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Boron doping with an adequate concentration is highly desirable for alloy development because it profoundly improves the material's interface cohesion via interfacial segregation. However, scientific and applicable potentials of soluble boron that resides at the alloy internal grains are generally overlooked. Here we report a strategy for overcoming the typically low strengths of face-centered cubic high-entropy alloys (HEAs) through exploiting soluble boron instead of the interfacial boron. We find that soluble boron increases stress/strain field at the recrystallized HEA grain structure, leading to the generation of short-range order (SRO) in those deformation structure under load at 77 K. The highly increased degree of SRO at planar dislocation slip band that forms during straining, proved by electron microscopy and synchrotron X-ray diffraction, strengthens a typical non-equimolar Fe40Mn40Co10Cr10 (at%) HEA, particularly increasing yield strengths by ∼32%, to ∼1.1 GPa compared to those of boron-free reference materials with similar grain sizes. The advent of deformation-induced SRO domains causes severe lattice distortion (specifically, contraction), leading to the increased cryogenic yield strength of ∼210 MPa, but generating micro-voids at grain boundaries. This study on deformation-induced SRO via boron advances the fundamental understanding of SRO impacts on HEA grains and mechanical properties at cryogenic temperatures, which may pave a general pathway for developing a wide range of ultrastrong alloys for cryogenic applications.

General design concept used in high-entropy alloys (HEAs) have deviated from forming an fcc single phase to utilizing hard intermetallic phases in ductile fcc matrix. Here, we effectively exploited strengthening effects of a brittle intermetallic sigma (σ) phase to improve cryogenic tensile properties of a non-equi-atomic ductile VCrFeNi four-component HEA. We preferentially selected vanadium as a candidate alloying element to efficiently produce the σ phase through computational thermodynamic approach. This σ phase has beneficial effects on grain refinement through retardation of grain growth due to grain-boundary pinning, thereby leading to yield strength of 0.79–0.93 GPa. The extensive strain hardening results in tensile strength of 1.33–1.49 GPa and ductility of 23–47% at cryogenic temperature, which are enabled by nano-sized dislocation substructures rather than deformation twinning. Our results demonstrate how the intermetallic σ phase, which has been avoided in typical HEAs because of ductility deterioration, could be used in high strength HEA design.

The fatigue crack propagation (FCP) behavior of β-annealed Ti-6Al-4V (Ti64) alloy was examined in air and 0.6 M NaCl solution under anodic and cathodic applied potentials and at two different R ratios of 0.1 and 0.7. β-annealed Ti64 alloy was sensitive to environmental FCP in NaCl solution under both anodic and cathodic applied potentials at an R ratio of 0.1, while the environmental effect was almost negligible at an R ratio of 0.7. The extent of crack branching in air and at an R ratio of 0.1 decreased substantially in NaCl solution and/or at an R ratio of 0.7. The EBSD (electron backscatter diffraction) and SEM (scanning electron microscope) fractographic analyses on the FCP tested specimens showed that microstructure-sensitive cracking, rather than crystallographic cleavage cracking, became encouraged in NaCl solution and/or high R ratio. It was suggested that the extent of crack branching played an important role in determining the environmental FCP behavior of β-annealed Ti64 alloy.

Rapid melting and solidification cycles during laser-based additive manufacturing create non-equilibrium microstructures in stainless steels (SSs) including atomic segregation-mediated ultrafine δ-ferrite, in contrast to coarse δ-ferrite in typical casting-produced SSs. The formation of metastable ultrafine δ-ferrite in additively manufactured SSs generates a new coherent interface in austenitic matrix. However, currently a consensus on how ultrafine δ-ferrite interacts with dislocations is lacking, particularly in directed energy deposition-processed 304L SS. Herein, the role of ultrafine δ-ferrite on the mechanical properties of directed energy deposition-processed 304L SS was investigated by modifying the laser scan speeds of 850 and 1150 mm/min and by performing electron microscopy-based characterization. We find that the ultrafine δ-ferrite maintains coherency with a γ-austenite matrix in the undeformed state and interacts with dislocations during plastic deformation. Additionally, the twin volume fraction depends on the initial grain size of 304L SSs, which results in a 23 MPa (for strength) and 5% (for ductility) mechanical property difference between the 850 (SLOW) and 1150 (FAST) mm/min scan speed conditions. Through the synergetic effects of ultrafine δ-ferrite, deformation-induced twins and twin intersections, the present additively manufactured 304L SS achieves an outstanding ductility that is larger than that of the previous directed energy deposition-processed SSs. This result proves that the ultrafine metastable phase contributes to the prolonged plasticity of the additively manufactured metallic alloys if the metastable phase maintains coherency with the matrix during plastic deformation.

