Yiming Jin, Jing Xue, Xiaoyan Chang, Meiqing Chen, Baifeng Luan, Rong Hu
{"title":"Microstructural evolution under irradiation in V-Ti-Ta-(Hf) refractory high-entropy alloys: Temperature effects revealed by atom probe tomography","authors":"Yiming Jin, Jing Xue, Xiaoyan Chang, Meiqing Chen, Baifeng Luan, Rong Hu","doi":"10.1016/j.jmst.2025.09.037","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.037","url":null,"abstract":"V-Ti-Ta-based refractory high-entropy alloys exhibit promising irradiation resistance and are considered strong candidates for structural materials in next-generation nuclear power systems. However, comprehensive studies on their compositional design and temperature-dependent irradiation behavior remain limited. In this study, irradiation-induced hardening and microstructural evolution of VTiTa and VTiTaHf alloys were systematically investigated under ion irradiation at room temperature (RT) and 773 K using nanoindentation and atom probe tomography. In the VTiTa alloy, RT irradiation led to the formation of V-enriched particles and dislocations, whose number density and size were closely correlated with local compositional variations. At 773 K, these V-enriched particles disappeared, the dislocation density decreased, and their average size increased. The addition of Hf further suppressed the formation of V-enriched particles and dislocations under RT irradiation. Moreover, an atomic-scale homogeneous elemental distribution was maintained in the VTiTaHf alloy at 773 K. These microstructural changes were consistent with the observed irradiation-induced hardening behavior, where the VTiTaHf alloy demonstrated superior radiation resistance at elevated temperatures. These findings suggest that Hf incorporation not only enhances the irradiation tolerance of the alloy at high temperatures but also contributes to reducing the radioactive decay period, which is a critical requirement for application in nuclear environments.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"126 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145203996","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Dynamic evolution of Cu-rich core-shell structures triggered by aluminum and its regulation on the stability and hardening effects of nanoparticles","authors":"Yangbo Li, Tian Li, Prajna Paramita Mohapatra, Xiandong Xu","doi":"10.1016/j.jmst.2025.09.035","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.035","url":null,"abstract":"Nanoparticle precipitation plays a pivotal role in determining the properties of structural materials, and understanding the mechanisms governing their formation and stability has been a central focus in materials science. In the context of advanced Fe-based alloys, key questions remain: What drives nanoparticle precipitation? How are core-shell structures formed? And what mechanisms underlie cooperative hardening? By introducing Al into Fe-Cu-Ni alloys, we demonstrate that Ni and Al co-cluster with Cu, forming BCC Cu(Ni,Al)-rich clusters that evolve into the thermally stable B2 phase, even after 100 h of annealing. Prolonged annealing leads to Cu diffusion into the precipitate core, resulting in a core-shell structure—a Cu-rich core surrounded by a B2-Ni(Al) shell—which correlates with a reduction in hardness. In contrast, FeCuNi alloys exhibit rapid precipitate nucleation due to the high diffusivity of Cu and Ni in the Fe matrix, but their core-shell structures show limited thermal and mechanical stability. The Cu(Ni,Al)-B2 precipitates, with their enhanced phase stability, achieve a higher number density and superior performance compared to FeCuNi alloys. Importantly, our findings reveal a strong correlation between the morphological evolution of precipitates with annealing time and their mechanical behavior, providing new insights into the design of high-performance structural materials.