Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders

Mooraj, Shahryar; Kim, George; Fan, Xuesong; Samuha, Shmuel; Xie, Yujun; Li, Tianyi; Tiley, Jaimie S.; Chen, Yan; Yu, Dunji; An, Ke; Hosemann, Peter; Liaw, Peter K.; Chen, Wei; Chen, Wen

doi:10.1038/s43246-024-00452-0

Title: Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders

Abstract

Laser powder-bed fusion (L-PBF) additive manufacturing presents ample opportunities to produce net-shape parts. The complex laser-powder interactions result in high cooling rates that often lead to unique microstructures and excellent mechanical properties. Refractory high-entropy alloys show great potential for high-temperature applications but are notoriously difficult to process by additive processes due to their sensitivity to cracking and defects, such as un-melted powders and keyholes. Here, we present a method based on a normalized model-based processing diagram to achieve a nearly defect-free TiZrNbTa alloy via in-situ alloying of elemental powders during L-PBF. Compared to its as-cast counterpart, the as-printed TiZrNbTa exhibits comparable mechanical properties but with enhanced elastic isotropy. This method has good potential for other refractory alloy systems based on in-situ alloying of elemental powders, thereby creating new opportunities to rapidly expand the collection of processable refractory materials via L-PBF.

Authors:

Mooraj, Shahryar ^[1]; Kim, George ^[2]; Fan, Xuesong ^[3]; Samuha, Shmuel ^[4]; Xie, Yujun ^[5];

^[6]; Tiley, Jaimie S. ^[7];

^[7];

^[7]; Hosemann, Peter ^[5];

^[3];

^[8];

^[1]

Univ. of Massachusetts, Amherst, MA (United States)
Illinois Institute of Technology, Chicago, IL (United States)
Univ. of Tennessee, Knoxville, TN (United States)
Univ. of California, Berkeley, CA (United States); NRCN, Beer-Sheva (Israel)
Univ. of California, Berkeley, CA (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Illinois Institute of Technology, Chicago, IL (United States); State Univ. of New York (SUNY), Buffalo, NY (United States)

Publication Date:: Fri Feb 16 00:00:00 EST 2024

Research Org.:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Spallation Neutron Source (SNS); Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

Sponsoring Org.:: USDOE; National Science Foundation (NSF); US Army Research Office (ARO)

OSTI Identifier:: 2317779

Grant/Contract Number:: AC05-00OR22725; DMR-2238204; DMR-1945380; OAC-2404816; DMR-1611180; DMR-1809640; DMR-2226508; W911NF-13–1-0438; W911NF-19–2-0049

Resource Type:: Accepted Manuscript

Journal Name:: Communications Materials

Additional Journal Information:: Journal Volume: 5; Journal Issue: 1; Journal ID: ISSN 2662-4443

Publisher:: Springer Nature

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    Mooraj, Shahryar, Kim, George, Fan, Xuesong, Samuha, Shmuel, Xie, Yujun, Li, Tianyi, Tiley, Jaimie S., Chen, Yan, Yu, Dunji, An, Ke, Hosemann, Peter, Liaw, Peter K., Chen, Wei, and Chen, Wen. Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders.  United States: N. p., 2024. 
Web.  doi:10.1038/s43246-024-00452-0.

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                    Mooraj, Shahryar, Kim, George, Fan, Xuesong, Samuha, Shmuel, Xie, Yujun, Li, Tianyi, Tiley, Jaimie S., Chen, Yan, Yu, Dunji, An, Ke, Hosemann, Peter, Liaw, Peter K., Chen, Wei, & Chen, Wen. Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders.  United States.  https://doi.org/10.1038/s43246-024-00452-0

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                    Mooraj, Shahryar, Kim, George, Fan, Xuesong, Samuha, Shmuel, Xie, Yujun, Li, Tianyi, Tiley, Jaimie S., Chen, Yan, Yu, Dunji, An, Ke, Hosemann, Peter, Liaw, Peter K., Chen, Wei, and Chen, Wen. Fri .  
"Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders".  United States.  https://doi.org/10.1038/s43246-024-00452-0.  https://www.osti.gov/servlets/purl/2317779.

