The unique structure and formation mechanism of medium-entropy alloys(MEAs)generally result in bet-ter comprehensive properties than traditional alloys.However,the strength-ductility trade-offremains a bottleneck,whic...The unique structure and formation mechanism of medium-entropy alloys(MEAs)generally result in bet-ter comprehensive properties than traditional alloys.However,the strength-ductility trade-offremains a bottleneck,which limits their applications.In this study,we designed novel high-performance CrNiCu x MEAs with a heterophase composition by incorporating a Cu-rich phase,and they were fabricated using laser-directed energy deposition(LDED).The results show that synergistic strengthening from multiple phases significantly improved the mechanical properties of the alloys,resulting in a tensile strength of 675 MPa and a ductility of 34.4%,demonstrating an excellent combination of high tensile strength and ductility.The improved mechanical properties of the CrNiCu x medium-entropy alloys are primarily due to the heterophase interfacial strengthening mechanism.In the alloy,numerous semi-coherent and coher-ent interfaces formed between the Cr-rich phase,Cu-rich phase,and the matrix,creating extensive lattice distortions at the interfaces.An increase in the Cu-rich phase content promoted the interaction between phases,enhancing the strain energy of the alloy and the barrier strength of the interfaces.The calcu-latedτint values,ranging from approximately 5.92-6.69 GPa,are significantly higher than those found in traditional alloys,providing a benchmark for designing new high-performance medium-entropy alloys.展开更多
Laser-directed energy deposition(L-DED)is an advanced additive manufacturing technology primarily adopted in metal three-dimensional printing systems.The L-DED process is characterized by various defects,thus necessit...Laser-directed energy deposition(L-DED)is an advanced additive manufacturing technology primarily adopted in metal three-dimensional printing systems.The L-DED process is characterized by various defects,thus necessitating the extensive use of in-situ monitoring to enable real-time adjustments of process parameters by detecting molten-pool features.To address the challenge of accurately extracting the molten-pool morphology from an undetached spatter,an innovative monitoring method based on the U-Net(U-shaped network)is proposed herein.A lightweight architecture accelerates the processing speed,whereas an enhanced loss function incorporating weight maps augments the segmentation precision.The model performance is evaluated by comparing its segmentation accuracy and processing speed with those of the conventional U-Net,using the mean intersection over union(MIoU)as the segmentation metric.The improved model demonstrates superior segmentation accuracy at the interface between the molten pool and spatter,with a peak MIoU of 0.9798 achieved on the test set.Furthermore,this model processes each image in an extremely short time of 17.9 ms.Using this segmentation algorithm,the error in extracting the molten-pool width from single-track experiments is within 0.1 mm.The proposed method for monitoring the molten-pool morphology is suitable for deployment in online monitoring systems,thus providing a foundation for subsequent process-parameter regulation.展开更多
The distinctive intrinsic heat treatment(IHT)originating from cyclic reheating in the laser-directed energy deposition(LDED) has attracted growing attention in recent years.In this investigation,simulations and experi...The distinctive intrinsic heat treatment(IHT)originating from cyclic reheating in the laser-directed energy deposition(LDED) has attracted growing attention in recent years.In this investigation,simulations and experimental characterizations were performed to examine the impact of IHT on the micros true ture and mechanical properties of LDED-fabricated CrCoNi medium-entropy alloy(MEA).The results show that the intensity of the IHT is proportional to the utilized laser energy density(LED).As the LED increased,significant dynamic recrystallization and grain refinement occurred within the alloy due to the enhanced intensity of IHT.However,the high LED leads to severe hot cracking within the as-built MEA,resulting in inferior ductility.By decreasing LED,the hot cracking was effectively eliminated.Meanwhile,low LED weakened the intensity of IHT and consequently inhibited kinetic conditions of dynamic recrystallization,resulting in a heterogeneous grain structure characterized by multi-scale-sized grains.This structure provides significant hetero-deformation-induced hardening during plastic deformation,enabling the alloy to have a sustainable work-hardening capacity.We expect that this work will have implications in taking full advantage of the unique IHT of the LDED process to fabricate ME As with excellent metallurgical quality and mechanical performance.展开更多
