Tailored deformation behavior of 304L stainless steel through control of the crystallographic texture with laser-powder bed fusion

Laser-powder bed fusion (L-PBF) has gained significant research interest, not only for its profound advantage of producing near-net shape complex geometries of metallic parts, but also for the possibility of producing tailored microstructures. Here we exploit the capability of manipulating the crystallographic texture by L-PBF to tailor the deformation behavior of austenitic stainless steels. In specific, by adjusting the laser power and the laser scanning speed, tailored crystallographic textures can be obtained, along the uniaxial loading direction in 304L stainless steel samples produced by L-PBF. In situ neutron diffraction and uniaxial tension and compression tests are undertaken to investigate the extent of the transformation induced plasticity effect and to correlate it with the tailored macrostructures. The influence of the initial and the evolving crystallographic texture on the deformation behavior is demonstrated and elaborated accordingly. The observed asymmetry in the deformation behavior between tension and compression is also discussed in detail.

Deformation mechanism in nanocrystalline FCC metals studied by atomistic simulations

Christian Brandl

Polycrystalline materials with crystallite diameters below hundred nanometer exhibit extraordinary strength which goes along with a decrease in ductility. In order to tailor tough materials, which combine strength and ductility, the underlying deformation mechanisms have to be understood. Molecular dynamics suggested partial dislocation mediated plasticity in nanocrystalline face-centred cubic (FCC) metals in terms of 1) dislocation nucleation at the grain boundaries, 2) dislocation propagation through the nano-grain, and 3) eventual dislocation absorption in the neighbouring grain boundary network. The partial dislocation nucleation sites were seen to exhibit stress concentrations such as in triple junctions. Moreover, it has been shown that the partial dislocation nucleation is energetically related to the so-called general stacking fault energies (GSFEs). Transmission electron microscopy, in-situ X-ray diffraction, and deformation experiments can be interpreted in terms of the aforementioned dislocation processes. On basis of this knowledge this thesis utilizes atomistic simulation methods to extend the understanding of the fundamental deformation mechanisms which mediate the plasticity in bulk nanocrystalline FCC metals. In the first part of this thesis, ab-initio simulations are exploited to investigate the effect of the superimposed strains in Ni, Al, and Cu on the GSFEs, which describe the energy penalty for rigidly shearing of the crystal. The energy curves are discussed in terms of a) the second and third order elastic constants b) the energy difference between hexagonal closed packed and face centred cubic structures, c) the GSFE / unstable-twinning-fault-energy interdependence and c) the implication on dislocation nucleation. The second part explores the strain rate, temperature, applied stress, and grain size dependence of nanocrystalline Al utilizing classical molecular dynamics simulations. The deformation behaviour is examined on the basis of the underlying deformation mechanism. The higher the strain rate the more the onset of dislocation mediated plasticity is delayed. This can manifest itself into a stress overshoot that diminishes as the strain rate is lowered. The associated critical resolved shear stresses are seen to cause the strain rate sensitivity in the flow stress. In conjunction with the rate dependence of the critical resolved shear stresses, the temperature dependence of the flow stresses supports the picture of thermally activated dislocation processes which control the deformation of nanocrystalline Al in molecular dynamics. Moreover, the strain rate simulations evidence that a subset of dislocation processes operate at the athermal limit which indicates, once more, the difficulty to extrapolate from the high strain rate regime of molecular dynamics towards common experimental conditions. Furthermore, using an iterative strain/relaxation method, athermal critical stresses are calculated for an isolated nano-grain with a nucleated dislocation therein. Dislocation cross-slip is seen to enable a dislocation to by-pass stress concentration, which can hinder the dislocation propagation through the grain, and allows the dislocation to be deposited in preferred grain regions as e.g. triple junctions. This rationalized the observed lack of strain hardening in the molecular dynamics study. Additionally dislocation cross-slip is more pronounced at lower strain rates which indicate the growing importance of the grain boundary structure for dislocation motion as the stresses are lowered. Slip transfer through a high angle grain boundary is observed and is understood in terms of the grain boundary structure, which exhibits regions of preferred dislocation transmission sites. Such structural features are discussed by means of the implication on mesoscopic models of dislocation transmission. Moreover, the grain size study shows discrete stress-drops, which are associated with dislocation mediated processes, in the so-called "inverse" Hall-Petch regime. The deformation behaviour of nanocrystalline Al in molecular dynamics is rationalized in terms of thermally activated processes, and therein the implications of the grain size dependencies are qualitatively discussed.

