Metals strengthen with increasing temperature at extreme strain rates.

The strength of materials depends on the rate at which they are tested, as defects, for example dislocations, that move in response to applied strains have intrinsic kinetic limitations1-4. As the deformation strain rate increases, more strengthening mechanisms become active and increase the strength4-7. However, the regime in which this transition happens has been difficult to access with traditional micromechanical strength measurements. Here, with microballistic impact testing at strain rates greater than 106 s-1, and without shock conflation, we show that the strength of copper increases by about 30% for a 157 °C increase in temperature, an effect also observed in pure titanium and gold. This effect is counterintuitive, as almost all materials soften when heated under normal conditions. This anomalous thermal strengthening across several pure metals is the result of a change in the controlling deformation mechanism from thermally activated strengthening to ballistic transport of dislocations, which experience drag through phonon interactions1,8-10. These results point to a pathway to better model and predict materials properties under various extreme strain rate conditions, from high-speed manufacturing operations11 to hypersonic transport12.

Microparticle Impact Testing at High Precision, Higher Temperatures, and with Lithographically Patterned Projectiles.

In the first decade of high-velocity microparticle impact research, hardly any modification of the original experimental setup has been necessary. However, future avenues for the field require advancements of the experimental method to expand both the impact variables that can be quantitatively assessed and the materials and phenomena that can be studied. This work explores new design concepts for the launch pad (the assembly that launches microparticles upon laser ablation) that can address the root causes of many experimental challenges that may limit the technique in the future. Among the design changes contemplated, the substitution of a stiff glass launch layer for the standard elastomeric polymer layer offers a number of improvements. First, it facilitates a reduction of the gap between launch pad and target from hundreds to tens of micrometers and thus unlocks a reproducibility in targeting a specific impact location better than the diameter of the test particle itself (±1.75 µm for SiO2 particles 7.38 µm in diameter). Second, the inert glass surface enables experiments at higher temperatures than previously possible. Finally-as demonstrated by the launch of thin-film Au disks-a launch pad made of materials standard in microfabrication paves the way to facile microfabrication of advanced impactors.

Low-hysteresis shape-memory ceramics designed by multimode modelling.

Zirconia ceramics exhibit a martensitic phase transformation that enables large strains of order 10%, making them prospects for shape-memory and superelastic applications at high temperature1-5. Similarly to other martensitic materials, this transformation strain can be engineered by carefully alloying to produce a more commensurate transformation with reduced hysteresis (difference in transformation temperature on heating and cooling)6-11. However, such 'lattice engineering' in zirconia is complicated by additional physical constraints: there is a secondary need to manage a large transformation volume change12, and to achieve transformation temperatures high enough to avoid kinetic barriers6. Here we present a method of augmenting the lattice engineering approach to martensite design to address these additional constraints, incorporating modern computational thermodynamics and data science tools to span complex multicomponent spaces for which no data yet exist. The result is a new zirconia composition with record low hysteresis of 15 K, which is about ten times less transformation hysteresis compared to typical values (and approximately five times less than the best values reported so far). This finding demonstrates that zirconia ceramics can exhibit hysteresis values of the order of those of widely deployed shape-memory alloys, paving the way for their use as viable high-temperature shape-memory materials.

Learning Grain-Boundary Segregation: From First Principles to Polycrystals.

The segregation of solute atoms at grain boundaries (GBs) can strongly impact the structural and functional properties of polycrystals. Yet, due to the limited availability of simulation tools to study polycrystals at the atomistic scale (i.e., interatomic potentials), there is a minimal understanding of the variation of solute segregation tendencies across the very complex space of GB microenvironments and the large range of alloys in which it can occur. Here, we develop an algorithmic framework that can directly learn the full spectrum of segregation energies for a metal solute atom in a metal polycrystal from ab initio methods, bypassing the need for alloy interatomic potentials. This framework offers a pathway to a comprehensive catalog of GB solute segregation with quantum accuracy, for the entire alloy space. As an initial demonstration in this pursuit, we build an extensive GB segregation database for aluminum-based alloys across the periodic table, including dozens of alloys for which there are substantially no prior data.

