Nitish Bibhanshu

The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition.

Graphic abstract

The hot workability of gamma titanium aluminide alloy, Ti-48Al-2V-2Nb, was assessed in the cast condition through a series of compression tests conducted over a range of temperatures (1000 to 1175 °C) and at the strain rate of 10 S^-1. The mechanism of dynamics recrystallization has been investigated from SEM Z-contrast images and from the Electron backscattered diffraction EBSD as well. It has been observed that volume fraction of the recrystallized grains increases with increasing the deformation temperature. The major volume fraction of the recrystallized grains was observed in the shear band which was forming at an angle 45 ̊ with respect to the compression direction. The mechanism of breaking of the laths and the region of the dynamic recrystallization were also investigated from the SEM Z-contrast image and EBSD. The dynamic recrystallization occurred in the region of the broken laths and shear bands. The breaking of the laths was because of the kinking of the lamellae. The shear band, kinked lamellae and dynamic recrystallized region where all investigated simultaneously.

Magnesium has been trending of late in automobile, aerospace, defense, sports, electronic and biomedical sectors as it offers an advantage in light-weighting. In aluminum, titanium, and steel dominated aerospace and defense sectors, applications of Mg were banned/restricted until recently due to perceived easy ignition and inability to self-extinguish immediately. Strength is generally inversely related to ductility, weak texture and unrelated to ignition resistance, making it challenging to optimize all four concurrently in a material. We address this challenge by designing a low density (~1.76 g.cm⁻³) in-situ Mg nanocomposite. It is a resultant of a sequence of in-situ reactions during melt processing and extrusion. The in-situ formed Y₂O₃ nanoparticles exhibit coherency with matrix and lead to development of large amount of elastic and plastic strain fields around them. These nanoparticles and secondary phases (Mg₂Ca and Mg₂Y) are responsible for the nanocomposite’s high tensile strength (~343 MPa). A weak texture mediated tensile ductility of 30% and compressive failure strain of 44% is observed. Further, the ignition temperature increased to 1045 °C (near the boiling point of Mg)  due to the formation of protective surficial oxide layers aided by the presence of insulating Y₂O₃ nanoparticles, rendering the nanocomposite outperform other traditional commercial Mg-based materials.