The passive films on typical stainless steels (SS) and on a newly developed high-Cr (17 wt%)-added 18 wt%-Mn steel (HCr-HMnS) were compared by Cs-corrected scanning transmission electron microscopy and atom probe tomography. Although the passive films of all samples having similar Cr contents had the same thickness, unprecedented hexagonal wurtzite MnO inside the passive film of HCr-HMnS specimen was susceptible to corrosion cracking; this was not observed in the SS samples. This MnO caused crack formation during potentiodynamic polarization test, suggesting that reducing the harmful MnO by adding Mo and Ni facilitates the development of high-Mn base SS materials . Furthermore, higher MoO2 composition of the passive films on 316 type austenitic SS than 304 type series might would result in primarily the improved pitting resistance.

Diffused hydrogen atoms in high-strength steels induce both cohesive energy drops and dislocation mobility enhancement, which usually degrade the mechanical properties of materials. However, the enhanced dislocation mobility could also increase the slip planarity, which enhances the mechanical properties of materials. In this study, effects of hydrogen charging on the mechanical properties of as-cast high-Mn steels were investigated. Hydrogen charging in the high-Mn steel promotes slip planarity with short-range ordering, which results in a large planar slip band fraction and strain hardening enhancement of the hydrogen-charged sample. This shows that hydrogen-induced ordering can be related to both deformation mechanism and mechanical property of hydrogen charged high-Mn steels.

Tensile and high cycle fatigue behaviors of high-Mn austenitic steels, including 25Mn, 25Mn0.2Al, 25Mn0.5Cu, 24Mn4Cr, 22Mn3Cr and 16Mn2Al specimens, were investigated at 298 and 110 K. Depending on the alloying elements, tensile ductility of high-Mn steels either increased or decreased with decreasing temperature from 298 to 110 K. Reasonable correlation between the tendency for martensitic tranformation, the critical twinning stress and the percent change in tensile elongation suggested that tensile deformation of high-Mn steels was strongly influenced by SFE determining TRIP and TWIP effects. Tensile strength was the most important parameter in determining the resistance to high cycle fatigue of high-Mn steels with an exceptional work hardening capability at room and cryogenic temperatures. The fatigue crack nucleation mechanism in high-Mn steels did not vary with decreasing tempertature, except Cr-added specimens with grain boundary cracking at 298 K and slip band cracking at 110 K. The EBSD (electron backscatter diffraction) analyses suggested that the deformation mechanism under fatigue loading was significantly different from tensile deformation which could be affected by TRIP and TWIP effects.

This study shows an artificial neural network (ANN) model of chlorophenol rejection from aqueous solutions and predicting the performance of spiral wound reverse osmosis (SWRO) modules. This type of rejection shows complex non-linear dependencies on feed pressure, feed temperature, concentration, and feed flow rate. It provides a demanding test of the application of ANN model analysis to SWRO modules. The predictions are compared with experimental data obtained with SWRO modules. The overall agreement between the experimental and ANN model predicted was almost 99.9% accuracy for the chlorophenol rejection. The ANN model approach has the advantage of understanding the complex chlorophenol rejection phenomena as a function of SWRO process parameters.