Nanotwinning-assisted dynamic recrystallization at high strains and strain rates.

Grain refinement is a widely sought-after feature of many metal production processes and frequently involves a process of recrystallization. Some processing methods use very high strain rates and high strains to refine the grain structure into the nanocrystalline regime. However, grain refinement processes are not clear in these extreme conditions, which are hard to study systematically. Here, we access those extreme conditions of strain and strain rate using single copper microparticle impact events with a laser-induced particle impact tester. Using a combined dictionary-indexing electron backscatter diffraction and scanning transmission electron microscopy approach for postmortem characterization of impact sites, we systematically explore increasing strain levels and observe a recrystallization process that is facilitated by nanotwinning, which we term nanotwinning-assisted dynamic recrystallization. It achieves much finer grain sizes than established modes of recrystallization and therefore provides a pathway to the finest nanocrystalline grain sizes through extreme straining processes.

Atomistic Assessment of Solute-Solute Interactions during Grain Boundary Segregation.

Grain boundary solute segregation is becoming increasingly common as a means of stabilizing nanocrystalline alloys. Thermodynamic models for grain boundary segregation have recently revealed the need for spectral information, i.e., the full distribution of environments available at the grain boundary during segregation, in order to capture the essential physics of the problem for complex systems like nanocrystalline materials. However, there has been only one proposed method of extending spectral segregation models beyond the dilute limit, and it is based on simple, fitted parameters that are not atomistically informed. In this work, we present a physically motived atomistic method to measure the full distribution of solute-solute interaction energies at the grain boundaries in a polycrystalline environment. We then cast the results into a simple thermodynamic model, analyze the Al(Mg) system as a case study, and demonstrate strong agreement with physically rigorous hybrid Monte Carlo/molecular statics simulations. This approach provides a means of rapidly measuring key interactions for non-dilute grain boundary segregation for any system with an interatomic potential.

Direct Electric-Field Induced Phase Transformation in Paraelectric Zirconia via Electrical Susceptibility Mismatch.

Electric field driven phase transformations require two phases with a mismatch in their electric polarization, as seen in antiferroelectric-to-ferroelectric transformations, where the ferroelectric phase has a permanent polarization that is favored under field. Many other nonferroelectric dielectric materials can become electrically polarized according to their electrical susceptibility, yet such induced polarizations are not generally considered capable of enabling a phase transformation. Here we explore a susceptibility-mismatch phase transformation in a paraelectric ceramic, yttria-doped zirconia. Using in situ x-ray diffraction at 550 °C we show that the monoclinic-to-tetragonal transformation can be driven directly by an electric field, providing experimental evidence of a paraelectric-to-paraelectric phase transformation. Considering the ∼1% mechanical strain of this transformation, the resulting electromechanical coupling may have potential for solid-state electrical actuators.

Learning grain boundary segregation energy spectra in polycrystals.

The segregation of solute atoms at grain boundaries (GBs) can profoundly impact the structural properties of metallic alloys, and induce effects that range from strengthening to embrittlement. And, though known to be anisotropic, there is a limited understanding of the variation of solute segregation tendencies across the full, multidimensional GB space, which is critically important in polycrystals where much of that space is represented. Here we develop a machine learning framework that can accurately predict the segregation tendency-quantified by the segregation enthalpy spectrum-of solute atoms at GB sites in polycrystals, based solely on the undecorated (pre-segregation) local atomic environment of such sites. We proceed to use the learning framework to scan across the alloy space, and build an extensive database of segregation energy spectra for more than 250 metal-based binary alloys. The resulting machine learning models and segregation database are key to unlocking the full potential of GB segregation as an alloy design tool, and enable the design of microstructures that maximize the useful impacts of segregation.

Global optimization for accurate determination of EBSD pattern centers.

