Enhancing the fatigue resistance of high and medium entropy alloys by manufacturing-driven microstructural developments

You Sub Kim; Mao Yuan Luo; Dunji Yu; Ke An; Yan Chen; In Hwan Oh; Eunjoo Shin; Wanchuck Woo; Hobyung Chae; Young Sang Na; Peter K. Liaw; Jayant Jain; Jun Hyun Han; E. Wen Huang; Soo Yeol Lee

doi:10.1016/j.addma.2024.104332

Enhancing the fatigue resistance of high and medium entropy alloys by manufacturing-driven microstructural developments

You Sub Kim, Mao Yuan Luo, Dunji Yu, Ke An, Yan Chen, In Hwan Oh, Eunjoo Shin, Wanchuck Woo, Hobyung Chae, Young Sang Na, Peter K. Liaw, Jayant Jain, Jun Hyun Han, E. Wen Huang, Soo Yeol Lee

Research output: Contribution to journal › Article › peer-review

Abstract

Excellent fatigue performance is essential for broader applications of structural materials. In the present work, we report a microstructural design that improves fatigue resistance for high and medium-entropy alloys fabricated by direct energy deposition and hot-rolling processes. Specifically, we discover that the concurrent evolution of microstructures with fine-structure, including stacking faults, nano-twins and hexagonal-close-packed (HCP) structures, leads to zig-zag fracture that hinders crack propagation under cyclic loadings. These multiple characteristic microstructures improve fatigue resistance, which are attributed to the combination of low effective stacking fault energy and a high capacity for strain energy density. Anisotropic microstructural evolution is driven by the correlation between partial dislocations and the resolved shear stresses depending on the crystallographic orientation relationship. Consequently, stacking faults and nano-twins form prominently in the {111} grains under tension and in the {200} grains under compression. The current work provides an effective method to design advanced alloys for high fatigue resistance through microstructural tuning that controls the stacking fault energy combined by manufacturing processes.

Original language	English
Article number	104332
Journal	Additive Manufacturing
Volume	91
DOIs	https://doi.org/10.1016/j.addma.2024.104332
State	Published - Jul 5 2024

Funding

The present work was supported by a National Research Foundation (NRF) grant funded by the Korean government (RS-2024-00398068, 2023R1A2C2007190, RS-2023-00281671). The work at Korea Atomic Energy Research Institute (KAERI) was funded by the Internal R&D program supported by the Ministry of Science and Information Communication Technology (ICT) of the Republic of Korea (524210-22). YSN was financially supported by the Nano & Material Technology Development Program through the NRF of Korea funded by Ministry of Science and ICT (RS-2003-00281246). A portion of the current research used resources at the Spallation Neutron Source, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory (IPTS-26479 and IPTS-29338). PKL appreciates the support from (1) the National Science Foundation (DMR-1611180, 1809640, and 2226508) and (2) the US Army Research Office (W911NF-13-1-0438 and W911NF-19\u20132-0049) with program managers. EWH appreciates the National Science and Technology Council (NSTC), Taiwan, for the financial support through Grant No. NSTC 112-2811-E-A49-521 and NSTC 112-2221-E-A49-027, and the travel support from the National Synchrotron Radiation Research Center (NSRRC)-Neutron Travel Program. The authors sincerely appreciate the help from the High Entropy Materials Center of the National Tsing Hua University from The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) in Taiwan for their support. The present work was supported by a National Research Foundation (NRF) grant funded by the Korean government (RS-2024-00398068, 2023R1A2C2007190, RS-2023-00281671). The work at Korea Atomic Energy Research Institute (KAERI) was funded by the Internal R&D program supported by the Ministry of Science and Information Communication Technology (ICT) of the Republic of Korea (524210-22). YSN was financially supported by the Nano & Material Technology Development Program through the NRF of Korea funded by Ministry of Science and ICT (RS-2003-00281246). A portion of the current research used resources at the Spallation Neutron Source, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory (IPTS-26479 and IPTS-29338). PKL appreciates the support from (1) the National Science Foundation (DMR-1611180, 1809640, and 2226508) and (2) the US Army Research Office (W911NF-13-1-0438, W911NF-19-2-0049, and FA9550-23-1-0503). EWH appreciates the National Science and Technology Council (NSTC), Taiwan, for the financial support through Grant No. NSTC 112-2811-E-A49-521, NSTC 112-2221-E-A49-027, NSTC 113-2221-E-A49-003, and NSTC 113-2811-E-A49-525, and the travel support from the National Synchrotron Radiation Research Center (NSRRC)-Neutron Travel Program. The authors sincerely appreciate the help from the High Entropy Materials Center of the National Tsing Hua University from The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) in Taiwan for their support.

