Strength-ductility materials by engineering a coherent interface at incoherent precipitates.

In the quest for excellent light-structural materials that can withstand mechanical extremes for advanced applications, design and control of microstructures beyond current material design strategies have become paramount. Herein, we design a coherent shell at incoherent precipitates in the 2195 aluminum alloy with multi-step metastable phase transitions. A high local strain rate via a neoteric deformation-driven metallurgy method facilitated the diffusion of Li. The original T1 (Al2CuLi) phases were transformed into coherent-shell (Li-rich) irregular-coated incoherent-core (Al2Cu) precipitates. The ultimate tensile strength and elongation reached 620 ± 18 MPa and 22.3 ± 2.2%, exhibiting excellent strength-ductility synergy. Grain boundaries, dislocation, solid solution atoms, and precipitates all contributed to the yield strength of the materials, among which precipitates occupied a dominant position, contributing approximately 56.07%. A new "incoherent-coherent interact" strain-hardening mechanism was also clarified, which was believed to be promoted in other heat-treatable alloy systems, especially with multi-step metastable phase transitions.

Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials.

To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricated holes in Al sheets and steel sheets, arranged in a zigzag array. The bars were stirred and mixed with Al sheets under severe plastic deformation (SPD), forming composite rivets to strengthen the mechanical joining. SiC particles were uniformly dispersed in the lower part of the welding nugget zone (WNZ). The smooth transition between the SiC mixed zone and extrinsic-riveting zone (ERZ) ensured the metallurgical bonding. The maximum tensile shear load of the joints reached 7.8 kN and the maximum load of the weld per unit length was 497 N/mm. The fracture occurred at the interface between the rivets and steel sheets rather than the conventional Al/steel joining interface. Moreover, ERFSLW can prolong the service life of joints due to three fracture stages. This method can be further extended to the welding of other dissimilar materials that conform to the model of "soft/hard".

Effect of Temperature and Material Flow Gradients on Mechanical Performances of Friction Stir Welded AA6082-T6 Joints.

The temperature and material flow gradients along the thick section of the weld seriously affect the welding efficiency of friction stir welding in medium-thick plates. Here, the effects of different gradients obtained by the two pins on the weld formation, microstructure, and mechanical properties were compared. The results indicated that the large-tip pin increases heat input and material flow at the bottom, reducing the gradient along the thickness. The large-tip pin increases the welding speed of defect-free joints from 100 mm/min to 500 mm/min compared to the small-tip pin. The ultimate tensile strength and elongation of the joint reached 247 MPa and 8.7%, equal to 80% and 65% of the base metal, respectively. Therefore, reducing the temperature and material flow gradients along the thickness by designing the pin structure is proved to be the key to improving the welding efficiency for thick plates.

Grain Boundary Engineering in Ta-Doped Garnet-Type Electrolyte for Lithium Dendrite Suppression.

Solid-state lithium batteries (SSLBs) based on Ta-doped Li6.5La3Zr1.5Ta0.5O12 (LLZTO) suffer from lithium dendrite growth, which hinders their practical application. Herein, first principles simulations indicate that the Ta element prefers to segregate along grain boundaries in the form of Ta2O5 precipitates due to a high energy difference induced by Ta doping. Grain boundary engineering is employed to regulate the distribution of the Ta element and enhance the density of LLZTO by introducing the La2O3 additive. The sufficient La2O3 additive reacts with the Ta2O5 precipitates, while the residual La2O3 nanoparticles fill up void defects, promoting the homogeneous distribution of the Ta element and improving the relative density to ∼98%. Critical current density of the symmetric Li battery reaches 2.12 mA·cm-2 at room temperature with the solid-state electrolyte (LLZTO + 5 wt % La2O3), which increases by 41% compared to pure LLZTO. SSLBs with the LiFePO4 cathode achieve a stable cycling performance with a discharge capacity of 138.6 mA·h·g-1 after 400 cycles at 0.2 C. This work provides theoretical insights into the distribution of Ta-doped LLZTO and inhibits lithium dendrite growth through grain boundary engineering.

Interface Formation of Medium-Thick AA6061 Al/AZ31B Mg Dissimilar Submerged Friction Stir Welding Joints.

The medium-thick Al/Mg dissimilar friction stir welding (FSW) joint has serious groove and cavity defects due to uneven thermal distribution in the thickness direction. The submerged friction stir welding (SFSW) was employed to decrease the peak temperature of the joint and control the thermal gradient of the thickness direction, which were beneficial in suppressing the coarsening of the intermetallic compounds (IMCs) layer and improving the weld formation. According to the SEM results, the thickness value of the IMC layer in the nugget zone and shoulder affect zone decreased from 0.78 µm and 1.31 µm in FSW process to 0.59 µm and 1.21 µm in SFSW process at the same parameter, respectively. Compared with the FSW process, SFSW improves the thermal accumulation during the process, which inhibits the formation of the IMCs and facilitates the material flow to form a mechanical interlocking structure. This firm interface formation elevates the effective contact area of the whole joint interface and provides a strong connection between the dissimilar metals. Thus, the ultimate strength of the 6 mm thick Al/Mg dissimilar SFSW joints was enhanced to 171 MPa, equivalent to 71.3% of AZ31B Mg alloys strength.

Heteroatom Modification Enhances Corrosion Durability in High-Mechanical-Performance Graphene-Reinforced Aluminum Matrix Composites.

