Fast and High‐Throughput Synthesis of Medium‐ and High‐Entropy Alloys Using Radio Frequency Inductively Coupled Plasma

Zhu, Bo; Alavi, Sina; Cheng, Changjun; Sun, Haokun; Kh, Kim; Mostaghimi, J.; Zou, Yu

doi:10.1002/adem.202001116

Cited by 14 publications

(10 citation statements)

References 46 publications

(52 reference statements)

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“…It is beneficial to use a neural network to determine process windows in a fast and effective way. Similar high-throughput approaches have been employed for selective laser melting and fabrication of high-entropy alloys (HEAs) Cold-sprayed materials exhibit heterogeneous microstructure, resulting in non-uniform mechanical property distributions.…”

Section: Discussionmentioning

confidence: 99%

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Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

Zou

2021

Acc. Mater. Res.

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Conspectus Most metal additive manufacturing (AM) methods involve the melting or sintering of feedstock powder or wire using an energy source (laser, electron beam, or electric arc). Solid-state AM, sometimes also known as non-beam-based AM, is a process in which the deposited material does not melt and is built up layer-by-layer, typically through severe plastic deformation. Initially considered to be a coating technique, by virtue of its high deposition rate, cold spray additive manufacturing (CSAM) is attractive as a solid-state AM technology. In the CSAM process, metal powder particles are impacted onto a substrate at a supersonic velocity and relatively low temperature. The CSAM process reduces or eliminates many problems associated with melting or beam-based AM methods, making the CSAM technically attractive for a wide range of applications, such as in the aerospace, automobile, marine, biomedical, machinery, and energy sectors. In this Account, the author briefly reviews the setup of a cold spray system and discusses the strengths and drawbacks of CSAM compared with thermal sprays and beam-based AM processes, as well as applications in relevant industries. The author summarizes the bonding mechanisms proposed for the cold spray process. The focus of this Account is to review the microstructure evolution of several typical model metals (copper, nickel, aluminum, and titanium) during the cold spray process. The author shows a large variety of microstructure characteristics (recrystallized grains, annealing twins, shear bands, submicron-sized grains, deformation twins, and nanometer-sized grains) in cold-sprayed copper, dynamic recrystallization of cold-sprayed nickel, and the formation of refined grains even below 10 nm in size in cold-sprayed aluminum. The magnitude of the stacking fault energy of as-sprayed materials considerably influences the microstructure after cold spray and postprocessing. Due to the relatively low thermal conductivity and ductility of titanium, cold spraying of titanium shows both a high deposition efficiency and relatively high porosity of as-sprayed parts, as well as a heterogeneous microstructure. Moreover, the Account introduces the postprocessing heat treatment and nanoindentation characterization of cold-sprayed materials. A fundamental understanding of microstructure evolution during and after the cold spray process is essential for optimal mechanical properties. Lastly, the author provides a perspective on applying old lessons and taking advantage of new techniques and materials, including powder characterization, hybrid additive manufacturing, machine learning for searching process windows, nanomechanical testing, and emerging alloys (high-entropy alloys, nanocrystalline alloys, and quasicrystals), to advance the research and applications of CSAM.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

Zou

2021

Acc. Mater. Res.

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“…4(e). 60) Typical samples were fabricated within 40 s per alloy, thereby significantly improving the fabrication efficiency and throughput. More specific reviews on DFT and screening are available elsewhere.…”

Section: Screening Via High-throughput Experimentsmentioning

confidence: 99%

High-Entropy Alloy Catalysts toward Multi-Functionality: Synthesis, Application, and Material Discovery

Fujita

2023

Mater. Trans.

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High-entropy alloy (HEA) catalysts have attracted tremendous research interest owing to their versatile performances in various applications. However, research on HEA catalysts remains in the early stages of exploration, and the fabrication process, element selection, and application remain difficult. Herein, we summarize the current literature on HEA catalysts from the viewpoint of facile synthesis routes, tunable morphologies, attractive applications, and material discoveries related to machine learning and high-throughput experiments. Finally, perspectives and concepts are presented to design the desired multifunctionality HEA catalysts.

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“…[22] The improved properties, especially superior mechanical performances brought by the microstructure of MEA have been widely reported in recent years. [23][24][25][26] A study on a Fe-based MEA catalyst reported outstanding activity and stability, [27] where the MEA thin film overperformed its HEA counterpart with lower oxygen evolution reaction (OER) overpotential values. [28,29] Noble metal-based MEA thin films are further expected to have better performance in electrocatalysis; however, the facile synthesis of MEA films remains challenging.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of PtIrPd Noble Metal Medium Entropy Alloy Thin Film by Atomic Layer Deposition

et al. 2022

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Noble metal medium entropy alloy (MEA) thin films have recently attracted enormous research interests recently because of their great potential in the catalytic application. However, conventional bottom‐up fabrication methods for MEA thin film such as magnetron sputtering face enormous challenges including precise control over film thickness and consumption of costly high‐purity noble metal targets. Herein, a facile and tunable approach is developed coupling sequential atomic layer deposition (ALD) of noble metal layers with electric Joule heating (EJH) alloying process to grow platinum‐iridium‐palladium (PtIrPd) MEA thin films. The PtIrPd MEA thin film with a thickness of ≈20 nm and an atomic ratio of 35:35:30 is successfully fabricated. The effect of EJH processing temperature on the film morphology and structure evolution is investigated. ALD provides flexibility in the metal deposition sequence with meticulous thickness control and atomic composition precision, while the ultrafast EJH ramping/cooling rates promote homogeneous alloying of MEA combinations inhibiting phase separation. Furthermore, the integrated method circumvents a major obstacle of finding a common ALD temperature window for different noble metal precursors as well as opens new pathways for the controllable synthesis of multicomponent metal alloy thin films with potential catalytic, magnetic, and optical properties.

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Fast and High‐Throughput Synthesis of Medium‐ and High‐Entropy Alloys Using Radio Frequency Inductively Coupled Plasma

Cited by 14 publications

References 46 publications

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

High-Entropy Alloy Catalysts toward Multi-Functionality: Synthesis, Application, and Material Discovery

Fabrication of PtIrPd Noble Metal Medium Entropy Alloy Thin Film by Atomic Layer Deposition

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