The wide application of additive-manufactured Ti alloys is impeded by coarse columnar grains along the building direction and thus the severe anisotropy of mechanical properties.To address this issue,a novel multiallo...The wide application of additive-manufactured Ti alloys is impeded by coarse columnar grains along the building direction and thus the severe anisotropy of mechanical properties.To address this issue,a novel multialloying CoCrMoSi strategy has been developed to produce near-equiaxed grains of a modified Ti6Al4V(TC4)alloy for laser-directed energy deposition(LDED)based on computational thermodynamic and experimental approaches.The results show that the microstructure of the TC4alloy consists of large columnar β grains and α/α'laths with a high aspect ratio of 5.73,exhibiting a strong anisotropy of tensile properties.In contrast,the TC4-1.5%CoCrMoSi alloy is characterized by mixed columnarequiaxed β grains and near-equiaxed β grains with increased CoCrMoSi additions to 4.5%.Additionally,the α/α'laths are successively refined with the increase of CoCrMoSi content,showing an aspect ratio of smaller than4.31.However,an excess addition of CoCrMoSi leads to the formation of micro voids.After multi-alloyingCoCrMoSi,the number density of twins increases remarkably with a substantially reduced width,because of the increased lattice distortion and dislocation density together with the reducedβ→αphase transformation temperature.The anisotropy of the tensile properties can be effectively eliminated by adding 3 wt%CoCrMoSi with an exemplary strength-ductility combination,superior to the LDEDed-modified TC4 alloy in the literature reporting the tensile properties along both horizontal(X)and vertical(Z)directions.The underlaying mechanisms for the evolution of the microstructure and the tensile properties induced by multi-alloying CoCrMoSi were discussed in detail.展开更多
Tungsten(W)particle-reinforced nickel(Ni)-based composites were fabricated via laser-direct energy de-position(L-DED).The influence of the W particle size on the microstructure and mechanical properties of the deposit...Tungsten(W)particle-reinforced nickel(Ni)-based composites were fabricated via laser-direct energy de-position(L-DED).The influence of the W particle size on the microstructure and mechanical properties of the deposited samples was systematically studied.The results indicate that refining the W particle size could refine theγ-Ni grains and subgrains,thin the(Ni,Cr)_(4)W interface layer,and increase the disloca-tion density of the intergranular matrix,thus improving the tensile strength and elongation of the L-DED samples.As W particle size decreased from 75 to 150μm to 6.5-12μm,the tensile strength and elonga-tion of the deposited samples increased by 150 MPa and 2.9 times to 1347.6±15.7 MPa and 17.5±0.4%,respectively.Based on the properties of the interface(Ni,Cr)_(4)W,a load-transfer efficiency factor suitable for this composite was proposed and the load-transfer strengthening formula was optimized.A quanti-tative analysis of the strengthening mechanisms was established considering load-transfer strengthening,Hall-Petch strengthening,thermal-mismatch strengthening,and solid-solution strengthening.The calcu-lated contribution of each strengthening mechanism to the yield strength and theoretical calculations were in good agreement with the experimental data.The article breaks the bottleneck of poor plasticity of W particle-reinforced Ni-based composites prepared by L-DED and provides a theoretical basis for the construction design of W particle-reinforced Ni-based composites with excellent mechanical properties.展开更多
