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We conduct in situ tensile straining experiments to investigate the role of hydrogen and slip in crack initiation in nickel-based alloy 725. Our experiments reveal no tendency for hydrogen to enhance localized slip and no necessity of slip for crack initiation. We use electrochemical charging to introduce hydrogen into samples, melt extraction to measure hydrogen content, and digital image correlation to analyze localized plastic strains during in situ tensile tests in a scanning electron microscope. Cracks initiate both in regions with and without nearby localized slip. Moreover, the fraction of cracks initiating with no nearby slip is greater at higher hydrogen content. Slip-assisted crack initiation generally occurs at locations where intergranular slip is arrested, especially at intersections of slipping coherent twin boundaries with thin twin lamellae. Cracks that initiate without nearby slip occur at a wider variety of microstructural features, including inclusions, triple junctions, and surface flaws.

Fatigue in metals involves gradual failure through incremental propagation of cracks under repetitive mechanical load. In structural applications, fatigue accounts for up to 90% of in-service failure 1,2 . Prevention of fatigue relies on implementation of large safety factors and inefficient overdesign 3 . In traditional metallurgical design for fatigue resistance, microstructures are developed to either arrest or slow the progression of cracks. Crack growth is assumed to be irreversible. By contrast, in other material classes, there is a compelling alternative based on latent healing mechanisms and damage reversal 4-9 . Here, we report that fatigue cracks in pure metals can undergo intrinsic self-healing. We directly observe the early progression of nanoscale fatigue cracks, and as expected, the cracks advance, deflect and arrest at local microstructural barriers. However, unexpectedly, cracks were also observed to heal by a process that can be described as crack flank cold welding induced by a combination of local stress state and grain boundary migration. The premise that fatigue cracks can autonomously heal in metals through local interaction with microstructural features challenges the most fundamental theories on how engineers design and evaluate fatigue life in structural materials. We discuss the implications for fatigue in a variety of service environments., (© 2023. The Author(s), under exclusive licence to Springer Nature Limited.)

Quantitative multi-image analysis (QMA) is the systematic extraction of new information and insight through the simultaneous analysis of multiple, related images. We present examples illustrating the potential for QMA to advance materials research in multi-image characterization, automatic feature identification, and discovery of novel processing-structure-property relationships. We conclude by discussing opportunities and challenges for continued advancement of QMA, including instrumentation development, uncertainty quantification, and automatic parsing of literature data., Supplementary Information: The online version contains supplementary material available at 10.1557/s43579-022-00265-7., (© The Author(s) 2022.)

Hydrogen embrittlement (HE) causes sudden, costly failures of metal components across a wide range of industries. Yet, despite over a century of research, the physical mechanisms of HE are too poorly understood to predict HE-induced failures with confidence. We use non-destructive, synchrotron-based techniques to investigate the relationship between the crystallographic character of grain boundaries and their susceptibility to hydrogen-assisted fracture in a nickel superalloy. Our data lead us to identify a class of grain boundaries with striking resistance to hydrogen-assisted crack propagation: boundaries with low-index planes (BLIPs). BLIPs are boundaries where at least one of the neighboring grains has a low Miller index facet-{001}, {011}, or {111}-along the grain boundary plane. These boundaries deflect propagating cracks, toughening the material and improving its HE resistance. Our finding paves the way to improved predictions of HE based on the density and distribution of BLIPs in metal microstructures.

One way of expediting materials development is to decrease the need for new experiments by making greater use of published literature. Here, we use data mining and automated image analysis to gather new insights on nanoporous gold (NPG) without conducting additional experiments or simulations. NPG is a three-dimensional porous network that has found applications in catalysis, sensing, and actuation. We assemble and analyze published images from among thousands of publications on NPG. These images allow us to infer a quantitative description of NPG coarsening as a function of time and temperature, including the coarsening exponent and activation energy. They also demonstrate that relative density and ligament size in NPG are not correlated, indicating that these microstructure features are independently tunable. Our investigation leads us to propose improved reporting guidelines that will enhance the utility of future publications in the field of dealloyed materials.

Damage caused by implanted helium (He) is a major concern for material performance in future nuclear reactors. We use a combination of experiments and modeling to demonstrate that amorphous silicon oxycarbide (SiOC) is immune to He-induced damage. By contrast with other solids, where implanted He becomes immobilized in nanometer-scale precipitates, He in SiOC remains in solution and outgasses from the material via atomic-scale diffusion without damaging its free surfaces. Furthermore, the behavior of He in SiOC is not sensitive to the exact concentration of carbon and hydrogen in this material, indicating that the composition of SiOC may be tuned to optimize other properties without compromising resistance to implanted He.

