Segregation, precipitation, and α-α' phase separation in Fe-Cr alloys: a multi-scale modelling approach
A. Kuronen, M. H. Heinonen, S. Granroth, R. E. Perälä, T. Kilpi, P. Laukkanen, J. Lång, J. Dahl, M. P. J. Punkkinen, K. Kokko, M. Ropo, B. Johansson, L. Vitos
Segregation, precipitation, and phase separation in Fe-Cr systems is investigated. Monte Carlo simulations using semiempirical interatomic potential, first-principles total energy calculations, and experimental spectroscopy are used. In order to obtain a general picture of the relation of the atomic interactions and properties of Fe-Cr alloys in bulk, surface, and interface regions several complementary methods has to be used. Using Exact Muffin-Tin Orbitals method the effective chemical potential as a function of Cr content (0-15 at.% Cr) is calculated for a surface, second atomic layer and bulk. At ~10 at.% Cr in the alloy the reversal of the driving force of a Cr atom to occupy either bulk or surface sites is obtained. The Cr containing surfaces are expected when the Cr content exceeds ~10 at.%. The second atomic layer forms about 0.3 eV barrier for the migration of Cr atoms between bulk and surface atomic layer. To get information on Fe-Cr in larger scales we use semiempirical methods. Using combined Monte Carlo molecular dynamics simulations, based on semiempirical potential, the precipitation of Cr into isolated pockets in bulk Fe-Cr and the upper limit of the solubility of Cr into Fe layers in Fe/Cr layer system is studied. The theoretical predictions are tested using spectroscopic measurements. Hard X-ray photoelectron spectroscopy and Auger electron spectroscopy investigations were carried out to explore Cr segregation and precipitation in Fe/Cr double layer and Fe_0.95Cr_0.05 and Fe_0.85Cr_0.15 alloys. Initial oxidation of Fe-Cr was investigated experimentally at 10^-8 Torr pressure of the spectrometers showing intense Cr_2O_3 signal. Cr segregation and the formation of Cr rich precipitates were traced by analysing the experimental spectral intensities with respect to annealing time, Cr content, and kinetic energy of the exited electron.
Atomistic simulations were carried out to analyze the interaction between $< a>$ basal dislocations and precipitates in Mg-Al alloys and the associated strengthening mechanisms.
Precipitation on deformation defects is essential for enhancing mechanical properties of age-hardenable alloys. {10-12} twinning is common in deformed alloys with hexagonal-close-packed structure. In this work, we revealed how {10-12} twin boundary (TB) influences beta-Mg17Al12 precipitation in Mg-9Al-1Zn alloy. The precipitates on the TB are rod-like, while others are lath-shape. The precipitates hold the Burgers orientation relationship (OR) only with twin or matrix, contrary to traditional wisdom in others alloys that precipitates on TB symmetrically keep an OR with both twin and matrix. Mo…
We apply a combinatorial approach to study the influence of Mg concentration on the precipitation kinetics in an Al-Cu-Li alloy using a diffusion couple made by linear friction welding. The precipitation kinetics is monitored in the composition gradient material using simultaneous space and time-resolved in-situ small-angle X-ray scattering measurements during ageing, and the strengthening of the precipitates is evaluated by micro-hardness profiles. This data provides an evaluation of the amount of Mg necessary to promote precipitation of the T1-Al2CuLi phase.
