A dual-phase alloy with ultrahigh strength-ductility synergy over a wide temperature range

Mechanical Properties of Aluminum Alloy Tubes Fabricated Through Surface Mechanical Grinding Treatment and Graphene Lubrication Under Biaxial Stress States

To enhance the mechanical properties of 6063-T4 aluminum alloy tubes, surface mechanical grinding treatment was conducted under graphene-assisted lubrication. The effects of rotational speed and cooling conditions on the mechanical properties of aluminum alloy tubes under biaxial stress were systematically explored. It was found that increasing the rotational speed and cooling rate facilitates the formation of finer lamellar grains, higher-density nano-precipitates, and a reduced dislocation density on the tube surface. These microstructural characteristics significantly contribute to an increased yield strength and sustained strain hardening capacity during bulging deformation. This study proposes an innovative approach for improving the strength and toughness of light alloy components during integral forming, providing meaningful insights for future engineering applications.

A Complex Concentrated Alloy with Record-High Strength-Toughness at 77 K

High strength and large ductility, leading to a high material toughness (area under the stress-strain curve), are desirable for alloys used in cryogenic applications. Assisted by domain-knowledge-informed machine learning, here a complex concentrated Fe35Co29Ni24Al10Ta2 alloy is designed, which uses L12 coherent nanoprecipitates in a high volume fraction (≈65 ± 3 vol.%) in a face-centered-cubic (FCC) solid solution matrix that undergoes FCC-to-body-centered-cubic (BCC) phase transformation upon tensile straining. Unlike FCC-to-BCT phase transformation involving brittle carbon-enriched martensite, the BCC martensite in this alloy does not cause brittleness at 77 K. The Fe35Co29Ni24Al10Ta2 multi-principal element alloy achieves a high yield strength ≈1.4 GPa, a high work hardening rate >4 GPa, an ultimate tensile strength ≈2.25 GPa, and a large uniform elongation ≈45%, leading to record-high material toughness compared with previous cryogenic alloys such as 316L series stainless steels and recent high-entropy alloys. The nanoprecipitates with nanoscale spacing (≈7.5 nm), apart from serving as dislocation obstacles for strengthening and dislocation sources for sustainable ductility, also undergo deformation twinning. Taken together, these mechanisms are found to be highly effective in strengthening and strain hardening upon tensile straining at liquid nitrogen temperature. These findings demonstrate how to effectively integrate strengthening mechanisms to synergize superior mechanical properties in special-purpose alloys.

Dual enhancement in strength and ductility of Fe-rich medium-entropy alloys via an in situ formed heterogeneous multi-phase structure

In this work, we successfully achieved an exceptional strength-ductility synergy in the brittle Ni0.6CoFe1.4 medium-entropy alloy (MEA) via in situ formation of a heterogeneous structure by doping with Si. The newly developed Ni0.6CoFe1.4Six (x = 0.1, 0.2 and 0.3) MEAs exhibited a multi-phase heterogeneous structure consisting of face-centered cubic (FCC), body-centered cubic (BCC) and NiSi phases, with some B2 nanoparticles precipitated inside the BCC matrix. This multi-phase heterogeneous structure combined with precipitation hardening resulted in a dual enhancement in the strength and ductility of the alloys. Notably, the tensile strength and strain of the Ni0.6CoFe1.4Si0.3 MEA were significantly increased to 1096.9 ± 39.0 MPa and 31.7 ± 0.3%, respectively, which were about 39.9% and 456.1% higher than those of the Ni0.6CoFe1.4 base alloy. Furthermore, density functional theory (DFT) results indicated that the charge redistribution caused by the addition of Si led to the presence of local charge enrichment and depletion regions, which facilitate plastic deformation and increase the ductility. The current study would provide valuable guidance to produce low-cost yet high-performance BCC-structured MEAs.

Low-Frequency Evolution Mechanism of Customized HEAs-Based Electromagnetic Response Modes Manipulated by Carbothermal Shock

An emerging carbothermal shock method is an ultra-convenient strategy for synthesizing high-entropy alloys (HEAs), in which the intelligent combination of carbon support and HEAs can be serve as a decisive factor for interpreting the trade-off relationship between conductive gene and dielectric gene. However, the feedback mechanism of HEAs ordering degree on electromagnetic (EM) response in 2-18 GHz has not been comprehensively demystified. Herein, while lignin-based carbon fiber paper (L-CFP) as carbon support, L-CFP/FeCoNiCuZn-X with is prepared by carbothermal shock method. The reflection loss of -82.6 dB with thickness of 1.31 mm is achieved by means of pointing electron enrichment within L-CFP/FeCoNiCuZn HEAs heterointerfaces verified by theoretical calculations. Simultaneously, low-frequency evolution with high-intensity and broadband EM response relies on a "sacrificing" strategy achieved by construction of polymorphic L-CFP/semi-disordered-HEAs heterointerfaces. The practicality of L-CFP/FeCoNiCuZn-X in complex environments is given prominence to thermal conductivity, hydrophobicity, and electrocatalytic property. This work is of great significance for insightful mechanism analysis of HEAs in the application of electromagnetic wave absorption.