Accurate pattern center determination has long been a challenge for the electron backscatter diffraction (EBSD) community and is becoming critically accuracy-limiting for more recent advanced EBSD techniques. Here, we study the parameter landscape over which a pattern center must be fitted in quantitative detail and reveal that it is both "sloppy" and noisy, which limits the accuracy to which pattern centers can be determined. To locate the global optimum in this challenging landscape, we propose a combination of two approaches: the use of a global search algorithm and averaging the results from multiple patterns. We demonstrate the ability to accurately determine pattern centers of simulated patterns, inclusive of effects of binning and noise on the error of the fitted pattern center. We also demonstrate the ability of this method to accurately detect changes in pattern center in an experimental dataset with noisy and highly binned patterns. Source code for our pattern center fitting algorithm is available online.

Melt-driven erosion in microparticle impact.

Impact-induced erosion is the ablation of matter caused by being physically struck by another object. While this phenomenon is known, it is empirically challenging to study mechanistically because of the short timescales and small length scales involved. Here, we resolve supersonic impact erosion in situ with micrometer- and nanosecond-level spatiotemporal resolution. We show, in real time, how metallic microparticles (~10-µm) cross from the regimes of rebound and bonding to the more extreme regime that involves erosion. We find that erosion in normal impact of ductile metallic materials is melt-driven, and establish a mechanistic framework to predict the erosion velocity.

Higher Temperatures Yield Smaller Grains in a Thermally Stable Phase-Transforming Nanocrystalline Alloy.

Grains in crystalline materials usually grow with increased thermal exposure. Classical phenomena such as recrystallization may lead to a purely temporary decrease in the grain size, while recent advances in alloy design can yield thermally stable nanocrystalline materials in which grain growth stagnates. But grains never shrink, since there is a lack of interface-generating mechanisms at high temperatures, which are required to decrease the grain size if such was the system's thermodynamic tendency. Here we sidestep this paradigm by designing a nanocrystalline alloy having an allotropic phase transformation-an interface-generating mechanism-such that only the high-temperature phase is stabilized against grain growth. We demonstrate that for an Fe-Au alloy cycled through the α↔γ transformation, the high-temperature phase (γ-Fe) has a stable fine grain size, smaller than its low-temperature counterpart (α-Fe). The result is an unusual material in which an increase in temperature leads to finer grains that are stable in size.

Achieving Ultralow Wear with Stable Nanocrystalline Metals.

Recent work suggests that thermally stable nanocrystallinity in metals is achievable in several binary alloys by modifying grain boundary energies via solute segregation. The remarkable thermal stability of these alloys has been demonstrated in recent reports, with many alloys exhibiting negligible grain growth during prolonged exposure to near-melting temperatures. Pt-Au, a proposed stable alloy consisting of two noble metals, is shown to exhibit extraordinary resistance to wear. Ultralow wear rates, less than a monolayer of material removed per sliding pass, are measured for Pt-Au thin films at a maximum Hertz contact stress of up to 1.1 GPa. This is the first instance of an all-metallic material exhibiting a specific wear rate on the order of 10-9 mm3 N-1 m-1 , comparable to diamond-like carbon (DLC) and sapphire. Remarkably, the wear rate of sapphire and silicon nitride probes used in wear experiments are either higher or comparable to that of the Pt-Au alloy, despite the substantially higher hardness of the ceramic probe materials. High-resolution microscopy shows negligible surface microstructural evolution in the wear tracks after 100k sliding passes. Mitigation of fatigue-driven delamination enables a transition to wear by atomic attrition, a regime previously limited to highly wear-resistant materials such as DLC.

Melting Can Hinder Impact-Induced Adhesion.

