Lightweight materials are of paramount importance to reduce energy consumption and emissions in today’s society. For materials to qualify for widespread use in lightweight structural assembly, they must be weldable or joinable, which has been a long-standing issue for high strength aluminum alloys, such as 7075 (AA7075) due to their hot crack susceptibility during fusion welding. Here, we show that AA7075 can be safely arc welded without hot cracks by introducing nanoparticle-enabled phase control during welding. Joints welded with an AA7075 filler rod containing TiC nanoparticles not only exhibit fine globular grains and a modified secondary phase, both which intrinsically eliminate the materials hot crack susceptibility, but moreover show exceptional tensile strength in both as-welded and post-weld heat-treated conditions. This rather simple twist to the filler material of a fusion weld could be generally applied to a wide range of hot crack susceptible materials.
While laser-printed metals do not tend to match the mechanical properties and thermal stability of conventionally-processed metals, incorporating and dispersing nanoparticles in them should enhance their performance. However, this remains difficult to do during laser additive manufacturing. Here, we show that aluminum reinforced by nanoparticles can be deposited layer-by-layer via laser melting of nanocomposite powders, which enhance the laser absorption by almost one order of magnitude compared to pure aluminum powders. The laser printed nanocomposite delivers a yield strength of up to 1000 MPa, plasticity over 10%, and Young’s modulus of approximately 200 GPa, offering one of the highest specific Young’s modulus and specific yield strengths among structural metals, as well as an improved specific strength and thermal stability up to 400 °C compared to other aluminum-based materials. The improved performance is attributed to a high density of well-dispersed nanoparticles, strong interfacial bonding between nanoparticles and Al matrix, and ultrafine grain sizes.
Effective control of melting and solidification behaviours of materials is significant for numerous applications. It has been a long-standing challenge to increase the melted zone (MZ) depth while shrinking the heat-affected zone (HAZ) size during local melting and solidification of materials. In this paper, nanoparticle-induced unusual melting and solidification behaviours of metals are reported that effectively solve this long-time dilemma. By introduction of Al 2 O 3 nanoparticles, the MZ depth of Ni is increased by 68%, while the corresponding HAZ size is decreased by 67% in laser melting at a pulse energy of 0.18 mJ. The addition of SiC nanoparticles shows similar results. The discovery of the unusual melting and solidification of materials that contain nanoparticles will not only have impacts on existing melting and solidification manufacturing processes, such as laser welding and additive manufacturing, but also on other applications such as pharmaceutical processing and energy storage.
The surface tension of superheated and undercooled liquid Ni–5 wt % Si alloy was measured by an electromagnetic oscillating drop method over a wide temperature range from 1417 to 1994 K. The maximum undercooling of 206 K (0.13 TL) was achieved. The surface tension of liquid Ni–5 wt % Si alloy is 1.697 N m−1 at the liquidus temperature 1623 K, and its temperature coefficient is −3.97×10−4 N m−1 K−1. On the basis of the experimental data of surface tension, the other thermophysical properties such as the viscosity, the solute diffusion coefficient, and the density of liquid Ni–5 wt % Si alloy were also derived.
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