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Refractory high entropy alloys (RHEAs) with multiple principal elements constitute a new paradigm in alloy design and have gained recent interest for advanced technical applications due to their unique properties and mechanical stability at high temperatures. However, the refractory metals that make up these alloys are pretty expensive, and they cause RHEAs to exhibit low plasticity behaviour at room temperature. The high stability properties of RHEAs from room temperature to high temperatures limit their machinability with traditional cutting methods. Therefore, it is vitally important to economically machine these alloys while preserving their mechanical properties and minimising waste. For this purpose, in this study, the machinability of a HfTaTiVZr RHEA was evaluated with wire electric discharge machining (WEDM). The surface morphology, crack formation, and mechanical characteristics of the surface layer were investigated as a function of three different cutting conditions: rough cutting, semi-finishing, and finishing. The RHEA was precision cut in three passes by reducing the volume of material in each pass, resulting in better surface quality with the optimal cutting speed and metal removal rate. However, rough cutting gave better results than semi-finish and finished cutting processes in preserving mechanical properties.

Refractory high entropy alloys (RHEAs) have shown great promise for a multitude of advanced engineering applications due to their high mechanical stability from cryogenic temperatures to 1600 °C. However, the low ductility they exhibit at room temperature limits their machinability when traditional machining techniques are used. Studies on the nontraditional machining of RHEAs, on the other hand, are very limited. In the present work, MoNbTaTiZr RHEAs subjected to wire electrical discharge machining (WEDM) were examined using electron microscopy, contact profilometry, and nanoindentation. Voids, microcracks, and recast material were observed on the machined surfaces. A transition from roughing to finishing decreased the amount of recast material, but the density of observable voids and microcracks on the surface increased. Optimal results were obtained by finishing, where the surface quality was improved by the removal of recast material remaining from prior passes. The brass wire electrode provided a smoother surface while the copper-core electrode provided minor heat-affected zone in the MoNbTaTiZr samples. In the roughing cuts, a 7.00% improvement in surface roughness was achieved using the copper-core electrode compared to the brass electrode. In the semi-finishing and finishing cuts, the brass wire electrode provided improvements of 13.68% and 22.68%, respectively, compared to the copper-core electrode. On the other hand, the wear of the brass electrode was as much as 20.98% higher than that of the copper-core electrode.

High-entropy alloys (HEAs) with multiple principal elements represent a paradigm shift in structural alloy design and show excellent surface degradation resistance in corrosive environment. Here, the tribo-corrosion response of laser-engineered net-shaped CoCrFeMnNi HEA was evaluated in 3.5 wt% NaCl solution at room temperature. The additively manufactured (AM-ed) CoCrFeMnNi showed five times lower wear rate, regenerative passivation, and nobler corrosion potential during tribo-corrosion test compared to its arc-melted counterpart. A significant anisotropy was seen in the tribo-corrosion response with 45° to the build direction showing better performance compared to tests along the build direction and perpendicular to it. The open circuit potential curves were characterized by a sharp drop to more negative values as wear began, followed by continuous change for the active tribo-corrosion duration and finally a jump to nobler value at the end of the test indicating excellent surface re-passivation for the AM-ed alloy. The superior tribo-corrosion resistance of AM-ed CoCrFeMnNi was attributed to the refined microstructure and highly protective surface passivation layer promoted by the sub-grain cellular structure formed during additive manufacturing. These results highlight the potential of utilizing additive manufacturing of HEAs for use in extreme environments that require a combination of tribo-corrosion resistance, mechanical durability, extended service life, and net shaping with low dimensional tolerance.

There is a strong surge in interest for hydrogen and direct alcohol fuel cells as zero-emission energy conversion and storage devices due to their high energy density compared to that for batteries...

