X.T. Wang , J. Cheng , H.H. Hassanzai , Y.Y. Hu , T.R. Xu , X.Y. Song , W.L. Zhao , Y.J. Ma , Z.H. Cao , S. Wu , J.B. Hu
{"title":"Enhanced strain rate hardening and phase transformation in body-centered cubic medium entropy alloy under dynamic deformation","authors":"X.T. Wang , J. Cheng , H.H. Hassanzai , Y.Y. Hu , T.R. Xu , X.Y. Song , W.L. Zhao , Y.J. Ma , Z.H. Cao , S. Wu , J.B. Hu","doi":"10.1016/j.msea.2025.148481","DOIUrl":"10.1016/j.msea.2025.148481","url":null,"abstract":"<div><div>In this study, we have studied the mechanical properties and microstructural evolution of Zr<sub>50</sub>Ti<sub>35</sub>Nb<sub>15</sub> body-centered cubic (bcc) medium-entropy alloy under dynamic loading. The yield strength increases approximately one-fold from 547 MPa to 995 MPa by increasing the quasistatic strain rates to the dynamic one, indicating a strong strain rate hardening. Furthermore, the strain rate sensitivity under dynamic loading is 0.099, which is eight times higher than that of quasistatic loading. Phase transformation from bcc to face-centered orthorhombic <em>α″</em> occurs in the alloy after dynamic loading instead of quasistatic loading, and the volume of <em>α″</em> phase increases with strain rates. The strong phonon drag effect and lattice friction enhance the resistance to dislocation motion under dynamic deformation, resulting in remarkable increase in yield strength. Moreover, the reduced activation volume due to local stress fluctuation and increased phase interface resulting from increasing strain rate are responsible for the high strain rate sensitivity.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"939 ","pages":"Article 148481"},"PeriodicalIF":6.1,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144069136","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wenzhe Li , Feng Qian , Chun Guo , Shiwei Pan , Yaojian Liang , Shun Xu , Xingwang Cheng
{"title":"Optimizing TiB2 inoculation strategies to achieve isotropic properties in AA6061 fabricated by interlayer-paused additive manufacturing","authors":"Wenzhe Li , Feng Qian , Chun Guo , Shiwei Pan , Yaojian Liang , Shun Xu , Xingwang Cheng","doi":"10.1016/j.msea.2025.148490","DOIUrl":"10.1016/j.msea.2025.148490","url":null,"abstract":"<div><div>Additive manufacturing (AM) has become an important technology for producing metallic parts, but the ultrafast solidification often triggers coarse columnar grains and severe hot cracking. Our previous work demonstrated that an appropriate interlayer pause (IP) strategy during laser melting deposition (LMD) can effectively alleviate hot cracking. However, the grains remain textured and filiform, leading to anisotropic mechanical properties. Building on the established optimal IP, this study introduces and optimizes TiB<sub>2</sub> inoculation strategies for the LMD-fabricated AA6061. We found 2 wt% nano-TiB<sub>2</sub> inoculation combining IP successfully achieves isotropic high strength and ductility (longitudinal: 301 ± 3 MPa, 8 ± 2 %; transverse direction: 310 ± 5 MPa, 7 ± 1 %). In contrast, 6 wt% nano-TiB<sub>2</sub> inoculation and 2 wt% micro-TiB<sub>2</sub> inoculation under the same IP yield inferior properties characterized by evident anisotropy. Microstructural investigations reveal the 2 wt% nano-TiB<sub>2</sub> inoculation combining IP promotes a dense and uniform distribution of nano-TiB<sub>2</sub> inoculants, which helps to eliminate cracks and results in an ultra-fine equiaxed microstructure. Conversely, excessive inoculation of 6 wt% nano-TiB<sub>2</sub> leads to severe particle agglomeration, forming large TiB<sub>2</sub> clusters. Similarly, with 2 wt% micro-TiB<sub>2</sub> inoculation, numerous oversized TiB<sub>2</sub> inoculants are observed. Consequently, both inoculation strategies can impair metallurgical bonding and re-induce various metallurgical defects, such as cracks. Furthermore, they can limit the efficiency of columnar to equiaxed transformation (CET), resulting in a relatively coarse microstructure consisting of partially columnar grains. We anticipate that the design strategy developed in this work can be extended beyond Al alloys to achieve isotropic mechanical performance.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"939 ","pages":"Article 148490"},"PeriodicalIF":6.1,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144068315","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhen Li , Jinglong Tang , Jie Su , Yingzhe Li , Zhen Luo