Melting has long been used to join metallic materials, from welding to selective laser melting in additive manufacturing. In the same school of thought, localized melting has been generally perceived as an advantage, if not the main mechanism, for the adhesion of metallic microparticles to substrates during a supersonic impact. Here, we conduct the first in situ supersonic impact observations of individual metallic microparticles aimed at the explicit study of melting effects. Counterintuitively, we find that under at least some conditions melting is disadvantageous and hinders impact-induced adhesion. In the parameter space explored, i.e., ∼10 µm particle size and ∼1 km/s particle velocity, we argue that the solidification time is much longer than the residence time of the particle on the substrate, so that resolidification cannot be a significant factor in adhesion.

Melt-driven mechanochemical phase transformations in moderately exothermic powder mixtures.

Usually, mechanochemical reactions between solid phases are either gradual (by deformation-induced mixing), or self-propagating (by exothermic chemical reaction). Here, by means of a systematic kinetic analysis of the Bi-Te system reacting to Bi2Te3, we establish a third possibility: if one or more of the powder reactants has a low melting point and low thermal effusivity, it is possible that local melting can occur from deformation-induced heating. The presence of hot liquid then triggers chemical mixing locally. The molten events are constrained to individual particles, making them distinct from self-propagating reactions, and occur much faster than conventional gradual reactions. We show that the mechanism is applicable to a broad variety of materials systems, many of which have important functional properties. This mechanistic picture offers a new perspective as compared to conventional, gradual mechanochemical synthesis, where thermal effects are generally ignored.

A compilation of ab-initio calculations of embrittling potencies in binary metallic alloys.

Segregation-induced changes in interfacial cohesion often control the mechanical properties of metals. The change in the work of separation of an interface upon segregation of a solute to the interface, termed the embrittling potency, is an atomic-level quantity used to predict and understand embrittlement phenomena. We present a compilation of calculations of embrittling potencies, along with references for these calculations. A discussion of this data is made in a separate article (Gibson and Schuh, 2016 [1]).

Effects of surface diffusion on high temperature selective emitters.

Using morphological and optical simulations of 1D tantalum photonic crystals at 1200K, surface diffusion was determined to gradually reduce the efficiency of selective emitters. This was attributed to shifting resonance peaks and declining emissivity caused by changes to the cavity dimensions and the aperture width. Decreasing the structure's curvature through larger periods and smaller cavity widths, as well as generating smoother transitions in curvature through the introduction of rounded cavities, was found to alleviate this degradation. An optimized structure, that shows both high efficiency selective emissivity and resistance to surface diffusion, was presented.

Accelerated sintering in phase-separating nanostructured alloys.

Sintering of powders is a common means of producing bulk materials when melt casting is impossible or does not achieve a desired microstructure, and has long been pursued for nanocrystalline materials in particular. Acceleration of sintering is desirable to lower processing temperatures and times, and thus to limit undesirable microstructure evolution. Here we show that markedly enhanced sintering is possible in some nanocrystalline alloys. In a nanostructured W-Cr alloy, sintering sets on at a very low temperature that is commensurate with phase separation to form a Cr-rich phase with a nanoscale arrangement that supports rapid diffusional transport. The method permits bulk full density specimens with nanoscale grains, produced during a sintering cycle involving no applied stress. We further show that such accelerated sintering can be evoked by design in other nanocrystalline alloys, opening the door to a variety of nanostructured bulk materials processed in arbitrary shapes from powder inputs.

Shape memory and superelastic ceramics at small scales.

Shape memory materials are a class of smart materials able to convert heat into mechanical strain (or strain into heat) by virtue of a martensitic phase transformation. Some brittle materials such as intermetallics and ceramics exhibit a martensitic transformation but fail by cracking at low strains and after only a few applied strain cycles. Here we show that such failure can be suppressed in normally brittle martensitic ceramics by providing a fine-scale structure with few crystal grains. Such oligocrystalline structures reduce internal mismatch stresses during the martensitic transformation and lead to robust shape memory ceramics that are capable of many superelastic cycles up to large strains; here we describe samples cycled as many as 50 times and samples that can withstand strains over 7%. Shape memory ceramics with these properties represent a new class of actuators or smart materials with a set of properties that include high energy output, high energy damping, and high-temperature usage.