Repairing the Ni-based superalloy component remains challenging due to the limited understanding of the role of the defect’s morphology on microstructure and related deformation responses.To address this issue,GH4099...Repairing the Ni-based superalloy component remains challenging due to the limited understanding of the role of the defect’s morphology on microstructure and related deformation responses.To address this issue,GH4099 Ni-based superalloy plate with U-shaped and V-shaped grooves was prepared and repaired by laser-directed energy deposition method using GH4099 powders.Both grooves exhibit three similar regions at the repaired interphase,which are the base metal region with equiaxed grains,repaired region with columnar or elongated equiaxed grains,and a transition region in between.High-temperature gradient in the repaired region induced a high density of substructures,and the repaired region in U-shaped grooves has an even higher temperature gradient due to fewer passes of the melted metal,which induces more metallic carbides in the subgrain boundaries and improves the tensile strength of the repaired samples.However,due to the steep side walls,local vortex might form at the bottom corner of the U-shaped groove,leaving macroscale holes and micro-cracks there.Such defects will decrease the alloy’s ductility.The relationship among groove morphology-macro-and microstructure-mechanical properties is then established,which suggesting the preferred V-shaped groove considering the flatter sidewall and more passes induced near equilibrium microstructure.展开更多
Pore formation is a significant challenges in the advancement of laser additive manufacturing(LAM)technologies.To address this issue,image data-driven pore detection techniques have become a research focus.However,exi...Pore formation is a significant challenges in the advancement of laser additive manufacturing(LAM)technologies.To address this issue,image data-driven pore detection techniques have become a research focus.However,existing methods are constrained by reliance on a single detection environment(e.g.,consistent brightness)and fixed input image sizes,limiting their predictive accuracy and application scope.This paper introduces an in-novative a pore detection method based on a deep learning model for laser-directed energy deposition(L-DED).The proposed method leverages the deep learning model’s ability to extract feature information from melt pool images captured by a high-speed camera,enabling efficient pore detection under varying brightness conditions and diverse image sizes.The detection results demonstrate that,under varying brightness levels,the proposed model achieves a pore detection accuracy of approximately 93.5% and a root mean square error(RMSE)of 0.42 for local porosity prediction.Additionally,even with changes in input image size,the model maintains robust performance,achieving a detection accuracy of 96% for pore status detection and an RMSE value of 0.09 for local porosity prediction.This study not only addresses the limitations of traditional detection techniques but also broadens the scope of online detection technologies.It highlights the potential of deep learning in complex industrial settings and provides valuable insights for advancing defect detection research in related fields.展开更多
The wear behavior of Ni-based single crystal(NBSC)superalloy SRR99 fabricated by laser-directed energy deposition(LDED)is investigated and compared with that of its cast counterpart.While γ'precipitate size in th...The wear behavior of Ni-based single crystal(NBSC)superalloy SRR99 fabricated by laser-directed energy deposition(LDED)is investigated and compared with that of its cast counterpart.While γ'precipitate size in the latter is>400 nm,that in the former is an order of magnitude lower.Dry sliding wear tests reveal that the wear rate and coefficient of friction of the LDED alloy are 75% and 20%lower than that of its cast counterpart,respectively.Detailed transmission electron microscopy investigation of the wear-tested cast alloy indicates that there is orientation change and formation of nanoscale grains only at the top layer of the worn surface,whereas regions below undergo moderate plastic deformation via dislocation slip.In contrast,the sub-surface of the worn LDED alloy has a graded microstructure,with a composite of NiO/γ-Ni on the top,γ'free nano-grains in the middle,and a highly deformed nanoscale layer at the bottom.The improved wear behavior of the LDED alloy is attributed to its higher dislocation density,finerγ'precipitates,and the formation of this graded microstructure.Finally,a detailed description of mechanisms that lead to the formation of this unique graded microstructure is provided.展开更多
基金supported by the National Natural Science Foundation of China(Grant No.U2341254)the National Natural Science Foundation of China(Grant No.52071124),the Natural Science Foundation of Jiangsu Province(No.BK20230502)the Jiangsu Funding Program for Excellent Postdoctoral Talent(No.2022ZB547).