The large strength difference between hard and soft components in heterogeneous structured materials leads to the evolution of high back-stress hardening, which increases the strength and ductility of materials simultaneously. Moreover, the combination of high shear strain and elevated temperature allows an increase in the strength of low-melting temperature metallic alloys by grain refinement, solute migration, and clustering. In this study, to design a new heterogeneous microstructure in the aluminum alloy, both room temperature (RT) and high-temperature (HT) ultrasonic nanocrystalline surface modification (UNSM) were conducted, and their mechanical properties and microstructural evolutions were investigated. The large shear strain from the UNSM treatment reduces the grain size at the sample surface and creates a gradient structure. The combination of shear strain and elevated temperature during UNSM treatment induces solute migration at a certain depth of the specimens, resulting in the nano-sized Mg-rich particles at the surface region. Both grain refinement and precipitation at the surface region of the HT sample provide strong back-stress hardening in the early stages of deformation that enhances the strength and ductility of materials. Therefore, a high shear strain and control of processing temperature allow the design of a unique heterogeneous microstructure in low-melting temperature metallic alloys, which is a good strategy for enhancing the mechanical properties of sheet or thin metallic products.

High frictional die and continuous rotation during high-pressure torsion provide not only a large shear strain but also a large amount of frictional heat that facilitates the generation of complex microstructural changes, including grain refinement, dynamic recovery, and solute migration. Since metallic alloys with low melting temperatures are sensitive to heat energy, the mechanical properties and microstructural evolution of high-pressure torsion-processed aluminum 7075 alloys are investigated in this study. The large shear strain resulting from high-pressure torsion induces both grain refinement and dislocation cell formation, leading to strength enhancement and ductility degradation of the alloy. The deformation and frictional heat become a driving force for solute migration, including brittle intermetallic compound dissolution and nano-sized precipitation generation in the matrix. These solute migration activities contribute toward enhancing both the strength and ductility by inducing precipitation hardening and dissolution of the brittle phase simultaneously. Consequently, both the strength and ductility of the high-pressure torsion-processed aluminum 7075 alloy become larger than that of the initial state. This result shows that the microstructural changes of the severe plastic deformation-processed low-melting-temperature metallic alloys induce a significant mechanical property enhancement of nanocrystalline materials.

Despite recent progress in achieving high mechanical properties of 3D printed metal products, the low productivity still remains a major limitation for their cost-effective feasibility in practical applications. To achieve high-speed printing with affordable mechanical properties, we increased the scanning speed of selective laser melting process with Ti–6Al–4V up to 1800 mm/s and applied a hot isostatic pressing (HIP) process to compensate for the porosity. In these high-speed printed specimens, the HIP process led to a microstructural change from αʹ-lath martensite to a Widmanstӓtten α-lamellar structure, which deteriorated their tensile properties due to the segregation of β-stabilizing atoms and caused inter-lamellar fracture. The deterioration phenomenon of high-speed printed Ti–6Al–4V specimens after the HIP process was found to be critically affected by the surface roughness of as-built state, which can be efficiently controlled with a build angle set-up.

A single-phase face-centered-cubic (FCC) high- or medium-entropy alloys (HEAs or MEAs) have attracted great attentions due to their novel damage-tolerance properties (strength, ductility, and fracture toughness) by generating nano-twins at cryogenic temperature. The fracture toughness assessment is essential for evaluating the reliability of high-performance materials for cryogenic applications; however, fracture studies on single-phase FCC HEAs showing transformation-induced plasticity (TRIP) have been hardly conducted. In this study, thus, damage-tolerance mechanisms of a V10Cr10Fe45Co30Ni5 HEA showing the FCC to body-centered-cubic (BCC) TRIP were investigated at room and cryogenic temperatures. At room temperature (298 K), the alloy shows the tensile strength of 731 MPa, elongation of 40%, and fracture toughness (KJIc) of 230 MPa m1/2. At cryogenic temperature (77 K), the strength and elongation improve to 1.2 GPa and 66%, respectively, while the KJIc remains almost constant at 237 MPa m1/2. Dislocation-mediated plasticity prevails at 298 K; however, the TRIP from FCC to BCC occurs at 77 K. Deformation and fracture mechanisms are analyzed by stacking fault energies and differences in Gibbs free energies between phases calculated by ab-initio methods, and are compared to those of CrMnFeCoNi, CrCoNi, Fe50Mn30Co10Cr10, and V10Cr10Fe45Co20Ni15 alloys. Despite the presence of a considerable amount of BCC which is intrinsically brittle at low temperature, the transformed BCC martensite shows ductile fracture after the fracture toughness test even in cryogenic environments. These results demonstrate that the FCC to BCC TRIP can be an attractive route in a field of HEA design to overcome the strength and toughness trade-off at cryogenic temperature.

