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Metallurgy involves science and engineering of metals, from fundamental understanding of physical and chemical behavior of metals to processing of metallic components. Metals serve as important structural components as load-bearing materials and provide protection against harsh environments. This collection highlights experimental and theoretical work published in Nature Communications on the science and engineering of load-bearing materials. Explore the latest research on high entropy alloys, bulk metallic glasses, grain boundaries, phase transitions, and crystal growth, and processing, defects, and mechanical properties.
Additively manufactured materials contain different types of volumetric defects. Here, the authors utilize the most distinguishing morphological features among different defect types to propose a defect classification methodology.
Fusion welding of 7000 series aluminum alloy is plagued by cracking from a fine equiaxed zone (FQZ). Here, the authors quantify key softening mechanisms, show the damage accumulation sequence, and propose a hybrid laser/arc welding strategy to mitigate the FQZ and increase weld strength and toughness.
Engineering metals often suffer from a small elastic deformation with a linear stress-strain relationship obeying Hooke’s law. Here the authors observe a large nonlinear tensile elastic deformation with a strain of >4.3% in a bulk Cu alloy that offers potential for elastic strain engineering.
High-strength nanocrystalline materials come at the expense of tensile ductility, thermal stability, and electrical conductivity. Here the authors report a nanodispersion-in-nanograins strategy where ultra-nano-carbon was used to concurrently achieve above four mutually exclusive properties.
By trapping hydrogen, nanoprecipitates can mitigate the hydrogen embrittlement of high strength steels. Here, the authors report direct evidences on the structural and chemical features underlying distinct hydrogen-trapping behaviors at the incoherent interfaces of precipitates and steel matrix.
Complexities of laser-material interactions pose a challenge to minimize defects in additively manufactured metal parts. Here the authors visualize all phases of matter simultaneously to expand understanding of the interactions and show atmospheric information can characterize process stability.
Recent demands to design alloys in a more sustainable way have discouraged the use of critical elements that are rare. Here the authors demonstrate a segregation-based strategy to produce a sustainable steel, Fe18Mn3Ti, without critical elements while achieving ultrahigh-strength.
Engineering applications of nanostructured metals are limited by their complex manufacturing technology and poor microstructural stability. Here the authors report a facile technology that enables a mass production of nanostructured Ti6Al4V5Cu alloys with high microstructural stability.
Understanding the keyhole porosity formation is important in laser powder bed fusion. Here the authors reveal the dynamics of keyhole fluctuation, and collapse that induces bubble formation with three main stages of evolution; growth, shrinkage, and being captured by the solidification front.
Defects induced by process instabilities in metal additive manufacturing limit its applications. Here, the authors report controlling laser-powder bed interaction instabilities by nanoparticles leads to defect lean metal additive manufacturing.
Traditional electrorefining process is limited by deposition potential of the metal itself. Here, the authors explore an in-situ anodic precipitation process based on different solubility of target metal chlorides that can efficiently separate components of aluminum alloys.
Wear-resistant metals have long been a pursuit of reducing wear-related energy and material loss. Here the authors present the ‘reactive wear protection’ strategy via friction-induced in situ formation of strong and deformable oxide nanocomposites on a surface.
Aggregation and coarsening of the second-phase oxide particles at grain boundaries have been a bottleneck for improving mechanical properties of oxide-dispersion-strengthened (ODS) alloys. Here the authors employ core-shell nanopowder precursors to achieve uniform dispersion of oxides in ODS alloys.
Conventional ultrafine grains can generate high-strength Mg alloys, but non-equilibrium grain boundaries deteriorates their corrosion resistance. Here, the authors present ultrafine grained Mg alloys with dense twins that display high strength and reduced corrosion rate by one order of magnitude.
Identifying scaling laws in metal 3D printing is key to process optimization and materials development. Here the authors report scaling laws to quantify correlation between process parameters, keyhole stability and pore formation by high-speed synchrotron X-ray imaging and multiphysics modeling.
Prismatic dislocation loops (PDLs) form during the elastic-to-plastic transition of a dislocation-free volume under nanoindentation. Here the authors observe the initial plasticity and burst-like emission of PDLs in Au nanowires by in-situ transmission electron microscopy, elucidating fundamental aspects of the formation process.
3D printing can allow for the efficient manufacturing of elaborate structures difficult to realise conventionally without waste, such as the hollow geometries of nickel-based superalloy aeronautic components. To fully exploit this method, we must move towards new alloys and processes.
Plate-lattices are predicted to reach the upper bounds of strength and stiffness compared to traditional beam-lattices, but they are difficult to manufacture. Here, the authors use two-photon polymerization 3D-printing and pyrolysis to make carbon plate-nanolattices which reach those theoretical bounds, making them up to 639% stronger than beam-nanolattices.
Understanding metal component microstructure during 3D printing remains a challenge. Here, the authors use local thermal parameters and the solidification microstructure to better understand how the printed microstructure varies with the laser scan strategy.
Adding minute amounts of rhenium to Ni-based single crystal superalloys extends their high temperature performance in engines, but the reasons behind that are still unclear. Here, the authors combine high resolution imaging and modelling to show that rhenium enriches and slows down partial dislocations to improve creep performance.
3D printing of metals produces elongated columnar grains which are usually detrimental to component performance. Here, the authors combine ultrasound and 3D printing to promote equiaxed and refined microstructures in a titanium alloy and a nickel-based superalloy resulting in improved mechanical properties.
Strengthening a metallic alloy without sacrificing ductility remains challenging. Here, the authors develop a hierarchical nanostructured aluminium alloy composed of nanograins surrounding by metallic glass shells that has both ultrahigh strength and good ductility.
Understanding the interactions between solute atoms and crystalline defects is essential for determining alloy properties. Here the authors use a linear regression model to propose a quantitative correlation between local electronic structure descriptors and the solute-defect interaction energies in bcc refractory alloys.
The impact of grain-scale residual stresses on the mechanical behaviour of 3D-printed metals and alloys remains unexplored. Here, the authors combine in situ synchrotron X-ray diffraction and computer simulations to link residual stresses in steel to its tensile behaviour.