Creep deformation and cavitation in an additively manufactured Al-8.6Cu-0.4Mn-0.9Zr (wt%) alloy

Rakhmonov, Jovid U.; Michi, Richard; Bahl, Sumit; Rahman, Obaidullah; Frederick, Curtis; Ziabari, Amir Koushyar; Dunand, David C.; Dehoff, Ryan; Plotkowski, Alex; Shyam, Amit

doi:10.1016/j.addma.2024.104097

Title: Creep deformation and cavitation in an additively manufactured Al-8.6Cu-0.4Mn-0.9Zr (wt%) alloy

Journal Article · 23 March 2024 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2024.104097 · OSTI ID:2336675

Rakhmonov, Jovid U. ^[1]; Michi, Richard ^[2];

^[2];

^[2]; Frederick, Curtis ^[3];

^[2]; Dunand, David C. ^[4];

^[2];

^[2]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Northwestern Univ., Evanston, IL (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Carl Zeiss Industrial Meteorology, LLC, Maple Grove, MN (United States)
Northwestern Univ., Evanston, IL (United States)

Creep deformation and cavitation were investigated at 300 ºC in both tension and compression for an additively manufactured Al-8.6Cu-0.5Mn-0.9Zr (wt%) alloy in the as-fabricated state and after various aging treatments (aging at 300 °C/200 h or 350 °C/24 h and overaging at 400 °C/200 h). Creep mechanisms at 300 °C were determined by relating the measured creep response to corresponding microstructural and X-ray computed tomography observations. In compression, alloys in the as-fabricated and two aging conditions exhibited similarly high creep resistance. Overaging (400 °C/200 h) led to substantial coarsening of intragranular θ-Al2Cu precipitates and an expected drop in their Orowan strengthening contribution. In tension, minimum strain rates comparable to those in compression were obtained at any given stress; however, upon accumulation of some plastic strain in the matrix, creep cavities started to form, leading to accelerated tertiary stage creep deformation and rupture. Cavitation occurred exclusively along melt pool boundaries due to locally enhanced diffusion enabled by (i) large grain-boundary area in adjacent fine-grained zones and (ii) localization of creep strain in nearby heat-affected zones. Although cavity growth was initially diffusion-controlled, its rate was determined by matrix creep rate, consistent with constrained cavity growth mechanisms. This study reveals how microstructural complexities induced by the additive manufacturing process affect the creep and cavitation behavior of Al-Cu-Mn-Zr alloys. The underlying creep and cavitation mechanisms uncovered in this study point to pathways that improve the high-temperature properties of additively manufactured alloys.

View Accepted Manuscript (DOE)

Cite

Export

Save

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

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2336675

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 84; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (42)