High-Mn austenitic steels utilizing TWIP (twinning induced plasticity) effect have excellent combination of tensile strength and ductility. The near-threshold fatigue crack propagation (FCP) behavior, as represented by the ΔK th value, of high-Mn steels was examined with the emphasis on the effect of stacking fault energy (SFE), grain size, twinning and tensile properties. Even though no predominant parameter determining the near-threshold FCP behavior of high-Mn steels was found, the SFE showed the most reasonable correlation to the ΔK th values among the variables examined. It was also suggested that the slip reversibility as determined by SFE could not solely explain the near-threshold FCP behavior of high-Mn steels. The presence of twin boundaries appeared to be not beneficial in improving the resistance to FCP of high-Mn steels in low ΔK regime. The near-threshold FCP characteristics of high-Mn austenitic steels were discussed and correlated with the well-known parameters presumably affecting FCP.

Artificial intelligence is widely employed in metallurgy for its ability to solve complex phenomena, which are associated with the learning process of previously obtained experimental data. Although numerous physical modeling techniques have been implemented for the prediction of mechanical strength using equations, several empirical efforts are necessitated to evaluate specific constants for different models. To address this issue, numerous recent studies have employed artificial neural networks for the prediction of mechanical properties based on the material composition and process conditions; however, majority of these works have been limited applications due to the extensive number of input parameter combinations of chemical compositions. Microstructure is a good feature to understand mechanical properties because it incorporates the effects of material composition and process conditions. The complex combination of material composition and process parameters determines the microstructure of steel. In this study, the information on microstructural volume fraction is utilized for the prediction of tensile strength, yield strength, and yield ratio via artificial neural networking. Various combinations of PF (polygonal ferrite), AF (acicular ferrite), GB (granular bainite), BF (bainitic ferrite), and M (martensite) are investigated for the prediction of yield strength, ultimate tensile strength, and yield of high strength steel via back-propagation linear regression and neural network based algorithm. The effects of each microstructure on the three mechanical properties were successfully predicted by employing back-propagation linear regression. A deep learning algorithm with hyper-parameter tuning and cross-validation enabled high accuracy in predicting experimental data with mean absolute percentage errors of 6.59% and 10.78% for the validation and test sets, respectively. These studies can open a new avenue for applying the microstructural design effects to find optimum yield strength, tensile strength, and yield ratio of high strength steel.

We devised a novel method to embed sensors or integrated circuit (IC) chips into metal components by using a selective laser melting (SLM) process. The concept of a protective layer is introduced to fabricate all parts without damaging the sensors during the laser scanning process. The operation of sensors in the parts is analyzed from a computational analysis on the thermal influence of laser heat. The fabricated metal parts show continuous microstructures including grains and phases between the base part and the new part formed after embedding the sensor despite the intermittent SLM process. The embedded sensor operates properly when compared to bare sensors. Plastic circuit board-based IC components were embedded into an Inconel 718C turbine blade, which accurately distinguished three-dimensional vibration along the X, Y, and Z axes. Our results imply that the proposed process can open new avenues for SLM technology to realize metal components with a self-cognitive ability using integrated sensors.

The micromechanics of plastic deformation and phase transformation in a three-phase advanced high strength steel are analyzed both experimentally and by microstructure-based simulations. The steel examined is a three-phase (ferrite, martensite and retained austenite) quenched and partitioned sheet steel with a tensile strength of ~980 MPa. The macroscopic flow behavior and the volume fraction of martensite resulting from the austenite–martensite transformation during deformation were measured. In addition, micropillar compression specimens were extracted from the individual ferrite grains and the martensite particles, and using a flat-punch nanoindenter, stress–strain curves were obtained. Finite element simulations idealize the microstructure as a composite that contains ferrite, martensite and retained austenite. All three phases are discretely modeled using appropriate crystal plasticity based constitutive relations. Material parameters for ferrite and martensite are determined by fitting numerical predictions to the micropillar data. The constitutive relation for retained austenite takes into account contributions to the strain rate from the austenite–martensite transformation, as well as slip in both the untransformed austenite and product martensite. Parameters for the retained austenite are then determined by fitting the predicted flow stress and transformed austenite volume fraction in a 3D microstructure to experimental measurements. Simulations are used to probe the role of the retained austenite in controlling the strain hardening behavior as well as internal stress and strain distributions in the microstructure.

