Materials design for hypersonics.

Hypersonic vehicles must withstand extreme conditions during flights that exceed five times the speed of sound. These systems have the potential to facilitate rapid access to space, bolster defense capabilities, and create a new paradigm for transcontinental earth-to-earth travel. However, extreme aerothermal environments create significant challenges for vehicle materials and structures. This work addresses the critical need to develop resilient refractory alloys, composites, and ceramics. We will highlight key design principles for critical vehicle areas such as primary structures, thermal protection, and propulsion systems; the role of theory and computation; and strategies for advancing laboratory-scale materials to manufacturable flight-ready components.

Chemical and Structural Factors Affecting the Stability of Wadsley-Roth Block Phases.

Wadsley-Roth phases have emerged as highly promising anode materials for Li-ion batteries and are an important class of phases that can form as part of the oxide scales of refractory multiprinciple element alloys. An algorithmic approach is described to systematically enumerate two classes of Wadsley-Roth crystallographic shear structures. An analysis of algorithmically generated Wadsley-Roth phases reveals that a diverse set of oxide crystal structures belongs to the Wadsley-Roth family of phases. First-principles calculations enable the identification of crystallographic and chemical factors that affect Wadsley-Roth phase stability, pointing in particular to the importance of the number and nature of the edges shared by neighboring metal-oxygen octahedra. A systematic study of Wadsley-Roth phases in the Ti-Nb-O ternary system shows that the cations with the highest oxidation states segregate to octahedral sites that minimize the number of shared edges, while cations with the lowest oxidation state accumulate to edge-sharing octahedra at shear boundaries.

A new elastic characterization method for anisotropic bilayer specimens via Bayesian resonant ultrasound spectroscopy.

A novel nondestructive method for complete elastic characterization of substrate-coating bilayer specimens with distinct anisotropic layers via resonant ultrasound spectroscopy (RUS) and Bayesian inversion is developed here. Bayesian formulations of the RUS inversion problem-of quantifying elastic properties given a measured list of resonance frequencies recorded from a single, typically small, precisely fabricated, macroscopically homogeneous, linear-elastic specimen-are a recent development. Here we report the first Bayesian formulation of the bilayer problem, and through a series of practical examples, demonstrate novel parameter estimation capabilities of our open-source CmdStan-RUS code. Finding specimen geometry and the number of resonance modes used for inversion strongly govern the ability to retrieve individual elastic moduli. The concept of "invertability" is explored for a range of relevant geometries using virtual specimens that resemble experimental bilayers of plasma sprayed ceramic coatings on single crystal metallic substrates. A range of Bayesian posterior evaluation methods are addressed, particularly considering the large computational cost of the bilayer forward model. Laplace approximation methods are thus developed and implemented for bilayer geometry design space modeling and expedient estimates of parameter uncertainties. Ideal specimen design, different noise models, the influence of prior distributions, dual-likelihood fits incorporating measurements of the bare substrate, and how Bayesian RUS methods differ from traditional RUS optimization are discussed.

Electron backscattered diffraction using a new monolithic direct detector: High resolution and fast acquisition.

A monolithic active pixel sensor based direct detector that is optimized for the primary beam energies in scanning electron microscopes is implemented for electron back-scattered diffraction (EBSD) applications. The high detection efficiency of the detector and its large array of pixels allow sensitive and accurate detection of Kikuchi bands arising from primary electron beam excitation energies of 4 keV to 28 keV, with the optimal contrast occurring in the range of 8-16 keV. The diffraction pattern acquisition speed is substantially improved via a sparse sampling mode, resulting from the acquisition of a reduced number of pixels on the detector. Standard inpainting algorithms are implemented to effectively estimate the information in the skipped regions in the acquired diffraction pattern. For EBSD mapping, an acquisition speed as high as 5988 scan points per second is demonstrated, with a tolerable fraction of indexed points and accuracy. The collective capabilities spanning from high angular resolution EBSD patterns to high speed pattern acquisition are achieved on the same detector, facilitating simultaneous detection modalities that enable a multitude of advanced EBSD applications, including lattice strain mapping, structural refinement, low-dose characterization, 3D-EBSD and dynamic in situ EBSD.

