Materials Design and Processing Optimization for Advanced Manufacturing: From Fundamentals to Application: Materials Design and Processing Optimization: Young Investigator Session III
Sponsored by: TMS Structural Materials Division, TMS: Alloy Phases Committee
Program Organizers: Wei Xiong, University of Pittsburgh; Dana Frankel; Gregory Olson, Massachusetts Institute of Technology

Tuesday 8:00 AM
March 1, 2022
Room: 253B
Location: Anaheim Convention Center

Session Chair: Xun Liu, The Ohio State University; Xiaoxiang Yu, Novelis Inc.

8:00 AM  Keynote
Design of Cold-workable Refractory Complex Concentrated Alloys for Applications at Ambient-to-elevated Temperatures: Cheng Zhang1; Enrique Lavernia2; 1University of California Irvine; 2National Academy of Engineering
    Refractory complex concentrated alloys (RCCAs) with ultrahigh melting points are considered as promising candidates for high-temperature structural application. However, poor ductility and negligible formability at ambient temperature are two critical properties that limit their use in many applications. To address these challenges, we employed CALPHAD to design a new class of RCCAs that can be severely cold-worked from the as-cast state without fracture. Such cold-worked RCCAs can be made homogeneous at lower annealing temperatures for shorter times, and microstructures in the current RCCAs can be tailored to achieve desired mechanical properties. Our MD simulation work demonstrates the mechanism that contributes to the easy-processability. In addition, the current RCCAs exhibit tensile strength-ductility synergy at ambient-to-elevated temperatures. Related strengthening and deformation mechanisms will be discussed. Our study proposed a feasible strategy to design and fabricate RCCAs with easy-processability.

8:30 AM  Invited
Laser Forming of Sheet Metal: Incorporating a Metallurgical Perspective: Victoria Miller1; 1University of Florida
    Laser forming has been researched as a flexible manufacturing technique for forming sheet metal since the 1980s, but the technology has stagnated because of poor understanding of the relationships between processing parameters and the final geometry and material properties. Recently, it has been shown that incorporation of more realistic property estimates can greatly improve predictability, but major fundamental gaps remain in understanding the metallurgy of laser sheet forming. In this talk, the role of dislocation mechanisms, recovery, and recrystallization are discussed and extended to implications for alloy design.

8:55 AM  Invited
Power Ultrasound in Advanced Manufacturing: Xun Liu1; Jiarui Kang1; Tianzhao Wang1; 1Ohio State University
    Power ultrasound (UA) is known to be able to modify material behavior and properties in solid and liquid states. Acoustic softening, which describes the flow stress reduction during plastic deformation induced by UA, has been utilized in reducing forming force. In liquid metals, acoustic streaming and cavitation effects have been employed for degassing and refining microstructure. In the first part of this talk, mechanisms of acoustic softening are studied with a new micro-tensile system. In situ DIC analysis and microstructure characterizations are performed to understand the UA influence on the mechanical behavior of pure copper and transformed induced plasticity steel. The second part of the talk focuses on a hybrid ultrasonically assisted wire arc additive manufacturing process for fabricating metal matrix nanocomposites. Superimposed UA in the local deposition pool is shown to reduce porosity, refine solidification microstructure and disperse nanoparticles, which accordingly improves mechanical properties.

9:20 AM  Invited
Design and Manufacturing of Tailorable Polymer Derived Ceramic Composites: Yan Li1; 1Dartmouth College
    The polymer derived ceramics (PDCs) route presents a flexible and energy-efficient approach to fabricate a broad spectrum of ceramic composites with arbitrary geometries and tailorable properties. Currently, however, a lack of knowledge about how atomic-level structural change affects the evolution of continuum-level phase composition—as well as the poor linkage among the process physics, material response, and key processing parameters—have kept our ability to tailor PDC properties to the level of trial and error. A computational framework that predicts continuum-scale ceramic phase formation from atomic-scale structure evolution is presented. The interplay between gas generation and gas diffusion, as well as its role on ceramic phase formation, is systematically studied. The computational model, which elucidates the intricate coupling between heat transfer and phase transition by resolving real-time temperature field and phase composition map, allows key mechanical properties to be predicted at any pyrolysis state.