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"115 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145195369","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Processing defects and damage mechanisms in refractory high-entropy alloys additively manufactured via directed energy deposition","authors":"Dingcong Cui, Shuya Zhang, Songyu Wang, Xiaoyu Bai, Chengyu Li, Junyu Chen, Boxin Wei, Kunlei Hou, Upadrasta Ramamurty, Jincheng Wang, Feng He","doi":"10.1016/j.jmst.2025.09.034","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.034","url":null,"abstract":"Refractory high-entropy alloys (RHEAs) are promising candidates for high-temperature applications due to their intrinsic resistance to plastic flow softening at elevated temperatures. However, their brittleness makes it difficult to manufacture engineering components with complex geometries. Additive manufacturing via direct energy deposition (DED) technique offers flexibility in design and forming, yet processing defects caused by marked differences in the physical properties of the constituent multi-principal elements and the rapid solidification conditions associated with DED limit RHEAs' practical application. This study elucidates the formation of inherent defects, strategies for their suppression, and their influence on the mechanical response of a DED Ti<sub>41</sub>V<sub>27</sub>Hf<sub>13</sub>Nb<sub>13</sub>Mo<sub>6</sub> RHEA prepared by mixed powders. Correlation of the molten pool characteristics to processing parameters reveals that laser power and scanning speed are pivotal in regulating defect formation. Insufficient energy input induces unmelted defects, rendering as-printed specimens brittle during tensile tests. Detailed microstructural characterization shows that the unmelted defects act as crack nucleation sites (through micropore coalescence), promoting premature failure. To address this, remelting (Strategy Ⅰ) and high-energy density processing (Strategy Ⅱ) were implemented via temperature field simulations and proved to be effective. The damage mechanism of the RHEA with moderate defects fabricated via Strategy Ⅰ is primarily governed by cracking, whereas that of the low-defect-content RHEA produced via Strategy Ⅱ is dominated by void nucleation. In the latter, reduced cracking effectively suppresses strain localization during deformation. The optimized RHEA exhibits a high tensile elongation of 17.9% and a yield strength exceeding 1 GPa. These findings offer a framework to design ductile DED RHEAs by tailoring processing parameters to avoid defect-induced brittleness.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"78 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145188936","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Microstructure and mechanical properties evolution of 16Cr-25Ni-4Mo superaustenitic stainless steel weld metal during 550°C aging","authors":"Chenghao Liu, Jian Sun, Shanping Lu","doi":"10.1016/j.jmst.2025.08.055","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.08.055","url":null,"abstract":"The long-term aging behavior at 550°C was investigated for a 16Cr-25Ni-4Mo weld metal (WM) and to elucidate how precipitation, deformation twins, microbands, and deformation bands jointly affect its plasticity and toughness. Specifically, aging promoted the precipitation of <em>M</em><sub>23</sub>C<sub>6</sub> carbides and <em>M</em><sub>2</sub>(C, N) carbonitrides. <em>M</em><sub>23</sub>C<sub>6</sub> carbides were distributed along grain boundaries (GBs) and interdendritic regions (IDRs), while <em>M</em><sub>2</sub>(C, N) carbonitrides were found only in IDRs. At GBs, <em>M</em><sub>23</sub>C<sub>6</sub> carbides coarsened, following the Lifshitz-Slyozov-Wagner (LSW) model. At aging 5000 h, their average size reached 402.1 nm. Moreover, their number density peaked at 1.6 μm<sup>−2</sup> at aging 1000 h. In the IDRs, <em>M</em><sub>23</sub>C<sub>6</sub> carbides showed multipoint nucleation with limited growth, whereas <em>M</em><sub>2</sub>(C, N) carbonitrides exhibited fewer nucleation with slow growth. At aging 5000 h, the number density and average size of <em>M</em><sub>23</sub>C<sub>6</sub> carbides were 15 μm<sup>−2</sup> and 47.0 nm, respectively, while those of <em>M</em><sub>2</sub>(C, N) carbonitrides were 6.0 μm<sup>−2</sup> and 162.5 nm, respectively. Both the plasticity and the toughness of the WM deteriorated with increasing aging time, but a more rapid decline occurred when cracks were initiated simultaneously at GBs and in IDRs. During tensile loading, cracks primarily initiated at GBs and gradually intensified with aging. At aging 3000 h, additional IDR cracks formed due to precipitate accumulation in IDRs, together with the marked reduction in the number of deformation twins and microbands, jointly contributed to a faster drop in elongation from 33.0% to 27.2% between 1000 and 3000 h. In contrast, impact cracks mainly originated in the IDRs, where crack severity also increased over time. At aging 5000 h, further GBs cracking induced by coarsened and continuously distributed <em>M</em><sub>23</sub>C<sub>6</sub> carbides at GBs, together with the disappearance of deformation twins near the impact fracture surface, jointly contributed to a faster drop in impact toughness from 164.0 J to 141.5 J between 3000 and 5000 h.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"67 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145183319","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Kai-Wen Kang, Ao-Xiang Li, Ming-Kun Xu, Sai-Ke Liu, Yi-Teng Jiang, Peng Cao, Gong Li