Lightweight energy-saving magnesium (Mg) nanocomposites could be titled materials of future. Remarkable specific strength along with acceptable ductility is two key features of these materials which have made them a unique class of emerging materials. However, magnesium nanocomposites are at the initial stages of development and therefore systematic research is required to establish microstructure/property relationships at different potential conditions (i.e. temperatures and strain rates). In this paper, a recently introduced magnesium-samarium oxide (Mg–Sm2O3) nanocomposite, with different volume fractions of nanosize Sm2O3 particles as reinforcement, is employed to study ambient temperature rate-dependent plastic response of the material. To study the rate-dependent response of the materials, a depth-sensing nanoindentation measurement technique was used which is considered a non-destructive, robust, and convenient method to assess the controlling mechanisms of creep phenomenon in small scales. Tests were performed on both nanocomposites and pure Mg for the purpose of comparison. Microstructural observations and nanoindentation data indicate that the creep resistance of the materials is directly associated with the volume fraction of the nanoparticles. The results of this study would provide the required reference lines for the forthcoming elevated temperature creep assessment of the materials.

The leaching out of toxic elements from metallic bioimplants has serious repercussions, including allergies, peripheral neuritis, cancer, and Alzheimer's disease, leading to revision or replacement surgeries. The development of advanced structural materials with excellent biocompatibility and superior corrosion resistance in the physiological environment holds great significance. High entropy alloys (HEAs) with a huge compositional design space and outstanding mechanical and functional properties can be promising for bioimplant applications. However, microstructural heterogeneity arising from elemental segregation in these multiprinciple alloy systems is the Achilles heel in the development of next-generation HEAs. Here, we demonstrate a pathway to homogenize the microstructure of a biocompatible dual-phase HEA, comprising refractory elements, namely, MoNbTaTiZr, through severe surface deformation using stationary friction processing (SFP). The strain and temperature field during processing homogenized the elemental distribution, which was otherwise unresponsive to conventional annealing treatments. Nearly 15 min of the SFP treatment resulted in a significant elemental homogenization across dendritic and interdendritic regions, similar to a week-long annealing treatment at 1275 K. The SFP processed alloy showed a nearly six times higher biocorrosion resistance compared to its as-cast counterpart. X-ray photoelectron spectroscopy was used to investigate the nature of the oxide layer formed on the specimens. Superior corrosion behavior of the processed alloy was attributed to the formation of a stable passive layer with zirconium oxide as the primary constituent and higher hydrophobicity. Biocompatibility studies performed using the human mesenchymal stem cell line, showed higher viability for the processed HEA compared to its as-cast counterpart as well as conventional metallic biomaterials including stainless steel (SS316L) and titanium alloy (Ti6Al4V).

Bioimplants are susceptible to simultaneous wear and corrosion degradation in the aggressive physiological environment. High entropy alloys with equimolar proportion of constituent elements represent a unique alloy design strategy for developing bioimplants due to their attractive mechanical properties, superior wear, and corrosion resistance. In this study, the tribo-corrosion behavior of an equiatomic MoNbTaTiZr high entropy alloy consisting of all biocompatible elements was evaluated and compared with 304 stainless steel as a benchmark. The high entropy alloy showed a low wear rate and a friction coefficient as well as quick and stable passivation in simulated body fluid. An increase from room temperature to body temperature showed excellent temperature assisted passivity and nobler surface layer of the high entropy alloy, resulting in four times better wear resistance compared to stainless steel. Stem cells and osteoblast cells displayed proliferation and migratory behavior, indicating in vitro biocompatibility. Several filopodia extensions on the cell periphery indicated early osteogenic commitment, and cell adhesion on the high entropy alloy. These results pave the way for utilizing the unique combination of tribo-corrosion resistance, excellent mechanical properties, and biocompatibility of MoNbTaTiZr high entropy alloy to develop bioimplants with improved service life and lower risk of implant induced cytotoxicity in the host body.

Multi-principal element alloys represent a new paradigm in structural alloy design with superior mechanical properties and promising ballistic performance. Here, the mechanical response of Al0.3CoCrFeNi alloy, with unique bimodal microstructure, was evaluated at quasistatic, dynamic, and ballistic strain rates. The microstructure after quasistatic deformation was dominated by highly deformed grains. High density of deformation bands was observed at dynamic strain rates but there was no indication of adiabatic shear bands, cracks, or twinning. The ballistic response was evaluated by impacting a 12 mm thick plate with 6.35 mm WC projectiles at velocities ranging from 1066 to 1465 m/s. The deformed microstructure after ballistic impact was dominated by adiabatic shear bands, shear band induced cracks, microbands, and dynamic recrystallization. The superior ballistic response of this alloy compared with similar AlxCoCrFeNi alloys was attributed to its bimodal microstructure, nano-scale L12 precipitation, and grain boundary B2 precipitates. Deformation mechanisms at quasistatic and dynamic strain rates were primarily characterized by extensive dislocation slip and low density of stacking faults. Deformation mechanisms at ballistic strain rates were characterized by grain rotation, disordering of the L12 phase, and high density of stacking faults.

