Systematic study was conducted on the microstructures and mechanical properties of nickel samples with two distinct types of heterostructures. The first is featured with coarse-grained lamellae ...embedded in a matrix consisting of a very high density of dislocation structures. The second is featured with coarse-grained zones embedded in the ultrafine-grained matrix. The second type of heterostructures exhibits better strength and ductility, although it has a smaller average grain size than the first type. The zone boundaries in the second type of heterostructures are less prone to cracking than those in the first type. Intersecting micro-shear-bands formed net-like patterns in the second type of heterostructures during tensile deformation. This is the first ever observation of structural micro-shear-bands in a heterostructured material. It supports the claim that heterostructure promotes the formation of dispersive shear bands. In contrast, a macroscopic shear band formed and caused early failure of the sample with the first type of heterostructures. Our results indicate that well-developed ultrafine/nano grained matrix in heterostructured materials are necessary for preventing crack formation and shear band localization. This should be considered as a key factor for optimizing the mechanical properties of heterostructured materials.
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Grain refinement can make conventional metals several times stronger, but this comes at dramatic loss of ductility. Here we report a heterogeneous lamella structure in Ti produced by asymmetric ...rolling and partial recrystallization that can produce an unprecedented property combination: as strong as ultrafine-grained metal and at the same time as ductile as conventional coarse-grained metal. It also has higher strain hardening than coarse-grained Ti, which was hitherto believed impossible. The heterogeneous lamella structure is characterized with soft micrograined lamellae embedded in hard ultrafine-grained lamella matrix. The unusual high strength is obtained with the assistance of high back stress developed from heterogeneous yielding, whereas the high ductility is attributed to back-stress hardening and dislocation hardening. The process discovered here is amenable to large-scale industrial production at low cost, and might be applicable to other metal systems.
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Interfaces play a crucial role in mechanical behaviors of both laminated and gradient structured materials. In this work, copper/bronze laminates with varying interface spacing were fabricated by ...accumulative roll bonding and subsequent annealing to systematically study the interface effect on mechanical properties. Heterogeneities exist in chemical composition, grain size, hardness and texture across the interfaces. Simultaneous improvement of strength and ductility with decreasing interface spacing is found in tensile tests. Extra geometrically necessary dislocations (GNDs) are found to accumulate in the vicinity of interfaces, which is due to mechanical incompatibility across the interfaces. Importantly, an interface-affected zone spanning a few micrometers was found, which is not affected by interface spacing. These observations suggest the existence of an optimum spacing, which may produce the highest hardening capacity and ductility without sacrificing strength.
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This study explores the evolution of GNDs and their effects on back stress through experimental and computational methods. Four large-grained tantalum tensile specimens were strained in uniaxial ...tension, electron backscatter diffraction (EBSD) data were collected, and geometrically necessary dislocation (GND) maps of the four specimens in the unloaded state were produced. EBSD-based GND maps revealed several types of features with high GND content which caused back stress in the specimens. Correlations between five geometrically-based grain boundary (GB) transmission factors and the GB GND content were evaluated, and statistically significant correlations were found for transmission factors based on Livingston and Chalmer’s N factor, Werner and Prantl’s slip transfer number, and GB misorientation. The sign of individual components of the Nye tensor were used to visually and quantitatively identify clustering of GNDs of the same sign, thus giving additional evidence of increasing back stress due to deformation. Deformation of one of the specimens was simulated using multiple CPFEM based modeling approaches and predicted stress-strain responses are compared. The super dislocation model (SD model) — a crystal plasticity finite element method (CPFEM) which incorporates elastic dislocation interactions — was able to isolate impact of back stress on the overall flow stress. The SD model predicted correct stresses when compared with experimental data; however, when the elastic interactions in the SD model were turned off, stress predictions were 25% too low. Thus, demonstrating the importance of incorporating back stress into the model.
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We report the annealing time-dependent microstructures and deformation mechanisms of the novel face-centered cubic Fe49.5Mn30Co10Cr10C0.2Ti0.1V0.1Mo0.1 HEA. Three types of precipitates, σ-phase, ...Cr-rich MC-type carbides, and nano-scale (Ti, V, Mo)C, are present after cold-rolling and annealing at 600 °C. Such hierarchical precipitates could lead to sluggish recrystallization and grain growth upon annealing. The partially recrystallized microstructures and hierarchical precipitates could lead to a high yield strength even for prolonged annealing conditions. Deformation mechanisms change with annealing time. The materials annealed for short times (< 2 h) are deformed by dislocation glide, deformation twinning, and deformation-induced ε phase. A longer annealing time (> 10 h) triggers a multi-variant ε phase, reverse transformation from ε to γ, and the multi-step sequential transformation, γ → ε → reverse transformed γ from ε → ε transformed from the reverse transformed γ. Further, materials annealed for longer times shows a higher contribution of back stress strengthening, which could be attributed to the increase in γ/ε and γ/σ interfaces. The activation of various deformation mechanisms and high back stress strengthening could lead to a superior strain hardening capacity and strength-ductility combination (YS: 699 MPa, UTS: 1041 MPa, TE: 45%) of the material annealed for 10 h. The present work provides the novel microstructure design solution of the metastable high entropy alloys with exceptional mechanical properties, utilizing hierarchical precipitates, sequential deformation-induced phase transformation, and enhanced back stress strengthening.
