Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Agrawal, Priyanshi; Thapliyal, Saket; Agrawal, Priyanka; Dhal, Abhijeet; Haridas, Ravi Sankar; Gupta, Sanya; Mishra, Rajiv S.

doi:10.1016/j.msea.2023.144938

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Journal Article · Wed Mar 22 00:00:00 EDT 2023 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing

DOI:https://doi.org/10.1016/j.msea.2023.144938· OSTI ID:1969809

^[1]; ^[1]; ^[2]; ^[2]; ^[2]; Gupta, Sanya ^[2]; ^[2]

Univ. of North Texas, Denton, TX (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of North Texas, Denton, TX (United States)

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe₄₀Mn₂₀Co₂₀Cr₁₅Si₅ (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $$\textit{J}$$ ≤ 31.25 J/mm³ and key-hole formation by melt pool destabilization in case of $$\textit{J}$$ ≥ 75 J/mm³. The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1969809

Journal Information:: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing, Journal Name: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing Vol. 872; ISSN 0921-5093

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (44)

A model for the FCC→HCP transformation, its applications, and experimental evidence Mahajan, S.; Green, M. L.; Brasen, D. Metallurgical Transactions A, Vol. 8, Issue 2 https://doi.org/10.1007/BF02661642	journal	February 1977
Strain Hardening of Hadfield Manganese Steel Adler, P. H.; Olson, G. B.; Owen, W. S. Metallurgical Transactions A, Vol. 17, Issue 10 https://doi.org/10.1007/BF02817271	journal	October 1986
Equilibrium partition coefficients in iron-based alloys Battle, Thomas P.; Pehlke, Robert D. Metallurgical Transactions B, Vol. 20, Issue 2 https://doi.org/10.1007/BF02825596	journal	April 1989
Prediction of dendrite arm spacing for low alloy steel casting processes El-Bealy, M.; Thomas, B. G. Metallurgical and Materials Transactions B, Vol. 27, Issue 4 https://doi.org/10.1007/BF02915668	journal	August 1996
Excellent combination of cryogenic strength and ductility of a metastable Fe65Ni15Co8Mn8Ti3Si medium entropy alloy through the exceptional deformation-induced martensitic transformation Haftlang, Farahnaz; Kwon, Jihye; Moon, Jongun Journal of Materials Science, Vol. 57, Issue 38 https://doi.org/10.1007/s10853-022-07400-8	journal	June 2022
Effects of Partition Coefficients, Diffusion Coefficients, and Solidification Paths on Microsegregation in Fe-Based Multinary Alloy Huang, Yunwei; Long, Mujun; Liu, Peng Metallurgical and Materials Transactions B, Vol. 48, Issue 5 https://doi.org/10.1007/s11663-017-1045-2	journal	August 2017
A formation mechanism of mechanical twins in F.C.C. Metals Fujita, H.; Mori, T. Scripta Metallurgica, Vol. 9, Issue 6 https://doi.org/10.1016/0036-9748(75)90476-7	journal	June 1975
Rapid solidification processing and microstructure formation Kurz, W.; Trivedi, R. Materials Science and Engineering: A, Vol. 179-180 https://doi.org/10.1016/0921-5093(94)90162-7	journal	May 1994
Solidification microstructures: A conceptual approach Trivedi, R.; Kurz, W. Acta Metallurgica et Materialia, Vol. 42, Issue 1 https://doi.org/10.1016/0956-7151(94)90044-2	journal	January 1994
Solidification microstructures and solid-state parallels: Recent developments, future directions Asta, M.; Beckermann, C.; Karma, A. Acta Materialia, Vol. 57, Issue 4 https://doi.org/10.1016/j.actamat.2008.10.020	journal	February 2009
Dependence of tensile deformation behavior of TWIP steels on stacking fault energy, temperature and strain rate Curtze, S.; Kuokkala, V. -T. Acta Materialia, Vol. 58, Issue 15 https://doi.org/10.1016/j.actamat.2010.05.049	journal	September 2010
The evolution of the growth morphology in Mg–Al alloys depending on the cooling rate during solidification Paliwal, Manas; Jung, In-Ho Acta Materialia, Vol. 61, Issue 13 https://doi.org/10.1016/j.actamat.2013.04.063	journal	August 2013
Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing Raghavan, Narendran; Dehoff, Ryan; Pannala, Sreekanth Acta Materialia, Vol. 112 https://doi.org/10.1016/j.actamat.2016.03.063	journal	June 2016
Comprehensive first-principles study of stable stacking faults in hcp metals Yin, Binglun; Wu, Zhaoxuan; Curtin, W. A. Acta Materialia, Vol. 123 https://doi.org/10.1016/j.actamat.2016.10.042	journal	January 2017