{"title":"Influence of persistent effects of initial microstructure on the evolution of microstructure and mechanical properties in CoCrFeNi-based high entropy alloys","authors":"Kai-Wen Kang, Ao-Xiang Li, Ming-Kun Xu, Sai-Ke Liu, Yi-Teng Jiang, Peng Cao, Gong Li","doi":"10.1016/j.jmst.2025.09.032","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.032","url":null,"abstract":"Thermomechanical processing is commonly employed to tailor the microstructure and enhance the mechanical properties of high entropy alloys (HEAs). However, the influence of the initial microstructure prior to deformation has received limited attention. In this study, we systematically investigate the influence of initial grain structure on microstructural evolution and mechanical performance in HEAs. Alloys with varying recrystallization degrees and initial grain sizes were fabricated. Results show that smaller initial grains promote finer recrystallized structures due to higher grain boundary density and stored energy. Notably, the recrystallized grain morphology exhibited strong persistence from the initial microstructure. Initial grain size also influenced precipitation behavior. Larger grains favored spherical precipitates and continuous precipitation, while smaller grains promoted lamellar precipitation. Tensile testing at room temperature revealed that the fully recrystallized alloy with the finest initial grains achieved the optimal strength-ductility combination, exhibiting a yield strength of 1567<span><span><math><mo is=\"true\">±</mo></math></span><script type=\"math/mml\"><math><mo is=\"true\">±</mo></math></script></span>32 MPa, an ultimate tensile strength of 1844<span><span><math><mo is=\"true\">±</mo></math></span><script type=\"math/mml\"><math><mo is=\"true\">±</mo></math></script></span>47 MPa, and a total elongation of (20.4<span><span><math><mo is=\"true\">±</mo></math></span><script type=\"math/mml\"><math><mo is=\"true\">±</mo></math></script></span>1.0)%. These findings highlight the pivotal role of initial microstructure in dictating recrystallization and precipitation pathways, offering a practical strategy for optimizing HEA performance through microstructural design.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"68 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145188937","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Long-term oxidation resistance and reusability of a ceramizable composite for reusable large-area thermal protection of hypersonic aircraft","authors":"Zhixiong Huang, Yuzhan Lu, Shaoxiong Weng, Guoqin Jiang, Wanglin Ying, Zongyi Deng","doi":"10.1016/j.jmst.2025.09.024","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.024","url":null,"abstract":"The rapid development of reusable hypersonic vehicles has put forward urgent demand for reusable large-area thermal protection materials. Herein, a novel ceramizable composite modified by Ti<sub>3</sub>AlC<sub>2</sub> and B<sub>4</sub>C was proposed, and its long-term oxidation resistance and reusability after isothermal cyclic high-temperature oxidation experiment at 1200°C for 30 min for 1–10 cycles were explored. The high-temperature bending strength after treated once reached 80.0 MPa, and it kept above 43 MPa and the structural integrity of the samples was good even after eight high-temperature oxidation treatments, demonstrating that the ceramizable composite possessed good application potential as reusable large-area thermal protection materials. The anti-oxidation mechanism was proposed based on microstructure evolution, element distribution, phase evolution, and thermodynamics analyses during the high-temperature oxidation cycles. Ti<sub>3</sub>AlC<sub>2</sub> and B<sub>4</sub>C underwent a series of ceramization reactions with O<sub>2</sub> and pyrolytic carbon (PyC), converting the ceramizable composite into a ceramized composite in-situ and playing the roles of oxygen consumption, self-healing, oxygen inhibition, carbon fixation, and heat absorption, by which carbon fibers and PyC were protected.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"29 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145183320","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Runxing Zhou, Zuming Liu, Cai Chen, Yongxia Li, Dan Zou, Yiming Chang, Xulin Cheng, Lei Chen