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Ductility, i.e., uniform strain achievable in uniaxial tension, diminishes for materials with very high yield strength. Even for the CrCoNi medium-entropy alloy (MEA), which has a simple ...face-centered cubic (FCC) structure that would bode well for high ductility, the fine grains processed to achieve gigapascal strength exhaust the strain hardening ability such that, after yielding, the uniform tensile strain is as low as ∼2%. Here we purposely deploy, in this MEA, a three-level heterogeneous grain structure (HGS) with grain sizes spanning the nanometer to micrometer range, imparting a high yield strength well in excess of 1 GPa. This heterogeneity results from this alloy’s low stacking fault energy, which facilitates corner twins in recrystallization and stores deformation twins and stacking faults during tensile straining. After yielding, the elastoplastic transition through load transfer and strain partitioning among grains of different sizes leads to an upturn of the strain hardening rate, and, upon further tensile straining at room temperature, corner twins evolve into nanograins. This dynamically reinforced HGS leads to a sustainable strain hardening rate, a record-wide hysteresis loop in load–unload–reload stress–strain curve and hence high back stresses, and, consequently, a uniform tensile strain of 22%. As such, this HGS achieves, in a single-phase FCC alloy, a strength–ductility combination that would normally require heterogeneous microstructures such as in dual-phase steels.
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Heterogeneous-structured materials are a new class of metallic materials that have recently emerged due to development of advanced processing and structural/architectural design techniques. These ...materials are made of heterogeneous domains having different constitutive behaviors and achieve superior mechanical properties, such as extra strengthening and work hardening, that are not accessible to conventional homogeneous-structured materials. Here we review recent experimental, theoretical and computational studies on microstructures, mechanical properties and deformation behaviors of heterogeneous-structured metals/alloys, highlighting the relationships between structural heterogeneity and mechanical property improvements, as well as some perspectives towards achieving fundamental understanding of plastic deformation based on strain gradient theory.
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The effect of back stress on the mechanical behaviors of heterogeneous material is studied in two modeled heterogeneous laminates, i.e. laminated structure with a nanostructured (NS) Cu-Zn alloy ...layer sandwiched between two coarse-grained (CG) pure Cu layers. The improved tensile ductility of NS layer is revealed and attributed to the constraint from the stable CG layers. It is found that the elastic/plastic interaction between NS and CG layers is capable of significantly improving the back stress, which makes a significant contribution to the synergetic strain hardening in low strain stage. Furthermore, a higher mechanical incompatibility permits stronger and longer mutual interaction between layers, i.e. coupling effect, which contributes to a higher back stress. These results improve our understanding about the role of back stress on mechanical behaviors of heterogeneous laminate materials.
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•A nonlocal crystal plasticity model explicitly including the interactions between dislocations and grain boundaries is developed.•Finite element implementation of the model quantitatively captures ...the grain size effect.•The strengthening mechanisms in gradient grained material are systematically investigated by the crystal plasticity finite element simulation.•Small grains contribute significantly to the geometrically necessary dislocation-related hardening in gradient grained materials.
Gradient grained metals whose microstructure is characterized by a spatially graded grain size distribution show a better strength-ductility combination than their homogeneous counterparts. Kinematic hardening associated with geometrically necessary dislocations (GNDs) is considered to be a dominant strengthening mechanism in gradient grained metals. However, the precise kinematics of GND accumulation and the nature of the back stress fields remain unclear, restricting the understanding of their deformation mechanisms. In this work, a nonlocal crystal plasticity model which explicitly accounts for the interaction between dislocations and grain boundaries is developed. The nonlocal feature is achieved by introducing a flux term to account for the spatial redistribution of dislocations due to their motion. In addition, back stress produced by the spatial variation of GND density introduces an explicit internal length scale into the model. The nonlocal nature of the model on the slip system level enables the direct investigation of strain gradient effects caused by internal deformation heterogeneities. Furthermore, the interaction between dislocations and grain boundaries leads to the formation of pileups near grain boundaries, which is key to studying the grain size effects in polycrystals. Finite element implementation of the model for polycrystals with different grain sizes quantitatively captures the grain size effect. Simulation results of gradient grained materials and their homogeneous counterparts demonstrate that smaller grains lead to higher GND density and enhanced back stress. Small grains significantly contribute to the GND-induced isotropic hardening and GND-induced kinematic hardening in gradient grained metals. This investigation helps to understand the underlying strengthening mechanisms of gradient grained metals, and the model can be readily applied to other kinds of heterogeneous materials.
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•SLM fabricated Al-Mg-Sc-Zr alloy showed a heterogeneous grain structure.•A good strength-ductility synergy was achieved in SLMed Al-Mg-Sc-Zr alloy.•Strain partitioning among ...heterogeneous grain structure provided additional back stress hardening.
In this work, a Sc/Zr modified Al-Mg alloy was processed by both selective laser melting (SLM) and directed energy deposition (DED). Due to different precipitation behavior of primary Al3(Sc,Zr)-L12 nucleation sites, a heterogeneous grain structure was formed in SLMed sample, which consisted of ultrafine equiaxed grains bands and columnar grains domains, while a fully equiaxed grain structure was obtained in DEDed sample. Tensile results showed that the as built SLMed sample had a good combination of strength and ductility. The yield strength of SLMed sample (335 ± 4 MPa) was about 2.8 times that of DEDed sample (118 ± 3 MPa), however, the ductility in uniform elongation (23.6 ± 1.9%) was still comparable to that of DEDed sample (23.8 ± 2.6%). Based on the relationship between the heterogeneous grain structure and strain hardening behavior, the strength-ductility synergy mechanism of the SLMed Al-Mg-Sc-Zr alloy was discussed. Stress partitioning tests showed that the contribution of back stress hardening to flow stress was higher in SLMed sample than DEDed sample, while effective stress hardening showed an opposite trend. Despite the overall strain hardening ability of SLMed sample was limited by the high dynamic recovery rate of ultrafine equiaxed grains, additional back stress hardening, which was caused by strain partitioning between equiaxed grains bands and columnar grains domains, improved its strain hardening ability and resulted in the good combination of strength and ductility.
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