{"title":"In situ nano-oxides and magnetic field engineering enable exceptional strength-ductility synergy in additively manufactured AlCoCrFeNi2.1 eutectic high-entropy alloys","authors":"Zhen Li , Jinglong Tang , Jie Su , Yingzhe Li , Zhen Luo","doi":"10.1016/j.msea.2025.148486","DOIUrl":"10.1016/j.msea.2025.148486","url":null,"abstract":"<div><div>Eutectic high-entropy alloys (EHEAs), exemplified by AlCoCrFeNi<sub>2.1</sub>, offer a promising pathway for developing alloys with exceptional strength–ductility synergy due to their unique microstructural features and deformation mechanisms. Building on these characteristics, this study proposes a strengthening and toughening strategy for additively manufactured AlCoCrFeNi<sub>2.1</sub> EHEA by integrating in situ nanometer-scale oxides with the assistance of a magnetic field. The results indicate that the application of a magnetic field refines the columnar grain width (reducing it by 44.9 %), weakens the texture intensity, but increases the dislocation density of the alloy. The external magnetic field does not alter the types of microstructures (FCC/L1<sub>2</sub> phase, BCC/B<sub>2</sub> phase, and nanometer-scale oxides); however, it refines the lamellar spacing, eliminates non-lamellar regions, and increases the volume fractions of the BCC/B<sub>2</sub> phase and nanometer-scale oxides. These microstructural evolutions activate multiple strengthening and toughening mechanisms. Consequently, the application of an external magnetic field enhances both the tensile strength and elongation, reaching 1591 MPa and 23.5 %, respectively, thereby achieving an outstanding strength–ductility synergy.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"938 ","pages":"Article 148486"},"PeriodicalIF":6.1,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143941390","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yali Xu , Shuaifeng Zhang , Haibin Liu , Xuefeng Cao , Weichao Wang , Wei Yu , Jinshan Li , Minjie Lai
{"title":"Microstructural evolution and impact properties of vacuum laser welded near-alpha Ti-6Al-3Nb-2Zr-1Mo titanium alloy: Effect of base metal microstructure","authors":"Yali Xu , Shuaifeng Zhang , Haibin Liu , Xuefeng Cao , Weichao Wang , Wei Yu , Jinshan Li , Minjie Lai","doi":"10.1016/j.msea.2025.148495","DOIUrl":"10.1016/j.msea.2025.148495","url":null,"abstract":"<div><div>The advancement of high-power laser welding has significantly improved the penetration capability for welding titanium and its alloys. In this study, four 25 mm-thick near-alpha Ti-6Al-3Nb-2Zr-1Mo titanium alloy plates with two distinct base metal microstructures (equiaxed and bimodal) were welded using vacuum laser beam welding. The microstructure evolution and impact properties of the laser welded joints were investigated. The results show that the impact toughness of the weld zone, heat affected zone, and base metal in joints with bimodal base metal is higher than that in joints with equiaxed base metal. The lowest impact toughness for the joints with bimodal base metal is in the weld zone, which is 41.63 J, owing to the formation of abundant acicular α′ martensite. For the joints with equiaxed base metal, the impact toughness of the weld zone is comparable with that of the base metal, which is attributed to a more tortuous crack propagation path. The microstructure of the base metal significantly influences the microstructure evolution of the joints. In joints with bimodal base metal, the grain size of the primary β in the weld zone is larger due to fewer nucleation sites in the heat affected zone near the fusion line. This results in the formation of thicker acicular α’ martensite, which enhances twin generation and dislocation movement, thus increasing the absorbed impact energy and impact toughness.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"939 ","pages":"Article 148495"},"PeriodicalIF":6.1,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144099566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jianping Qu , Yu-Ping Xu , Jinchuan Jie , Hai-Shan Zhou , Guang-Nan Luo , Tingju Li