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@article{osti_2317779,

  title        = {Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders},

  author       = {Mooraj, Shahryar and Kim, George and Fan, Xuesong and Samuha, Shmuel and Xie, Yujun and Li, Tianyi and Tiley, Jaimie S. and Chen, Yan and Yu, Dunji and An, Ke and Hosemann, Peter and Liaw, Peter K. and Chen, Wei and Chen, Wen},

  abstractNote = {Laser powder-bed fusion (L-PBF) additive manufacturing presents ample opportunities to produce net-shape parts. The complex laser-powder interactions result in high cooling rates that often lead to unique microstructures and excellent mechanical properties. Refractory high-entropy alloys show great potential for high-temperature applications but are notoriously difficult to process by additive processes due to their sensitivity to cracking and defects, such as un-melted powders and keyholes. Here, we present a method based on a normalized model-based processing diagram to achieve a nearly defect-free TiZrNbTa alloy via in-situ alloying of elemental powders during L-PBF. Compared to its as-cast counterpart, the as-printed TiZrNbTa exhibits comparable mechanical properties but with enhanced elastic isotropy. This method has good potential for other refractory alloy systems based on in-situ alloying of elemental powders, thereby creating new opportunities to rapidly expand the collection of processable refractory materials via L-PBF.},

  doi          = {10.1038/s43246-024-00452-0},

  journal      = {Communications Materials},

  number       = 1,

  volume       = 5,

  place        = {United States},

  year         = {Fri Feb 16 00:00:00 EST 2024},

  month        = {Fri Feb 16 00:00:00 EST 2024}

}

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High-entropy alloys (HEAs) have attracted great attention for many biomedical applications. However, the nature of interatomic interactions in this class of complex multicomponent alloys is not fully understood. We report, for the first time, the results of theoretical modeling for porosity in a large biocompatible HEA TiNbTaZrMo using an atomistic supercell of 1024 atoms that provides new insights and understanding. Our results demonstrated the deficiency of using the valence electron count, quantification of large lattice distortion, validation of mechanical properties with available experimental data to reduce Young's modulus. We utilized the novel concepts of the total bond order density (TBOD)more »« less
https://doi.org/10.1039/d3ra07313k

Full Text Available
Superior High-Temperature Strength in a Supersaturated Refractory High-Entropy Alloy

Journal Article Feng, Rui ; Feng, Bojun ; Gao, Michael C. ; ... - Advanced Materials

Abstract Refractory high‐entropy alloys (RHEAs) show promising applications at high temperatures. However, achieving high strengths at elevated temperatures above 1173K is still challenging due to heat softening. Using intrinsic material characteristics as the alloy‐design principles, a single‐phase body‐centered‐cubic (BCC) CrMoNbV RHEA with high‐temperature strengths (beyond 1000 MPa at 1273 K) is designed, superior to other reported RHEAs as well as conventional superalloys. The origin of the high‐temperature strength is revealed by in situ neutron scattering, transmission‐electron microscopy, and first‐principles calculations. The CrMoNbV's elevated‐temperature strength retention up to 1273 K arises from its large atomic‐size and elastic‐modulus mismatches, the insensitive temperature dependencemore »« less
https://doi.org/10.1002/adma.202102401

Full Text Available
Lattice-Distortion-Enhanced Yield Strength in a Refractory High-Entropy Alloy

Journal Article Lee, Chanho ; Chou, Yi ; Kim, George ; ... - Advanced Materials
https://doi.org/10.1002/adma.202004029

Full Text Available

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Title: Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders

Abstract

Citation Formats

Comparative study of the microstructures and mechanical properties of laser metal deposited and vacuum arc melted refractory NbMoTa medium-entropy alloy journal, April 2020

Generalized Gradient Approximation Made Simple journal, October 1996

Emerging metallic systems for additive manufacturing: In-situ alloying and multi-metal processing in laser powder bed fusion journal, June 2021

Projector augmented-wave method journal, December 1994

Alloy design, micromechanical and macromechanical properties of CoCrFeNiTax eutectic high entropy alloys journal, February 2018

Manufacturing and analysis of VNbMoTaW refractory high-entropy alloy fabricated by selective laser melting journal, June 2022

Additive manufacturing of in-situ strengthened dual-phase AlCoCuFeNi high-entropy alloy by selective electron beam melting journal, February 2022

Influence of Local Lattice Distortion on Elastic Properties of Hexagonal Close‐Packed TiZrHf and TiZrHfSc Refractory Alloys journal, May 2021

Interface coherency strain relaxation due to plastic deformation in single crystal Ni-base superalloys journal, April 2013

A novel Fe 20 Co 20 Ni 41 Al 19 eutectic high entropy alloy with excellent tensile properties journal, April 2018

Additive Manufacturing of High-Entropy Alloys: Microstructural Metastability and Mechanical Behavior journal, August 2021

Additive manufacturing of high strength copper alloy with heterogeneous grain structure through laser powder bed fusion journal, November 2021

Charting the complete elastic properties of inorganic crystalline compounds journal, March 2015

Compositional variation effects on the microstructure and properties of a refractory high-entropy superalloy AlMo0.5NbTa0.5TiZr journal, February 2018

Microstructure and room temperature properties of a high-entropy TaNbHfZrTi alloy journal, May 2011

Reduction of residual stress in porous Ti6Al4V by in situ double scanning during laser additive manufacturing journal, February 2021

Microstructure and mechanical behavior of additively manufactured CoCrFeMnNi high-entropy alloys: Laser directed energy deposition versus powder bed fusion journal, May 2023

Strong yet ductile nanolamellar high-entropy alloys by additive manufacturing journal, August 2022

Computational Assessment of Thermokinetics and Associated Microstructural Evolution in Laser Powder Bed Fusion Manufacturing of Ti6Al4V Alloy journal, May 2020

VULCAN: A “hammer” for high-temperature materials research journal, November 2019

Anisotropic Lattice Distortions in Random Alloys from First-Principles Theory journal, September 2001

High-entropy alloys journal, June 2019

Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging journal, February 2019

Residual Stress in Metal Additive Manufacturing journal, January 2018

Influence of erbium addition on the defects of selective laser-melted 7075 aluminium alloy journal, October 2021

High-strength lamellar high-entropy alloys in-situ synthesized by laser additive manufacturing journal, March 2023

A novel quaternary equiatomic Ti-Zr-Nb-Ta medium entropy alloy (MEA) journal, October 2018

Diffraction and single-crystal elastic constants of Inconel 625 at room and elevated temperatures determined by neutron diffraction journal, September 2016

Elastic and plastic anisotropy in a refractory high entropy alloy utilizing combinatorial instrumented indentation and electron backscatter diffraction journal, March 2022

Texture Analysis with MTEX – Free and Open Source Software Toolbox journal, February 2010

Phase-specific deformation behavior of a NiAl–Cr(Mo) lamellar composite under thermal and mechanical loads journal, January 2016

Finite element analysis of the influence of elastic anisotropy on stress intensification at stress corrosion cracking initiation sites in fcc alloys journal, May 2018

A fracture-resistant high-entropy alloy for cryogenic applications journal, September 2014

In-situ Synchrotron imaging of keyhole mode multi-layer laser powder bed fusion additive manufacturing journal, September 2020

In situ X-ray and thermal imaging of refractory high entropy alloying during laser directed deposition journal, January 2022