Six low-carbon high-strength bainitic steels containing Cr, Mo, and B were fabricated by controlling finish cooling temperature, and the effect of bainitic microstructure on tensile and Charpy impact properties were investigated. All the specimens were composed primarily of bainitic ferrite, together with small amounts of granular bainite, acicular ferrite, martensite–austenite constituent. These bainitic microstructures were more critically affected by the finish cooling temperature than by the alloying elements. The H-series specimens with a high finish cooling temperature had larger amount of acicular ferrite and smaller amount of granular bainite and bainitic ferrite, compared to the L-series specimens with the low finish cooling temperature at the same chemical composition. The L-series specimens exhibited higher strength and yield ratio, and lower uniform and total elongations than the H-series specimens because the volume fraction of BF was higher in the L-series specimens than in the H-series specimens. On the other hand, the energy transition temperature decreased with increasing the volume fraction of AF having fine effective grain size, while it increased with an increase in the volume fraction of GB having coarse effective grain size. Thus, the energy transition temperature of the H-series specimens with the high finish cooling temperature were slightly lower than that of the L-series specimens with the low finish cooling temperature because the H-series specimens had a larger amount of AF than the L-series specimens.

Representative face-centered-cubic (FCC) high-entropy alloys (HEAs) or medium-entropy alloys (MEAs), e.g., equi-atomic CoCrFeMnNi or CrCoNi alloys, have drawn many attentions due to the excellent damage-tolerance at cryogenic temperature. The investigation of fracture toughness at 77 K is basically required for the reliable evaluation of high-performance alloys used for cryogenic applications; however, it has been rarely carried out for the non-equi-atomic FCC HEAs yet. In this study, tensile and fracture toughness tests were conducted on the non-equi-atomic V10Cr10Fe45Co20Ni15 alloy, and the results were compared with those of the equi-atomic CoCrFeMnNi and CrCoNi alloys. The present alloy shows a good damage tolerance at cryogenic temperature with tensile strength of 1 GPa and elongation of ∼60%. The KJIc fracture toughness values are 219 and 232 MPa m1/2 at 298 and 77 K, respectively, showing the increase in toughness with decreasing temperature. This increase results from the absence of twins at 298 K and the increased propensity to twin formation at 77 K, which is well confirmed by the variation of stacking fault energies (SFEs) by using Ab-initio calculations. The mechanical properties of the present alloy are actually similar or slightly lower than those of the other CoNiCr or FeMnCoNiCr alloy; instead, this study provides that neither composition nor certain elements are the most important factors dictating damage-tolerance of HEAs or MEAs.

The microstructural-mechanical correlative study has been conducted for characterization of selective laser melted H13 tool steel. Transformation behavior from austenite to martensite has been observed with partitioning of C in matrix with correlative atomic diffusivity during selective laser melting process. During solidification, columnar grain structures are formed due to epitaxial growth following the build direction of H13 tool steels. Columnar microstructures are mostly composed of martensite with small amount of retained austenite. Supercooling of H13 with high laser scan speed increased the nucleation sites, which reduced the diameter of columnar grain. During tensile test, deformation appeared in grain boundary while there was no significant martensitic phase transformation confirmed by X-ray diffraction (XRD) method and electron backscattered diffraction (EBSD) analysis. S2 (scan speed of 200 mm/s specimen had the better tensile property with tensile strength of 1700 MPa and elongation of 1.6% than the rest(

Two-ply Al/Cu sheets were prepared via roll bonding with different reduction ratios. Al/Cu sheets fabricated below 50% of reduction ratio exhibited relatively equiaxed grains without interface reaction, which resulted in weak joint-bonding strength. However, both strong metallurgical bonding at interface and fine, elongated grains from constituent alloys adjacent to the interface were successfully introduced under the reduction ratio of 65%, leading to a strongly enhanced bonding strength of 17.1 N/mm together with an increased elongation up to fracture by 28%.