The antagonism between strength and corrosion resistance in graphene-reinforced aluminum matrix composites is an inherent challenge to designing reliable structural components. Heteroatom microstructural modification is highly appreciated to conquer the obstacle. Here, a bottom-up strategy to exploit the heterogeneous phase interface to enable high corrosion durability is proposed. Deformation-driven metallurgy derived from severe plastic deformation is developed to produce Mg-alloyed fluorinated graphene structures with homogeneous dispersion. These structures allow for absorbing corrosion products, forming a dense protective layer against corrosion, and local micro-tuning of the suppression of charge transfer. This results in superior corrosion resistance with an outstanding strength-ductility balance of the composites via ultrafine-grained and precipitation strengthening. The anti-corrosion polarization resistance remains 89% of the initial state after 2-month immersion in chloride-containing environment, while the ultra-tensile strength and elongation of 532 ± 39 MPa and 17.3 ± 1.2% are obtained. The economical strategy of heteroatom modification broadens the horizon for anti-corrosion engineering in aluminum matrix composites, which is critical for the design of carbonaceous nanomaterial-reinforced composites to realize desired performances for practical applications.

Oriented Attachment Strategy Toward Enhancing Ionic Conductivity in Garnet-Type Electrolytes for Solid-State Lithium Batteries.

Solid-state lithium batteries (SSLBs) based on garnet-type solid-state electrolytes (SSEs) have attracted much attention due to their high energy density and chemical stability. However, poor room-temperature ionic conductivity and low density of SSEs induced by conventional preparation routes limit their potential future applications. In this work, an oriented attachment strategy is employed to enhance the Li-ion conductivity and density of garnet-type SSE Li6.5La3Zr1.5Ta0.5O12 by introducing La2O3 nanoparticles. The oriented attachment of the ZrO2(Ta2O5) matrix mediates the epitaxial growth of the La-Zr(Ta)-O intermediate phase due to the addition of La2O3 nanoparticles. Continuous Li-ion transport pathways along grain boundaries are produced by the combination of residual La2O3 and gas Li2O. A densification interface is obtained when 10 wt % La2O3 is doped. The maximum value of Li-ion conductivity reaches 8.20 × 10-4 S·cm-1, with a relative density of 97.3%. SSLBs with a LiFePO4 cathode showing a stable cycling performance with a discharge capacity of 123.1 mA·h·g-1 and a Coulombic efficiency of 99.2% after 300 cycles (0.5C) at room temperature. This work is comparable to the state-of-the-art methodology, which provides a feasible approach to creating SSEs with high performances for SSLBs.

Homogeneously Dispersed Graphene Nanoplatelets as Long-Term Corrosion Inhibitors for Aluminum Matrix Composites.

Deformation-driven metallurgy was implemented to prepare graphene nanoplatelet (GNP)-reinforced aluminum matrix composites with a time-dependent self-enhancement in corrosion resistance. Severe plastic deformation contributed to the sufficient brokenness, thinning, enfolding, and redispersion of GNPs, as well as grain refinement. The homogeneously dispersed GNPs showed a great corrosion inhibition mechanism in a chloride-containing environment, ascribed to the formation of a carbon-doped protective film via diffusion and chemical bonding between GNPs and the surface oxide film. Electrochemical and intergranular corrosion tests were conducted to show the enhancement of long-term corrosion resistance. First-principles calculations were performed to explore the high corrosion resistance of the carbon-doped protective film. The energy barriers of vacancy formation, Cl ingress, and charge transfer were synchronously enhanced with the addition of GNPs into aluminum matrix composites as long-term corrosion inhibitors.

Joining Alumina and Sapphire by Growing Aluminium Borate Whiskers In-Situ, and the Whiskers' Orientation Relationship with the Sapphire Substrate.

Bonding between polycrystal alumina and sapphire with (0001), (10 1 ¯ 0), (11 2 ¯ 0), (1 1 ¯ 02) orientations is successfully achieved by growing aluminium borate whiskers in the joint. The morphology of the whiskers in the joint is characterised by (Scanning Electron Microscopy) SEM. The relationship between the growing direction of the aluminium borate whiskers and the orientation of the sapphire substrate is investigated. The effect of the growing direction of the aluminium borate whiskers on the mechanical properties of the joint is discussed. The results show that the whiskers on the sapphire with (10 1 ¯ 0) orientation grow perpendicular to the surface of the substrate while the whiskers show a random growth on the other substrates. It is found that there is an orientation relationship between the whiskers (220) and sapphire (10 1 ¯ 0) and the morphology of the whiskers has great influence on the mechanical properties of the joint. The joint between polycrystal alumina and sapphire with (10 1 ¯ 0) orientation exhibits the highest strength, which reaches 26 MPa.

A ground-based radio frequency inductively coupled plasma apparatus for atomic oxygen simulation in low Earth orbit.

A radio frequency (rf) inductively coupled plasma apparatus has been developed to simulate the atomic oxygen environment encountered in low Earth orbit (LEO). Basing on the novel design, the apparatus can achieve stable, long lasting operation, pure and high density oxygen plasma beam. Furthermore, the effective atomic oxygen flux can be regulated. The equivalent effective atomic oxygen flux may reach (2.289-2.984) x 10(16) at.cm(2) s at an oxygen pressure of 1.5 Pa and rf power of 400 W. The equivalent atomic oxygen flux is about 100 times than that in the LEO environment. The mass loss measured from the polyimide sample changes linearly with the exposure time, while the density of the eroded holes becomes smaller. The erosion mechanism of the polymeric materials by atomic oxygen is complex and involves initial reactions at the gas-surface interface as well as steady-state material removal.