Precise identification of recrystallizing grains in partially recrystallized microstructures is essential to obtain quantitative information regarding the recrystallization process. Automatic, robust, user-friendly, and unbiased identification methods that do not rely on hard-coded, preselected values would be highly advantageous. In this study, we test convolutional neural network instance segmentation models to achieve automatic segmentation of individual recrystallizing grains in partially recrystallized microstructures. Our training dataset includes micrographs obtained using electron backscattered diffraction from five alloys with different thermal-mechanical histories and more than 100,000 recrystallizing grains. We adapt and train two state of the art deep learning models, namely Mask R-CNN and PointRend. Both models provide instance segmentation results of good quality, enabling quantitative determination of the microstructural parameters. The PointRend model demonstrates better performance for grains with irregular shapes than Mask R-CNN. Compared to conventional methods, the trained deep learning approach is easier to use, more flexible, and applicable to a wide range of materials. 

Zinc is emerging as a key material for next-generation biodegradable implants1, 2, 3, 4-5. However, its inherent softness limits its use in load-bearing orthopaedic implants. Although reducing the grain size of zinc can make it stronger, it also destabilizes its mechanical properties and thus makes it less durable at body temperature6. Here we show that extruded Zn alloys of dilute compositions can achieve ultrahigh strength and excellent durability when their micron-scale grain size is increased while maintaining a basal texture. In this inverse Hall-Petch effect, the dominant deformation mode changes from inter-granular grain boundary sliding and dynamic recrystallization at the original grain size to intra-granular pyramidal slip and unusual twinning at the increased grain size. The role of the anomalous twins, termed 'accommodation twins' in this work, is to accommodate the altered grain shape in the plane lying perpendicular to the external loading direction, in contrast to the well-known 'mechanical twins' whose role is to deliver plasticity along the external loading direction7,8. The strength level achieved in these dilute zinc alloys is nearly double those of biodegradable implants made of magnesium alloys-making them the strongest and most stable biodegradable alloys available, to our knowledge, for fabricating bone fixation implants.

A high-alloy (Cr-Mo-V) cold-work tool steel was manufactured by laser powder-bed fusion (PBF-LB) without preheating and by electron-beam powder-bed fusion (PBF-EB) with the build temperature set at 850 degrees C. The solidification rates, cooling, and thermal cycles that the material was subjected to during manufacturing were different in the laser powder-bed fusion than electron-beam powder-bed fusion, which resulted in very different microstructures and properties. During the solidification of the PBF-LB steel, a cellular-dendritic structure was formed. The primary cell size was 0.28-0.32 mu m, corresponding to a solidification rate of 2.0-2.5 x 106 degrees C/s. No coarse primary carbides were observed in the microstructure. Further rapid cooling resulted in the formation of a martensitic microstructure with high amounts of retained austenite. The high-retained austenite explained the low hardness of 597 +/- 38 HV. Upon solidification of the PBF-EB tool steel, dendrites with well-developed secondary arms and a carbide network in the interdendritic space were formed. Secondary dendrite arm spacing was in the range of 1.49-3.10 mu m, which corresponds to solidification rates of 0.5-3.8 x 104 degrees C/s. Cooling after manufacturing resulted in the formation of a bainite needle-like microstructure within the dendrites with a final hardness of 701 +/- 17 HV. These findings provide a background for the selection of a manufacturing method and the development of the post-treatment of a steel to obtain a desirable final microstructure, which ensures that the final tool's performance is up to specification.

Hot isostatic pressing (HIP) is a near-net shape powder metallurgy (PM) technique, which has emerged as an efficient technique, offering precise control over the microstructure and properties of materials, particularly in high-performance alloys. This technology finds applications across a wide range of industries, such as aerospace, automotive, marine, oil and gas, medical, and tooling. This paper provides an overview of powder metallurgy and hot isostatic pressing, covering their principles, process parameters, and applications. Additionally, it conducts an analysis of PM-HIPed alloys, focusing on their microstructure and fatigue behavior to illustrate their potential in diverse engineering applications. Specifically, this paper focuses on nickel-based superalloys and martensitic tool steels. The diverse microstructural characteristics of these alloys provide valuable insights into the PM-HIP-induced fatigue defects and properties.

“Unconventional twins” were reported by Cayron and Logé [1] to form in plastically deformed magnesium. They were used to show the occurrence of a new twinning mode which was used to argue for reconsidering the theory of deformation twinning that is based on simple shear [1], and to support a concept of axial weak twins [2]. Our paper demonstrates the incorrect interpretation of their electron back-scatter diffraction map in [1], and that the so-called “unconventional” twins are just conventional extension twins that have impinged with each other. Therefore, the so-called habit plane of the “unconventional twins” is a boundary resulting from impingement of these two different variants of the extension twin, and is therefore not expected to be invariant. © 2022 Acta Materialia Inc.