Funders	Funder number
National Tsing Hua University
Korea Atomic Energy Research Institute
Ministry of Education
Office of Science
National Synchrotron Radiation Research Center
Ministry of Science, ICT and Future Planning	RS-2003-00281246
National Science and Technology Council	NSTC 113-2811-E-A49-525, NSTC 112-2221-E-A49-027, NSTC 113-2221-E-A49-003, NSTC 112-2811-E-A49-521
Army Research Office	FA9550-23-1-0503, W911NF-19–2-0049, W911NF-13-1-0438
National Research Foundation of Korea	RS-2023-00281671, 2023R1A2C2007190, RS-2024-00398068
Oak Ridge National Laboratory	IPTS-26479, IPTS-29338
Ministry of Science and Information Communication Technology (ICT) of the Republic of Korea	524210-22
National Science Foundation	DMR-1611180, 2226508, 1809640

Keywords

CoCrFeNiMn
CoCrNi
Low-cycle fatigue
Manufacturing process
Stacking-fault energy

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10.1016/j.addma.2024.104332

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Kim, Y. S., Luo, M. Y., Yu, D., An, K., Chen, Y., Oh, I. H., Shin, E., Woo, W., Chae, H., Na, Y. S., Liaw, P. K., Jain, J., Han, J. H., Huang, E. W., & Lee, S. Y. (2024). Enhancing the fatigue resistance of high and medium entropy alloys by manufacturing-driven microstructural developments. Additive Manufacturing, 91, Article 104332. https://doi.org/10.1016/j.addma.2024.104332

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abstract = "Excellent fatigue performance is essential for broader applications of structural materials. In the present work, we report a microstructural design that improves fatigue resistance for high and medium-entropy alloys fabricated by direct energy deposition and hot-rolling processes. Specifically, we discover that the concurrent evolution of microstructures with fine-structure, including stacking faults, nano-twins and hexagonal-close-packed (HCP) structures, leads to zig-zag fracture that hinders crack propagation under cyclic loadings. These multiple characteristic microstructures improve fatigue resistance, which are attributed to the combination of low effective stacking fault energy and a high capacity for strain energy density. Anisotropic microstructural evolution is driven by the correlation between partial dislocations and the resolved shear stresses depending on the crystallographic orientation relationship. Consequently, stacking faults and nano-twins form prominently in the {111} grains under tension and in the {200} grains under compression. The current work provides an effective method to design advanced alloys for high fatigue resistance through microstructural tuning that controls the stacking fault energy combined by manufacturing processes.",

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AU - Oh, In Hwan

AU - Shin, Eunjoo

AU - Woo, Wanchuck

AU - Chae, Hobyung

AU - Na, Young Sang

AU - Liaw, Peter K.

AU - Jain, Jayant

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AU - Huang, E. Wen

AU - Lee, Soo Yeol

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N2 - Excellent fatigue performance is essential for broader applications of structural materials. In the present work, we report a microstructural design that improves fatigue resistance for high and medium-entropy alloys fabricated by direct energy deposition and hot-rolling processes. Specifically, we discover that the concurrent evolution of microstructures with fine-structure, including stacking faults, nano-twins and hexagonal-close-packed (HCP) structures, leads to zig-zag fracture that hinders crack propagation under cyclic loadings. These multiple characteristic microstructures improve fatigue resistance, which are attributed to the combination of low effective stacking fault energy and a high capacity for strain energy density. Anisotropic microstructural evolution is driven by the correlation between partial dislocations and the resolved shear stresses depending on the crystallographic orientation relationship. Consequently, stacking faults and nano-twins form prominently in the {111} grains under tension and in the {200} grains under compression. The current work provides an effective method to design advanced alloys for high fatigue resistance through microstructural tuning that controls the stacking fault energy combined by manufacturing processes.

AB - Excellent fatigue performance is essential for broader applications of structural materials. In the present work, we report a microstructural design that improves fatigue resistance for high and medium-entropy alloys fabricated by direct energy deposition and hot-rolling processes. Specifically, we discover that the concurrent evolution of microstructures with fine-structure, including stacking faults, nano-twins and hexagonal-close-packed (HCP) structures, leads to zig-zag fracture that hinders crack propagation under cyclic loadings. These multiple characteristic microstructures improve fatigue resistance, which are attributed to the combination of low effective stacking fault energy and a high capacity for strain energy density. Anisotropic microstructural evolution is driven by the correlation between partial dislocations and the resolved shear stresses depending on the crystallographic orientation relationship. Consequently, stacking faults and nano-twins form prominently in the {111} grains under tension and in the {200} grains under compression. The current work provides an effective method to design advanced alloys for high fatigue resistance through microstructural tuning that controls the stacking fault energy combined by manufacturing processes.

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Enhancing the fatigue resistance of high and medium entropy alloys by manufacturing-driven microstructural developments

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Keywords

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