Maximilien E. Launey

A damage-tolerant glass

Owing to a lack of microstructure, glassy materials are inherently strong but brittle, and often demonstrate extreme sensitivity to flaws. Accordingly, their macroscopic failure is often not initiated by plastic yielding, and almost always terminated by brittle fracture. Unlike conventional brittle glasses, metallic glasses are generally capable of limited plastic yielding by shear-band sliding in the presence of a flaw, and thus exhibit toughness-strength relationships that lie between those of brittle ceramics and marginally tough metals. Here, a bulk glassy palladium alloy is introduced, demonstrating an unusual capacity for shielding an opening crack accommodated by an extensive shear-band sliding process, which promotes a fracture toughness comparable to those of the toughest materials known. This result demonstrates that the combination of toughness and strength (that is, damage tolerance) accessible to amorphous materials extends beyond the benchmark ranges established by the toughest and strongest materials known, thereby pushing the envelope of damage tolerance accessible to a structural metal.

A novel biomimetic approach to the design of high-performance ceramic–metal composites

The prospect of extending natural biological design to develop new synthetic ceramic–metal composite materials is examined. Using ice-templating of ceramic suspensions and subsequent metal infiltration, we demonstrate that the concept of ordered hierarchical design can be applied to create fine-scale laminated ceramic–metal (bulk) composites that are inexpensive, lightweight and display exceptional damage-tolerance properties. Specifically, Al2O3/Al–Si laminates with ceramic contents up to approximately 40 vol% and with lamellae thicknesses down to 10 µm were processed and characterized. These structures achieve an excellent fracture toughness of 40 MPa√m at a tensile strength of approximately 300 MPa. Salient toughening mechanisms are described together with further toughening strategies.

Direct write assembly of calcium phosphate scaffolds using a water-based hydrogel.

The development of materials to support bone regeneration requires flexible fabrication technologies able to tailor chemistry and architecture for specific applications. In this work we describe the preparation of ceramic-based inks for robotic-assisted deposition (robocasting) using Pluronic F-127 solutions. This approach allows the preparation of pseudoplastic inks with solid contents ranging between 30 and 50 vol.%, enabling them to flow through a narrow printing nozzle while supporting the weight of the printed structure. Ink formulation does not require manipulation of the pH or the use of highly volatile organic components. Therefore, the approach can be used to prepare materials with a wide range of compositions, and here we use it to build hydroxyapatite (HA), beta-tricalcium phosphate (beta-TCP) and biphasic (HA/beta-TCP) structures. The flow of the inks is controlled by the Pluronic content and the particle size distribution of the ceramic powders. The use of wide size distributions favors flow through the narrow printing nozzles and we have been able to use printing nozzles as narrow as 100 microm in diameter, applying relatively low printing pressures. The microporosity of the printed lines increases with increasing Pluronic content and lower sintering temperatures. Microporosity can play a key role in determining the biological response to the materials, but it also affects the strength of the structure.

Solution to the problem of the poor cyclic fatigue resistance of bulk metallic glasses

The recent development of metallic glass-matrix composites represents a particular milestone in engineering materials for structural applications owing to their remarkable combination of strength and toughness. However, metallic glasses are highly susceptible to cyclic fatigue damage, and previous attempts to solve this problem have been largely disappointing. Here, we propose and demonstrate a microstructural design strategy to overcome this limitation by matching the microstructural length scales (of the second phase) to mechanical crack-length scales. Specifically, semisolid processing is used to optimize the volume fraction, morphology, and size of second-phase dendrites to confine any initial deformation (shear banding) to the glassy regions separating dendrite arms having length scales of ≈2 μm, i.e., to less than the critical crack size for failure. Confinement of the damage to such interdendritic regions results in enhancement of fatigue lifetimes and increases the fatigue limit by an order of magnitude, making these “designed” composites as resistant to fatigue damage as high-strength steels and aluminum alloys. These design strategies can be universally applied to any other metallic glass systems.

Mixed-mode fracture of human cortical bone

Although the mode I (tensile opening) fracture toughness has been the focus of most fracture mechanics studies of human cortical bone, bones in vivo are invariably loaded multiaxially. Consequently, an understanding of mixed-mode fracture is necessary to determine whether a mode I fracture toughness test provides the appropriate information to accurately quantify fracture risk. In this study, we examine the mixed-mode fracture of human cortical bone by characterizing the crack-initiation fracture toughness in the transverse (breaking) orientation under combined mode I (tensile opening) plus mode II (shear) loading using samples loaded in symmetric and asymmetric four-point bending. Whereas in most structural materials, the fracture toughness is increased with increasing mode-mixity (i.e., where the shear loading component gets larger), in the transverse orientation of bone the situation is quite different. Indeed, the competition between the maximum applied mechanical mixed-mode driving force and the weakest microstructural paths in bone results in a behavior that is distinctly different to most homogeneous brittle materials. Specifically, in this orientation, the fracture toughness of bone is markedly decreased with increasing mode-mixity.

Fracture toughness and crack-resistance curve behavior in metallic glass-matrix composites

Nonlinear-elastic fracture mechanics methods are used to assess the fracture toughness of bulk metallic glass (BMG) composites; results are compared with similar measurements for other monolithic and composite BMG alloys. Mechanistically, plastic shielding gives rise to characteristic resistance-curve behavior where the fracture resistance increases with crack extension. Specifically, confinement of damage by second-phase dendrites is shown to result in enhancement of the toughness by nearly an order of magnitude relative to unreinforced glass.

Origin of embrittlement in metallic glasses.

Significance Annealing embrittlement of metallic glasses is widely recognized as detrimental to their technological advancement, yet lacks fundamental understanding. Here, we identify a one-to-one correspondence between fracture toughness and shear modulus, which points to a correlation between liquid fragility and annealing embrittlement sensitivity. From a scientific perspective, this finding provides a thermodynamic and structural origin of annealing embrittlement, revealing that lower potential energy glass states having higher flow barriers and atomic structures with higher degree of order will demonstrate a lower fracture toughness. From a technological perspective, this result suggests that fragile glass formers would be more prone to annealing embrittlement compared with stronger glass formers, and as such, their fracture toughness would be more sensitive to their processing history. Owing to their glassy nature, metallic glasses demonstrate a toughness that is extremely sensitive to the frozen-in configurational state. This sensitivity gives rise to “annealing embrittlement,” which is often severe and in many respects limits the technological advancement of these materials. Here, equilibrium configurations (i.e., “inherent states”) of a metallic glass are established around the glass transition, and the configurational properties along with the plane-strain fracture toughness are evaluated to associate the intrinsic glass toughness with the inherent state properties and identify the fundamental origin of embrittlement. The established correlations reveal a one-to-one correspondence between toughness and shear modulus continuous over a broad range of inherent states, suggesting that annealing embrittlement is controlled almost solely by an increasing resistance to shear flow. This annealing embrittlement sensitivity is shown to vary substantially between metallic glass compositions, and appears to correlate well with the fragility of the metallic glass.