The influence of initial heat treatment on anomalous Cr precipitation within high temperature solubility region in Fe-9Cr alloy has been investigated using positron lifetime studies. Air-quenched samples with pre-existing dislocations exhibited a distinct annealing stage in positron lifetime between 800 and 1100 K corresponding to Cr-precipitation. During this stage, Transmission Electron Microscopy showed fine precipitates of average size 4 nm, dispersed throughout the sample and from EDS analysis they are found to be Cr-enriched. The existence of dislocations is found to be responsible for C…
Solute segregation plays an important role in formation of long-period stacking ordered (LPSO) structure in Mg-M-RE (M: Zn, Ni etc., RE: Y, Gd, etc.) alloy systems. In this work, the planar segregation in Mg-Al-Gd alloy is characterized by high angle annular dark field (HAADF) scanning transmission electron microscopy (STEM) and three-dimensional atom probe (3DAP). It is found there is no planar fault accompanying the segregation, and the spatial distribution of segregation may resemble the periodicity of LPSO structure. The segregation is further quantified by 3DAP, and it mainly enriches wit…
Bimetallic alloys have drawn extensive attentions in materials science due to their widespread applications in electronics, engineering and catalysis. A very fundamental question of alloy is its surface segregation phenomenon. Many recent observations have shown that reactive gases or supports may have strong effects on alloy segregation. However, segregation in water, the most common solvent and environment, has not received enough attention. In this paper we give the quantitative descriptions on the surface segregation energies of 23 transition-metal impurities in Cu hosts under the conditio…
Understanding the composition evolution of grain boundaries and grain boundary precipitation at near-atomic scale in aluminum alloys is crucial to tailor mechanical properties and to increase resistance to corrosion and stress corrosion cracking. Here, we elucidate the sequence of precipitation on grain boundaries in comparison to the bulk in a model Al-Zn-Mg-Cu alloy. We investigate the material from the solution heat treated state (475{\textdegree}C), through the very early stages of aging to the peak aged state at 120{\textdegree}C and further into the overaged regime at 180{\textdegree}C. …
Mg grain boundary (GB) segregation and GB diffusion can impact the processing and properties of Al-Mg alloys. Yet, Mg GB diffusion in Al has not been measured experimentally or predicted by simulations. We apply atomistic computer simulations to predict the amount and the free energy of Mg GB segregation, and the impact of segregation on GB diffusion of both alloy components. At low temperatures, Mg atoms segregated to a tilt GB form clusters with highly anisotropic shapes. Mg diffuses in Al GBs slower than Al itself, and both components diffuse slowly in comparison with Al GB self-diffusion. …
A multidisciplinary approach is presented to analyse the precipitation process in a model Al-Cu alloy. Although this topic has been extensively studied in the past, most of the investigations are focussed either on transmission electron microscopy or on thermal analysis of the processes. The information obtained from these techniques cannot, however, provide a coherent picture of all the complex transformations that take place during decomposition of supersaturated solid solution. Thermal analysis, high resolution dilatometry, (high resolution) transmission electron microscopy and density func…
Strengthening in age-hardenable alloys is mainly achieved through nano-scale precipitates whose formation paths from the atomic-scale, solute-enriched entities are rarely analyzed and understood in a directly-verifiable way. Here, we discover a pathway for the earliest-stage precipitation in Al-Mg-Si alloys: solute clustering leading to three successive variants of FCC clusters, followed by the formation of non-FCC $GP$-$zones$. The clusters, which originally assume a spherical morphology ($C1$), evolve into elongated clusters and orient themselves on $\{111\}_{Al}$ ($C2$) and subsequently on …
Microalloying elements tend to segregate to the matrix-precipitate phase boundaries to reduce the interfacial energy. The segregation mechanism is emerging as a novel design strategy for developing precipitation-hardened alloys with significantly improved coarsening resistance for high temperature applications. In this paper, we report a nanoscopic diffuse-interface thermodynamic model that describes multicomponent segregation behavior in two-phase substitutional alloys. Following classical approaches for grain boundaries, we employ the regular solution thermodynamics to establish segregation …