Laser Precise Synthesis of Oxidation-Free High-Entropy Alloy Nanoparticle Libraries

High-entropy alloy nanoparticles (HEA-NPs) show exceptional properties and great potential as a new generation of functional materials, yet a universal and facile synthetic strategy in air toward nonoxidized and precisely controlled composition remains a huge challenge. Here we provide a laser scribing method to prepare single-phase solid solution HEA-NPs libraries in air with tunable composition at the atomic level, taking advantage of the laser-induced metastable thermodynamics and substrate-assisted confinement effect. The three-dimensional porous graphene substrate functions as a microreactor during the fast heating/cooling process, which is conductive to the generation of the pure alloy phase by effectively blocking the binding of oxygen and metals, but is also beneficial for realizing accurate composition control via microstructure confinement-endowed favorable vapor pressure. Furthermore, by combining an active learning approach based on an adaptive design strategy, we discover an optimal composition of quinary HEA-NP catalysts with an ultralow overpotential for Li-CO2 batteries. This method provides a simple, fast, and universal in-air route toward the controllable synthesis of HEA-NPs, potentially integrated with machine learning to accelerate the research on HEAs.

Ultrastrong and ductile medium-entropy alloys via hierarchical ordering

Long-range ordered phases in most high-entropy and medium-entropy alloys (HEAs/MEAs) exhibit poor ductility, stemming from their brittle nature of complex crystal structure with specific bonding state. Here, we propose a design strategy to severalfold strengthen a single-phase face-centered cubic (fcc) Ni2CoFeV MEA by introducing trigonal κ and cubic L12 intermetallic phases via hierarchical ordering. The tri-phase MEA has an ultrahigh tensile strength exceeding 1.6 GPa and an outstanding ductility of 30% at room temperature, which surpasses the strength-ductility synergy of most reported HEAs/MEAs. The simultaneous activation of unusual dislocation multiple slip and stacking faults (SFs) in the κ phase, along with nano-SF networks, Lomer-Cottrell locks, and high-density dislocations in the coupled L12 and fcc phases, contributes to enhanced strain hardening and excellent ductility. This work offers a promising prototype to design super-strong and ductile structural materials by harnessing the hierarchical ordered phases.

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.

Significantly Improving the High-Temperature Tensile Properties of Al17Cr10Fe36Ni36Mo1 Alloys by Microalloying Hf

Dual-phase high-entropy alloys with excellent room temperature and high-temperature properties have been widely studied as potential high-temperature structural materials. However, interface weakening causes its high-temperature performance to decline at higher temperatures, severely limiting further development. In this study, a series of Al17Cr10Fe36Ni36Mo1Hfx (x = 0, 0.03, 0.15, 0.3, 0.5, and 0.8 at%) alloys were prepared to study the effect of Hf content on the microstructure and mechanical properties of the matrix alloy. The results indicate that with the addition of the Hf, the Hf-rich phase began to precipitate at the interface and inside the B2 phase in the matrix alloy. In contrast, the morphology of both the FCC and B2 phases had no noticeable change. With the increase in Hf content, the high-temperature strength and ductility of the alloy first increased and then decreased, while the room temperature performance remained almost unchanged. Benefiting from the hindrance of the Hf-rich phase to grain boundary sliding and dislocation movement during high-temperature deformation, the tensile strength, yield strength, and plasticity of the matrix alloy increased from 474 MPa, 535 MPa, and 8.7% to 816 MPa, 923 MPa, and 42.0% for the Al17Cr10Fe36Ni36Mo1Hf0.5 alloys, respectively. This work provides a new path for designing a high-entropy alloy with excellent high-temperature mechanical properties.