Expanded dataset of mechanical properties and observed phases of multi-principal element alloys.

This data article presents a compilation of mechanical properties of 630 multi-principal element alloys (MPEAs). Built upon recently published MPEA databases, this article includes updated records from previous reviews (with minor error corrections) along with new data from articles that were published since 2019. The extracted properties include reported composition, processing method, microstructure, density, hardness, yield strength, ultimate tensile strength (or maximum compression strength), elongation (or maximum compression strain), and Young's modulus. Additionally, descriptors (e.g. grain size) not included in previous reviews were also extracted for articles that reported them. The database is hosted and continually updated on an open data platform, Citrination. To promote interpretation, some data are graphically presented.

Multiplicity of dislocation pathways in a refractory multiprincipal element alloy.

Refractory multiprincipal element alloys (MPEAs) are promising materials to meet the demands of aggressive structural applications, yet require fundamentally different avenues for accommodating plastic deformation in the body-centered cubic (bcc) variants of these alloys. We show a desirable combination of homogeneous plastic deformability and strength in the bcc MPEA MoNbTi, enabled by the rugged atomic environment through which dislocations must navigate. Our observations of dislocation motion and atomistic calculations unveil the unexpected dominance of nonscrew character dislocations and numerous slip planes for dislocation glide. This behavior lends credence to theories that explain the exceptional high temperature strength of similar alloys. Our results advance a defect-aware perspective to alloy design strategies for materials capable of performance across the temperature spectrum.

A defect-resistant Co-Ni superalloy for 3D printing.

Additive manufacturing promises a major transformation of the production of high economic value metallic materials, enabling innovative, geometrically complex designs with minimal material waste. The overarching challenge is to design alloys that are compatible with the unique additive processing conditions while maintaining material properties sufficient for the challenging environments encountered in energy, space, and nuclear applications. Here we describe a class of high strength, defect-resistant 3D printable superalloys containing approximately equal parts of Co and Ni along with Al, Cr, Ta and W that possess strengths in excess of 1.1 GPa in as-printed and post-processed forms and tensile ductilities of greater than 13% at room temperature. These alloys are amenable to crack-free 3D printing via electron beam melting (EBM) with preheat as well as selective laser melting (SLM) with limited preheat. Alloy design principles are described along with the structure and properties of EBM and SLM CoNi-base materials.

Advanced detector signal acquisition and electron beam scanning for high resolution SEM imaging.

The advancement of materials science at the mesoscale requires improvements in both sampling volumes/areas and spatial resolution in order to make statistically significant measurements of microstructures that influence higher-order material properties, such as fatigue and fracture. Therefore, SEM-based techniques have become desirable due to improvements in imaging resolution, large sample handling capability, and flexibility for in-situ instrumentation. By using fast sampling of SEM electron detector signals, intrinsic beam scanning defects have been identified that are related to the response time of the SEM electron beam deflectors and electron detectors. Mitigation of these beam scanning defects using detector sampling approaches and an adaptive model for settling time is shown to produce higher resolution SEM images, at faster image acquisition times, with a means to quantify the different response functions for various beam deflectors and detectors including those for electrons and ions.

Enhancing Thermoelectric Properties through Control of Nickel Interstitials and Phase Separation in Heusler/Half-Heusler TiNi1.1Sn Composites.

