5 Werkstofftechnik
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Chemical Short-Range Order (CSRO) has attracted recent attention from many researchers, creating intense debates about its impact on material properties.
The challenges lie in confirming and quantifying CSRO, as its detection proves exceptionally demanding, contributing to conflicting data in the literature regarding its true effects on mechanical properties. Our work uses highprecision calorimetric data to unambiguously prove the existence and, coupled with atomistic simulations, quantify the type of CSRO. This methodology allows us to propose a mechanism for its formation and destruction based on the heat evolution during thermal analysis and facilitates a precise identification of local ordering in CoCrNi alloys. Samples of CoCrNi (Co33Cr33Ni33) and CrNi2 (Cr33Ni66) alloys are fabricated in varying ordered states, extensively characterized via synchrotron X-ray diffraction, X-ray absorption spectroscopy, and transmission electron microscopy. Samples with considerably different ordered states are submitted to tensile tests with in-situ synchrotron X-ray diffraction. We demonstrate, despite inducing varied CSRO levels in CoCrNi, no significant alterations in overall mechanical behavior emerge.
However, the CrNi2 alloy, which undergoes long-range ordering, experiences significant shifts in yield strength, ultimate tensile stress and ductility.
In this letter, we demonstrate the robust presence of an elastic microstructure in a Zr-based metallic glass (MG) with a characteristic length-scale of the order of 100 nm. This length scale increases systematically towards the MG surface in differently sized casts, whereas thermal relaxation homogenizes both the internal length-scale gradient and the magnitude of the elastic fluctuations. Strongest changes during relaxation arise in the stiffest parts of the elastic microstructure. These findings indicate that the elastic microstructure emerges due to cooling constraints and may therefore be a microstructural manifestation of the internal residual stresses that arise during MG-solidification.
An attempt has been made in this work, to observe the influence on alloy aging by the sodium oxide (Na2O) in solar salt (60 wt% NaNO3 + 40 wt% KNO3). The accelerated aging was established by adding Na2O (0.005, 0.07, 0.135 and 0.2 wt%) to the solar salt and their effect on corrosion of 316L stainless steel (SS) at 600 ◦C in that oxide-rich solar salts for 168 h in synthetic air was investigated. Corrosion is significantly more in oxide-rich solar salt compared to pure solar salt. Strikingly, the oxide scale-base metal interface is wavy in solar salt containing 0.005 % Na2O clearly shows the oxide addition to salt melt influences Cr-rich inner oxide layer formation and its selective dissolution at early stage that leads to non-uniform corrosion. Interestingly, with increase of Na2O to 0.07 %, steel corrosion proceeded uniformly by accelerated disintegration of Cr-rich inner layer and subsequent dissolution. Severe scale spallation and weight loss in nitrate melt containing 0.2 % Na2O fostering more rapid corrosion, alarming that substantial tolerance of oxide content in solar salt is ≥ 0.135 % for an acceptable corrosion of 316L SS. Despite preferential dissolution of Cr and scale degradation/spallation with increased oxide content in solar salt, the corrosion layer in all cases comprised of sodium ferrite, and Cr-rich Cr-Fe mixed oxides with the Ni enrichment at the scale-metal interface. Competing processes between oxide scale growth, degradation and dissolution or even spallation has been discussed with an emphasis of Na2O addition to solar salt.
The control of stress development in cast ceramics during drying is usually one of critical steps in ceramic processes, which is important also for additive manufacturing technologies using a suspension as feedstock. This work introduces a method based on the cantilever deflection method, to simultaneously quantify the kinetics of solvent evaporation, the shrinkage and the intensity of in-plane stresses developed during drying. Particular attention is given here to the experimental limits of the method and to the optimization of the experimental conditions to suitably measure the intensity of in-planar stress in the coating. The optimized method is applied to
four alumina slurries for the water-based additive manufacturing technology LSD-print. Four stages of drying are identified and discussed in relation with the granulometry and morphology of the alumina ceramic particles.
Powder bed technologies are amongst the most successful Additive Manufacturing (AM) techniques. The application of these techniques to most ceramics has been difficult so far, because of the challenges related to the deposition of homogeneous powder layers when using fine powders.
In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method enabling the use of powder bed AM technologies also for advanced ceramic materials. The layerwise slurry deposition consists of the layer-by-layer deposition of a ceramic slurry by means of a doctor blade, in which the slurry is deposited and dried to achieve a highly packed powder. Not only very fine, submicron powders can be processed with low organics, but also the dense powder bed provides excellent support to the parts built.
The latest development of this technology shows that it is possible to print ceramic parts in a continuous process by depositing a layer onto a rotating platform, growing a powder bed following a spiral motion. The unique mechanical stability of the layers in LSD-print allows to grow a powder bed several centimeters thick without any lateral support. The continuous layer deposition allows to achieve a productivity more than 10X higher compared to the linear deposition, approaching a build volume of 1 liter/hour.
Hybrid additive manufacturing plays a crucial role in the restoration of gas turbine blades, where e.g., the damaged blade tip is reconstructed by the additive manufacturing process on the existing blade made of a parent nickel-based alloy. However, inherent process-related defects in additively manufactured material, along with the interface created between the additively manufactured and the cast base material, impact the fatigue crack growth behavior in bi-material components. This study investigates the fatigue crack growth behavior in bi-material specimens of nickel-based alloys, specifically, additively manufactured STAL15 and cast alloy 247DS. The tests were conducted at 950 °C with stress ratios of 0.1 and -1. Metallographic and fractographic investigations were carried out to understand crack growth mechanisms. The results revealed significant retardation in crack growth at the interface. This study highlights the potential contributions of residual stresses and microstructural differences to the observed crack growth retardation phenomenon, along with the conclusion from an earlier study on the effect of yield strength mismatch on crack growth behavior at a perpendicular interface in bi-material specimens.