{"title":"Significant improvement in creep resistance of Cu-Cr-Zr alloys induced by trace Si","authors":"Jianping Qu , Yu-Ping Xu , Jinchuan Jie , Hai-Shan Zhou , Guang-Nan Luo , Tingju Li","doi":"10.1016/j.msea.2025.148485","DOIUrl":"10.1016/j.msea.2025.148485","url":null,"abstract":"<div><div>To adapt to harsher fusion circumstance, it is of great importance to develop a new generation of Cu-Cr-Zr-X alloy with good creep resistance for divertor in DEMO or CFETR. In this paper, the effects of Si addition on microstructural evolution and creep behavior of Cu-Cr-Zr alloy was investigated under varying applied stresses (50–150 MPa) at 450 °C and 550 °C. The present results reveal that the steady-state creep rate of Cu-Cr-Zr alloys ranges from 10<sup>−10</sup> to 10<sup>−9</sup> s<sup>−1</sup> at 450 °C and from 10<sup>−8</sup> to 10<sup>−6</sup> s<sup>−1</sup> at 550 °C under varying stresses. In comparison, Si-containing alloys maintain a steady-state creep rate of 10<sup>−10</sup> s<sup>−1</sup> at 450 °C and span only two orders of magnitude, ranging from 10<sup>−9</sup> to 10<sup>−8</sup> s<sup>−1</sup> at 550 °C. In addition, the creep life of alloys containing Si is significantly higher than that of alloys without Si under identical conditions. This suggests that the creep resistance of Cu-Cr-Zr alloy can be enhanced by adding Si, primarily due to the synergistic effect of nano-sized Cr precipitates, which exhibit limited growth and stable Cr<sub>3</sub>Si intermetallic phase. These features help pin dislocation and grain boundaries, thereby obstructing their motion. This work provides theoretical guidance for the development of new creep-resistant alloys for use in the fusion field.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"939 ","pages":"Article 148485"},"PeriodicalIF":6.1,"publicationDate":"2025-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144068312","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Evolution of microstructures and mechanical properties in coarse- and fine-grained Zn during drawing deformation at room temperature","authors":"Hong Zhao , Bo Yang , Yuping Ren , Gaowu Qin","doi":"10.1016/j.msea.2025.148484","DOIUrl":"10.1016/j.msea.2025.148484","url":null,"abstract":"<div><div>Pure Zn with different grain sizes obtained via extrusion at different temperatures was drawn in multiple passes at room temperature. The evolution of the microstructures and mechanical properties during drawing was examined using scanning electron microscopy and room-temperature tensile tests. The results indicated that pure Zn with a grain size of 80 μm broke frequently when the drawing deformation reached 4 % and could not be drawn further. A high density of parallel or intersected <span><math><mrow><mo>{</mo><mrow><mn>10</mn><mover><mn>1</mn><mo>‾</mo></mover><mn>2</mn></mrow><mo>}</mo></mrow></math></span> compression twins was generated after drawing, leading to a drawing direction (DD)//<0001> deformation texture and work-hardening phenomenon. When the grain size was reduced to 15 μm, pure Zn could be drawn continuously at room temperature without breaking, exhibiting unusual work softening. In particular, when the cumulative deformation was 4 %, the grain size of Zn increased to >10 times the initial size and decreased to approximately 70 μm with further drawing. With increasing deformation, the grains gradually rotated, and the non-basal texture gradually changed completely, which was conducive to continuous deformation. The fracture elongation of Zn reached 140 % owing to the initiation of the intergranular deformation mechanism and non-basal texture; however, the tensile strength decreased from 130 MPa to 90–110 MPa after drawing.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"938 ","pages":"Article 148484"},"PeriodicalIF":6.1,"publicationDate":"2025-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143941254","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yijie Chen , Yunping Jia , Shuanglin Hu , Huahai Shen , Canhui Xu , Xiaosong Zhou , Yuexia Wang