The grain boundary (GB) microchemistry and precipitation behaviour in high-strength Al-Zn-Mg-Cu alloys has an important influence on their mechanical and electrochemical properties. Simulation of the GB segregation, precipitation, and solute distribution in these alloys requires an accurate description of the thermodynamics and kinetics of this multi-component system. CALPHAD databases have been successfully developed for equilibrium thermodynamic calculations in complex multi-component systems, and in recent years have been combined with diffusion simulations. In this work, we have directly i…
This paper studies how solute segregation and its relationship to grain boundary energy in binary alloys is captured in the phase field crystal (PFC) formalism, a continuum method that incorporates atomic scale elasto-plastic effects on diffusional time scales. Grain boundaries are simulated using two binary alloy PFC models --- the original binary model by Elder et al (2007) and the XPFC model by Greenwood et al (2011). In both cases, grain boundary energy versus misorientation data is shown to be well described by Read-Shockley theory. The Gibbs Adsorption Theorem is then used to derive a se…
Grain boundary segregations were investigated by Atom Probe Tomography in an Al-Mg alloy, a carbon steel and Armco\trademark Fe processed by severe plastic deformation (SPD). In the non-deformed state, the GBs of the aluminium alloy are Mg depleted, but after SPD some local enrichment up to 20 at.% was detected. In the Fe-based alloys, large carbon concentrations were also exhibited along GBs after SPD. These experimental observations are attributed to the specific structure of GBs often described as "non-equilibrum" in ultra fine grained materials processed by SPD. The grain boundary segregat…
Grain boundary engineering via dopant segregation can dramatically change the properties of a material. For metallic systems, most current studies concerning interfacial segregation and subsequent transitions of grain boundary structure are limited to binary alloys, yet many important alloy systems contain more than one type of dopant. In this work, hybrid Monte Carlo/molecular dynamics simulations are performed to investigate the behavior of dopants at interfaces in two model ternary alloy systems: Cu-Zr-Ag and Al-Zr-Cu. Trends in boundary segregation are studied, as well as the propensity fo…
While it is known that alloy components can segregate to grain boundaries (GBs), and that the atomic mobility in GBs greatly exceeds the atomic mobility in the lattice, little is known about the effect of GB segregation on GB diffusion. Atomistic computer simulations offer a means of gaining insights into the segregation-diffusion relationship by computing the GB diffusion coefficients of the alloy components as a function of their segregated amounts. In such simulations, thermodynamically equilibrium GB segregation is prepared by a semi-grand canonical Monte Carlo method, followed by calculat…
The segregation behavior of Cr in dilute Fe-Cr alloys is known to be anomalous since the main barrier for surface segregation of Cr in these alloys arises not from the topmost surface layer but from the subsurface layer where the solution energy of Cr is much more endothermic as compared to the topmost surface layer. The Fe-Cr alloys are candidate structural materials for the new generation of nuclear reactors. The surfaces of these alloys will be exposed to hydrogen or its isotopes in these reactors, and although hydrogen is soluble neither in Fe nor in Fe-Cr alloys, it is known that the adso…
X-ray Reflectivity Studies of Atomic-level Surface-segregation in a Liquid Eutectic Alloy of AuSn
X射线反射率的研究揭示了在共晶Au 71 Sn 29液态合金的自由表面原子级的表面偏析。的表面偏析延伸到三层，其中顶层几乎是一个纯的单层的锡，第二层几乎是一个纯的单层的金和第三层似乎略有增强的金。尽管Defay-Prigogine和Strohl-King的理论可以定性地解释表面偏析浓度分布，但它们不能令人满意地解释测量的表面张力。PACS编号：61.20。p，61.10。i，68.03。G
A high-throughput methodology is proposed, based on the combination of diffusion couples and advanced nanomechanical testing methods, to directly measure alloying effects on the critical resolved shear stress (CRSS) of individual deformation modes in Mg alloys. The methodology is tested in Mg-Zn alloys by assessing the alloying effects, up to Zn contents of 2 at.%, on basal slip, extension twining and pyramidal slip in two metallurgical condition: as-quenched, for which the Zn solute atoms remain homogenously dispersed in solid solution; and peak-aged, for which the Zn atoms form rod-shape $Mg…
Precipitation during high temperature aging of Al-Cu alloys is analyzed by means of the integration of classical nucleation theory and phase-field simulations into a multiscale modelling approach based on well-established thermodynamics principles. In particular, thermal stability of $θ''$, $θ'$ and $θ$ precipitates was assessed from first principles calculations of the Helmholtz free energy while homogeneous and heterogeneous nucleation of $θ''$ and $θ'$ was analysed using classical nucleation theory. Precipitate growth was finally computed by means of mesoscopic phase-field model. The model …
