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Additive manufacturing (AM) as a disruptive technique has offered great potential to design and fabricate many metallic components for aerospace, medical, nuclear, and energy applications where parts have complex geometry. However, a limited number of materials suitable for the AM process is one of the shortcomings of this technique, in particular laser AM of copper (Cu) is challenging due to its high thermal conductivity and optical reflectivity, which requires higher heat input to melt powders. Fabrication of composites using AM is also very challenging and not easily achievable using the current powder bed technologies. Here, the feasibility to fabricate pure copper and copper-carbon nanotube (Cu-CNT) composites was investigated using laser powder bed fusion additive manufacturing (LPBF-AM), and 10 × 10 × 10 mm3 cubes of Cu and Cu-CNTs were made by applying a Design of Experiment (DoE) varying three parameters: laser power, laser speed, and hatch spacing at three levels. For both Cu and Cu-CNT samples, relative density above 90% and 80% were achieved, respectively. Density measurement was carried out three times for each sample, and the error was found to be less than 0.1%. Roughness measurement was performed on a 5 mm length of the sample to obtain statistically significant results. As-built Cu showed average surface roughness (Ra) below 20 µm; however, the surface of AM Cu-CNT samples showed roughness values as large as 1 mm. Due to its porous structure, the as-built Cu showed thermal conductivity of ~108 W/m·K and electrical conductivity of ~20% IACS (International Annealed Copper Standard) at room temperature, ~70% and ~80% lower than those of conventionally fabricated bulk Cu. Thermal conductivity and electrical conductivity were ~85 W/m·K and ~10% IACS for as-built Cu-CNT composites at room temperature. As-built Cu-CNTs showed higher thermal conductivity as compared to as-built Cu at a temperature range from 373 K to 873 K. Because of their large surface area, light weight, and large energy absorbing behavior, porous Cu and Cu-CNT materials can be used in electrodes, catalysts and their carriers, capacitors, heat exchangers, and heat and impact absorption. 

Abstract The compositional dependence and influence of relaxation state on the deformation behavior of a Pt–Pd-based bulk metallic glasses model system was investigated, where platinum is systematically replaced by topologically equivalent palladium atoms. The hardness and modulus increased with rising Pd content as well as by annealing below the glass transition temperature. Decreasing strain-rate sensitivity and increasing serration length are observed in nano indentation with increase in Pd content as well as thermal relaxation. Micro-pillar compression for alloys with different Pt/Pd ratios validated the greater tendency for shear localization and brittle behavior of the Pd-rich alloys. Based on total scattering experiments with synchrotron X-ray radiation, a correlation between the increase in stiffer 3-atom cluster connections and reduction in strain-rate sensitivity, as a measure of ductility, with Pd content and thermal history is suggested. 

Abstract High-entropy alloys (HEAs) with multiple principal elements represent a paradigm shift in structural alloy design and show excellent surface degradation resistance in corrosive environment. Here, the tribo-corrosion response of laser-engineered net-shaped CoCrFeMnNi HEA was evaluated in 3.5 wt% NaCl solution at room temperature. The additively manufactured (AM-ed) CoCrFeMnNi showed five times lower wear rate, regenerative passivation, and nobler corrosion potential during tribo-corrosion test compared to its arc-melted counterpart. A significant anisotropy was seen in the tribo-corrosion response with 45° to the build direction showing better performance compared to tests along the build direction and perpendicular to it. The open circuit potential curves were characterized by a sharp drop to more negative values as wear began, followed by continuous change for the active tribo-corrosion duration and finally a jump to nobler value at the end of the test indicating excellent surface re-passivation for the AM-ed alloy. The superior tribo-corrosion resistance of AM-ed CoCrFeMnNi was attributed to the refined microstructure and highly protective surface passivation layer promoted by the sub-grain cellular structure formed during additive manufacturing. These results highlight the potential of utilizing additive manufacturing of HEAs for use in extreme environments that require a combination of tribo-corrosion resistance, mechanical durability, extended service life, and net shaping with low dimensional tolerance. 

Creep is a serious concern reducing the efficiency and service life of components in various structural applications. Multi-principal element alloys are attractive as a new generation of structural materials due to their desirable elevated temperature mechanical properties. Here, time-dependent plastic deformation behavior of two multi-principal element alloys, CoCrNi and CoCrFeMnNi, was investigated using nano-indentation technique over the temperature range of 298 K to 573 K under static and dynamic loads with applied load up to 1000 mN. The stress exponent was determined to be in the range of 15 to 135 indicating dislocation creep as the dominant mechanism. The activation volume was ~25b3 for both CoCrNi and CoCrFeMnNi alloys, which is in the range indicating dislocation glide. The stress exponent increased with increasing indentation depth due to higher density and entanglement of dislocations, and decreased with increasing temperature owing to thermally activated dislocations. The results for the two multi-principal element alloys were compared with pure Ni. CoCrNi showed the smallest creep displacement and the highest activation energy among the three systems studied indicating its superior creep resistance. 

There is a strong demand for materials with inherently high creep resistance in the harsh environment of next-generation nuclear reactors. High entropy alloys have drawn intense attention in this regard due to their excellent elevated temperature properties and irradiation resistance. Here, the time-dependent plastic deformation behavior of two refractory high entropy alloys was investigated, namely HfTaTiVZr and TaTiVWZr. These alloys are based on reduced activity metals from the 4-5-6 elemental palette that would allow easy post-service recycling after use in nuclear reactors. The creep behavior was investigated using nano-indentation over the temperature range of 298 K to 573 K under static and dynamic loads up to 5 N. Creep stress exponent for HfTaTiVZr and TaTiVWZr was found to be in the range of 20–140 and the activation volume was ~16–20b3, indicating dislocation dominated mechanism. The stress exponent increased with increasing indentation depth due to a higher density of dislocations and their entanglement at larger depth and the exponent decreased with increasing temperature due to thermally activated dislocations. Smaller creep displacement and higher activation energy for the two high entropy alloys indicate superior creep resistance compared to refractory pure metals like tungsten.