{"title":"Evolution of ordering in TiV-M (M = Cr, Nb, Mo, Ta) medium entropy alloys: A combinational study of cluster expansion and Monte Carlo simulations","authors":"Yijie Chen , Yunping Jia , Shuanglin Hu , Huahai Shen , Canhui Xu , Xiaosong Zhou , Yuexia Wang","doi":"10.1016/j.msea.2025.148483","DOIUrl":"10.1016/j.msea.2025.148483","url":null,"abstract":"<div><div>Combined with density functional theory, cluster expansion, and Monte Carlo simulation, the ordering evolution, phase stability, microscopic structures, and mechanical properties of body-centered cubic TiV-M (M = Cr, Nb, Mo, Ta) medium entropy alloys are investigated. The disorder-order transition temperatures and phase transitions induced by the evolution of atomic chemical ordering for these alloys are determined. The observed phase segregation or random solid solutions in these alloys are consistent with some available theoretical and experimental reports. The localized chemical concentration fluctuations caused by segregation substantially enhance the yield strength. Notably, the pronounced enhancement of yield strength of TiVCr in local chemical ordered structure over random solid solution may be attributed to the large atomic size mismatch and the localized B2-phase formation. This work provides a temperature-dependent atomic structural landscape for TiV-M MEAs, and would provide insights for designing medium and high entropy alloys.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"939 ","pages":"Article 148483"},"PeriodicalIF":6.1,"publicationDate":"2025-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144099010","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
H.T. Zhang , N. Xiao , S.H. Sun , H.L. Yan , M.H. Cai
{"title":"Effects of texture and mechanical anisotropy on the superplastic behavior in warm-rolled Fe–10Mn–4Al–1.5Si–0.3C medium Mn steel","authors":"H.T. Zhang , N. Xiao , S.H. Sun , H.L. Yan , M.H. Cai","doi":"10.1016/j.msea.2025.148471","DOIUrl":"10.1016/j.msea.2025.148471","url":null,"abstract":"<div><div>This study investigates the mechanical anisotropy and superplastic behavior of warm-rolled Fe–10Mn–4Al–1.5Si–0.3C steel, emphasizing the relationship between texture evolution and deformation-induced ferrite transformation. Experimental results reveal exceptional superplasticity in the rolling direction (RD), with a maximum elongation of 1564 %, significantly exceeding that of hot-rolled and cold-rolled medium Mn steels. The transverse direction (TD) and diagonal direction (DD) samples exhibited elongations of 620 % and 1060 %, respectively. The observed mechanical anisotropy is primarily attributed to texture evolution and dynamic ferrite transformation (<em>γ</em>→<em>α</em>). The RD sample exhibited a strong FCC Cube texture after warm rolling, which facilitated deformation-induced ferrite transformation during superplastic deformation. This transformation refined the microstructure and enhanced grain boundary sliding (GBS), leading to superior elongation. In contrast, the TD sample retained a dominant Brass rolling texture of FCC phase, which limited ferrite transformation and reduced superplasticity. Strain rate sensitivity (<em>m</em>) analysis at 800 °C confirmed GBS as the primary deformation mechanism, with the RD sample showing the highest <em>m</em> value of 0.72, correlating with its superior elongation. Further, dynamic grain co-rotation maintained the Kurdjumov–Sachs orientation relationship between deformation-induced <em>α</em>-ferrite and parent <em>γ</em>-austenite grains, facilitating GBS and uniform deformation. This study highlights the critical role of optimizing initial texture and phase transformation behavior in enhancing the superplasticity of warm-rolled medium Mn steels, providing valuable insights for improving superplastic forming processes.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"937 ","pages":"Article 148471"},"PeriodicalIF":6.1,"publicationDate":"2025-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931349","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Irina Yu Grubova , Maria Kozadaeva , Dmitriy Khrapov , Vladimir Rybakov , Anna A. Sharonova , Roman A. Surmenev , Andrey V. Koptyug , Alexander Tyurin , Dmitry V. Korost , Dmitriy Yu Rasposienko , Vladimir V. Makarov , Maria A. Surmeneva