Metallic glasses exhibit excellent properties such as ultrahigh strength and excellent wear and corrosion resistance, but there is limited understanding on the relationship between their atomic structure and mechanical properties as a function of their structural state. In this paper, we bridge the processing-structure-property gap by utilizing molecular dynamics simulation for a model binary metallic glass, namely Ni80P20. The structural statistics including the fraction of Voronoi index, the distribution of Voronoi volume, and medium-range ordering are calculated to explain the observed changes in mechanical behavior and strain localization upon relaxation and rejuvenation. Our findings demonstrate that the evolution of mechanical properties can be linked to the atomic structure change in terms of short- and medium-range ordering. With the help of structural statistics, the mechanical properties are determined based on simple Voronoi analysis.

The effect of ion irradiation on the hardness and yield strength of Zr57Nb5Cu15.4Ni12.6Al10 bulk metallic glass has been studied using nanoindentation and micropillar compression tests. The results for the amorphous alloy were compared with those for 304 stainless steel. After Ni2+ ion irradiation, the metallic glass was found on an average to have 16% lower hardness and 13% lower yield strength. In contrast, 304 stainless steel showed significant hardening (~ 50% hardness and strength increase) after irradiation under identical conditions. The irradiation-induced hardening of the steel was attributed to hindrance of dislocation movement from the defects generated, while the softening behavior of the metallic glass was attributed to structural change in the irradiated region while retaining a fully amorphous state. The present work paves the way for better understanding of the irradiation response of metallic glasses to develop degradation-resistant alloys for next-generation nuclear applications.

An AlCoCrFeNi2.1 eutectic high entropy alloy (EHEA), comprising of FCC phase and a high volume fraction of plate and irregularly shaped BCC-ordered intermetallic B2 domains, was subjected to normal impact by spherical Tungsten–Carbide projectiles. Depending on projectile velocity, the impacted AlCoCrFeNi2.1 plates were partially penetrated (at the lowest velocity of 803 m/s), plugged (intermediate velocity of 1159 m/s), and fully penetrated (highest velocity of 1388 m/s). Electron microscopy was utilized to characterize the residual damage or deformation features in the recovered specimens. Failure in the partially penetrated conditions was dominated by interfacial decohesion at the plate-like B2 and FCC interfaces. At higher velocities where plugging occurred, failure was dominated by crack formation in regions containing adiabatic shear band. These results indicated a transition in failure modes as a function of projectile velocities, where the FCC-B2 microstructure dominate failure at lower velocities, while such microstructural features do not influence dynamic failure at higher velocities.

The strain gradient plasticity of multiprincipal element alloys, CoCrNi and CoCrFeMnNi, was investigated in work-hardened and annealed conditions using nano-indentation. The hardness of the alloys demonstrated significant dependence on indentation depth, which was explained by geometrically necessary dislocations resulting from the high strain gradients due to the shape of the indenter. The characteristic length-scale of the indentation size effect for the multiprincipal element alloys was found to be larger than pure nickel due to higher friction stress, which constrains the storage volume of geometrically necessary dislocations.

In this study, we demonstrate a novel pathway to engineer the properties of metallic alloys for limiting their cavitation erosion-corrosion. A facile single-step processing technique was used to develop bimodal grain structure in stainless steel. The bimodal steel was tested in cavitation erosion and erosion-corrosion conditions. In both the cases, bimodal steel showed exceptionally high degradation resistance, nearly 7 times higher compared to as-received steel. The remarkable cavitation erosion resistance demonstrated by bimodal steel is attributed to its high yield strength along with high work-hardening rate. In addition, the bimodal steel showed significantly low corrosion rate of 0.001 mm/year in 3.5 wt % NaCl solution compared to 0.088 mm/year for as-received stainless steel.