Ontologies and data pipelines - a field report from the development of multilayer ferrite inductors
(2024)
Digitalization is a current and prominent cross-cutting topic in ceramics and materials science in general. Many research initiatives and levels of significance are associated with this term. The Initiative Platform MaterialDigital (PMD), for example, aims to create a material data space filled with semantically linked data. The concept envisages that semantic relationships between the data are described as ontologies and that processing of data takes place via automated data pipelines. Various research projects from all areas of materials science are working on the implementation of this concept based on specific use cases. In the project presented here, the use case is the development of multilayer ferrite inductors as passive microelectronic components. The inductors are fabricated by ceramic multilayer technology and co-firing of metallized tapes of NiCuZn ferrite and a dielectric base material. Investigations focus on the effects of fabrication technology on the permeability of the ferrite. A data pipeline is introduced that automatically processes the unstructured experimental data into structured, machine-readable and semantically linked data. The concrete implementation of the data pipeline and a domain ontology is presented using examples. Challenges and advantages are discussed.
Electron-beam-induced conversion of materials in a transmission electron microscope uses the high power density of a localized electron beam of acceleration voltages above 100 kV as an energy source to transform matter at the sub-micron scale. Here, the e-beam-induced transformation of precursor microparticles employing a low-energy e-beam with an acceleration voltage of 30 kV in a scanning electron microscope is developed to increase the versatility and efficiency of the technique. Under these conditions, the technique can be classified between e-beam lithography, where the e-beam is used to mill holes in or grow some different material onto a substrate, and e-beam welding, where matter can be welded together when overcoming the melting phase. Modifying gold microparticles on an amorphous SiOx substrate reveals the dominant role of inelastic electron-matter interaction and subsequent localized heating for the observed melting and vaporization of the precursor microparticles under the electron beam. Monte-Carlo scattering simulations and thermodynamic modeling further support the findings.
Interaction of electromagnetic waves, such as electron beams or light, with conductive material can lead to localized surface plasmon resonances (LSPRs) where the incoming energy can be deposited in a collective excitation of electrons of the conduction band, which in turn can result in coherent localized plasmon oscillations. LSPR in metallic nanostructures, such as nanoparticles (NPs), which are sensitive to geometry, material composition and environment, are currently utilized in a wide range of applications, such as surface-enhanced Raman spectroscopy, plasmonic wave guides, improved solar cells, on-chip particle accelerators and nanoantennas. A host of studies that focus on plasmonic NPs ranging from single NPs with several shapes (cubic, spherical, tetrahedral) over 1D assemblies of NPs such as chains, to ordered 2D assemblies of NPs show an increase of the complexity regarding the hybridization behavior of LSPRs eventually lead to delocalized Surface Plasmons. Furthermore, Anderson predicted in 1977 the absence of diffusion or delocalization of waves in disordered systems, which has been discussed as the underlying mechanism for LSPRs localization in disordered metallic thin films and ultrathin 2D networks. Our aim is to further develop these studies on the surface plasmon localization in disordered structures by (1) developing a novel NPs assembly fabrication method that allows fabricating disordered assemblies of NPs of a wide range of NPs sizes, and (2) probing the LSPR with high-resolution electron energy-loss spectroscopy (EELS). Moreover, the dominant dipolar interaction between the NPs, also facilitates an efficient numerical modeling of these systems, which in comparison with the experiments allows for an in-depth study of the impact of various geometric parameters as well as retardation and life-time damping on the observed localization behavior.
To synthesize 2D disordered assemblies of gold NPs on a TEM transparent silicon oxide substrate, a new synthesis routine was developed. This procedure is based on sublimation and redeposition of a gold microparticle precursor induced by an electron beam in a scanning electron microscope (SEM) operated at 30 kV. To characterize the assembly of synthesized NPs in terms of size, shape and spreading over the substrate, TEM measurements were conducted subsequently. To study LSPRs experimentally, EELS in scanning transmission electron microscopy (STEM) mode was carried out. The numerical modelling of LSPRs was performed using a self-consistent dipole model.
The synthesized 2D disordered gold NPs assemblies exhibit a gradient in the NPs mean size, which ranges from 100 nm close to the precursor location down to 2 nm at a distance of more than 20 µm from the precursor location. Additionally, the interparticle distance between the gold NPs increases with increasing distance to the precursor location.
The experimental investigation as well as the numerical simulation of the LSPRs demonstrate a localization behavior that decreases toward larger energies, which is driven by the disorder of the NPs assembly (mainly the random particle distance). That localization behavior stays in contrast to what was found in ultrathin 2D gold networks showing increasing of localization towards higher LSPRs energies. By varying the geometric parameters of the NPs assembly in the simulation, we could identify the NPs thickness as the parameter, that determines the energy-dependence of the localization. Specifically, a critical thickness of approx. 10 nm separates the two localization regimes, which correlates to the energy of the dipole mode resonance crucially depending on the thickness of the NPs.
2D disordered assemblies of gold NPs of a wide range of NPs sizes and distances can be synthesized directly on thin substrates facilitating structural characterization and EELS measurements in a TEM. It could be shown that such assemblies exhibit LSPRs with a localization behavior that may be tuned by the NPs sizes (including thickness) and interparticle distances. The proposed synthesis of random NPs assemblies opens new avenues for fundamental studies on Anderson localization in disordered plasmonic structures as well as its applications such as surface-enhanced Raman spectroscopy where localization behavior must be tuned to specific wave lengths.