Micro-and meso-structures and their influence on mechanical properties of selectively laser melted Ti-6Al-4V Kumar, Punit; Prakash, Om; Ramamurty, Upadrasta Acta Materialia, Vol. 154 https://doi.org/10.1016/j.actamat.2018.05.044	journal	August 2018
Deformation mechanisms and ductile fracture characteristics of a friction stir processed transformative high entropy alloy Sinha, S.; Nene, S. S.; Frank, M. Acta Materialia, Vol. 184 https://doi.org/10.1016/j.actamat.2019.11.056	journal	February 2020
An ultra-high strength martensitic steel fabricated using selective laser melting additive manufacturing: Densification, microstructure, and mechanical properties Seede, Raiyan; Shoukr, David; Zhang, Bing Acta Materialia, Vol. 186 https://doi.org/10.1016/j.actamat.2019.12.037	journal	March 2020
Segregation engineering of grain boundaries of a metastable Fe-Mn-Co-Cr-Si high entropy alloy with laser-powder bed fusion additive manufacturing Thapliyal, Saket; Agrawal, Priyanshi; Agrawal, Priyanka Acta Materialia, Vol. 219 https://doi.org/10.1016/j.actamat.2021.117271	journal	October 2021
In situ absorptivity measurements of metallic powders during laser powder-bed fusion additive manufacturing Trapp, Johannes; Rubenchik, Alexander M.; Guss, Gabe Applied Materials Today, Vol. 9 https://doi.org/10.1016/j.apmt.2017.08.006	journal	December 2017
The enhancement of transformation induced plasticity effect through preferentially oriented substructure development in a high entropy alloy Hassanpour-Esfahani, M.; Zarei-Hanzaki, A.; Abedi, H. R. Intermetallics, Vol. 109 https://doi.org/10.1016/j.intermet.2019.03.013	journal	June 2019
Grain morphology evolution behavior of titanium alloy components during laser melting deposition additive manufacturing Wang, T.; Zhu, Y. Y.; Zhang, S. Q. Journal of Alloys and Compounds, Vol. 632 https://doi.org/10.1016/j.jallcom.2015.01.256	journal	May 2015
Metastability driven hierarchical microstructural engineering: Overview of mechanical properties of metastable complex concentrated alloys Mishra, R. S.; Nene, S. S.; Frank, M. Journal of Alloys and Compounds, Vol. 842 https://doi.org/10.1016/j.jallcom.2020.155625	journal	November 2020
Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing King, Wayne E.; Barth, Holly D.; Castillo, Victor M. Journal of Materials Processing Technology, Vol. 214, Issue 12 https://doi.org/10.1016/j.jmatprotec.2014.06.005	journal	December 2014
Investigation of crystal growth mechanism during selective laser melting and mechanical property characterization of 316L stainless steel parts Wang, Di; Song, Changhui; Yang, Yongqiang Materials & Design, Vol. 100 https://doi.org/10.1016/j.matdes.2016.03.111	journal	June 2016
Processing parameters in laser powder bed fusion metal additive manufacturing Oliveira, J. P.; LaLonde, A. D.; Ma, J. Materials & Design, Vol. 193 https://doi.org/10.1016/j.matdes.2020.108762	journal	August 2020
A four parameter hardening model for TWIP and TRIP steels Lloyd, J. T.; Field, D. M.; Limmer, K. R. Materials & Design, Vol. 194 https://doi.org/10.1016/j.matdes.2020.108878	journal	September 2020
Microstructurally flexible high entropy alloys: Linkages between alloy design and deformation behavior Nene, S. S.; Frank, M.; Agrawal, P. Materials & Design, Vol. 194 https://doi.org/10.1016/j.matdes.2020.108968	journal	September 2020
Design approaches for printability-performance synergy in Al alloys for laser-powder bed additive manufacturing Mishra, Rajiv S.; Thapliyal, Saket Materials & Design, Vol. 204 https://doi.org/10.1016/j.matdes.2021.109640	journal	June 2021
Role of Cu addition in enhancing strength-ductility synergy in transforming high entropy alloy Agrawal, Priyanka; Gupta, Sanya; Shukla, Shivakant Materials & Design, Vol. 215 https://doi.org/10.1016/j.matdes.2022.110487	journal	March 2022
Strain rate sensitive microstructural evolution in a TRIP assisted high entropy alloy: Experiments, microstructure and modeling Haridas, Ravi Sankar; Agrawal, Priyanshi; Thapliyal, Saket Mechanics of Materials, Vol. 156 https://doi.org/10.1016/j.mechmat.2021.103798	journal	May 2021