High entropy alloys represent a new paradigm of structural alloy design consisting of (near) equal proportions of constituent elements resulting in a number of attractive properties. In particular, eutectic high entropy alloys offer a remarkable combination of high strength and good ductility from the synergistic contribution of each phase in the eutectic, thereby circumventing the strength-ductility trade-off in conventional structural materials. In the present study, wear and corrosion behavior were evaluated for the AlCoCrFeNi2.1 eutectic high entropy alloy consisting of BCC (B2), and FCC (L12) lamellae. A transition from adhesive to oxidative wear was observed in reciprocating wear analysis. The L12 phase with lower hardness preferentially deformed during the wear test. The ratio of hardness to modulus was almost two times higher for the B2 phase as compared to L12. The overall corrosion resistance of the eutectic high entropy alloy was comparable to 304 stainless steel in 3.5 wt% NaCl solution. However, detailed microscopy revealed preferential dissolution of the B2 phase. Phase-specific scanning kelvin probe analysis showed relatively higher electropositivity for the B2 phase as compared with L12, supporting the selective corrosion and higher coefficient of friction of B2.

Hypereutectoid SAE 52100 steel is extensively used in bearing applications. Microstructure modification in terms of dislocation martensite and carbide refinement was achieved for SAE 52100 steel through a simple duplex heat treatment. Refinement of prior austenite grains to less than 5 μm resulted in the conversion of conventional high-carbon twinned martensite to dislocation martensite. The concurrent refinement of austenite grains and carbide precipitates was accomplished by high-temperature austenitization followed by low-temperature tempering. This resulted in nanoscale nonstoichiometric e-carbides within a heavily twinned martensitic structure. These nanoscale carbides acted as grain boundary pinning agents after their transformation to θ-carbides during the final austenitization process. The resulting microstructure was characterized by a fine dispersion of θ-carbides within dislocation martensite and showed roughly 24% increase in tensile strength and 30% better wear resistance compared to conventional structure.

An integrated experimental and molecular dynamics approach was used for developing low-activation high entropy alloys, potentially attractive for next generation nuclear reactor applications. These alloys were based on the concept of high entropy phase formation from a palette of elements with intrinsic low activity, namely Ta–Ti–V–Zr–X (X = Hf or W), with constituents in equimolar proportions. Molecular dynamics predicted homogenous alloy formation for Ta–Ti–V–Zr–Hf. In contrast, a tendency for Ta–W atomic-pair clustering was seen for Ta–Ti–V–Zr–W, in agreement with microstructure after melt-casting and homogenization. Both alloys showed stable microstructure with high hardness, which was retained up to 300 °C.

Metallic glasses are a unique class of materials combining ultrahigh strength together with plastic-like processing ability. However, the currently used melt quenching route to obtain amorphous alloys has a high cost basis in terms of manufacturing and expensive constituent elements often necessary to achieve the glassy state, thus hindering widespread adoption. In contrast, multimaterial electrodeposition offers a low-cost and versatile alternative to obtain amorphous alloys. Here, we demonstrate multiscale manufacturing of a model binary amorphous system by a facile and scalable pulsed electrodeposition approach. The structural and mechanical characteristics of electrodeposited Ni-P metallic glasses are investigated by a combination of experiments and molecular dynamics simulations. The property dependence on slight change in alloy chemistry is explained by the fraction of short-range-order clusters and geometrically unfavorable motifs. Bicapped square antiprism polyhedra clusters with two-atom connections result in more homogeneous deformation for Ni

The performance of complex concentrated alloys (or high entropy alloys) with widely varying microstructure is evaluated by ballistically impacting targets with spheres fired at normal incidence. By changing alloy composition in the Al-Co-Cr-Fe-Ni multi-principal system, the variation in microstructure included single-phase equiaxed grains, single-phase with bimodal grain-size distribution, and eutectic two-phase lamellar microstructure. Rigorous characterization in the form of bulk mechanical testing, scanning electron microscopy, and spatially resolved nano-indentation on initial and ballistically impacted plates was used to connect microstructural details to aspects of ballistic behavior governing performance. Based on the results, it was shown that although the addition of a harder secondary phase improves strength, cracks that initiate and propagate within the harder phase and ultimately across the target plate drastically reduce the ballistic performance of the two-phase material. The single-phase alloy with bimodal grain-size distribution exhibited superior ballistic performance compared to the other high entropy alloys, although none of these materials exceeded the performance of conventional rolled homogeneous armor steel. These results pave the way for development of high-performance concentrated alloys for ballistic applications by appropriate microstructural design.