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy journal, June 2017

Mechanical characterisation of V-4Cr-4Ti alloy: Tensile tests under high energy synchrotron diffraction journal, October 2022

An improved X-ray diffraction analysis method to characterize dislocation density in lath martensitic structures journal, July 2015

Effect of Build Height on Temperature Evolution and Thermally Induced Residual Stresses in Plasma Arc Additively Manufactured Stainless Steel journal, November 2021

Microscale residual stresses in additively manufactured stainless steel journal, September 2019

Efficient stochastic generation of special quasirandom structures journal, September 2013

Processing and characterization of crack-free 7075 aluminum alloys with elemental Zr modification by laser powder bed fusion journal, March 2022

Metal Additive Manufacturing: A Review journal, April 2014

Elastic behavior of binary and ternary refractory multi-principal-element alloys journal, July 2022

Composition design of high-entropy alloys with deep sets learning journal, April 2022

Metal additive manufacturing in aerospace: A review journal, November 2021

Additive manufacturing of high entropy alloys: A practical review journal, June 2021

Normalised model-based processing diagrams for additive layer manufacture of engineering alloys journal, April 2016

Solidification and solid-state transformation sciences in metals additive manufacturing journal, July 2017

Development and exploration of refractory high entropy alloys—A review journal, June 2018

Universal Elastic Anisotropy Index journal, August 2008

Efficiency of ab-initio total energy calculations for metals and semiconductors using a plane-wave basis set journal, July 1996

Formation of printing defects and their effects on mechanical properties of additively manufactured metal alloys journal, December 2022

High-throughput additive manufacturing and characterization of refractory high entropy alloys journal, June 2020

Efficient iterative schemes for ab initio total-energy calculations using a plane-wave basis set journal, October 1996

Evaluating elastic properties of a body-centered cubic NbHfZrTi high-entropy alloy – A direct comparison between experiments and ab initio calculations journal, June 2019

Additively manufactured hierarchical stainless steels with high strength and ductility journal, October 2017

In situ investigation of phase transformations in Ti-6Al-4V under additive manufacturing conditions combining laser melting and high-speed micro-X-ray diffraction journal, November 2017

Investigation on solid-state phase transformation in a Ti-47Al-2Cr-2V alloy due to thermal cycling during laser additive manufacturing process journal, August 2019

Investigation of the Nb element segregation for laser additive manufacturing of nickel-based superalloys journal, December 2021

Elastic and plastic properties of as-cast equimolar TiHfZrTaNb high-entropy alloy journal, January 2016

Special quasirandom structures journal, July 1990

Equiaxed grain formation by intrinsic heterogeneous nucleation via rapid heating and cooling in additive manufacturing of aluminum-silicon hypoeutectic alloy journal, October 2022

Microstructure evolution and performance enhancement of NbTaTiV-(Cr, Zr, W) single-phase refractory high-entropy alloy coatings: Role of additional elements journal, August 2023

Effect of solid-state phase transformation on residual stress of selective laser melting Ti6Al4V journal, July 2021

New alloy design approach to inhibiting hot cracking in laser additive manufactured nickel-based superalloys journal, April 2023

Design considerations for high entropy alloys in advanced nuclear applications journal, August 2022

In-situ alloying in laser-based additive manufacturing processes: A critical review journal, August 2021

Rapid thermokinetics driven nanoscale vanadium clustering within martensite laths in laser powder bed fused additively manufactured Ti6Al4V journal, June 2020

Coarsening of martensite with multiple generations of twins in laser additively manufactured Ti6Al4V journal, July 2021

A simplified model connecting lattice distortion with friction stress of Nb-based equiatomic high-entropy alloys journal, April 2019

Characterisation of in-situ alloyed titanium-tantalum lattice structures by laser powder bed fusion using finite element analysis journal, November 2022

Comparative study of the microstructures and mechanical properties of laser metal deposited and vacuum arc melted refractory NbMoTa medium-entropy alloy
journal, April 2020