{"title":"Achieving high mechanical properties of ultrafine-grained WC-Co cemented carbide via material extrusion additive manufacturing","authors":"Runxing Zhou, Zuming Liu, Cai Chen, Yongxia Li, Dan Zou, Yiming Chang, Xulin Cheng, Lei Chen","doi":"10.1016/j.jmst.2025.08.064","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.08.064","url":null,"abstract":"The urgent demand for additive manufacturing (AM) cemented carbide parts with complex geometric structures has emerged. However, the powder bed fusion AM WC-Co cemented carbide exhibits poor mechanical properties due to cracks, pores, and abnormal WC grain growth caused by low formability, particularly ultrafine-grained cemented carbide. We employed material extrusion (MEX) AM to prepare an ultrafine-grained WC-0.5Cr<sub>3</sub>C<sub>2</sub>-0.2CeO<sub>2</sub>-9Co cemented carbide. MEX AM eliminated defects, inhibited the abnormal WC grain growth, and increased the residual α-Co content at room temperature by improving the W and C solubility in α-Co to increase the stacking fault energy. The cemented carbide achieved a relative density of 99.52%, as well as α-Co content, an average grain size of WC, the adjacency of the WC phase, and the mean free path of the Co phase were measured at 16.5 vol.%, 384.6 nm, 0.58, and 208 nm, respectively. The synergistic effects of densification reinforcement, fine grain strengthening, and residual α-Co phase toughening, simultaneously improved the mechanical properties of the cemented carbide, achieving a Vickers hardness of 2123 ± 11 HV<sub>30</sub>, a transverse rupture strength of 3639 ± 28 MPa, and a fracture toughness of 13.13 ± 0.03 MPa m<sup>1/2</sup>, respectively, which demonstrated significantly superior mechanical properties compared with cemented carbide prepared via AM or traditional powder metallurgy. These findings effectively address the challenge of simultaneously enhancing the hardness and fracture toughness of ultrafine-grained cemented carbide and provide important guidance for the development of cemented carbide with excellent mechanical properties via AM.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"106 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145182784","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jinghui Meng, Ji Teng, Mengfan Ying, Panbin Zhu, Jiaying Jin, Mi Yan, Guang Liu, Chen Wu
{"title":"Intelligent conductive hydrogels for wearable motion monitoring and stress-driven switching between electromagnetic shielding and conversion","authors":"Jinghui Meng, Ji Teng, Mengfan Ying, Panbin Zhu, Jiaying Jin, Mi Yan, Guang Liu, Chen Wu","doi":"10.1016/j.jmst.2025.09.025","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.025","url":null,"abstract":"Wearable electronics stimulate substantial demands for flexible hydrogels with exceptional softness and biocompatibility, but remain challenging to achieve multifunctional integration and intelligent function switching. In this study, conductive hydrogels enabling wearable sensing and switchable electromagnetic protection have been designed by incorporating LM and FeNi<sub>3</sub>@carbon nanotubes into the polyvinyl alcohol matrix. Benefitted from the cross-linked conductive networks induced by cyclic freezing-thawing, the hydrogel exhibits excellent flexibility, durability, and stability for real-time human motion monitoring and efficient electromagnetic interference (EMI) shielding. Stretching stress triggers an intelligent function switching from EMI shielding to wave absorption due to optimized impedance matching and enhanced attenuation, giving rise to a broadband electromagnetic absorption of 4.8 GHz. Space electromagnetic field and radar cross-section simulations unravel multiscale electromagnetic interactions, demonstrating the static shielding characteristic and stress-driven enhanced absorption. This work not only provides a novel strategy for the intelligent switchable electromagnetic compatible materials, but also advances insights into multifunctional wearable electronics for extended design in intelligent actuation, human-machine interaction, and healthcare.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"20 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145182788","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yuang Li, Yingli Zhu, Gangtao Luo, Pingan Chen, Mengke Qiao, Fu Chen, Xiangcheng Li