Thermoelectric devices, which allow direct conversion of heat into electrical energy, require materials with improved figures of merit ( z T ) in order to ensure widespread adoption. Several techniques have been proposed to increase the z T of known thermoelectric materials through the reduction of thermal conductivity, including heavy atom substitution, grain size reduction and inclusion of a semicoherent second phase. The goal in these approaches is to reduce thermal conductivity through phonon scattering without modifying the electronic properties. In this work, we demonstrate that Ni interstitials in the half-Heusler thermoelectric TiNiSn can be created and controlled in order to improve physical properties. Ni interstitials in TiNi 1.1 Sn are not thermodynamically stable and, instead, are kinetically trapped using appropriate heat treatments. The Ni interstitials, which act as point defect phonon scattering centers and modify the electronic states near the Fermi level, result in reduced thermal conductivity and enhance the Seebeck coefficient. The best materials tested here, created from controlled heat treatments of TiNi 1.1 Sn samples, display z T = 0.26 at 300 K, the largest value reported for compounds in the Ti⁻Ni⁻Sn family.

Bayesian inference of elastic properties with resonant ultrasound spectroscopy.

Bayesian modeling and Hamiltonian Monte Carlo (HMC) are utilized to formulate a robust algorithm capable of simultaneously estimating anisotropic elastic properties and crystallographic orientation of a specimen from a list of measured resonance frequencies collected via Resonance Ultrasound Spectroscopy (RUS). Unlike typical optimization procedures which yield point estimates of the unknown parameters, computing a Bayesian posterior yields probability distributions for the unknown parameters, and HMC is an efficient way to compute this posterior. The algorithms described are demonstrated on RUS data collected from two parallelepiped specimens of structural metal alloys. First, the elastic constants for a specimen of fine-grain polycrystalline Ti-6Al-4 V with random crystallographic texture and isotropic elastic symmetry are estimated. Second, the elastic constants and crystallographic orientation for a single crystal Ni-based superalloy CMSX-4 specimen are accurately determined, using only measurements of the specimen geometry, mass, and resonance frequencies. The unique contributions of this paper are as follows: the application of HMC for sampling the Bayesian posterior of a probabilistic RUS model, and the procedure for simultaneous estimation of elastic constants and lattice-specimen misorientation. Compared to previous approaches these algorithms demonstrate superior convergence behavior, particularly when the initial parameterization is unknown, and enable substantially simplified experimental procedures.

Transmission scanning electron microscopy: Defect observations and image simulations.

The new capabilities of a FEG scanning electron microscope (SEM) equipped with a scanning transmission electron microscopy (STEM) detector for defect characterization have been studied in parallel with transmission electron microscopy (TEM) imaging. Stacking faults and dislocations have been characterized in strontium titanate, a polycrystalline nickel-base superalloy and a single crystal cobalt-base material. Imaging modes that are similar to conventional TEM (CTEM) bright field (BF) and dark field (DF) and STEM are explored, and some of the differences due to the different accelerating voltages highlighted. Defect images have been simulated for the transmission scanning electron microscopy (TSEM) configuration using a scattering matrix formulation, and diffraction contrast in the SEM is discussed in comparison to TEM. Interference effects associated with conventional TEM, such as thickness fringes and bending contours are significantly reduced in TSEM by using a convergent probe, similar to a STEM imaging modality, enabling individual defects to be imaged clearly even in high dislocation density regions. Beyond this, TSEM provides significant advantages for high throughput and dynamic in-situ characterization.

Oxygen evolution on Fe-doped NiO electrocatalysts deposited via microplasma.