The dynamic behaviour of thermally driven segregation of Cr to the surface of WCrY smart alloy is studied with low energy ion scattering (LEIS). Sputtering the WCrY sample with 500 eV D$_2^+$ ions at room temperature results in preferential removal of the lighter alloy constituents and causes an almost pure W surface layer. At elevated temperatures above 700 K the segregation of Cr atoms towards the surface sets in and prevents the formation of a pure W layer. The simultaneous heating and sputtering of the sample leads to a surface state which reflects the balance between sputter removal and s…
An age-hardenable Al-Cu-Mg alloy (A2024) was processed by high-pressure torsion (HPT) for producing an ultrafine-grained structure. The alloy was further aged for extra strengthening. The tensile strength then reached a value as high as ~1 GPa. The microstructures were analyzed by transmission electron microscopy and atom probe tomography. The mechanism for the high strength was clarified in terms of solid-solution hardening, cluster hardening, work hardening, dispersion hardening and grain boundary hardening. It is shown that the segregation of solute atoms at grain boundaries including subgr…
Based on ab-initio simulations, we report on the nature of principally different mechanisms for interaction of Mg and Zn atoms with grain boundaries in Al alloys leading to different morphology of segregation. The Mg atoms segregate in relatively wide GB region with heterogeneous agglomerations due to the deformation mechanism of solute-GB interaction. In contrast, in the case of Zn atoms an electronic mechanism associated with the formation of directional bonding is dominating in the solute-GB interaction. As a result, for Zn atoms it is energetically beneficial to occupy interstitial positio…
Bimetallic catalysts can undergo segregation or redistribution of the metals driven by oxidizing and reducing environments. Bragg coherent diffraction imaging (BCDI) was used to relate displacement fields to compositional distributions in crystalline Pt-Rh alloy nanoparticles. 3D images of internal composition showed that the radial distribution of compositions reverses partially between the surface shell and the core when gas flow changes between O2 and H2. Our observation suggests that the elemental segregation of nanoparticle catalysts should be highly active during heterogeneous catalysis …
The mechanisms of dislocation/precipitate interactions were analyzed in an Al-Cu alloy containing a homogeneous dispersion of $θ'$ precipitates by means of discrete dislocation dynamics simulations. The simulations were carried out within the framework of the discrete-continuous method and the precipitates were assumed to be impenetrable by dislocations. The main parameters that determine the dislocation/precipitate interactions (elastic mismatch, stress-free transformation strains, dislocation mobility and cross-slip rate) were obtained from atomistic simulations, while the size, shape, spati…
The composition, crystal structure and precipitation crystallography of a newly found precipitate are characterized by a Cs-corrected scanning transmission electron microscopy (STEM). The composition of the plate-like precipitate could be expressed as MgxAl2-xGd (x = 0.38), and its crystal structure is the same as the fcc type Laves phases Mg2Gd and Al2Gd with the lattice parameter of 7.92 Angstrom (space group No. 227, Fd-3m). The orientation relationship between the matrix and precipitate is found to be (0001)m // (111)p and [10-10]m // [1-10]p, and the habit plane is parallel to (0001)m // …
The occurrence of segregation in highly dilute alloys under irradiation is an unusual phenomenon that has so far eluded theoretical explanation. Using ab initio calculations, we are able to explain the origin of radiation-induced rhenium segregation in dilute tungsten-rhenium alloys.
The energy of segregation of Cr from the bulk to the topmost surface layer in dilute Fe-Cr alloys is endothermic but small. On the other hand, the segregation energy from the bulk to the subsurface layer is not only endothermic but relatively large. Thus, the subsurface layer presents a huge barrier, not only for the segregation of Cr from the bulk to the surface, but also for its diffusion from the surface into the bulk. This means that the topmost layer alone cannot be used to determine the barrier for Cr segregation (the segregation energy), which is determined in these alloys by the subsur…
We study order transitions and defect formation in a model high-entropy alloy (CuNiCoFe) under ion irradiation by means of molecular dynamics simulations. Using a hybrid Monte-Carlo/molecular dynamics scheme a model alloy is generated which is thermodynamically stabilized by configurational entropy at elevated temperatures, but partly decomposes at lower temperatures by copper precipation. Both the high-entropy and the multiphase sample are then subjected to simulated particle irradiation. The damage accumulation is analyzed and compared to an elemental Ni reference system. The results reveal …
Grain boundaries (GBs) can critically influence the microstructural evolution and various materials properties. However, a fundamental understanding of GBs in high-entropy alloys (HEAs) is lacking because of the complex couplings of the segregations of multiple elements and interfacial disordering, which can generate new phenomena and challenge the classical theories. Here, by combining large-scale atomistic simulations and machine learning, we demonstrate the feasibility of predicting the GB properties as functions of four independent compositional degrees of freedoms and temperature in a 5D …