{"title":"Energy input effects on the microstructure and mechanical behavior of Ti–Nb alloy additivelymanufactured by electron beam melting","authors":"Irina Yu Grubova , Maria Kozadaeva , Dmitriy Khrapov , Vladimir Rybakov , Anna A. Sharonova , Roman A. Surmenev , Andrey V. Koptyug , Alexander Tyurin , Dmitry V. Korost , Dmitriy Yu Rasposienko , Vladimir V. Makarov , Maria A. Surmeneva","doi":"10.1016/j.msea.2025.148480","DOIUrl":"10.1016/j.msea.2025.148480","url":null,"abstract":"<div><div>The critical niobium content required to maintain the β phase in additively manufactured Ti–Nb alloys, preventing martensitic transformation, is still unclear. Our previous study showed that 42 wt% Nb was insufficient. Therefore, in this study, new pre-alloyed β-titanium alloys with high niobium percentage (56 wt%, Ti–56Nb) were successfully produced by Electron Beam Powder Bed Fusion (PBF-EB), and the effect of varying beam current (4 mA, 5 mA, and 7 mA) on microstructure and mechanical properties was studied. All processing regimes achieved proper fusion, with a uniform porosity distribution (∼0.3 %) and minimal niobium-enriched regions, attributed to powder heterogeneity. Beam current variations significantly affected melt pool dynamics, phase constitution, and heat distribution. Planar growth along layer boundaries and cellular structures within melt pools was observed, caused by high thermal gradients and high cooling rates. Texture analysis revealed that higher beam currents induced fiber-like textures due to zigzag beam movement and deep remelting, while 4 mA and 5 mA beam currents produced biaxial textures with minimal fiber contributions. TEM analysis indicated that higher energy input facilitated martensitic transformation, whereas lower energy enhanced β-phase stabilization. Mechanical testing identified the 4 mA regime as optimal, achieving the highest yield strength, favorable β-phase fraction, reduced elastic modulus, and enhanced wear resistance. This study demonstrates how varying beam energy inputs during PBF-EB printing can tailor the meso- and micro-scale structure and mechanical properties of Ti–56Nb alloys, providing valuable insights for optimizing densification, microstructure, texture, and mechanical performance in additive manufacturing applications.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"938 ","pages":"Article 148480"},"PeriodicalIF":6.1,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yuzhong Wang , Wenhua Guo , Yaru Zhang , Kaiyue Ma , Qianyu Ji , Rui Han , Chenwei Wang , Yihui Zhang , Pei Wei , Bingheng Lu
{"title":"Ex-situ XCT tracking of keyhole pore evolution and induced damage mechanisms in L-PBF IN718 for mechanical testing","authors":"Yuzhong Wang , Wenhua Guo , Yaru Zhang , Kaiyue Ma , Qianyu Ji , Rui Han , Chenwei Wang , Yihui Zhang , Pei Wei , Bingheng Lu","doi":"10.1016/j.msea.2025.148476","DOIUrl":"10.1016/j.msea.2025.148476","url":null,"abstract":"<div><div>Keyhole pores are a prevalent defect in laser powder bed fusion (L-PBF) additive manufacturing. Although the formation mechanism of keyhole pores is well understood, research on their deformation under load and subsequent impact on component damage behavior remains lacking. In this study, the dynamic evolution of L-PBF IN718 components with keyhole pores under coaxial tensile load was tracked through ex-situ XCT mechanical testing. The digital models derived from XCT reconstructions were directly applied to high-fidelity structural mechanics simulations via the immersed boundary finite element method (IBFEM). The results indicate that keyhole pores induced significant stress concentrations, with the maximum von Mises stress around the pores exceeding 8 times the material's yield strength. Keyhole pores exhibited a negligible tendency for closure throughout the entire lifecycle of the component, with a mean sphericity up to 0.97 even after cracking. Furthermore, for L-PBF IN718 components with a minimum section thickness of 2 mm, keyhole pores buried deeper than 360 μm beneath the surface did not contribute to premature cracking. The uneven deformation caused by skewed pore distribution did not alter the priority of cracking locations in the components. Open keyhole pores, particularly those adjacent to other keyhole pores, served as the initial points of cracking. Additionally, the accumulation of keyhole pores with angles less than 50° (between the long axis of the pore and the loading direction) was identified as a significant precursor to cracking failure. This study enhances understanding of the mechanisms governing load-induced keyhole pore evolution and the associated damage behavior.</div></div>","PeriodicalId":385,"journal":{"name":"Materials Science and Engineering: A","volume":"938 ","pages":"Article 148476"},"PeriodicalIF":6.1,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143941256","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}