Generalized Gradient Approximation Made Simple
journal, October 1996

Emerging metallic systems for additive manufacturing: In-situ alloying and multi-metal processing in laser powder bed fusion
journal, June 2021

Projector augmented-wave method
journal, December 1994

Alloy design, micromechanical and macromechanical properties of CoCrFeNiTax eutectic high entropy alloys
journal, February 2018

Manufacturing and analysis of VNbMoTaW refractory high-entropy alloy fabricated by selective laser melting
journal, June 2022

Additive manufacturing of in-situ strengthened dual-phase AlCoCuFeNi high-entropy alloy by selective electron beam melting
journal, February 2022

Influence of Local Lattice Distortion on Elastic Properties of Hexagonal Close‐Packed TiZrHf and TiZrHfSc Refractory Alloys
journal, May 2021

Interface coherency strain relaxation due to plastic deformation in single crystal Ni-base superalloys
journal, April 2013

A novel Fe 20 Co 20 Ni 41 Al 19 eutectic high entropy alloy with excellent tensile properties
journal, April 2018

Additive Manufacturing of High-Entropy Alloys: Microstructural Metastability and Mechanical Behavior
journal, August 2021

Additive manufacturing of high strength copper alloy with heterogeneous grain structure through laser powder bed fusion
journal, November 2021

Charting the complete elastic properties of inorganic crystalline compounds
journal, March 2015

Compositional variation effects on the microstructure and properties of a refractory high-entropy superalloy AlMo0.5NbTa0.5TiZr
journal, February 2018

Microstructure and room temperature properties of a high-entropy TaNbHfZrTi alloy
journal, May 2011

Reduction of residual stress in porous Ti6Al4V by in situ double scanning during laser additive manufacturing
journal, February 2021

Microstructure and mechanical behavior of additively manufactured CoCrFeMnNi high-entropy alloys: Laser directed energy deposition versus powder bed fusion
journal, May 2023

Strong yet ductile nanolamellar high-entropy alloys by additive manufacturing
journal, August 2022

Computational Assessment of Thermokinetics and Associated Microstructural Evolution in Laser Powder Bed Fusion Manufacturing of Ti6Al4V Alloy
journal, May 2020

VULCAN: A “hammer” for high-temperature materials research
journal, November 2019

Anisotropic Lattice Distortions in Random Alloys from First-Principles Theory
journal, September 2001

High-entropy alloys
journal, June 2019

Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging
journal, February 2019

Residual Stress in Metal Additive Manufacturing
journal, January 2018

Influence of erbium addition on the defects of selective laser-melted 7075 aluminium alloy
journal, October 2021

High-strength lamellar high-entropy alloys in-situ synthesized by laser additive manufacturing
journal, March 2023

A novel quaternary equiatomic Ti-Zr-Nb-Ta medium entropy alloy (MEA)
journal, October 2018

Diffraction and single-crystal elastic constants of Inconel 625 at room and elevated temperatures determined by neutron diffraction
journal, September 2016

Elastic and plastic anisotropy in a refractory high entropy alloy utilizing combinatorial instrumented indentation and electron backscatter diffraction
journal, March 2022

Texture Analysis with MTEX – Free and Open Source Software Toolbox
journal, February 2010

Phase-specific deformation behavior of a NiAl–Cr(Mo) lamellar composite under thermal and mechanical loads
journal, January 2016

Finite element analysis of the influence of elastic anisotropy on stress intensification at stress corrosion cracking initiation sites in fcc alloys
journal, May 2018

A fracture-resistant high-entropy alloy for cryogenic applications
journal, September 2014

In-situ Synchrotron imaging of keyhole mode multi-layer laser powder bed fusion additive manufacturing
journal, September 2020

In situ X-ray and thermal imaging of refractory high entropy alloying during laser directed deposition
journal, January 2022

