Ductile and ultrahigh-strength eutectic high-entropy alloys by large-volume 3D printing

doi:10.1016/j.jmst.2022.04.004

Abstract

Abstract:

3D printing of high-strength alloys enables efficient manufacturing of complex metallic components. Yet, the as-built parts are often characterized by unsatisfied ductility due to micro-defects, requiring additional heat treatment to optimize the structure before in-site applications. The post heat-processing, however, often changes the shape of the printed parts, deteriorating the quality of the printed components. In addition, many printed large-scale alloy parts with complex shapes are difficult to be processed by hot isostatic pressing. This requires that the alloys can be printed with good strength and ductility without the necessity of additional thermal processing. Here, we show that excellent ductility and ultrahigh strength can be achieved in a eutectic high-entropy alloy (EHEA) by large-volume 3D printing. The as-printed EHEA has a tensile yield strength of 1040 MPa, and a total elongation of 24%, as well as superior corrosion resistance in seawater environment. The excellent combination of properties outperforms that of all other existing metallic materials. Note that these astonishing properties are from specimens directly after 3D printing without any subsequent heat treatment and hot isostatic pressing. The exceptional mechanical properties are mainly ascribed to the fine lamella spacing in the composite structure consisting of face-centered cubic matrix and B2 precipitates, which renders high resistance for dislocation movement and extends work hardening capability. The EHEA printed in large volume without post processing thus shows high applicability for mass-production at an industrial scale.

Key words: Eutectic high-entropy alloys, 3d printing, Mechanical properties, Microstructure

Yiping Lu, Xiaoxiang Wu, Zhenghong Fu, Qiankun Yang, Yong Zhang, Qiming Liu, Tianxin Li, Yanzhong Tian, Hua Tan, Zhiming Li, Tongmin Wang, Tingju Li. Ductile and ultrahigh-strength eutectic high-entropy alloys by large-volume 3D printing[J]. J. Mater. Sci. Technol., 2022, 126: 15-21.

Figures/Tables 5

Fig. 1. Mechanical properties. (a) Engineering stress-strain curve of the current EHEA prepared by 3D printing (red solid line) comparing to that by casting (black dashed line). (b) Corresponding strain hardening rate and true stress-true strain curves of the EHEA prepared by the two different methods. (c) Mechanical properties comparison with other types of alloys prepared by 3D printing. (d) Mechanical properties comparison with other types of EHEAs prepared in different ways.

Fig. 2. XRD and SEM analysis. (a) XRD patterns showing the presence of FCC (L12) and BCC (B2) phases in the powders and the printed bulk. (b) SEM secondary electron image showing a representative heat affected zone. (c) EBSD phase map confirming the two-phase microstructure. (d) EBSD IPF (inverse pole figure) map of a representative sample region. (e) ECCI analysis from the region highlighted by the white rectangle in (c). (f) Enlarged ECC image from the highlighted region in (e).

Fig. 3. STEM analysis for the 3D-printed EHEA prior to tensile deformation. (a) STEM HAADF image showing rod-like composite microstructure. (b) Enlarged view showing the interface region. (c) HRSTEM HAADF image showing the FCC structure confirmed with FFT, with the beam parallel to [011] zone axis. (d) HRSTEM HAADF analysis showing the B2 phase, with the beam parallel to [111] zone axis. (e) STEM EDS analysis showing elemental distribution at the two phases.

Fig. 4. APT analysis of the phase structure in the 3D-printed EHEA. (a) Elemental distribution along the tip; nano-precipitates inside the B2 phase are highlighted with Cr isocomposition of 23 at.%. (b) 1D compositional profiles showing the elemental distribution across the FCC-B2 phase boundary marked in (a). (c) An example of the Cr-rich nano-precipitate in the B2 phase. (d) 1D proxigram of 10 nano-precipitates showing elemental distribution in the interface region.

Fig. 5. STEM analysis revealing the microstructure evolution at different deformation stages. At a local strain of 20%: (a) STEM HAADF image showing the populated dislocation structure and the two-phase microstructure. (b) STEM BF image showing the highlighted region from (a). (c) STEM HAADF images showing the sheared BCC (B2) phases with the serrated features, indicated by orange arrows. (d) STEM BF images showing the lamellar structure of the two-phases, and the lower insert presents the SAD pattern of ordered L12 phase. At a local strain of 60%: (e) STEM HAADF image showing the enhanced dislocation density within FCC phase. (f) STEM BF image of the same region in (e). (g) STEM HAADF image highlights the blurred phase boundary populated with dislocations. (h) STEM BF image of the same region in (g).

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