Lamellar eutectic structure of Al0.7CoCrFeNi high-entropy alloy (HEA) is emerging as a promising candidate for structural applications because of its high strength-ductility combination. The alloy consists of a fine-scale lamellar fcc+B2 microstructure with high flow stresses >1500 MPa under quasi-static conditions. The response to shear loading was not investigated so far. This is the first report on the shear deformation of an eutectic structured HEA and effect of precipitation on shear deformation. The dynamic shear response (DSR) of the eutectic HEA was examined in two microstructural conditions, with and without the presence of L12 precipitates. A split-Hopkinson pressure bar (SHPB) was used to compress the hat-shaped specimens to study the local DSR of the alloy. The adiabatic shear bands (ASBs) in two different microstructural conditions were characterized after deformation at dynamic strain rates. The adiabatic shear localization occurs at low strains for the high strength material, and the eutectic microstructure does not delay cracking. The width of ASBs and the extent of plastic deformation around them has been correlated with the rate of straining. Dynamic recrystallization within ASBs and profuse twinning around it was observed. Local mechanical response of individual lamellae before and after shear deformation was examined using nano-indentation.

Lamellar eutectic structure in Al0.7CoCrFeNi high-entropy alloy (HEA) is emerging as apromising candidate for structural applications because of its high strength-ductility combination.The alloy consists of a fine-scale lamellar fcc + B2 microstructure with high flow stresses &gt, 1300 MPaunder quasi-static tensile deformation and &gt, 10% ductility. The response to shear loading was notinvestigated so far. This is the first report on the shear deformation of a eutectic structured HEA andeffect of precipitation on shear deformation. A split-Hopkinson pressure bar (SHPB) was used tocompress the hat-shaped specimens to study the local dynamic shear response of the alloy. Thechange in the width of shear bands with respect to precipitation and deformation rates was studied.The precipitation of L12 phase did not delay the formation of adiabatic shear bands (ASB) or affectthe ASB width significantly, however, the deformed region around ASB, consisting of high densityof twins in fcc phase, was reduced from 80 &mu, m to 20 &mu, m in the stronger precipitation strengthenedcondition. We observe dynamic recrystallization of grains within ASBs and local mechanicalresponse of individual eutectic lamellae before and after shear deformation and within the shearbands was examined using nano-indentation.

Eutectic high entropy alloys, with lamellar arrangement of solid solution phases, represent a new paradigm for simultaneously achieving high strength and ductility, thereby circumventing this well-known trade-off in conventional alloys. However, dynamic strengthening mechanisms and phase-boundary interactions during external loading remain unclear for these eutectic systems. In this study, small-scale mechanical behavior was evaluated for AlCoCrFeNi2.1 eutectic high entropy alloy, consisting of a lamellar arrangement of L12 and B2 solid-solution phases. The ultimate tensile strength was 1165 MPa with ductility of ~18% and ultimate compressive strength was 1863 MPa with a total compressive fracture strain of ~34%. Dual mode fracture was observed with ductile failure for L12 phase and brittle mode for B2 phase. Phase-specific mechanical tests using nano-indentation and micro-pillar compression showed higher hardness and strength and larger strain rate sensitivity for B2 compared with L12. Micro-pillars on B2 phase deformed by plastic barreling while L12 micro-pillars showed high density of slip steps due to activation of more slip systems and homogenous plastic flow. Mixed micro-pillars containing both the phases exhibited dual yielding behavior while the interface between L12 and B2 was well preserved without any sign of separation or cracking. Phase-specific friction analysis revealed higher coefficient of friction for B2 compared to L12. These results will pave the way for fundamental understanding of phase-specific contribution to bulk mechanical response of concentrated alloys and help in designing structural materials with high fracture toughness.

