Saturday, October 11, 2025

Uncovering new physics in metals manufacturing

Amazing stuff! A surprise discovery in a well researched field like metals.

"For decades, it’s been known that subtle chemical patterns exist in metal alloys, but researchers thought they were too minor to matter — or that they got erased during manufacturing.
However, recent studies have shown that in laboratory settings, these patterns can change a metal’s properties, including its mechanical strength, durability, heat capacity, radiation tolerance, and more.

Now, researchers ... have found that these chemical patterns also exist in conventionally manufactured metals. The surprising finding revealed a new physical phenomenon that explains the persistent patterns.

In a paper ... the researchers describe how they tracked the patterns and discovered the physics that explains them. The authors also developed a simple model to predict chemical patterns in metals, and they show how engineers could use the model to tune the effect of such patterns on metallic properties, for use in aerospace, semiconductors, nuclear reactors, and more. ...

findings offer vindication for exploring a crowded field that he says few believed would lead to unique or broadly impactful results. ..."

From the abstract:
"Metallic alloys are routinely subjected to nonequilibrium processes during manufacturing, such as rapid solidification and thermomechanical processing.
It has been suggested in the high-entropy alloy literature that chemical short-range order (SRO) could offer a new knob to tailor materials properties. While evidence of the effect of SRO on materials properties accumulates, the state of SRO evolution during alloy manufacturing remains obscure.
Here, we employ high-fidelity atomistic simulations to track SRO evolution during the solidification and thermomechanical processing of alloys.
Our investigation reveals that alloy processing can lead to nonequilibrium steady-states of SRO that are different from any equilibrium state. The mechanism behind nonequilibrium SRO formation is shown to be an inherent ordering bias present in nonequilibrium events.
These results demonstrate that conventional manufacturing processes provide pathways for tuning SRO that lead to a broad nonequilibrium spectrum of SRO states beyond the equilibrium design space of alloys."

Uncovering new physics in metals manufacturing | MIT News | Massachusetts Institute of Technology "MIT researchers discovered a hidden atomic order that persists in metals even after extreme processing."



Fig. 1: Remnant SRO after nonequilibrium materials processing.


Fig. 3: Physical framework for nonequilibrium SRO.


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