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<p>Conventional additive manufacturing (AM) of metallic materials demands costly high-vacuum or ultra-pure inert atmospheres to suppress impurity-induced embrittlement. Here, we overturn this paradigm by demonstrating that ambient trace O and N in an inert atmosphere can be turned into potent in-situ alloying species so that the strength and ductility of the material can be simultaneously enhanced. In a Ti<sub>56</sub>Zr<sub>30</sub>Nb<sub>14</sub> medium-entropy alloy (MEA) additively manufactured with optimized air doping, the yield strength rises by 67% to ≈1 GPa and the tensile ductility increases by 64% to ≈18%, achieving a simultaneous gain that defies the classical strength-ductility trade-off. Atom-probe tomography, enhanced by a machine-learning workflow, identifies two distinct families of nanoscale ordered interstitial complexes (OICs): O-rich OIC1 (O-Zr-Ti) and N-rich OIC2 (N-Zr-Ti). These complexes act as potent dislocation-pinning sites while promoting extensive cross-slip of dislocations and activating Frank-Read sources during plastic deformation. The resultant wavy slip and sustained work-hardening capacity give rise to exceptional strength-ductility synergy. Eliminating the need for high-purity inert gas, this air-alloying route delivers a low-cost, scalable pathway to strong-yet-ductile AM metallic materials.</p>

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Strength-ductility synergy in medium-entropy alloys via harnessing trace air in additive manufacturing

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年4月29日

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  • Yansheng Li,
  • Jiawei Yin,
  • Meiyuan Jiao,
  • Tengfei Zheng,
  • Yuan Wu,
  • Shimiao Li,
  • Guohui Zhang,
  • Jiabin Yu,
  • Yunzhuo Lu,
  • Chun Shang,
  • Haiou Yang,
  • Yang He,
  • Huihui Zhu,
  • Sheng Zhang,
  • Xiaobin Zhang,
  • Xiongjun Liu,
  • Suihe Jiang,
  • Hui Wang,
  • Zhaoping Lu

摘要

Conventional additive manufacturing (AM) of metallic materials demands costly high-vacuum or ultra-pure inert atmospheres to suppress impurity-induced embrittlement. Here, we overturn this paradigm by demonstrating that ambient trace O and N in an inert atmosphere can be turned into potent in-situ alloying species so that the strength and ductility of the material can be simultaneously enhanced. In a Ti56Zr30Nb14 medium-entropy alloy (MEA) additively manufactured with optimized air doping, the yield strength rises by 67% to ≈1 GPa and the tensile ductility increases by 64% to ≈18%, achieving a simultaneous gain that defies the classical strength-ductility trade-off. Atom-probe tomography, enhanced by a machine-learning workflow, identifies two distinct families of nanoscale ordered interstitial complexes (OICs): O-rich OIC1 (O-Zr-Ti) and N-rich OIC2 (N-Zr-Ti). These complexes act as potent dislocation-pinning sites while promoting extensive cross-slip of dislocations and activating Frank-Read sources during plastic deformation. The resultant wavy slip and sustained work-hardening capacity give rise to exceptional strength-ductility synergy. Eliminating the need for high-purity inert gas, this air-alloying route delivers a low-cost, scalable pathway to strong-yet-ductile AM metallic materials.