Material degradation due to precipitation of implanted helium (He) is a key concern in nuclear energy. Decades of research have mapped out the fate of He precipitates in metals, from nucleation and growth of equiaxed bubbles and voids to formation and bursting of surface blisters. By contrast, we show that He precipitates confined within nanoscale metal layers depart from their classical growth trajectories: They self-organize into elongated channels. These channels form via templated nucleation of He precipitates along layer surfaces followed by their growth and spontaneous coalescence into stable precipitate lines. The total line length and connectivity increases with the amount of implanted He, indicating that these channels ultimately interconnect into percolating "vascular" networks. Vascularized metal composites promise a transformative solution to He-induced damage by enabling in operando outgassing of He and other impurities while maintaining material integrity.

Despite recent interest in amorphous ceramics for a variety of nuclear applications, many details of their structure before and after irradiation/implantation remain unknown. Here we investigated the short-range order of amorphous silicon oxycarbide (SiOC) alloys by using the atomic pair-distribution function (PDF) obtained from electron diffraction. The PDF results show that the structure of SiOC alloys are nearly unchanged after both irradiation up to 30 dpa and He implantation up to 113 at%. TEM characterization shows no sign of crystallization, He bubble or void formation, or segregation in all irradiated samples. Irradiation results in a decreased number of Si-O bonds and an increased number of Si-C and C-O bonds. This study sheds light on the design of radiation-tolerant materials that do not experience helium swelling for advanced nuclear reactor applications.

Clean, safe and economical nuclear energy requires new materials capable of withstanding severe radiation damage. One strategy of imparting radiation resistance to solids is to incorporate into them a high density of solid-phase interfaces capable of absorbing and annihilating radiation-induced defects. Here we show that elastic interactions between point defects and semicoherent interfaces lead to a marked enhancement in interface sink strength. Our conclusions stem from simulations that integrate first principles, object kinetic Monte Carlo and anisotropic elasticity calculations. Surprisingly, the enhancement in sink strength is not due primarily to increased thermodynamic driving forces, but rather to reduced defect migration barriers, which induce a preferential drift of defects towards interfaces. The sink strength enhancement is highly sensitive to the detailed character of interfacial stresses, suggesting that 'super-sink' interfaces may be designed by optimizing interface stress fields. Such interfaces may be used to create materials with unprecedented resistance to radiation-induced damage.

Interface engineering has become an important strategy for designing radiation-resistant materials. Critical to its success is fundamental understanding of the interactions between interfaces and radiation-induced defects, such as voids. Using transmission electron microscopy, here we report an interesting phenomenon in their interaction, wherein voids adhere to only one side of the bimetal interfaces rather than overlapping them. We show that this asymmetrical void-interface interaction is a consequence of differing surface energies of the two metals and non-uniformity in their interface formation energy. Specifically, voids grow within the phase of lower surface energy and wet only the high-interface energy regions. Furthermore, because this outcome cannot be accounted for by wetting of interfaces with uniform internal energy, our report provides experimental evidence that bimetal interfaces contain non-uniform internal energy distributions. This work also indicates that to design irradiation-resistant materials, we can avoid void-interface overlap via tuning the configurations of interfaces.

Amorphous silicon oxycarbide (SiOC) is of great technological interest. However, its atomic-level structure is not well understood. Using density functional theory calculations, we show that the clustering tendency of C atoms in SiOC is extremely sensitive to hydrogen (H): without H, the C-C interaction is attractive, leading to enrichment of aggregated SiC4 tetrahedral units; with hydrogen, the C-C interaction is repulsive, leading to enrichment of randomly distributed SiCO3 tetrahedral units. Our results suggest that conflicting experimental characterizations of C distributions may be due to differing amounts of H present in the samples investigated. Our work also opens a path for tailoring the properties of SiOC by using the total H content to control the C distribution.

Hydrogen embrittlement (HE) causes engineering alloys to fracture unexpectedly, often at considerable economic or environmental cost. Inaccurate predictions of component lifetimes arise from inadequate understanding of how alloy microstructure affects HE. Here we investigate hydrogen-assisted fracture of a Ni-base superalloy and identify coherent twin boundaries (CTBs) as the microstructural features most susceptible to crack initiation. This is a surprising result considering the renowned beneficial effect of CTBs on mechanical strength and corrosion resistance of many engineering alloys. Remarkably, we also find that CTBs are resistant to crack propagation, implying that hydrogen-assisted crack initiation and propagation are governed by distinct physical mechanisms in Ni-base alloys. This finding motivates a re-evaluation of current lifetime models in light of the dual role of CTBs. It also indicates new paths to designing materials with HE-resistant microstructures.