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy
journal, June 2017

Mechanical characterisation of V-4Cr-4Ti alloy: Tensile tests under high energy synchrotron diffraction
journal, October 2022

An improved X-ray diffraction analysis method to characterize dislocation density in lath martensitic structures
journal, July 2015

Effect of Build Height on Temperature Evolution and Thermally Induced Residual Stresses in Plasma Arc Additively Manufactured Stainless Steel
journal, November 2021

Microscale residual stresses in additively manufactured stainless steel
journal, September 2019

Efficient stochastic generation of special quasirandom structures
journal, September 2013

Processing and characterization of crack-free 7075 aluminum alloys with elemental Zr modification by laser powder bed fusion
journal, March 2022

Metal Additive Manufacturing: A Review
journal, April 2014

Elastic behavior of binary and ternary refractory multi-principal-element alloys
journal, July 2022

Composition design of high-entropy alloys with deep sets learning
journal, April 2022

Metal additive manufacturing in aerospace: A review
journal, November 2021

Additive manufacturing of high entropy alloys: A practical review
journal, June 2021

Normalised model-based processing diagrams for additive layer manufacture of engineering alloys
journal, April 2016

Solidification and solid-state transformation sciences in metals additive manufacturing
journal, July 2017

Development and exploration of refractory high entropy alloys—A review
journal, June 2018

Universal Elastic Anisotropy Index
journal, August 2008

Efficiency of ab-initio total energy calculations for metals and semiconductors using a plane-wave basis set
journal, July 1996

Formation of printing defects and their effects on mechanical properties of additively manufactured metal alloys
journal, December 2022

High-throughput additive manufacturing and characterization of refractory high entropy alloys
journal, June 2020

Efficient iterative schemes for ab initio total-energy calculations using a plane-wave basis set
journal, October 1996

Evaluating elastic properties of a body-centered cubic NbHfZrTi high-entropy alloy – A direct comparison between experiments and ab initio calculations
journal, June 2019

Additively manufactured hierarchical stainless steels with high strength and ductility
journal, October 2017

In situ investigation of phase transformations in Ti-6Al-4V under additive manufacturing conditions combining laser melting and high-speed micro-X-ray diffraction
journal, November 2017

Investigation on solid-state phase transformation in a Ti-47Al-2Cr-2V alloy due to thermal cycling during laser additive manufacturing process
journal, August 2019

Investigation of the Nb element segregation for laser additive manufacturing of nickel-based superalloys
journal, December 2021

Elastic and plastic properties of as-cast equimolar TiHfZrTaNb high-entropy alloy
journal, January 2016

Special quasirandom structures
journal, July 1990

Equiaxed grain formation by intrinsic heterogeneous nucleation via rapid heating and cooling in additive manufacturing of aluminum-silicon hypoeutectic alloy
journal, October 2022

Microstructure evolution and performance enhancement of NbTaTiV-(Cr, Zr, W) single-phase refractory high-entropy alloy coatings: Role of additional elements
journal, August 2023

Effect of solid-state phase transformation on residual stress of selective laser melting Ti6Al4V
journal, July 2021

New alloy design approach to inhibiting hot cracking in laser additive manufactured nickel-based superalloys
journal, April 2023

Design considerations for high entropy alloys in advanced nuclear applications
journal, August 2022

In-situ alloying in laser-based additive manufacturing processes: A critical review
journal, August 2021

Rapid thermokinetics driven nanoscale vanadium clustering within martensite laths in laser powder bed fused additively manufactured Ti6Al4V
journal, June 2020

Coarsening of martensite with multiple generations of twins in laser additively manufactured Ti6Al4V
journal, July 2021

A simplified model connecting lattice distortion with friction stress of Nb-based equiatomic high-entropy alloys
journal, April 2019

Characterisation of in-situ alloyed titanium-tantalum lattice structures by laser powder bed fusion using finite element analysis
journal, November 2022