Seth D. Imhoff

Nucleation of shear bands in amorphous alloys

Significance A shear band is a region of highly localized plastic flow that develops during loading in both crystalline and amorphous materials. Shear bands directly determine the ductility of an amorphous phase, but relatively little is known about their nucleation. We use nanoindentation to probe shear band nucleation by measuring the first pop-in event during loading which is associated with shear band formation. We analyze a large number of independent measurements on four different metallic glasses and reveal a bimodal distribution of nucleation events that operate at different stress levels. The discovery of multiple shear band nucleation sites challenges the current view of a single type of site and offers opportunities for controlling the ductility of amorphous alloys. The initiation and propagation of shear bands is an important mode of localized inhomogeneous deformation that occurs in a wide range of materials. In metallic glasses, shear band development is considered to center on a structural heterogeneity, a shear transformation zone that evolves into a rapidly propagating shear band under a shear stress above a threshold. Deformation by shear bands is a nucleation-controlled process, but the initiation process is unclear. Here we use nanoindentation to probe shear band nucleation during loading by measuring the first pop-in event in the load–depth curve which is demonstrated to be associated with shear band formation. We analyze a large number of independent measurements on four different bulk metallic glasses (BMGs) alloys and reveal the operation of a bimodal distribution of the first pop-in loads that are associated with different shear band nucleation sites that operate at different stress levels below the glass transition temperature, Tg. The nucleation kinetics, the nucleation barriers, and the density for each site type have been determined. The discovery of multiple shear band nucleation sites challenges the current view of nucleation at a single type of site and offers opportunities for controlling the ductility of BMG alloys.

Proton Radiography Peers into Metal Solidification

Historically, metals are cut up and polished to see the structure and to infer how processing influences the evolution. We can now peer into a metal during processing without destroying it using proton radiography. Understanding the link between processing and structure is important because structure profoundly affects the properties of engineering materials. Synchrotron x-ray radiography has enabled real-time glimpses into metal solidification. However, x-ray energies favor the examination of small volumes and low density metals. Here we use high energy proton radiography for the first time to image a large metal volume (>10,000 mm3) during melting and solidification. We also show complementary x-ray results from a small volume (<1 mm3), bridging four orders of magnitude. Real-time imaging will enable efficient process development and the control of structure evolution to make materials with intended properties; it will also permit the development of experimentally informed, predictive structure and process models.

Three-dimensional Dendritic Needle Network model with application to Al-Cu directional solidification experiments

We present a three-dimensional (3D) extension of a previously proposed multi-scale Dendritic Needle Network (DNN) approach for the growth of complex dendritic microstructures. Using a new formulation of the DNN dynamics equations for dendritic paraboloid-branches of a given thickness, one can directly extend the DNN approach to 3D modeling. We validate this new formulation against known scaling laws and analytical solutions that describe the early transient and steady-state growth regimes, respectively. Finally, we compare the predictions of the model to in situ X-ray imaging of Al-Cu alloy solidification experiments. The comparison shows a very good quantitative agreement between 3D simulations and thin sample experiments. It also highlights the importance of full 3D modeling to accurately predict the primary dendrite arm spacing that is significantly over-estimated by 2D simulations.

The effect of distribution of second phase on dynamic damage

For ductile metals, dynamic fracture occurs principally through void nucleation, growth, and coalescence at heterogeneities in the microstructure. Previous experimental research on high purity metals has shown that microstructural features, such as grain boundaries, inclusions, vacancies, and heterogeneities, can act as initial void nucleation sites. In addition, other research on two-phase materials has also highlighted the importance of the properties of a second phase itself in determining the dynamic response of the overall material. However, previous research has not investigated the effects of the distribution of a second phase on damage nucleation and evolution. To approach this problem in a systematic manner, two copper alloys with 1% lead materials, with the same Pb concentration but different Pb distributions, have been investigated. A new CuPb alloy was cast with a more homogeneous distribution of Pb as compared to a CuPb where the Pb congregated in large “stringer” type configurations. These m...