Patterning is a familiar approach for imparting novel functionalities to free surfaces. We extend the patterning paradigm to interfaces between crystalline solids. Many interfaces have non-uniform internal structures comprised of misfit dislocations, which in turn govern interface properties. We develop and validate a computational strategy for designing interfaces with controlled misfit dislocation patterns by tailoring interface crystallography and composition. Our approach relies on a novel method for predicting the internal structure of interfaces: rather than obtaining it from resource-intensive atomistic simulations, we compute it using an efficient reduced order model based on anisotropic elasticity theory. Moreover, our strategy incorporates interface synthesis as a constraint on the design process. As an illustration, we apply our approach to the design of interfaces with rapid, 1-D point defect diffusion. Patterned interfaces may be integrated into the microstructure of composite materials, markedly improving performance.

A novel interface engineering strategy is proposed to simultaneously achieve superior irradiation tolerance, high strength, and high thermal stability in bulk nanolayered composites of a model face-centered-cubic (Cu)/body-centered-cubic (Nb) system. By synthesizing bulk nanolayered Cu-Nb composites containing interfaces with controlled sink efficiencies, a novel material is designed in which nearly all irradiation-induced defects are annihilated., (© 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.)

We present a new mechanism--discovered using molecular dynamics simulations--that leads to complete healing of nanocracks. This mechanism relies on the generation of crystal defects known as disclinations by migrating grain boundaries. Crack healing by disclinations does not require any compressive loads applied normal to the crack faces and even occurs under monotonic tensile loading. By closing small cracks and suppressing the propagation of others, this mechanism may provide a novel way of mitigating internal damage that influences ductility in nanocrystalline metals.

We use molecular dynamics simulations to show that glass transition in a model phase separating amorphous alloy, Cu(50)Nb(50), occurs by gelation. At the glass transition, a mechanically stiff, percolating network of atoms with icosahedral local packing forms at the interfaces between compositionally enriched regions. This low-energy network halts coarsening of the phase-separated structure and imparts shear resistance. These features of glass transition are remarkably similar to gelation processes in polymeric and colloidal gels.

He implanted into metals precipitates into nanoscale bubbles that may later grow into voids, degrading the properties of engineering alloys. Using multiscale modeling, we show that a different class of He precipitates may form at semicoherent interfaces: nanoscale platelets. These platelets grow by wetting high-energy interface regions, remain stable under irradiation, and reduce He-induced swelling. Stable storage of He at interfaces may impart unprecedented He resistance to future structural materials.

Magnetron sputtered thin films of Cu, Nb, and Cu-Nb multilayers with 2.5 and 5 nm nominal layer thickness were deposited on Si and implanted with 4He+ and 3He+ ions. Secondary ion mass spectroscopy and nuclear reaction analysis, respectively, were used to measure the 4He+ and 3He+ concentration profile with depth inside the films. Cross-sectional transmission electron microscopy was used to characterize the helium bubbles. Analysis of the contrast from helium bubbles in defocused transmission electron microscope images showed a minimum bubble diameter of 1.25 nm. While pure Cu and Nb films showed bubble contrast over the entire range of helium implantation, the multilayers exhibited bubbles only above a critical He concentration that increased almost linearly with decreasing layer thickness. The work shows that large amounts of helium can be trapped at incoherent interfaces in the form of stable, nanometer-size bubbles.

We use atomistic simulations to show that upon removal or insertion of atoms, misfit dislocations in Cu-Nb interfaces shift between two adjacent planes, forming pairs of extended jogs. Different jog combinations give rise to interface structures with unlike densities but nearly degenerate energies, making Cu-Nb interfaces virtually inexhaustible sinks for radiation-induced point defects and catalysts for efficient Frenkel pair recombination.

Molecular dynamics simulations show that plastic deformation of amorphous Si modeled by the Stillinger-Weber potential is very sensitive to the density of the initial unstressed state. Low-density systems exhibit a pronounced yield phenomenon, strain softening, and a dramatic drop in pressure during deformation at a constant volume. This behavior is explained by the presence in every system of a certain concentration of solidlike and liquidlike components, the latter being denser and more amenable to plastic flow.