The high temperature mechanical properties and the correlated microstructure/ texture evolutions of a TWIP high entropy alloy Nabizada, A.; Zarei-Hanzaki, A.; Abedi, H. R. Materials Science and Engineering: A, Vol. 802 https://doi.org/10.1016/j.msea.2020.140600	journal	January 2021
Evidence of FCC to HCP and BCC-martensitic transformations in a CoCrFeNiMn high-entropy alloy by severe plastic deformation Shahmir, Hamed; Asghari-Rad, Peyman; Mehranpour, Mohammad Sajad Materials Science and Engineering: A, Vol. 807 https://doi.org/10.1016/j.msea.2021.140875	journal	March 2021
High entropy alloys – Tunability of deformation mechanisms through integration of compositional and microstructural domains Mishra, Rajiv S.; Haridas, Ravi Sankar; Agrawal, Priyanshi Materials Science and Engineering: A, Vol. 812 https://doi.org/10.1016/j.msea.2021.141085	journal	April 2021
Metastable high entropy alloys: An excellent defect tolerant material for additive manufacturing Agrawal, Priyanshi; Haridas, Ravi Sankar; Thapliyal, Saket Materials Science and Engineering: A, Vol. 826 https://doi.org/10.1016/j.msea.2021.142005	journal	October 2021
Additive manufacturing of metallic components – Process, structure and properties DebRoy, T.; Wei, H. L.; Zuback, J. S. Progress in Materials Science, Vol. 92 https://doi.org/10.1016/j.pmatsci.2017.10.001	journal	March 2018
Mechanistic models for additive manufacturing of metallic components Wei, H. L.; Mukherjee, T.; Zhang, W. Progress in Materials Science, Vol. 116 https://doi.org/10.1016/j.pmatsci.2020.100703	journal	February 2021
Investigation of strain-induced martensitic transformation in metastable austenite using nanoindentation Ahn, T. -H.; Oh, C. -S.; Kim, D. H. Scripta Materialia, Vol. 63, Issue 5 https://doi.org/10.1016/j.scriptamat.2010.05.024	journal	September 2010
Solidification and solid-state transformation sciences in metals additive manufacturing Kirka, Michael M.; Nandwana, Peeyush; Lee, Yousub Scripta Materialia, Vol. 135 https://doi.org/10.1016/j.scriptamat.2017.01.005	journal	July 2017
Reversed strength-ductility relationship in microstructurally flexible high entropy alloy Nene, S. S.; Frank, M.; Liu, K. Scripta Materialia, Vol. 154 https://doi.org/10.1016/j.scriptamat.2018.05.043	journal	September 2018
Nanoscale origins of the damage tolerance of the high-entropy alloy CrMnFeCoNi Zhang, ZiJiao; Mao, M. M.; Wang, Jiangwei Nature Communications, Vol. 6, Issue 1 https://doi.org/10.1038/ncomms10143	journal	December 2015
Printability of alloys for additive manufacturing Mukherjee, T.; Zuback, J. S.; De, A. Scientific Reports, Vol. 6, Issue 1 https://doi.org/10.1038/srep19717	journal	January 2016
Understanding pop-ins in spherical nanoindentation Pathak, Siddhartha; Riesterer, Jessica L.; Kalidindi, Surya R. Applied Physics Letters, Vol. 105, Issue 16 https://doi.org/10.1063/1.4898698	journal	October 2014
Heat transfer and fluid flow during keyhole mode laser welding of tantalum, Ti–6Al–4V, 304L stainless steel and vanadium Rai, R.; Elmer, J. W.; Palmer, T. A. Journal of Physics D: Applied Physics, Vol. 40, Issue 18 https://doi.org/10.1088/0022-3727/40/18/037	journal	August 2007
Correlation between solidification parameters and weld microstructures David, S. A.; Vitek, J. M. International Materials Reviews, Vol. 34, Issue 1 https://doi.org/10.1179/imr.1989.34.1.213	journal	January 1989

Similar Records

Investigating the deformation mechanisms of a highly metastable high entropy alloy using in-situ neutron diffraction

Journal Article · Sun Dec 22 19:00:00 EST 2019 · Materials Today Communications · OSTI ID:1649352

Irradiation-induced shift in the thermodynamic stability of phases and the self-healing effect in transformative high entropy alloys

Journal Article · Mon Apr 15 20:00:00 EDT 2024 · Journal of Nuclear Materials · OSTI ID:2479436

Design metastability in high-entropy alloys by tailoring unstable fault energies

Journal Article · Thu Sep 08 20:00:00 EDT 2022 · Science Advances · OSTI ID:1982948

Related Subjects

36 MATERIALS SCIENCE
Additive manufacturing
High entropy alloy
Microstructural characterization
Solidification
Transformation induced plasticity

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Citation Formats

References (44)

Similar Records

Related Subjects