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The repair of damaged Ni-based superalloy single-crystal turbine blades has been a long-standing challenge. Additive manufacturing by an electron beam is promising to this end, but there is a formidable obstacle: either the residual stress and γ/γ  ' microstructure in the single-crystalline fusion zone after e-beam melting are unacceptable (e.g., prone to cracking), or, after solutionizing heat treatment, recrystallization occurs, bringing forth new grains that degrade the high-temperature creep properties. Here, a post-3D printing recovery protocol is designed that eliminates the driving force for recrystallization, namely, the stored energy associated with the high retained dislocation density, prior to standard solution treatment and aging. The post-electron-beam-melting, pre-solutionizing recovery via sub-solvus annealing is rendered possible by the rafting (i.e., directional coarsening) of γ  ' particles that facilitates dislocation rearrangement and annihilation. The rafted microstructure is removed in subsequent solution treatment, leaving behind a damage-free and residual-stress-free single crystal with uniform γ  ' precipitates indistinguishable from the rest of the turbine blade. This discovery offers a practical means to keep 3D-printed single crystals from cracking due to unrelieved residual stress, or stress-relieved but recrystallizing into a polycrystalline microstructure, paving the way for additive manufacturing to repair, restore, and reshape any superalloy single-crystal product.

Magnesium, the lightest structural metal, usually exhibits limited ambient plasticity when compressed along its crystallographic c-axis (the "hard" orientation of magnesium). Here we report large plasticity in c-axis compression of submicron magnesium single crystal achieved by a dual-stage deformation. We show that when the plastic flow gradually strain-hardens the magnesium crystal to gigapascal level, at which point dislocation mediated plasticity is nearly exhausted, the sample instantly pancakes without fracture, accompanying a conversion of the initial single crystal into multiple grains that roughly share a common rotation axis. Atomic-scale characterization, crystallographic analyses and molecular dynamics simulations indicate that the new grains can form via transformation of pyramidal to basal planes. We categorize this grain formation as "deformation graining". The formation of new grains rejuvenates massive dislocation slip and deformation twinning to enable large plastic strains. Understanding deformation of Mg along the c-axis is important for wrought processing of Mg. Here the authors report deformation graining in submicron single crystal Mg where the initial single crystal evolves into ultrafine grains that rejuvenates dislocation activities, enabling large plasticity. [ABSTRACT FROM AUTHOR]

Radiation-induced grain-boundary helium bubbles are the cause of the significant helium embrittlement. However, the influence of grain-interior helium bubbles on the cracking behavior of metals has not been explored. Here, we investigate the cracking propensity of helium-irradiated small-volume Cu single-crystals, and compare with those of Cu single-crystals and Cu bicrystals. We found that the irradiation-induced helium bubbles only slightly increased the cracking propensity of the single-crystal Cu, while the cracking resistance of the helium-irradiated Cu single-crystals was superior to that of the Cu bicrystals, both with and without helium bubbles. [ABSTRACT FROM AUTHOR]

Under very high stresses, dislocations can be accelerated to approach the speed of shear wave over a distance as short as 10 1 nm. Our atomistic simulations demonstrate that dislocations with such high speeds often react in counter-intuitive manners that are beyond textbook descriptions of conventional dislocation behavior. A high-speed dislocation can “rebound” when hitting a free surface rather than simply annihilate. When two high-speed dislocations collide, they can “penetrate” through each other. An individual dislocation can even spontaneously generate multiple dislocations via self-dissociation. These anomalous mechanisms lead to rapid proliferation of dislocations that are strongly correlated both spatially and temporally, and as such may play a role in high-stress and high-strain-rate plastic deformation; a potentially related case is nanoscale pristine single crystals, which often yield via a large strain burst at ultrahigh stresses. [ABSTRACT FROM AUTHOR]

Boundaries created through basal-prismatic transformation in submicron-sized single crystal magnesium have been investigated systematically using in situ transmission electron microscopy. We found that these boundaries not only deviated significantly from the twin plane associated with { 1 0 1 ¯ 2 } twin, but also possessed a non-planar morphology. After the sample was thinned to be less than 90 nm, aberration-corrected scanning transmission electron microscopy observation found that the basic components of these boundaries are actually terrace-like basal-prismatic interfaces. [ABSTRACT FROM AUTHOR]