There is limited understanding of time-dependent plastic deformation behavior of amorphous alloys as a function of their structural state. Here, the creep behavior of Zr52.5Ti5Cu17.9Ni14.6Al10 bulk metallic glass was investigated in its as-cast and relaxed states using nanoindentation technique with applied load in the range of 500–1500 mN and temperature in the range of room temperature to 573 K. The creep displacement increased with increasing load and temperature since the creep process is thermally activated and diffusion rate is enhanced at elevated temperature and higher load. The creep strain rate sensitivity, which is a measure of the creep mechanism, increased with increase in temperature and decrease in applied load. This was attributed to the transition from localized to more homogeneous creep. Reduction in free volume for the relaxed alloy resulted in lower creep displacement and larger strain rate sensitivity compared to its as-cast counterpart. The results suggest that diffusion-based deformation dominate at higher temperature in contrast to shear transformation mediated plasticity at room temperature. The volume of shear transformation zone for the metallic glass was calculated using cooperative shearing model and correlated with the structural state for fundamental insights into the deformation process as a function of temperature and load.

Design of high-entropy alloys with complex microstructures presents a unique opportunity to combine the best of solid solution strengthening and precipitation hardening. These alloys are potentially disruptive for several high-performance applications including aerospace, oil and gas, nuclear industry, and next-generation tribology. This study presents the thermo-mechanical treatment, microstructural evolution, and surface degradation resistance in precipitation hardenable Al0.3Cu0.3Ti0.2CoCrFeNi high-entropy alloy. The heat-treated alloy consisted of fine precipitates of L12 and L21, strengthening the face-centered cubic solid solution matrix. Potentiodynamic polarization showed nano-galvanic coupling between the intermetallic particles and the matrix. Phase-specific nano-indentation showed that hard intermetallic particles caused three-body wear and higher friction values during sliding wear. The microstructure was correlated with processing conditions and resulting surface degradation resistance using transmission electron microscopy imaging and analysis. Hardening high-entropy alloys by introducing precipitates negatively effects corrosion resistance. A team led by Rajarshi Banerjee at the University of North Texas designed a new high entropy alloy, Al0.3Cu0.3Ti0.2CoCrFeNi, whose composition promoted precipitation strengthening of nanometer-scale L12 intermetallics as well as copper clusters. By using cold rolling and annealing at different times and temperatures, the alloys ranged from a solid solution to an alloy with two different types of intermetallics. This caused two different types of corrosion patterns: the more traditional large pits, and basket-weave elongated pits resulting from the galvanic coupling between the two intermetallic phases. These hard intermetallic phases were also dislodged during sliding, contributing to increased wear. Better understanding the corrosion and wear of high-entropy alloys may hasten their industrial implementation.

The reciprocating sliding wear behavior of two high entropy alloys, CoCrFeMnNi and Al0.1CoCrFeNi, was evaluated in dry and marine environments. Both the alloys showed better wear performance in marine environment as compared to dry condition, indicating negative synergy of wear and corrosion. Al0.1CoCrFeNi was more wear resistant compared to CoCrFeMnNi in both environments. Accelerated electrochemical corrosion tests were carried out to quantify the effect of passive layer on marine wear behavior. Al0.1CoCrFeNi showed lower corrosion rate, higher pitting resistance and greater degree of passivation. A strong correlation was found between the electrochemical polarization resistance and wear resistance.

An Al 0.25 Ti 0.75 CoCrFeNi high entropy alloy (HEA), consisting of multiple principal elements, forms the uncommonly observed chi-phase, which is a large lattice parameter intermetallic phase based on the body centered cubic crystal structure, as the matrix phase and a L2 1 phase (ordered Huesler phase, X 2 YZ-type based on the face-centered cubic structure) as a major secondary phase. Additionally, a face centered cubic phase with a high density of nano-twins is also present in the microstructure as a third phase. The extremely high Vicker's hardness of the matrix chi phase (1090Hv ± 14) and of the L2 1 phase (570 ± 9 H V ) along with low sliding coefficient of friction (∼0.3) and low wear rate (∼1.2 × 10 −5 mm 3 /N m) makes this HEA a promising candidate for mechanical wear-resistant applications.