Delineating the Ultra-Low Misorientation between the Dislocation Cellular Structures in Additively Manufactured 316L Stainless Steel.

Sub-micro dislocation cellular structures formed during rapid solidification break the strength-ductility trade-off in laser powder bed fusion (LPBF)-processed 316L stainless steel through high-density dislocations and segregated elements or precipitates at the cellular boundaries. The high-density dislocation entangled at the cellular boundary accommodates solidification strains among the cellular structures and cooling stresses through elastoplastic deformation. Columnar grains with cellular structures typically form along the direction of thermal flux. However, the ultra-low misorientations between the adjacent cellular structures and their interactions with the cellular boundary formation remain unclear. In this study, we revealed the ultra-low misorientations between the cellular structures in LPBF-processed 316L stainless steel using conventional electron backscatter diffraction (EBSD), transmission Kikuchi diffraction (TKD), and transmission electron microscopy (TEM). The conventional EBSD and TKD analysis results could provide misorientation angles smaller than 2°, while the resolution mainly depends on the specimen quality and scanning step size, and so on. A TEM technique with higher spatial resolution provides accurate information between adjacent dislocation cells with misorientation angles smaller than 1°. This study presents evidence that the TEM method is the better and more precise analytical method for the misorientation measurement of the cellular structures and provides insights into measuring the small misorientation angles between adjacent dislocation cells and nanograins in nanostructured metals and alloys with ultrafine-grained microstructures.

Martensitic Phase-Transforming Metamaterial: Concept and Model.

We successfully developed a mechanical metamaterial that displays martensitic transformation for the first time. This metamaterial has a bistable structure capable of transitioning between two stable configurations through shear deformation. The outer shape of the unit cell of this structure is a parallelogram, with its upper and lower sides forming the bases of two solid triangles. The vertices from these triangles within the parallelogram are linked by short beams, while the remaining vertices are linked by long beams. The elastic energy of the essential model of the metamaterial was formulated analytically. The energy barrier between these two stable configurations consists of the elastic strain energy due to the tensile deformation of the short beams, the compressive deformation of the long beams, and the bending deformation of the connecting hinges. One example of a novel metamaterial was additively manufactured via the materials extrusion (MEX) process of thermoplastic polyurethane. The metamaterial exhibited deformation behaviors characteristic of martensitic transformations. This mechanical metamaterial has the potential to obtain properties caused by martensitic transformation in actual materials, such as the shape memory effect and superelasticity.

Fusion of Ni Plating on CP-Titanium by Electron Beam Single-Track Scanning: Toward a New Approach for Fabricating TiNi Self-Healing Shape Memory Coating.

The limited wear resistance of commercially pure titanium (CP-Ti) hinders its use in abrasive and erosive environments, despite its good strength-weight ratio and corrosion resistance. This paper reports the first study proposing a novel method for wear-resistant TiNi coating through Ni plating and electron beam (EB) irradiation in an in situ synthetic approach. Single-track melting experiments were conducted using the EB to investigate the feasibility of forming a TiNi phase by fusing the Ni plate with the CP-Ti substrate. Varying beam powers were employed at a fixed scanning speed to determine the optimal conditions for TiNi phase formation. The concentration of the melt region was found to be approximate as estimated from the ratio of the Ni-plate thickness to the depth of the melt region, and the region with Ni-48.7 at.% Ti was successfully formed by EB irradiation. The study suggests that the mixing of Ti atoms and Ni atoms was facilitated by fluid flow induced by Marangoni and thermal convections. It is proposed that a more uniform TiNi layer can be achieved through multi-track melting under appropriate conditions. This research demonstrates the feasibility of utilizing EB additive manufacturing as a coating method and the potential for developing TiNi coatings with shape memory effects and pseudoelasticity.

Big-Volume SliceGAN for Improving a Synthetic 3D Microstructure Image of Additive-Manufactured TYPE 316L Steel.

A modified SliceGAN architecture was proposed to generate a high-quality synthetic three-dimensional (3D) microstructure image of TYPE 316L material manufactured through additive methods. The quality of the resulting 3D image was evaluated using an auto-correlation function, and it was discovered that maintaining a high resolution while doubling the training image size was crucial in creating a more realistic synthetic 3D image. To meet this requirement, modified 3D image generator and critic architecture was developed within the SliceGAN framework.