While the three-dimensional (3D) shape and stress field of a twin in hexagonal close-packed (HCP) metals have attracted considerable interest in recent years due to their substantial impact on internal stress and mechanical properties, a detailed understanding of their variation with twin size is still lacking. An analytical model that is not restricted by spatial scale is developed in this work by considering the effects of anisotropic twin boundary energy, elastic strain energy and plastic relaxation to predict the 3D shape with the minimum energy, and the stress field, of an isolated ellipsoidal twin of different sizes. The model is applied to Mg with a focus on the {101¯2} twin type. The analytical calculation results show that the nucleation of the nano-sized twin embryos is facilitated by the stress field near structural defects such as dislocations. During the expansion of this nano-sized twin embryo, the interplay between the elastic strain energy and interfacial energy changes the length of the twin along the twin shear (forward) direction from being shorter to longer than that along the lateral direction. In contrast to the current understandings, the maximum shear stress on the twin plane along the twin shear direction occurs at the lateral, rather than the forward, side of the twin. At the forward side, the maximum shear stress occurs at a distance ahead of the twin tip and this distance increases with increasing twin thickness.

High-nitrogen-chromium alloyed powder metallurgy (PM) tool steels offer many attractive features including high strength and corrosion resistance. The PM route offers various advantages such as advanced alloy composition, high homogeneity, and well-defined size distribution of hard phase particles. This study presents microstructure and mechanical properties of a PM Cr-Mo-V-N alloy. The conventional manufacturing route for this alloy is hot isostatic pressing (HIP) followed by hot working. To investigate the possibility of near-net-shape manufacturing, a comprehensive comparison of the performance was made between steels produced by as-HIPed and HIPed followed by hot working. Both steel types were heat treated in the same way to obtain martensitic matrix with limited retained austenite. In the present investigation, microstructure and phase analyses were performed by X-ray diffraction and scanning electron microscopy. Mechanical tests were carried out by hardness measurements and tensile fatigue tests in the very high cycle fatigue regime using ultrasonic fatigue testing. 

During static recrystallization, grains often have non-constant and non-uniform growth rates, significantly affecting the recrystallization kinetics and the microstructure after recrystallization. A cellular automaton model was employed in order to evaluate the relative influences of gradients of stored energy, grain boundary curvature, and heterogeneity of grain boundary mobility on the non-uniform migration of grain boundary segments, leading to the formation of protrusions and retrusions. Electron back-scatter diffraction measurements of a cold-rolled copper microstructure served to feed the model. Orientation maps obtained after partial recrystallization were used to assess the model outcome. The model was capable to predict the shapes of recrystallized grains with retrusions and protrusions. Effects of different model assumptions were compared to reveal individual contributions of different factors to grain size distribution, grain shape and boundary roughness. The model predicted a decreasing average grain growth rate as a result of the progressive immobilization of an increasing fraction of grain boundary segments. The model prediction was compared with experimental results, explaining the origin of stationary boundaries and indicating some further improvements necessary to reach quantitative agreement.

Abstract: The annealing kinetics of cold-rolled AA5182 and AA5657 aluminum alloy sheets have been investigated and compared. The microstructures of a series of partially recrystallized samples are characterized by electron back scattered diffraction and key stereological parameters including volume fraction recrystallized, interfacial areas and contiguity are determined. The overall recrystallization kinetics as well as the nucleation and growth rates are thereby quantified. The results reveal that the nuclei develop in clusters. This matches well with the observation of a low kinetics exponent n = 2 in AA5182. Much more surprising is that n is 2.8 in AA5657, even though the nucleation is clustered. Also, it is higher than almost all recrystallization kinetics investigations which generally find values significantly below 3. Effects of nucleation rate, spatial distribution of nuclei and growth rate are discussed and used in a quantitative analysis of recrystallization kinetics in the two alloys. Graphic Abstract: [Figure not available: see fulltext.] © 2021, The Minerals, Metals & Materials Society and ASM International.

In previous work [1], we analyzed the recrystallization kinetics in cold-rolled AA5657 and AA5182 based on measurements of the volume fraction of recrystallized material, the free (unimpinged) surface area density and the average size of the recrystallizing grains, plus the contiguity between recrystallizing grains, for a series of partially recrystallized samples. In that work, the calculated growth and nucleation rates were used as basis from the analysis. These two properties are derived from the measured parameters, which, as shown in the present work, adds to their uncertainty. In the present paper, we revisit the kinetics using improved stereological data and perform a full microstructural path analysis. The new analysis results are compared to the previous ones and the implications of using the different types of data sets and analytical approach for the interpretation of the kinetics are discussed.