Special zone in multi-layer and multi-pass welded metal and its role in the creep behavior of 9Cr 1Mo welded joint Liu, Wen; Lu, Fenggui; Wei, Yuanhang Materials & Design, Vol. 108 https://doi.org/10.1016/j.matdes.2016.06.102	journal	October 2016
Multi-scale modelling of creep cavity nucleation and growth in polycrystalline Type 316 stainless steel Petkov, Markian P.; Elmukashfi, Elsiddig; Cocks, Alan C. F. Philosophical Magazine, Vol. 102, Issue 23 https://doi.org/10.1080/14786435.2022.2121867	journal	September 2022
Progression of creep deformation from grain boundaries to grain interior in Al-Cu-Mn-Zr alloys Rakhmonov, J. U.; Milligan, B.; Bahl, S. Acta Materialia, Vol. 250 https://doi.org/10.1016/j.actamat.2023.118886	journal	May 2023
Theory of intergranular creep cavity nucleation, growth and interaction Davanas, K.; Solomon, A. A. Acta Metallurgica et Materialia, Vol. 38, Issue 10 https://doi.org/10.1016/0956-7151(90)90302-W	journal	October 1990
Creep cavitation in metals Kassner, M. E.; Hayes, T. A. International Journal of Plasticity, Vol. 19, Issue 10 https://doi.org/10.1016/S0749-6419(02)00111-0	journal	October 2003
Cavitation-resistant intergranular precipitates enhance creep performance of θ′-strengthened Al-Cu based alloys Rakhmonov, Jovid U.; Bahl, Sumit; Shyam, Amit Acta Materialia, Vol. 228 https://doi.org/10.1016/j.actamat.2022.117788	journal	April 2022
A procedure to obtain correlation curve between local misorientation and plastic strain Kamaya, Masayuki; Maekawa, Naoko Materials Characterization, Vol. 198 https://doi.org/10.1016/j.matchar.2023.112725	journal	April 2023
The relation between minimum creep rate and time to fracture Dobeš, F.; Milička, K. Metal Science, Vol. 10, Issue 11 https://doi.org/10.1080/03063453.1976.11683560	journal	January 1976
Strengthening of an Al–Cu–Sn alloy by deformation-resistant precipitate plates Nie, J. F.; Muddle, B. C. Acta Materialia, Vol. 56, Issue 14 https://doi.org/10.1016/j.actamat.2008.03.028	journal	August 2008
Elevated temperature microstructural stability in cast AlCuMnZr alloys through solute segregation Shyam, A.; Roy, S.; Shin, D. Materials Science and Engineering: A, Vol. 765 https://doi.org/10.1016/j.msea.2019.138279	journal	September 2019
An additively manufactured near-eutectic Al-Ce-Ni-Mn-Zr alloy with high creep resistance Bahl, Sumit; Wu, Tiffany; Michi, Richard A. Acta Materialia, Vol. 268 https://doi.org/10.1016/j.actamat.2024.119787	journal	April 2024
Fast Model-Based X-Ray CT Reconstruction Using Spatially Nonhomogeneous ICD Optimization Yu, Zhou; Thibault, Jean-Baptiste; Bouman, Charles A. IEEE Transactions on Image Processing, Vol. 20, Issue 1 https://doi.org/10.1109/TIP.2010.2058811	journal	January 2011
Microstructure and properties of a high temperature Al–Ce–Mn alloy produced by additive manufacturing Plotkowski, A.; Sisco, K.; Bahl, S. Acta Materialia, Vol. 196 https://doi.org/10.1016/j.actamat.2020.07.014	journal	September 2020
An additively manufactured AlCuMnZr alloy microstructure and tensile mechanical properties Shyam, A.; Plotkowski, A.; Bahl, S. Materialia, Vol. 12 https://doi.org/10.1016/j.mtla.2020.100758	journal	August 2020
Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy Michi, Richard A.; Sisco, Kevin; Bahl, Sumit Materials Science and Engineering: A, Vol. 840 https://doi.org/10.1016/j.msea.2022.142928	journal	April 2022
Type IV Creep Damage Behavior in Gr.91 Steel Welded Joints Hongo, Hiromichi; Tabuchi, Masaaki; Watanabe, Takashi Metallurgical and Materials Transactions A, Vol. 43, Issue 4 https://doi.org/10.1007/s11661-011-0967-6	journal	October 2011
Microstructure and mechanical properties of Al-Mg-Zr alloys processed by selective laser melting Croteau, Joseph R.; Griffiths, Seth; Rossell, Marta D. Acta Materialia, Vol. 153 https://doi.org/10.1016/j.actamat.2018.04.053	journal	July 2018
Recent advances in the metallurgy of aluminum alloys. Part II: Age hardening Sigli, Christophe; De Geuser, Frédéric; Deschamps, Alexis Comptes Rendus Physique, Vol. 19, Issue 8 https://doi.org/10.1016/j.crhy.2018.10.012	journal	December 2018
Cavity nucleation at high temperatures involving pile-ups of grain boundary dislocations Lim, L. C. Acta Metallurgica, Vol. 35, Issue 7 https://doi.org/10.1016/0001-6160(87)90114-3	journal	July 1987
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
Monkman-grant analysis of creep fracture in dispersion-strengthened and particulate-reinforced aluminum Dunand, D. C.; Han, B. Q.; Jansen, A. M. Metallurgical and Materials Transactions A, Vol. 30, Issue 3 https://doi.org/10.1007/s11661-999-0076-y	journal	March 1999
Comparing evolution of precipitates and strength upon aging of cast and laser-remelted Al–8Ce-0.2Sc-0.1Zr (wt.%) Rakhmonov, Jovid U.; Weiss, David; Dunand, David C. Materials Science and Engineering: A, Vol. 840 https://doi.org/10.1016/j.msea.2022.142990	journal	April 2022
A creep-resistant additively manufactured Al-Ce-Ni-Mn alloy Michi, Richard A.; Sisco, Kevin; Bahl, Sumit Acta Materialia, Vol. 227 https://doi.org/10.1016/j.actamat.2022.117699	journal	April 2022