In this study, drop-weight tear tests (DWTT) were conducted on API X80 pipeline steels fabricated with different finish rolling temperatures in order to analyze abnormal fracture appearance, i.e ., inverse fracture, occurring in the region impacted by a hammer. Area fractions of fracture modes were measured from fractured DWTT specimens, and the measured data were analyzed in relation to microstructures, DWTT absorbed energy, and strain hardening of the hammer-impacted region. As the finish rolling temperature decreased, the volume fraction of fine-grained acicular ferrite increased, while that of large-grained upper bainite or granular bainite decreased. According to the DWTT results, the absorbed energy tended to increase with increasing volume fraction of acicular ferrite (with decreasing finish rolling temperature). A large area of inverse fracture of cleavage type was found in the hammer-impacted region of the steels fabricated with high finish rolling temperatures, but the area fraction of inverse fracture was reduced in the steels fabricated with low finish rolling temperatures. Since the area fraction of inverse fracture was closely related with strain hardening of the hammer-impacted region, it could be successfully reduced by lowering strain hardening and by promoting the formation of acicular ferrite via low finish rolling temperatures.

The effects of carbon equivalent and cooling rateon tensile and Charpy impact properties of high-strength bainitic steels were investigated. Eight steel plates were fabricated with varying C, Cr, and Nb additions under two different cooling rates, and their microstructures, tensile, and Charpy impact properties were evaluated. Volume fractions of microstructural components present in the steels increased in the order of granular bainite, acicular ferrite, bainitic ferrite, and martensite as the carbon equivalent or cooling rate increased, which resulted in decreased ductility and upper shelf energy and increased energy transition temperature in spite of increased strength. In the steels containing about 50 vol.% of bainitic ferrite and martensite, the tensile strength was about 900 MPa, while the elongation and upper shelf energy were about 20% and 200 J, respectively. In order to achieve the best combination of tensile strength, ductility, and upper shelf energy, e.g., 860–900 MPa, 20%, and 200 J, respectively, granular bainite, and acicular ferrite were produced by controlling the carbon equivalent and cooling rate, while about 50 vol.% of bainitic ferrite and martensite were maintained to keep the high strength.

This study was concerned with effects of acicular ferrite on Charpy impact properties in heat affected zones (HAZs) of two API X80 linepipe steels containing oxides. In the one steel, Mg and O 2 were additionally added to form a larger amount of oxides than the other steel, which was a conventional X80 steel containing a considerable amount of Al and Ti. Various HAZ microstructures were obtained by conducting HAZ simulation tests under different heat inputs of 35 kJ cm −1 and 60 kJ cm −1 . Oxides present in the API X80 linepipe steels were complex oxides whose average size was 1–2 μm, and the number of oxides increased with increasing amount of Mg and O 2 . The volume fraction of acicular ferrite present in the steel HAZs increased with increasing number of oxides, and decreased with increasing heat input. When the volume fraction of acicular in the HAZ was higher than 20%, Charpy impact energy at −20 °C was higher than 100 J as the ductile fracture mode was dominant. Particularly in the steel HAZs having a larger amount of oxides, Charpy impact properties were excellent because oxides worked as nucleation sites of acicular ferrite during welding. Charpy impact properties of the HAZs could be well correlated with the volume fraction of acicular ferrite and number of oxides under different heat input conditions.

Sticking phenomena occurring during hot rolling of a modified STS 430J1L ferritic stainless steel were investigated in this study by using a pilot-plant-scale rolling machine. As the rolling pass proceeded, the Fe-Cr oxide layer formed in a reheating furnace was destroyed, and the destroyed oxides infiltrated into the rolled steel to form a thin oxide layer in the surface region. The sticking did not occur in the surface region containing oxides, whereas it occurred in the surface region without oxides by the separation of the rolled steel at high temperatures. This indicated that the resistance to sticking increased by the increase in the surface hardness when a considerable amount of oxides were formed in the surface region, and that the sticking could be evaluated by the volume fraction and distribution of oxides formed in the surface region. The lubrication and the increase of the rolling speed and rolling temperature beneficially affected to the resistance to sticking because they accelerated the formation of oxides on the steel surface region. In order to prevent or minimize the sticking, thus, it was suggested to increase the thickness of the oxide layer formed in the reheating furnace and to homogeneously distribute oxides along the surface region by controlling the hot-rolling process.