration effect of hydrostatic pressure on the corrosion rate was calculated to be 1.611 × 10^-6 g·cm^-2·d^-1·MPa^-1.

A mechanically strong and ductile soft magnet with extremely low coercivity

Soft magnetic materials (SMMs) serve in electrical applications and sustainable energy supply, allowing magnetic flux variation in response to changes in applied magnetic field, at low energy loss¹. The electrification of transport, households and manufacturing leads to an increase in energy consumption owing to hysteresis losses². Therefore, minimizing coercivity, which scales these losses, is crucial³. Yet meeting this target alone is not enough: SMMs in electrical engines must withstand severe mechanical loads; that is, the alloys need high strength and ductility⁴. This is a fundamental design challenge, as most methods that enhance strength introduce stress fields that can pin magnetic domains, thus increasing coercivity and hysteresis losses⁵. Here we introduce an approach to overcome this dilemma. We have designed a Fe–Co–Ni–Ta–Al multicomponent alloy (MCA) with ferromagnetic matrix and paramagnetic coherent nanoparticles (about 91 nm in size and around 55% volume fraction). They impede dislocation motion, enhancing strength and ductility. Their small size, low coherency stress and small magnetostatic energy create an interaction volume below the magnetic domain wall width, leading to minimal domain wall pinning, thus maintaining the soft magnetic properties. The alloy has a tensile strength of 1,336 MPa at 54% tensile elongation, extremely low coercivity of 78 A m⁻¹ (less than 1 Oe), moderate saturation magnetization of 100 A m² kg⁻¹ and high electrical resistivity of 103 μΩ cm.

An iron–cobalt–nickel–tantalum–aluminium multicomponent alloy with ferromagnetic matrix and paramagnetic coherent nanoparticles is described, showing high tensile strength and ductility, along with very low coercivity.

Revealing the Potential of Ternary Medium-Entropy Alloys as Exceptional Electrocatalysts toward Nitrogen Reduction: An Example of Heusler Alloys

With less energy consumption and environmental pollution, electrochemical ammonia synthesis is regarded as the most promising way to replace the industrial Haber-Bosch process, which greatly contributes to global energy consumption and CO₂ emission. At present, the best metal electrocatalyst for N₂ fixation is ruthenium although its performance still suffers from a low Faradaic efficiency and a high overpotential. Alloy engineering is a promising way to discover more metal-based electrocatalysts for dinitrogen reduction reaction (N2RR), and almost all reported alloy catalysts so far are binary alloys. In this work, we proposed a large group of ternary alloy electrocatalysts (Heusler alloys) for N2RR and demonstrated their superior catalytic performance. As an example, alloying Ru with Mn and Si led to a reduced Ru-Ru distance on the surface, which facilitates an uncommon horizontal adsorption mode of N₂ and results in effective activation of N₂ molecules. The theoretical overpotential of N2RR on Ru₂MnSi(100-Ru) is only around 0.28 V, which ranks among the best reported results, and the usage of precious Ru is greatly reduced. Meanwhile, the adsorption of N₂ on Ru₂MnSi(100-Ru) was much stronger than that of protons, and it also took less energy to drive N2RR than the hydrogen evolution reaction (HER), making HER less competitive on this catalyst. Considering the successful synthesis of numerous Heusler alloys including the six members mentioned here, our work provided a wider range of practical and excellent N2RR electrocatalysts in terms of both catalytic performance and economical cost.

Nanoprecipitate-Strengthened High-Entropy Alloys

Multicomponent high-entropy alloys (HEAs) can be tuned to a simple phase with some unique alloy characteristics. HEAs with body-centered-cubic (BCC) or hexagonal-close-packed (HCP) structures are proven to possess high strength and hardness but low ductility. The faced-centered-cubic (FCC) HEAs present considerable ductility, excellent corrosion and radiation resistance. However, their strengths are relatively low. Therefore, the strategy of strengthening the ductile FCC matrix phase is usually adopted to design HEAs with excellent performance. Among various strengthening methods, precipitation strengthening plays a dazzling role since the characteristics of multiple principal elements and slow diffusion effect of elements in HEAs provide a chance to form fine and stable nanoscale precipitates, pushing the strengths of the alloys to new high levels. This paper summarizes and review the recent progress in nanoprecipitate-strengthened HEAs and their strengthening mechanisms. The alloy-design strategies and control of the nanoscale precipitates in HEAs are highlighted. The future works on the related aspects are outlined.

The Influence of Metastable Cellular Structure on Deformation Behavior in Laser Additively Manufactured 316L Stainless Steel

Metastable cellular structures (MCSs) play a crucial role for the mechanical performance in concentrated alloys during non-equilibrium solidification process. In this paper, typifying the heterogeneous 316L stainless steel by laser additive manufacturing (LAM) process, we examine the microstructures in cellular interiors and cellular boundaries in detail, and reveal the interactions of dislocations and twins with cellular boundaries. Highly ordered coherent precipitates present along the cellular boundary, resulting from spinodal decomposition by local chemical fluctuation. The co-existences of precipitates and high density of tangled dislocations at cellular boundaries serve as walls for extra hardening. Furthermore, local chemical fluctuation in MCSs inducing variation in stacking fault energy is another important factor for ductility enhancement. These findings shed light on possible routines to further alter nanostructures, including precipitates and dislocation structures, by tailoring local chemistry in MCSs during LAM.

Ultrahigh strength and ductility in newly developed materials with coherent nanolamellar architectures

Nano-lamellar materials with ultrahigh strengths and unusual physical properties are of technological importance for structural applications. However, these materials generally suffer from low tensile ductility, which severely limits their practical utility. Here we show that markedly enhanced tensile ductility can be achieved in coherent nano-lamellar alloys, which exhibit an unprecedented combination of over 2 GPa yield strength and 16% uniform tensile ductility. The ultrahigh strength originates mainly from the lamellar boundary strengthening, whereas the large ductility correlates to a progressive work-hardening mechanism regulated by the unique nano-lamellar architecture. The coherent lamellar boundaries facilitate the dislocation transmission, which eliminates the stress concentrations at the boundaries. Meanwhile, deformation-induced hierarchical stacking-fault networks and associated high-density Lomer-Cottrell locks enhance the work hardening response, leading to unusually large tensile ductilities. The coherent nano-lamellar strategy can potentially be applied to many other alloys and open new avenues for designing ultrastrong yet ductile materials for technological applications.