The control of solute segregation at grain boundaries (GBs) is essential in engineering alloy properties, however the structure-activity relationship of the key parameter-the segregation energies-still remains elusive. Here we propose the electronic and geometric descriptors of GB segregation based on the valence, electronegativity and size of solutes and the non-local coordination number of free surfaces, with which we build a predictive framework to determine the segregation energies across different solutes, matrices, GB structures and segregation sites. This framework uncovers not only the…
Grain size engineering, particularly reducing grain size into the nanocrystalline regime, offers a promising pathway to further improve the strength-to-weight ratio of Al alloys. Unfortunately, the fabrication of nanocrystalline metals often requires non-equilibrium processing routes, which typically limit the specimen size and require large energy budgets. In this study, multiple dopant atoms in ternary Al alloys are deliberately selected to enable segregation to the grain boundary region and promote the formation of amorphous complexions. Three different fully dense bulk nanocrystalline Al a…
We use first principles calculations to study the influence of thermomechanical loads on the energetics of precipitation in magnesium-aluminum alloys. Using Density Functional Theory simulations, we present expressions of the energy of magnesium-aluminum binary solid solutions as a function of concentration, strain and temperature. Additionally, from these calculations, we observe an increase in equilibrium volume (and hence the equilibrium lattice constants) with the increase in concentration of magnesium. We also observe an increase in the cohesive energy of solutions with increase in concen…
Compositionally complex alloys or concentrated solid solutions are the latest frontier in catalyst design, but mixing different elements in one catalyst may result in surface segregation. Atomistic simulations can predict segregation patterns, but standard approaches based on mean-field models, cluster expansion, or classical interatomic potentials are often limited for the description of multicomponent alloys. We present machine learning potentials that can describe surface segregation with near DFT accuracy. The method is used to study a complex Co-Cu-Fe-Mo-Ni quinary alloy. For this alloy, …
Age hardening induced by the formation of (semi)-coherent precipitate phases is crucial for the processing and final properties of the widely used Al-6000 alloys. Early stages of precipitation are particularly important from the fundamental and technological side, but are still far from being fully understood. Here, an analysis of the energetics of nanometric precipitates of the meta-stable $β''$ phases is performed, identifying the bulk, elastic strain and interface energies that contribute to the stability of a nucleating cluster. Results show that needle-shape precipitates are unstable to g…
The Ni-based superalloy Alloy 718 is used in aircraft engines as high-pressure turbine discs and must endure challenging demands on high-temperature yield strength, creep-, and oxidation-resistance. Nanoscale $γ^{\prime}$- and $γ^{\prime \prime}$-precipitates commonly found in duplet and triplet co-precipitate morphologies provide high-temperature strength under these harsh operating conditions. Direct ageing of Alloy 718 is an attractive alternative manufacturing route known to increase the yield strength at 650 $^°$C by at least +10 $\%$, by both retaining high dislocation densities and chan…
In this paper we report phonon dynamics in chemically synthesized Zn1- xMgxO (0\leqx\leq0.07) and Zn1-yCdyO (0\leqy\leq0.03) alloy nanostructures of sizes ~10 nm using non-resonant Raman and Fourier Transformed Infrared Spectroscopy (FTIR). Substitution by Mg makes the unit cell compact while Cd substitution leads to unit cell expansion. On alloying, both A1(LO) and E1(LO) mode of wurtzite ZnO show blue shift for Zn1-xMgxO and red shift for Zn1-yCdyO alloy nanostructures due to mass defect and volume change induced by the impurity atoms. Significant shift has been observed in E1(LO) mode for Z…
The precipitation microstructure of the γ' (AlAg2) intermetallic phase has been examined in aluminium-silver-copper alloys. The microstructure developed in an Al-0.90at.%Ag-0.90at.%Cu alloy was significantly different from that reported for binary Al-Ag alloys. The orientation relationship between the matrix and precipitate was unchanged; however, the γ' phase formed as aggregates with a two-dimensional open assemblies. Each such assembly contained two variants of the γ' phase alternately arranged to form a faceted elliptical unit. The θ' (Al2Cu) phase formed on these assemblies after further …
