The historical success of friction stir welding (FSW) on materials such as aluminum and magnesium alloys is associated with the absence of melting and solidification during the solid-state process. However, commercial adoption of FSW on steels and other non-ferrous high-strength, high-temperature materials such as nickel-base and titanium-base alloys is limited due to the high costs associated with the process. In this dissertation, the feasibility of using an FSW approach to fabricate certain structural components made of nitrogen containing austenitic stainless steels that go into the vacuum vessel and magnetic systems of tokamak devices was demonstrated. The FSW weldments possessed superior application-specific mechanical and functional properties when compared to fusion weldments reported in the technical literature. However, as stated earlier, the industrial adoption of FSW on high temperature materials such as the ferrous alloys used in the present study is greatly limited due to the high costs associated with the process. The cost is mainly dictated by the high temperature FSW tools used to accomplish the weldments. Commercially available high temperature FSW tools are exorbitantly priced and often have short lifetimes. To overcome the high-cost barrier, we have explored the use of integrated computational materials engineering (ICME) combined with experimental prototyping …

Small-scale fracture behavior of four model alloy systems were investigated in the order of increasing microstructural complexity, namely: (i) a Ni-based Bulk Metallic Glass (Ni-BMG) with an isotropic amorphous microstructure; (ii) a single-phase high entropy alloy, HfTaTiVZr, with body centered cubic (BCC) microstructure; (iii) a dual-phase high entropy alloy, AlCoCrFeNi2.1, with eutectic FCC (L12) -BCC (B2) microstructure; and (iv) a Medium-Mn steel with hierarchical microstructure. The micro-mechanical response of these model alloys was investigated using nano-indentation, micro-pillar compression, and micro-cantilever bending. The relaxed Ni-BMG showed 6% higher hardness, 22% higher yield strength, and 26% higher bending strength compared to its as-cast counterpart. Both the as-cast and corresponding relaxed BMGs showed stable notch opening and blunting during micro-cantilever bending tests rather than unstable crack propagation. However, pronounced notch weakening was observed for both the structural states, with the bending strength lower by ~ 25% for the notched samples compared to the un-notched samples. Deformation behavior of HfTaTiVZr was evaluated by micropillar compression and micro-cantilever bending as a function of two different grain orientations, namely [101] and [111]. The [111] oriented micropillars demonstrated higher strength and strain hardening rate compared to [101] oriented micropillars. The [111] oriented micropillars showed transformation induced plasticity …

Metallic Glasses are multi-component alloys with disordered atomic structures and unique and attractive properties such as ultra-high strength, soft magnetism, and excellent corrosion/wear resistance. In addition, they may be thermoplastically processed in the supercooled liquid region to desired shapes across multiple length-scales. Recently developed metallic glasses based on noble metals (such as Pt and Pd) are highly active in catalytic reactions such as hydrogen oxidation, oxygen reduction, and degradation of organic chemicals for environmental remediation. However, there is a limited understanding of the underlying electrochemical mechanisms and surface characteristics of catalytically active metallic glasses. Here, we demonstrate the influence of alloy chemistry and the associated electronic structure on the activity of a systematic series of Pt42.5−xPdxCu27Ni9.5P21 bulk metallic glasses (BMGs) with x = 0 to 42.5 at%. The activity and electrochemically active surface area as a function of composition are in the form of volcano plots, with a peak around an equal proportion of Pt and Pd. These amorphous alloys showed more than two times the hydrogen oxidation reactivity compared to pure Pt. This high activity was attributed to their lower electron work function and higher binding energy of Pt core level that reduced charge-transfer resistance and improved electrocatalytic activity …