The oxygen evolution reaction (OER) in alkaline media was investigated on nanostructured Fe2O3, NiO, and Ni1-xFexO (Fe-doped, rocksalt NiO, x = 0.05-0.19) electrocatalysts deposited via microplasma on indium tin oxide. A detailed investigation of film morphology, structure, and chemical surface state using SEM, XRD, and XPS, respectively, was carried out to understand catalytic activity, which was assessed using cyclic voltammetry and chronopotentiometry. Iron was seen to be fully incorporated into the parent rocksalt NiO lattice during microplasma deposition, and overpotentials (η) decreased from 360 mV for NiO to 310 mV for Ni1-xFexO at 10 mA cm-2. Interestingly, overpotential did not change significantly for Fe compositions from 5-19%. The Ni1-xFexO films displayed relatively low Tafel slopes of 20-30 mV dec-1 at 0.01-1 mA cm-2, demonstrating their high activity for (OER). Turn-over-frequency (TOF, i.e., O2 molecules per Ni atom per s) at η = 350 mV revealed a continuous improvement in activity of the NiO surface with increasing Fe content, where values of 0.07 and 0.48 s-1 were measured for undoped NiO and Ni0.81Fe0.19O films, respectively. Chronopotentiometry measurements followed by SEM and XPS verified that the as-deposited Ni1-xFexO catalysts were mechanically and chemically stable for OER under alkaline conditions. This work highlights that microplasma-based deposition is a general approach to realize conformal coatings of nanostructured, doped oxides with high activity for OER.

Thermoelectric performance and the role of anti-site disorder in the 24-electron Heusler TiFe2Sn.

Heusler compounds XY 2 Z with 24 valence electrons per formula unit are potential thermoelectric materials, given their thermal and chemical stability and their relatively earth-abundant constituent elements. We present results on the 24-electron compound TiFe2Sn here. First principles calculations on this compound suggest semiconducting behavior. A relatively flat conduction band that could be associated with a high Seebeck coefficient upon electron doping is found. A series of compounds have been prepared and characterized using a combination of synchrotron x-ray and neutron diffraction studies to understand the effects of site order/disorder phenomena and n-type doping. Samples fabricated by a three step processing approach were subjected to high temperature Seebeck and electrical resistivity measurements. Ti:Fe anti-site disorder is present in the stoichiometric compound and these defects are reduced when starting Ti-rich compositions are employed. Additionally, we investigate control of the Seebeck coefficient through the introduction of carriers through the substitution of Sb on the Sn site in these intrinsically p-type materials.

3D printing of high-strength aluminium alloys.

Metal-based additive manufacturing, or three-dimensional (3D) printing, is a potentially disruptive technology across multiple industries, including the aerospace, biomedical and automotive industries. Building up metal components layer by layer increases design freedom and manufacturing flexibility, thereby enabling complex geometries, increased product customization and shorter time to market, while eliminating traditional economy-of-scale constraints. However, currently only a few alloys, the most relevant being AlSi10Mg, TiAl6V4, CoCr and Inconel 718, can be reliably printed; the vast majority of the more than 5,500 alloys in use today cannot be additively manufactured because the melting and solidification dynamics during the printing process lead to intolerable microstructures with large columnar grains and periodic cracks. Here we demonstrate that these issues can be resolved by introducing nanoparticles of nucleants that control solidification during additive manufacturing. We selected the nucleants on the basis of crystallographic information and assembled them onto 7075 and 6061 series aluminium alloy powders. After functionalization with the nucleants, we found that these high-strength aluminium alloys, which were previously incompatible with additive manufacturing, could be processed successfully using selective laser melting. Crack-free, equiaxed (that is, with grains roughly equal in length, width and height), fine-grained microstructures were achieved, resulting in material strengths comparable to that of wrought material. Our approach to metal-based additive manufacturing is applicable to a wide range of alloys and can be implemented using a range of additive machines. It thus provides a foundation for broad industrial applicability, including where electron-beam melting or directed-energy-deposition techniques are used instead of selective laser melting, and will enable additive manufacturing of other alloy systems, such as non-weldable nickel superalloys and intermetallics. Furthermore, this technology could be used in conventional processing such as in joining, casting and injection moulding, in which solidification cracking and hot tearing are also common issues.

Reconstruction of Laser-Induced Surface Topography from Electron Backscatter Diffraction Patterns.