EPFL2010

In-situ Laue Diffraction During Compression of Directionally Solidified Mo Micropillars

Julien René André Zimmermann

With recent developments in micro and nano-technologies, mechanical components such as those used in medicine or electronics tend to be miniaturized, requiring a new set of testing techniques to study their reliability and performance. One of the new methods is micro-pillar compression testing, which allows the study of mechanical properties of confined volumes precisely shaped by focused ion beam (FIB) milling from sometimes complex microstructures. This technique has garnered a great deal of interest in recent years; on one hand because of its apparent simplicity, on the other hand because it revealed an unexpected size dependence in the flow stress of single crystals when the pillar diameter was reduced below a few tenths of a micrometre. The flow stress of FIB milled face centred cubic (fcc) micro-pillars appears to follow a power law as a function of their size. In contrast, non-FIB milled, body centred cubic (bcc) eutectic Molybdenum (Mo) alloy pillars prepared by directional growth exhibit, in their pristine state, whisker-like behaviour without a size effect. Furthermore, after FIB milling or moderate pre-deformation, the whisker character is lost and the typical scatter of the flow stress usually observed for FIB milled pillars is reproduced. After large pre-deformation the scatter vanishes and the pillars exhibit no size effect. These findings show that 1) the deterministic parameter in the size effect can be correlated with the initial microstructure of the pillar, and 2) FIB milling influences this microstructure. This study aims to link the deformation modes occurring in small-scale pillars with their initial microstructure by studying directionally solidified eutectic Mo-alloy pillars with a diameter of 1 micrometre. In-situ Laue diffraction experiments during the compression of such defect-free pillars show that with readily-available dislocation sources from a concave pillar top, the {112}[111] slip system with the highest Schmid factor is initially activated and not the allegedly assumed {110}[111] slip system that is typical for bcc metals. Post-mortem slip trace analysis and TEM observations confirm this finding. Moreover, 3D atom probe measurements and TEM images show that this behaviour can be linked to the presence of both alloying elements and fcc nano-precipitates found in the bcc Mo-alloy. Both can lead to a decrease of the critical temperature and the observation of an fcc-like deformation. Additionally, it is shown that both FIB milling and pre-deformation introduce defects in the initially dislocation-free pillars. In addition to this, pillars prepared under similar conditions yield quite different microstructures. The angle between the focused ion beam and the crystal orientation is found to play an important role in the creation of defects. It can also be shown that pillars with high initial dislocation density deform bulk-like and exhibit strain hardening, while pillars with low initial dislocation content demonstrate a large scatter in the flow and yield stress and exhibit large strain burst at later deformation stages. Furthermore several slip systems are activated before the flow stress is reached for pillars containing initially low dislocation content. Interestingly the first activated slip system can be linked to the initial streaking direction; slip is observed on the {112} plane that contains excess dislocations. For both the as-prepared pillars and the pillars with low initial dislocation content, the yield seems to be source limited, which is not the case for pillars with high initial dislocation content.

EPFL2011

Additive manufacturing of a precious bulk metallic glass

Jamasp Jhabvala, Güven Kurtuldu, Roland Logé, Antonia Neels, Navid Sohrabi

For the first time, a high-density amorphous and crack-free bulk metallic glass (BMG) based on a precious metal (PdCuNiP) was produced via additive manufacturing (AM). Laser powder-bed fusion (LPBF) was used for the fabrication of the samples, and led to a density of 99.6%. Excellent mechanical properties such as high hardness and compressive strength were achieved, overcoming the limitations usually found for precious metals in jewelry and watchmaking. Furthermore, without any post-processing, a mirror-like smooth and brilliant surface was directly obtained, which is highly beneficial for applications where surface finish or aesthetics matters. The effect of the main processing parameters, such as laser power and laser-scanning speed, on the shape of single tracks was investigated by laser confocal microscopy (LCM). Following the single-track experiments, highly amorphous LPBF samples were produced. The samples were characterized by optical microscopy (OM), scanning electron microscopy (SEM), conventional and synchrotron X-ray diffraction (XRD), micro-computed tomography (μ-CT), compression tests, and microhardness. The crystallization kinetics of the powder alloy was investigated via fast differential scanning calorimetry (FDSC). A small quantity of the powder (< 70 g) was used for the fabrication of samples, alleviating the cost of the process. Efficient production of precious metal parts with enhanced mechanical properties is demonstrated.