From Solidification Processing to Microstructure to Mechanical Properties: A Multi-scale X-ray Study of an Al-Cu Alloy Sample

We follow an Al-12 at. pct Cu alloy sample from the liquid state to mechanical failure, using in situ X-ray radiography during directional solidification and tensile testing, as well as three-dimensional computed tomography of the microstructure before and after mechanical testing. The solidification processing stage is simulated with a multi-scale dendritic needle network model, and the micromechanical behavior of the solidified microstructure is simulated using voxelized tomography data and an elasto-viscoplastic fast Fourier transform model. This study demonstrates the feasibility of direct in situ monitoring of a metal alloy microstructure from the liquid processing stage up to its mechanical failure, supported by quantitative simulations of microstructure formation and its mechanical behavior.

Demonstration of transmission high energy electron microscopy

High energy electrons have been used to investigate an extension of transmission electron microscopy. This technique, transmission high energy electron microscopy (THEEM), provides two additional capabilities to electron microscopy. First, high energy electrons are more penetrating than low energy electrons, and thus, they are able to image through thicker samples. Second, the accelerating mode of a radio-frequency linear accelerator provides fast exposures, down to 1 ps, which are ideal for flash radiography, making THEEM well suited to study the evolution of fast material processes under dynamic conditions. Initial investigations with static objects and during material processing have been performed to investigate the capabilities of this technique.High energy electrons have been used to investigate an extension of transmission electron microscopy. This technique, transmission high energy electron microscopy (THEEM), provides two additional capabilities to electron microscopy. First, high energy electrons are more penetrating than low energy electrons, and thus, they are able to image through thicker samples. Second, the accelerating mode of a radio-frequency linear accelerator provides fast exposures, down to 1 ps, which are ideal for flash radiography, making THEEM well suited to study the evolution of fast material processes under dynamic conditions. Initial investigations with static objects and during material processing have been performed to investigate the capabilities of this technique.

From Alloy Processing to Performance: An In Situ Experimental and Modeling Effort

Solidification is present in almost all materials. It is influenced by grain size and shape, chemical homogeneity, defect type and density, and mechanical properties. During micro-mechanical testing, the following occur: 1) Micro-CT (as processed) - Map Initial 3D Microstructure 2) Nano-Radiography (In situ under Tension) - Observe of Damage Initiation/Propagation 3) Micro-CT (Post Mortem) - Global Fracture Study 4) Nano-CT (Post Mortem) - High-Resolution Fracture Study.

Imaging the Rapid Solidification of Metallic Alloys in the TEM

The macroscopic properties of a metal solidified from a liquid melt are strongly dependent on the final microstructure, which in turn is the result of the solidification conditions. With the growing popularity of laser-based additive manufacturing (AM), there is an increasing need to understand the microstructures that result from rapid solidification processes. Rapidly solidified alloy microstructures are typically far from equilibrium and therefore traditional thermodynamic approaches used to predict structure and composition (i.e., phase diagrams) must be extended to describe these deviations from equilibrium and ensuing metastable states. This work highlights progress toward corroborating predictive (phase-field) modeling capabilities [1] with in situ experimental observations [2] in order to better understand the non-equilibrium structures produced during rapid solidification following laser melting.

Crystallization control in highly undercooled liquids and glasses

Abstract Crystallization of highly undercooled materials either from the melt during cooling or from an amorphous phase during heating can yield novel phases with useful properties, but a reliable control of phase selection has been elusive. In bulk volumes fluxing is a common method to promote high undercooling due to nucleant removal or deactivation, but the mechanism is not defined clearly. From experiments on Au with well controlled conditions the operation of fluxing has been identified as a nucleant refining process. Moreover, structural studies have discovered that fluxing can also affect the melt structure and dynamics in multicomponent alloys. During primary nanocrystallization of amorphous Al alloys, solute substitution has a significant effect on the glass forming ability and crystallization kinetics primarily through the change in diffusion that impacts the crystal nucleation rate through transient effects.