文摘The unique structure and formation mechanism of medium-entropy alloys(MEAs)generally result in bet-ter comprehensive properties than traditional alloys.However,the strength-ductility trade-offremains a bottleneck,which limits their applications.In this study,we designed novel high-performance CrNiCu x MEAs with a heterophase composition by incorporating a Cu-rich phase,and they were fabricated using laser-directed energy deposition(LDED).The results show that synergistic strengthening from multiple phases significantly improved the mechanical properties of the alloys,resulting in a tensile strength of 675 MPa and a ductility of 34.4%,demonstrating an excellent combination of high tensile strength and ductility.The improved mechanical properties of the CrNiCu x medium-entropy alloys are primarily due to the heterophase interfacial strengthening mechanism.In the alloy,numerous semi-coherent and coher-ent interfaces formed between the Cr-rich phase,Cu-rich phase,and the matrix,creating extensive lattice distortions at the interfaces.An increase in the Cu-rich phase content promoted the interaction between phases,enhancing the strain energy of the alloy and the barrier strength of the interfaces.The calcu-latedτint values,ranging from approximately 5.92-6.69 GPa,are significantly higher than those found in traditional alloys,providing a benchmark for designing new high-performance medium-entropy alloys.
基金supported by National Natural Science Foundation of China(Grant Nos.52305440,52204263)Natural Science Foundation of Changsha City(Grant Nos.kq2208272,kq2208274)+1 种基金Tribology Science Fund of the State Key Laboratory of Tribology in Advanced Equipment(Grant SKLTKF22B09)National Key Research and Development Program of China(2022YFB3706902).
文摘Laser-directed energy deposition(L-DED)is an advanced additive manufacturing technology primarily adopted in metal three-dimensional printing systems.The L-DED process is characterized by various defects,thus necessitating the extensive use of in-situ monitoring to enable real-time adjustments of process parameters by detecting molten-pool features.To address the challenge of accurately extracting the molten-pool morphology from an undetached spatter,an innovative monitoring method based on the U-Net(U-shaped network)is proposed herein.A lightweight architecture accelerates the processing speed,whereas an enhanced loss function incorporating weight maps augments the segmentation precision.The model performance is evaluated by comparing its segmentation accuracy and processing speed with those of the conventional U-Net,using the mean intersection over union(MIoU)as the segmentation metric.The improved model demonstrates superior segmentation accuracy at the interface between the molten pool and spatter,with a peak MIoU of 0.9798 achieved on the test set.Furthermore,this model processes each image in an extremely short time of 17.9 ms.Using this segmentation algorithm,the error in extracting the molten-pool width from single-track experiments is within 0.1 mm.The proposed method for monitoring the molten-pool morphology is suitable for deployment in online monitoring systems,thus providing a foundation for subsequent process-parameter regulation.
基金financially supported by the funding from Guangdong Province Basic and Applied Research Key Projects (No.2020B0301030001)National Key R&D Programme,Ministry of Science and Technology of China (Nos. 2018YFB1105200 and 2019YFA0209904)the National Natural Science Foundation of China (Nos.52371106 and 52371025)。
文摘The distinctive intrinsic heat treatment(IHT)originating from cyclic reheating in the laser-directed energy deposition(LDED) has attracted growing attention in recent years.In this investigation,simulations and experimental characterizations were performed to examine the impact of IHT on the micros true ture and mechanical properties of LDED-fabricated CrCoNi medium-entropy alloy(MEA).The results show that the intensity of the IHT is proportional to the utilized laser energy density(LED).As the LED increased,significant dynamic recrystallization and grain refinement occurred within the alloy due to the enhanced intensity of IHT.However,the high LED leads to severe hot cracking within the as-built MEA,resulting in inferior ductility.By decreasing LED,the hot cracking was effectively eliminated.Meanwhile,low LED weakened the intensity of IHT and consequently inhibited kinetic conditions of dynamic recrystallization,resulting in a heterogeneous grain structure characterized by multi-scale-sized grains.This structure provides significant hetero-deformation-induced hardening during plastic deformation,enabling the alloy to have a sustainable work-hardening capacity.We expect that this work will have implications in taking full advantage of the unique IHT of the LDED process to fabricate ME As with excellent metallurgical quality and mechanical performance.
