E. Ma

High tensile ductility in a nanostructured metal

Nanocrystalline metals—with grain sizes of less than 100 nm—have strengths exceeding those of coarse-grained and even alloyed metals, and are thus expected to have many applications. For example, pure nanocrystalline Cu (refs 1–7) has a yield strength in excess of 400 MPa, which is six times higher than that of coarse-grained Cu. But nanocrystalline materials often exhibit low tensile ductility at room temperature, which limits their practical utility. The elongation to failure is typically less than a few per cent; the regime of uniform deformation is even smaller. Here we describe a thermomechanical treatment of Cu that results in a bimodal grain size distribution, with micrometre-sized grains embedded inside a matrix of nanocrystalline and ultrafine (<300 nm) grains. The matrix grains impart high strength, as expected from an extrapolation of the Hall–Petch relationship. Meanwhile, the inhomogeneous microstructure induces strain hardening mechanisms that stabilize the tensile deformation, leading to a high tensile ductility—65% elongation to failure, and 30% uniform elongation. We expect that these results will have implications in the development of tough nanostructured metals for forming operations and high-performance structural applications including microelectromechanical and biomedical systems.

Atomic packing and short-to-medium-range order in metallic glasses

Unlike the well-defined long-range order that characterizes crystalline metals, the atomic arrangements in amorphous alloys remain mysterious at present. Despite intense research activity on metallic glasses and relentless pursuit of their structural description, the details of how the atoms are packed in amorphous metals are generally far less understood than for the case of network-forming glasses. Here we use a combination of state-of-the-art experimental and computational techniques to resolve the atomic-level structure of amorphous alloys. By analysing a range of model binary systems that involve different chemistry and atomic size ratios, we elucidate the different types of short-range order as well as the nature of the medium-range order. Our findings provide a reality check for the atomic structural models proposed over the years, and have implications for understanding the nature, forming ability and properties of metallic glasses.

Instabilities and ductility of nanocrystalline and ultrafine-grained metals

Abstract High-strength nanocrystalline (nc) and ultrafine-grained (ufg) metals often show much reduced room-temperature tensile ductility compared with their coarse-grained counterparts. We discuss the various plastic and/or failure instabilities the nc and ufg metals are susceptible to, and present strategies to enhance the ductility, especially in terms of improving the uniform tensile strain.

Effects of nanocrystalline and ultrafine grain sizes on constitutive behavior and shear bands in iron

The mechanical behaviors of consolidated iron with average grain sizes from tens of nanometers to tens of microns have been systematically studied under uniaxial compression over a wide range of strain rates. In addition to the well-known strengthening due to grain size refinement, grain size dependence is observed for several other key properties of plastic deformation. In contrast with conventional coarse-grained Fe, high-strength nanocrystalline and submicron-grained Fe exhibit diminished effective strain rate sensitivity of the flow stress. The observed reduction in effective rate sensitivity is shown to be a natural consequence of low-temperature plastic deformation mechanisms in bcc metals through the application of a constitutive model for the behavior of bcc Fe in this strain rate and temperature regime. The deformation mode also changes, with shear localization replacing uniform deformation as the dominant deformation mode from the onset of plastic deformation at both low and high strain rates. The evolution and multiplication of shear bands have been monitored as a function of plastic strain. The grain size dependence is discussed with respect to possible enhanced propensity for plastic instabilities at small grain sizes.

Bulk metallic glass formation in the binary Cu-Zr system

Using the Cu–Zr model system, we demonstrate that bulk amorphous alloys can be obtained by copper mold casting even in a binary metallic system. The narrow, off-eutectic, bulk-glass-forming range was found to require composition pinpointing to <1 at. %. A phase selection diagram is used to explain the success of our microstructure-based approach to pinpoint the best glass former in a given system. The implications of discovering simple binary bulk amorphous alloys are discussed, in terms of its impact on understanding the formation and physics of bulk metallic glasses.

Deformation behavior and plastic instabilities of ultrafine-grained titanium

Ultrafine-grained (UFG) Ti samples have been prepared using equal channel angular pressing followed by cold rolling and annealing. The deformation behavior of these materials, including strain hardening, strain rate dependence of flow stress, deformation/failure mode, and tensile necking instability, have been systematically characterized. The findings are compared with those for conventional coarse-grained Ti and used to explain the limited tensile ductility observed so far for UFG or nanocrystalline metals.

Strong crystal size effect on deformation twinning

Deformation twinning in crystals is a highly coherent inelastic shearing process that controls the mechanical behaviour of many materials, but its origin and spatio-temporal features are shrouded in mystery. Using micro-compression and in situ nano-compression experiments, here we find that the stress required for deformation twinning increases drastically with decreasing sample size of a titanium alloy single crystal, until the sample size is reduced to one micrometre, below which the deformation twinning is entirely replaced by less correlated, ordinary dislocation plasticity. Accompanying the transition in deformation mechanism, the maximum flow stress of the submicrometre-sized pillars was observed to saturate at a value close to titanium’s ideal strength. We develop a ‘stimulated slip’ model to explain the strong size dependence of deformation twinning. The sample size in transition is relatively large and easily accessible in experiments, making our understanding of size dependence relevant for applications.

Strain hardening and large tensile elongation in ultrahigh-strength nano-twinned copper

A high density of growth twins in pure Cu imparts high yield strength while preserving the capacity for efficient dislocation storage, leading to high strain hardening rates at high flow stresses, especially at 77 K. Uniform tensile deformation is stabilized to large plastic strains, resulting in an ultrahigh tensile strength of similar to1 GPa together with an elongation to failure of similar to30%

Nanostructured high-strength molybdenum alloys with unprecedented tensile ductility

The high-temperature stability and mechanical properties of refractory molybdenum alloys are highly desirable for a wide range of critical applications. However, a long-standing problem for these alloys is that they suffer from low ductility and limited formability. Here we report a nanostructuring strategy that achieves Mo alloys with yield strength over 800 MPa and tensile elongation as large as ~ 40% at room temperature. The processing route involves a molecular-level liquid-liquid mixing/doping technique that leads to an optimal microstructure of submicrometre grains with nanometric oxide particles uniformly distributed in the grain interior. Our approach can be readily adapted to large-scale industrial production of ductile Mo alloys that can be extensively processed and shaped at low temperatures. The architecture engineered into such multicomponent alloys offers a general pathway for manufacturing dispersion-strengthened materials with both high strength and ductility.

Evolution and microstructure of shear bands in nanostructured Fe

Shear band development in consolidated nanocrystalline and ultrafine-grained Fe has been monitored as a function of overall strain from the onset of plastic deformation. The deformation mechanisms of the grains inside the shear bands, the origin of the inhomogeneous deformation, and the propensity for shear localization in nanostructures are explained based on microstructural information acquired using transmission electron microscopy.