Dislocation-θ′ (Al2Cu) interactions during creep deformation of an Al-Cu alloy Milligan, Brian; Ma, Dong; Allard, Lawrence Scripta Materialia, Vol. 217 https://doi.org/10.1016/j.scriptamat.2022.114739	journal	August 2022
Elevated temperature ductility dip in an additively manufactured Al-Cu-Ce alloy Bahl, Sumit; Plotkowski, Alex; Sisco, Kevin Acta Materialia, Vol. 220 https://doi.org/10.1016/j.actamat.2021.117285	journal	November 2021
The formation of water vapor bubbles in copper and their effect on intergranular creep fracture Nieh, T. G.; Nix, W. D. Acta Metallurgica, Vol. 28, Issue 5 https://doi.org/10.1016/0001-6160(80)90122-4	journal	May 1980
Review Type IV cracking in ferritic power plant steels Francis, J. A.; Mazur, W.; Bhadeshia, H. K. D. H. Materials Science and Technology, Vol. 22, Issue 12 https://doi.org/10.1179/174328406X148778	journal	December 2006
Diffusive intergranular cavity growth in creep in tension and torsion Stanzl, S. E.; Argon, A. S.; Tschegg, E. K. Acta Metallurgica, Vol. 31, Issue 6 https://doi.org/10.1016/0001-6160(83)90111-6	journal	June 1983
Nucleation of cavities at second phase particles in grain boundaries Raj, Rishi Acta Metallurgica, Vol. 26, Issue 6 https://doi.org/10.1016/0001-6160(78)90050-0	journal	June 1978
Coarsening- and creep resistance of precipitation-strengthened Al–Mg–Zr alloys processed by selective laser melting Griffiths, S.; Croteau, J. R.; Rossell, M. D. Acta Materialia, Vol. 188 https://doi.org/10.1016/j.actamat.2020.02.008	journal	April 2020
Effect of grain-boundary θ-Al2Cu precipitates on tensile and compressive creep properties of cast Al–Cu–Mn–Zr alloys Bahl, Sumit; Rakhmonov, Jovid U.; Kenel, Christoph Materials Science and Engineering: A, Vol. 840 https://doi.org/10.1016/j.msea.2022.142946	journal	April 2022
Load shuffling during creep deformation of an additively manufactured AlCuMnZr alloy Michi, Richard A.; Bahl, Sumit; Fancher, Christopher M. Acta Materialia, Vol. 244 https://doi.org/10.1016/j.actamat.2022.118557	journal	January 2023
Mechanisms and controlling factors in creep fracture Nix, W. D. Materials Science and Engineering: A, Vol. 103, Issue 1 https://doi.org/10.1016/0025-5416(88)90556-3	journal	August 1988
Nonhomogeneous microstructure related creep damage of the CrMoV multi-pass weld metal Yang, Bin; Xuan, Fu-Zhen Materials Science and Engineering: A, Vol. 763 https://doi.org/10.1016/j.msea.2019.138122	journal	August 2019
Analysis of cavity nucleation in solids subjected to external and internal stresses Hirth, J. P.; Nix, W. D. Acta Metallurgica, Vol. 33, Issue 3 https://doi.org/10.1016/0001-6160(85)90078-1	journal	March 1985
Aging behavior and strengthening mechanisms of coarsening resistant metastable θ' precipitates in an Al–Cu alloy Bahl, Sumit; Xiong, Lianghua; Allard, Lawrence F. Materials & Design, Vol. 198 https://doi.org/10.1016/j.matdes.2020.109378	journal	January 2021
Criteria for developing castable, creep-resistant aluminum-based alloys – A review Knipling, Keith E.; Dunand, David C.; Seidman, David N. International Journal of Materials Research, Vol. 97, Issue 3 https://doi.org/10.1515/ijmr-2006-0042	journal	March 2006
Practical cone-beam algorithm Feldkamp, L. A.; Davis, L. C.; Kress, J. W. Journal of the Optical Society of America A, Vol. 1, Issue 6 https://doi.org/10.1364/JOSAA.1.000612	journal	January 1984
Diffusive growth of grain-boundary cavities Chen, I-W.; Argon, A. S. Acta Metallurgica, Vol. 29, Issue 10 https://doi.org/10.1016/0001-6160(81)90009-2	journal	October 1981
Change in microstructural characteristics of laser powder bed fused Al–Fe binary alloy at elevated temperature Qi, Xing; Takata, Naoki; Suzuki, Asuka Journal of Materials Science & Technology, Vol. 97 https://doi.org/10.1016/j.jmst.2021.04.038	journal	January 2022
Mechanical properties of Al(Sc,Zr) alloys at ambient and elevated temperatures Fuller, Christian B.; Seidman, David N.; Dunand, David C. Acta Materialia, Vol. 51, Issue 16 https://doi.org/10.1016/S1359-6454(03)00320-3	journal	September 2003
Intergranular fracture at elevated temperature Raj, Rishi; Ashby, M. F. Acta Metallurgica, Vol. 23, Issue 6 https://doi.org/10.1016/0001-6160(75)90047-4	journal	June 1975

Similar Records

Microstructural evolution and strengthening mechanisms in a heat-treated additively manufactured Al–Cu–Mn–Zr alloy

Journal Article · 2022 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:1855664

Michi, Richard A.; Sisco, Kevin D.; Bahl, Sumit; +7 more

Microstructure and strengthening of Al-6Ce-3Ni-0.7Fe (wt%) alloy manufactured by laser powder-bed fusion

Journal Article · 2023 · Additive Manufacturing · OSTI ID:2333818

Wu, Tiffany; Poplawsky, Jonathan D.; Allard, Lawrence F.; +3 more

Cavitation-resistant intergranular precipitates enhance creep performance of θ'-strengthened Al-Cu based alloys

Journal Article · 2022 · Acta Materialia · OSTI ID:1863293

Rakhmonov, Jovid U.; Bahl, Sumit; Shyam, Amit; +1 more

Related Subjects

36
additive manufacturing
aluminum alloys
creep
cavitation
microstructure

Title: Creep deformation and cavitation in an additively manufactured Al-8.6Cu-0.4Mn-0.9Zr (wt%) alloy

Citation Formats

References (42)

Similar Records

Related Subjects