基金financially supported by the National Natural Science Foundation of China(No.52375341)Hunan Provincial Natural Science Foundation(No.2022JJ30494)
文摘The wide application of additive-manufactured Ti alloys is impeded by coarse columnar grains along the building direction and thus the severe anisotropy of mechanical properties.To address this issue,a novel multialloying CoCrMoSi strategy has been developed to produce near-equiaxed grains of a modified Ti6Al4V(TC4)alloy for laser-directed energy deposition(LDED)based on computational thermodynamic and experimental approaches.The results show that the microstructure of the TC4alloy consists of large columnar β grains and α/α'laths with a high aspect ratio of 5.73,exhibiting a strong anisotropy of tensile properties.In contrast,the TC4-1.5%CoCrMoSi alloy is characterized by mixed columnarequiaxed β grains and near-equiaxed β grains with increased CoCrMoSi additions to 4.5%.Additionally,the α/α'laths are successively refined with the increase of CoCrMoSi content,showing an aspect ratio of smaller than4.31.However,an excess addition of CoCrMoSi leads to the formation of micro voids.After multi-alloyingCoCrMoSi,the number density of twins increases remarkably with a substantially reduced width,because of the increased lattice distortion and dislocation density together with the reducedβ→αphase transformation temperature.The anisotropy of the tensile properties can be effectively eliminated by adding 3 wt%CoCrMoSi with an exemplary strength-ductility combination,superior to the LDEDed-modified TC4 alloy in the literature reporting the tensile properties along both horizontal(X)and vertical(Z)directions.The underlaying mechanisms for the evolution of the microstructure and the tensile properties induced by multi-alloying CoCrMoSi were discussed in detail.
基金supported by the Key Projects of the National Natural Science Foundation of China(Nos.92066201 and 92266101)the Jiangxi Provincial Key R&D Programme Projects(No.20212BBE51011).
文摘Tungsten(W)particle-reinforced nickel(Ni)-based composites were fabricated via laser-direct energy de-position(L-DED).The influence of the W particle size on the microstructure and mechanical properties of the deposited samples was systematically studied.The results indicate that refining the W particle size could refine theγ-Ni grains and subgrains,thin the(Ni,Cr)_(4)W interface layer,and increase the disloca-tion density of the intergranular matrix,thus improving the tensile strength and elongation of the L-DED samples.As W particle size decreased from 75 to 150μm to 6.5-12μm,the tensile strength and elonga-tion of the deposited samples increased by 150 MPa and 2.9 times to 1347.6±15.7 MPa and 17.5±0.4%,respectively.Based on the properties of the interface(Ni,Cr)_(4)W,a load-transfer efficiency factor suitable for this composite was proposed and the load-transfer strengthening formula was optimized.A quanti-tative analysis of the strengthening mechanisms was established considering load-transfer strengthening,Hall-Petch strengthening,thermal-mismatch strengthening,and solid-solution strengthening.The calcu-lated contribution of each strengthening mechanism to the yield strength and theoretical calculations were in good agreement with the experimental data.The article breaks the bottleneck of poor plasticity of W particle-reinforced Ni-based composites prepared by L-DED and provides a theoretical basis for the construction design of W particle-reinforced Ni-based composites with excellent mechanical properties.
基金support of the Mount Taishan Industrial Leading Talent Project.