Effect of Rapid Heating and Cooling Conditions on Microstructure Formation in Powder Bed Fusion of Al-Si Hypoeutectic Alloy: A Phase-Field Study.

Al alloy parts fabricated by powder bed fusion (PBF) have attracted much attention because of the degrees of freedom in both shapes and mechanical properties. We previously reported that the Si regions in Al-Si alloy that remain after the rapid remelting process in PBF act as intrinsic heterogeneous nucleation sites during the subsequent resolidification. This suggests that the Si particles are crucial for a novel grain refinement strategy. To provide guidelines for grain refinement, the effects of solidification, remelting, and resolidification conditions on microstructures were investigated by multiphase-field simulation. We revealed that the resolidification microstructure is determined by the size and number of Si regions in the initial solidification microstructures and by the threshold size for the nucleation site, depending on the remelting and resolidification conditions. Furthermore, the most refined microstructure with the average grain size of 4.8 µm is predicted to be formed under conditions with a large temperature gradient of Gsol = 106 K/m in the initial solidification, a high heating rate of HR = 105 K/s in the remelting process, and a fast solidification rate of Rresol = 10-1 m/s in the resolidification process. Each of these conditions is necessary to be considered to control the microstructures of Al-Si alloys fabricated via PBF.

Effects of carbon addition on wear mechanisms of CoCrMo metal-on-metal hip joint bearings.

The wear behaviors of biomedical CoCrMo prosthetic alloys containing various amounts of carbon were investigated using a standard hip joint simulator in a simulated body fluid. A few chunks and punctate σ-phase precipitates were observed in the low-carbon (LC) alloy; these were responsible for the abrasion and run-in wear. Increasing the carbon content led to greater precipitation of globular M23C6-type carbides. As a result, lower wear loss was observed in the high-carbon (HC) alloy. However, the Student's t-test analysis on wear loss indicated that there was no significant difference in wear loss between the LC-LC and HC-HC combinations. Surface fatigue caused by torn-off of Mo-rich carbides was the dominant wear mechanism in the HC alloy. Further, Cr-rich carbides prevent three-body abrasion and increase the wear resistance.

Effects of surface friction treatment on the in vitro release of constituent metals from the biomedical Co-29Cr-6Mo-0.16N alloy.

Due to the ignorance by many researchers on the influence of starting microstructure on the metal release of biomedical materials in human body after implant, in this study, the effect of surface friction treatment on the in vitro release of the constituent elements of the biomedical Co-29Cr-6Mo-0.16N (CCM) alloy is investigated for the first time by immersion test in lactic acid solution combined with electron backscatter diffraction, transmission electron microscope, X-ray diffraction, X-ray photoelectron spectroscopy, and inductively coupled plasma atomic emission spectroscopy (ICP-EOS). The results indicate that friction treatment on the as-annealed CCM alloy sample surface leads to a planar strain-induced martensitic transformation (SIMT) on sample surface; this greatly accelerates the release of all the constituent elements and, in particular, that of Co as indicated by the ICP-EOS analysis. This increase can be ascribed to a localized deformation that occurred over the entire sample surface, with the dislocation density being high within the SIMTed phase and low in the alloy matrix.

Uneven damage on head and liner contact surfaces of a retrieved Co-Cr-based metal-on-metal hip joint bearing: An important reason for the high failure rate.

Detailed metallurgical investigations have been performed on a used Co-Cr-based metal-on-metal (MoM) hip joint bearing containing a type of liner that is commonly used in such joints. The damage on the metal-liner sliding surface was considerably more severe than that on the metal head counterpart, in terms of wear-scar density and width and microcrack frequency. Cross-sectional transmission electron microscopy revealed that a thick (>3 µm) nanocrystalline layer formed on the sliding surface of the head, whereas the liner had coarse carbides embedded in it and nanocrystals were formed in a very limited region no deeper than 1 µm. Comparative investigation of an unused head and a liner of identical type showed that although the chemical compositions of the liner and head were nearly identical, their microstructures were significantly different. Specifically, the grain size in the liner was larger than that in the head on average, and the grain boundaries of the liner were decorated with coarse carbides. Moreover, X-ray diffraction analysis revealed a large tensile residual stress only in the liner. These differences are possibly responsible for the wear damage on the liner being more serious than that on the head.