Investigation of the Micromechanical Behavior of a Ti68Nb7Ta3Zr4Mo18 (at.%) High-Entropy Alloy

Intense research efforts are focused on the development of advanced high-entropy alloys intended for premium aerospace components and other applications, where high strength and good formability are crucial. The mechanical properties of these alloys are closely related to the phase transformation, dislocation evolution, and grain size, and these factors are affected by the deformation temperature. The response of the retained austenite to strain-induced martensitic transformation at various temperatures was studied in an advanced Ti₆₈Nb₇Ta₃Zr₄Mo₁₈ (at.%) high-entropy alloy via molecular dynamics simulation. It was found that the Ti₆₈Nb₇Ta₃Zr₄Mo₁₈ alloy changes from a single crystal to a polycrystal during the tensile process, and the transition of the Ti₆₈Nb₇Ta₃Zr₄Mo₁₈ (at.%) high-entropy alloy from the BCC phase to the FCC phase occurs. At high temperatures and low strain rates, grain boundary slip is the main deformation mechanism, and at low temperatures and high strain rates, dislocation slip replaces grain boundary slip as the dominant deformation mechanism, which improves the strength of the alloy. Moreover, when the grain size is too small, the strength of the alloy decreases, which does not satisfy the fine grain strengthening theory and shows an inverse Hall-Petch relationship. This study offers a new compositional window for the additive manufactured lightweight high-strength material categories for various applications including the aerospace industry.

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.

Plasticity Improvement in a Co-Rich Co40Fe25Cr20Ni15 High-Entropy Alloy via Al Alloying

The mechanical properties of high-entropy alloys (HEAs) can be regulated by altering the stacking fault energy (SFE) through compositional modulation. The Co-rich HEAs, exhibiting deformation twinning and even strain-induced martensitic transformation at room temperature, suffer from insufficient ductility at high strength. In this work, we developed Co-rich (Co₄₀Fe₂₅Cr₂₀Ni₁₅)_100-xAl_x (x = 0 and 5 at.%) HEAs and investigated their tensile behaviors at room temperature. The addition of Al resulted in a massive improvement in the strength-ductility product, even at similar grain sizes, and also altered the fracture mode from quasi-cleavage to ductile dimple fracture. Interestingly, both alloys were deformed by mechanical twinning, which was also verified by molecular dynamics (MD) simulations. The MD simulations revealed the SFE increased upon Al addition; however, the slip energy barrier was reduced, which favored the mobility of dislocations and twinning propensity to prolong strain hardening. The present findings provide further insights into the regulation of mechanical properties of HEAs by Al-alloying.

A crystal glass-nanostructured Al-based electrocatalyst for hydrogen evolution reaction

Platinum-based catalysts are widely used in hydrogen evolution reactions; however, their applications are restricted because of the cost-efficiency trade-off. Here, we present a thermodynamics-based design strategy for synthesizing an Al₇₃Mn₇Ru₂₀ (atomic %) metal catalyst via combinatorial magnetron co-sputtering. The new electrocatalyst is composed of ~2 nanometers of medium-entropy nanocrystals surrounded by ~2 nanometers of amorphous regions. The catalyst exhibits exceptional performance, similar to that of single-atom catalysts and better than that of nanocluster-based catalysts. We use aluminum rather than a noble metal as the principal element of the catalyst and ruthenium, which is cheaper than platinum, as the noble metal component. The design strategy provides an efficient route for the development of electrocatalysts for use in large-scale hydrogen production. Moreover, the superior hydrogen reaction evolution created by the synergistic effect of the nano-dual-phase structure is expected to guide the development of high-performance catalysts in other alloy systems.

Influence of Mo on the Microstructure and Corrosion Behavior of Laser Cladding FeCoCrNi High-Entropy Alloy Coatings

FeCoCrNi and FeCoNiCrMo_0.2 high-entropy alloy powders were prepared by gas atomization. Two kinds of coatings were prepared on the surface of 304 stainless steel by laser cladding technology. The effect of Mo element on the microstructure of laser cladding FeCoCrNi coating and its corrosion behavior in 3.5 wt.% NaCl solution was investigated. Both FeCoCrNi and FeCoCrNiMo_0.2 powders exhibit a single-phase FCC structure. Due to the remelting and multiple heat treatments during the preparation of the laser cladding coating, a small amount of σ and μ phases appeared in the FeCoCrNiMo_0.2 coating. The microstructures of the two coatings from the bonding area to the top layer are planar, columnar and equiaxed grains, respectively. The addition of the Mo element causes the dendrite size in the middle region of the FeCoCrNiMo_0.2 coating increases significantly and exhibits obvious orientation characteristics. FeCoCrNiMo_0.2 coating has high corrosion potential (−0.01 V_SHE) and low current density (0.94 × 10⁻⁷ A/cm²) in 3.5 wt.% NaCl solution, showing excellent corrosion resistance. The passivation film formed on corroded the FeCoCrNiMo_0.2 coating contains high content of oxides of Cr and Mo. The addition of the Mo element enhances the compactness and pitting resistance of the passivation film.