文摘Repairing the Ni-based superalloy component remains challenging due to the limited understanding of the role of the defect’s morphology on microstructure and related deformation responses.To address this issue,GH4099 Ni-based superalloy plate with U-shaped and V-shaped grooves was prepared and repaired by laser-directed energy deposition method using GH4099 powders.Both grooves exhibit three similar regions at the repaired interphase,which are the base metal region with equiaxed grains,repaired region with columnar or elongated equiaxed grains,and a transition region in between.High-temperature gradient in the repaired region induced a high density of substructures,and the repaired region in U-shaped grooves has an even higher temperature gradient due to fewer passes of the melted metal,which induces more metallic carbides in the subgrain boundaries and improves the tensile strength of the repaired samples.However,due to the steep side walls,local vortex might form at the bottom corner of the U-shaped groove,leaving macroscale holes and micro-cracks there.Such defects will decrease the alloy’s ductility.The relationship among groove morphology-macro-and microstructure-mechanical properties is then established,which suggesting the preferred V-shaped groove considering the flatter sidewall and more passes induced near equilibrium microstructure.
基金supported by National Natural Science Foundation of China(Grant No.52475155)National Science Foundation for Hunan Province,China(Grant No.2023JJ30137)+2 种基金Guangdong Basic and Applied Basic Research Foundation(Grant No.2024A1515010684)Guangdong Basic and Applied Basic Research Foundation(Grant No.2023A1515240059)Program sponsored by the Foundation of Yuelushan Center for Industrial Innovation(Grant No.2023YCII0138).
文摘Pore formation is a significant challenges in the advancement of laser additive manufacturing(LAM)technologies.To address this issue,image data-driven pore detection techniques have become a research focus.However,existing methods are constrained by reliance on a single detection environment(e.g.,consistent brightness)and fixed input image sizes,limiting their predictive accuracy and application scope.This paper introduces an in-novative a pore detection method based on a deep learning model for laser-directed energy deposition(L-DED).The proposed method leverages the deep learning model’s ability to extract feature information from melt pool images captured by a high-speed camera,enabling efficient pore detection under varying brightness conditions and diverse image sizes.The detection results demonstrate that,under varying brightness levels,the proposed model achieves a pore detection accuracy of approximately 93.5% and a root mean square error(RMSE)of 0.42 for local porosity prediction.Additionally,even with changes in input image size,the model maintains robust performance,achieving a detection accuracy of 96% for pore status detection and an RMSE value of 0.09 for local porosity prediction.This study not only addresses the limitations of traditional detection techniques but also broadens the scope of online detection technologies.It highlights the potential of deep learning in complex industrial settings and provides valuable insights for advancing defect detection research in related fields.
基金supported by the National Key R&D Program of China(Grant Nos.2023YFB3712002 and 2021YFB3702503)the National Natural Science Foundation of China(Grant Nos.51927801 and U2032205)the National Science and Technology Major Project(Grant Nos.Y2019-VII-0011-0151 and 2019-VII-0019-0161)。
文摘The wear behavior of Ni-based single crystal(NBSC)superalloy SRR99 fabricated by laser-directed energy deposition(LDED)is investigated and compared with that of its cast counterpart.While γ'precipitate size in the latter is>400 nm,that in the former is an order of magnitude lower.Dry sliding wear tests reveal that the wear rate and coefficient of friction of the LDED alloy are 75% and 20%lower than that of its cast counterpart,respectively.Detailed transmission electron microscopy investigation of the wear-tested cast alloy indicates that there is orientation change and formation of nanoscale grains only at the top layer of the worn surface,whereas regions below undergo moderate plastic deformation via dislocation slip.In contrast,the sub-surface of the worn LDED alloy has a graded microstructure,with a composite of NiO/γ-Ni on the top,γ'free nano-grains in the middle,and a highly deformed nanoscale layer at the bottom.The improved wear behavior of the LDED alloy is attributed to its higher dislocation density,finerγ'precipitates,and the formation of this graded microstructure.Finally,a detailed description of mechanisms that lead to the formation of this unique graded microstructure is provided.