{"title":"Fe-induced stacking faults engineering for breakthrough broadband absorption in SiBCN ceramics","authors":"Yuang Li, Yingli Zhu, Gangtao Luo, Pingan Chen, Mengke Qiao, Fu Chen, Xiangcheng Li","doi":"10.1016/j.jmst.2025.08.063","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.08.063","url":null,"abstract":"Polymer-derived SiBCN ceramics (PDCs-SiBCN) have emerged as promising candidates for high-performance electromagnetic wave absorption applications. However, their strong electromagnetic loss, attributed to high crystalline phase content, simultaneously causes impedance mismatch and a narrow absorption bandwidth. To address this challenge, this study proposes an innovative stacking faults (SFs) defect engineering strategy, which can achieve high dielectric loss at low crystallinity. Specifically, SiC whiskers with high-density SFs were catalytically grown using an Fe-mediated liquid-solid interface during polyborosilazane pyrolysis. These SFs serve as effective polarization centers, significantly enhancing dielectric loss capability. By optimizing Fe content, fewer crystalline phases and high SFs density were achieved in SiBCN, thereby realizing impedance matching and strong dielectric loss. Consequently, the unique microstructure expanded the effective absorption bandwidth of SiBCN from 4.82 to 6.36 GHz at 2.1 mm thickness, demonstrating record-breaking broadband absorption performance among PDCs. This Fe-mediated SFs defect engineering provides a strategic pathway to resolve the long-standing conflict between “impedance matching and strong dielectric loss” in PDCs.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"29 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145182786","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yuanyuan Qiao, Taikun Hao, Xiaoying Liu, Di Liu, Hongwei Liang, Ning Zhao
{"title":"Slip-twinning synergistic deformation mechanism in Cu/SAC305/Cu micro solder joints during in-situ tensile test","authors":"Yuanyuan Qiao, Taikun Hao, Xiaoying Liu, Di Liu, Hongwei Liang, Ning Zhao","doi":"10.1016/j.jmst.2025.09.031","DOIUrl":"https://doi.org/10.1016/j.jmst.2025.09.031","url":null,"abstract":"The slip-twinning synergistic deformation mechanism in Cu/SAC305/Cu micro solder joints during in-situ tensile test was systematically studied. The joints exhibited an ultimate tensile strength of 91–97 MPa, with fracture surfaces characterized by dimpled zones and fractured brittle intermetallic compounds (IMCs) grains, revealing a ductile-brittle mixed fracture mode strongly correlated with Sn grain orientation. The formation of subgrains and mechanical twins during tensile indicated that the plastic deformation was governed by the concurrent activation of dislocation slip and twinning. Subgrains formation originated from dislocations slipping along the dominant {100}<001>, {110}<001>, and {101}<111>/2 slip systems, as well as the rotation of Sn lattices constrained by the solder/Cu interfaces. Meanwhile, mechanical twins occurred via atomic deformation along the [−101] direction in the {101}<101> twin system. Specifically, one out of four atoms displayed along the slip direction, while the other three atoms rearranged to occupy new lattice positions, with subsequent crystal layers shifting to support mechanical twins formation. In general, under tensile conditions, geometrically necessary dislocations initially generated near grain boundaries, progressively accumulated at subgrain boundaries, and stored within grains, ultimately activated twinning to form mechanical twins upon subsequent dislocation blockage. And the results pointed out that Sn grain with small |∆<em>λ</em>| preferred to form subgrains by slip, while Sn grain with large |∆<em>λ</em>| would generate twin grains by twinning during tensile. Thus, a slip-twinning synergistic deformation mechanism was established, highlighting the synergistic effect of slip and twinning on the formation of subgrains and twins during the plastic deformation of solder joints under tensile conditions.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"4 1","pages":""},"PeriodicalIF":10.9,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145183381","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}