We demonstrate that the surface topography of a sample can be reconstructed from electron backscatter diffraction (EBSD) patterns collected with a commercial EBSD system. This technique combines the location of the maximum background intensity with a correction from Monte Carlo simulations to determine the local surface normals at each point in an EBSD scan. A surface height map is then reconstructed from the local surface normals. In this study, a Ni sample was machined with a femtosecond laser, which causes the formation of a laser-induced periodic surface structure (LIPSS). The topography of the LIPSS was analyzed using atomic force microscopy (AFM) and reconstructions from EBSD patterns collected at 5 and 20 kV. The LIPSS consisted of a combination of low frequency waviness due to curtaining and high frequency ridges. The morphology of the reconstructed low frequency waviness and high frequency ridges matched the AFM data. The reconstruction technique does not require any modification to existing EBSD systems and so can be particularly useful for measuring topography and its evolution during in situ experiments.

Electrically pumped continuous wave quantum dot lasers epitaxially grown on patterned, on-axis (001) Si.

High performance III-V lasers at datacom and telecom wavelengths on on-axis (001) Si are needed for scalable datacenter interconnect technologies. We demonstrate electrically injected quantum dot lasers grown on on-axis (001) Si patterned with {111} v-grooves lying in the [110] direction. No additional Ge buffers or substrate miscut was used. The active region consists of five InAs/InGaAs dot-in-a-well layers. We achieve continuous wave lasing with thresholds as low as 36 mA and operation up to 80°C.

Solute segregation and deviation from bulk thermodynamics at nanoscale crystalline defects.

It has long been known that solute segregation at crystalline defects can have profound effects on material properties. Nevertheless, quantifying the extent of solute segregation at nanoscale defects has proven challenging due to experimental limitations. A combined experimental and first-principles approach has been used to study solute segregation at extended intermetallic phases ranging from 4 to 35 atomic layers in thickness. Chemical mapping by both atom probe tomography and high-resolution scanning transmission electron microscopy demonstrates a markedly different composition for the 4-atomic-layer-thick phase, where segregation has occurred, compared to the approximately 35-atomic-layer-thick bulk phase of the same crystal structure. First-principles predictions of bulk free energies in conjunction with direct atomistic simulations of the intermetallic structure and chemistry demonstrate the breakdown of bulk thermodynamics at nanometer dimensions and highlight the importance of symmetry breaking due to the proximity of interfaces in determining equilibrium properties.

Improving the thermoelectric properties of half-Heusler TiNiSn through inclusion of a second full-Heusler phase: microwave preparation and spark plasma sintering of TiNi(1+x)Sn.

Half-Heusler thermoelectrics offer the possibility to choose from a variety of non-toxic and earth-abundant elements. TiNiSn is of particular interest and - with its relatively high electrical conductivity and Seebeck coefficient - allows for optimization of its thermoelectric figure of merit, reaching values of up to 1 in heavily-doped and/or phase-segregated systems. In this contribution, we used an energy- and time-efficient process involving solid-state preparation in a commercial microwave oven and a fast consolidation technique, Spark Plasma Sintering, to prepare a series of Ni-rich TiNi1+xSn with small deviations from the half-Heusler composition. Spark Plasma Sintering plays an important role in the process by being a part of the synthesis of the material rather than solely a densification technique. Synchrotron powder X-ray diffraction and microprobe data confirm the presence of a secondary TiNi2Sn full-Heusler phase within the half-Heusler matrix. We observe a clear correlation between the amount of full-Heusler phase and the lattice thermal conductivity of the samples, resulting in decreasing total thermal conductivity with increasing TiNi2Sn fraction. This trend shows that phonons are scattered effectively as a result of the microstructure of the materials with full-Heusler inclusions in the size range of microns to tens of microns. The best performing samples with around 5% of TiNi2Sn phase exhibit maximum figures of merit of almost 0.6 between 750 K and 800 K which is an increase of ca. 35% compared to the zT of the parent compound TiNiSn.