Max-Planck-Institut für Nachhaltige Materialien GmbH
The Ni and Ti-based superalloys primarily used in high-temperature applications are comprised of various rare earth and strategic alloying elements. Therefore, the primary research in the materials community has been geared towards developing cost-effective and sustainable alloys from abundantly available cheaper material resources. The design of new alloys also requires a quick assessment of their strength at extreme conditions relevant to actual service periods, such as high temperature and high strain rates–mimicking different manufacturing processes (e.g., forging) or impacts/drops. However, due to the lack of well-established high throughput mechanical testing available at extreme conditions, quick modification in the alloy design process is limited either by the cost-effective mass fabrication of test samples or the testing technique itself. To close this gap and provide more sustainable alternatives, we present the case study on iron-aluminium (Fe-Al) alloy, wherein the solid-state dewetting process is used to fabricate single-crystal alloyed microparticles from thin films. It was observed that dewetting of Fe-Al films on sapphire at different annealing times leads to the formation of microparticles with different orientations and shapes. Subsequently, the micro-compression in the strain rate range of 0.01-1000 s-1, performed using a custom modified high-strain rate micromechanical testing setup, showed characteristic dislocation nucleation events in the stress-strain curves. The results obtained in this study sheds light on both the thermal stability of Fe-Al thin films and the rate-dependent mechanical behavior of Fe-Al microparticles.
Abstract
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