Quantitative in vivo biocompatibility of new ultralow-nickel cobalt-chromium-molybdenum alloys.

Nickel (Ni) eluted from metallic biomaterials is widely accepted as a major cause of allergies and inflammation. To improve the safety of cobalt-chromium-molybdenum (Co-Cr-Mo) alloy implants, new ultralow-Ni Co-Cr-Mo alloys with and without zirconium (Zr) have been developed, with Ni contents of less than 0.01%. In the present study, we investigated the biocompatibility of these new alloys in vivo by subcutaneously implanting pure Ni, conventional Co-Cr-Mo, ultralow-Ni Co-Cr-Mo, and ultralow-Ni Co-Cr-Mo with Zr wires into the dorsal sides of mice. After 3 and 7 days, tissues around the wire were excised, and inflammation; the expression of IL-1ß, IL-6, and TNF-α; and Ni, Co, Cr, and Mo ion release were analyzed using histological analyses, qRT-PCR, and inductively coupled plasma mass spectrometry (ICP-MS), respectively. Significantly larger amounts of Ni eluted from pure Ni wires than from the other wires, and the degree of inflammation depended on the amount of eluted Ni. Although no significant differences in inflammatory reactions were identified among new alloys and conventional Co-Cr-Mo alloys in histological and qRT-PCR analyses, ICP-MS analysis revealed that Ni ion elution from ultralow-Ni Co-Cr-Mo alloys with and without Zr was significantly lower than from conventional Co-Cr-Mo alloys. Our study, suggests that the present ultralow-Ni Co-Cr-Mo alloys with and without Zr have greater safety and utility than conventional Co-Cr-Mo alloys. © 2016 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 34:1505-1513, 2016.

Local strain evolution due to athermal γ→ε martensitic transformation in biomedical CoCrMo alloys.

Locally developed strains caused by athermal γ face-centered cubic (fcc)→ε hexagonal close-packed (hcp) martensitic transformation were investigated for the γ matrix of Ni-free Co-29Cr-6Mo (wt%) alloys prepared with or without added nitrogen. Electron-backscatter-diffraction-(EBSD)-based strain analysis revealed that in addition to ε-martensite interiors, the N-free alloy that had a duplex microstructure consisting of the γ matrix and athermal ε-martensite plates showed larger magnitudes of both elastic and plastic strains in the γ phase matrix than the N-doped counterpart that did not have a ε-martensite phase. Transmission electron microscopy (TEM) results indicated that the ε-martensite microplates were aggregates of thin ε-layers, which were formed by three different {111}γ〈112¯ã€‰Î³ Shockley partial dislocations in accordance with a previously proposed mechanism (Putaux and Chevalier, 1996) that canceled the shear strains of the individual variants. The plastic strains are believed to have originated from the martensitic transformation itself, and the activity of dislocations is believed to be the origin of the transformation. We have revealed that the elastic strains in the γ matrix originate from interactions among the ε-martensite phase, extended dislocations, and/or thin ε-layers. The dislocations highly dissociated into stacking faults, making stress relaxation at intersections difficult and further introducing local strain evolution.

Detwining in Mg alloy with a high density of twin boundaries.

To investigate the role of preexisting twin boundaries in magnesium alloys during the deformation process, a large number of {10-12} tensile twins were introduced by a radial compression at room temperature before hot compressive tests with both low and high strain rates. Unlike the stable twins in Cu-based alloys with low stacking fault energies, {10-12} twins in Mg alloy are extremely unstable or easy to detwin through {10-12}-{10-12} re-twinning. As a result, non-lenticular residual twins and twin traces with misorientation of 5°-7° were present, as confirmed by electron backscatter diffraction. The extreme instability of the twins during compression indicates that both twin and detwinning require extremely low resolved shear stresses under our experimental conditions.

Copper-catalyzed synthesis of esters from ketones. Alkyl group as a leaving group.

The conversion of ketones to esters has been achieved through the use of Cu catalyst and tetrabutylammonium nitrite. This reaction involves the activation of the less activated C-C bond, and the alkyl group is removed as a leaving group. Various isopropyl ketones are found to be good substrates for this reaction.