In this study, three-dimensional functionally graded NiTi bulk materials were fabricated using laser powder bed fusion (LPBF) by in-situ adding Ni powder into equiatomic NiTi powder. The gradient zone exhibited a Ni composition ranging from approximately 49.6 to 52.4 at.% over a distance of about 2.75 mm. The functionalities along the compositional gradient were examined through differential scanning calorimetry analysis and spherical indentation. This unique gradient resulted in location-specific functionalities, including superelasticity characterized by wide and narrow hysteresis loops, shape memory effect, and various phase transformation temperatures. The rapid cooling rate during fabrication led to the presence of excess Ni in the solid-solute state within NiTi. This unique solid-solute compositional gradient in NiTi resulted in varying lattice parameters, influencing the compatibility between martensite and austenite and allowing for tailored hysteresis. This discovery presents new avenues for designing multifunctional materials through in-situ additive manufacturing.

This study concentrates on the fatigue crack propagation behaviour of a high-strength low-alloy (HSLA) steel and austenitic stainless (AS) steel bi-material part, as obtained by wire arc additive manufacturing (WAAM). Due to partial mixing in the weld pool, the first layer of AS steel laid onto the previously deposited HSLA steel results in a diluted interface layer of distinct chemical and microstructural characteristics. Average Paris parameters are obtained for the interface layer along transverse and longitudinal planes to the deposition direction (BD-LD plane: m = 2.79, log₁₀(C) = –7.83 log₁₀(da/dN)) (BD-TD plane: m = 3.47, log₁₀(C) = –8.39 log₁₀(da/dN)). However, it is observed that this interface layer manifests an intriguing crack propagation behaviour. FCGR consistently drop as the crack front transitions from undiluted AS steel to the interface. At ΔK = 20 MPa⋅m^0.5, the greatest Δ is −0.77 log₁₀ steps (R = 0.1). As cracks near the HSLA fusion line, rates re-accelerate up to + 0.75 log₁₀ steps (R = 0.5). The phenomenon is attributed to the interplay between deformation-induced martensitic transformation and pre-existing allotropic martensite. Our findings, derived from a series of fatigue tests in correlation with multiscale microstructural and fracture characterization, offer insights into the damage-tolerant behaviour of these bi-material structures.

Boron doped MoSi₂ particles have been envisioned as sacrificial particles for self-healing thermal barrier coatings (TBCs) but their oxidation behaviour is yet not well understood. In this work, oxidation of MoSi₂ based particle is studied in the temperature range of 1050–1200 °C. The oxidation proceeds from a transient to a steady-state oxidation stage. The kinetics during steady-state oxidation is captured with a thermal diffusion-based model. As compared to the oxidation of pure MoSi₂ particles, the addition of boron strongly enhances the silica formation. Also, a finer dispersion of MoB_x in the MoSi₂ matrix accelerates the formation of silica. The oxide growth rate constant increases proportional with the boron content of the MoSi₂ particles. This enhanced oxidation is related to the microstructure of the oxide scale. Upon oxidation, boron yields B₂O₃, which promptly merge with SiO₂ to form amorphous borosilicate, hindering the formation of crystalline SiO₂. Consequently, the migration of oxygen in the borosilicate oxide scale is faster than in the silica oxide scale on pure MoSi₂ particles.

Mo(Al_xSi_1-x)₂ alloy with x in the range of 0.35–0.65 were prepared by a one-step spark plasma sintering. To study the exclusive formation of an α-Al₂O₃ scale, oxidation experiments were conducted in low and high oxygen partial pressure ambient at 1373 K; viz.: 10⁻¹⁴ and 0.21 atm. The oxidation kinetics follows a parabolic rate law after a transient period. A counter-diffusion process of O and Al along grain boundaries of Al₂O₃ scale is responsible for the equiaxed and columnar grain growth based on a two-layered microstructure. The formation of a dense equiaxed α-Al₂O₃ layer contributes to excellent oxidation resistance.

The pursuit of enhancing NiTi superelasticity through laser powder bed fusion (L-PBF) and [001] texture creation poses a challenge due to increased susceptibility to hot cracking in the resulting microstructure with columnar grains. This limitation restricts NiTi's application and contributes to material waste. To overcome this, we introduce a pioneering approach: utilising spark plasma sintering (SPS) to heal directional cracks in [001] textured L-PBF NiTi shape memory alloy. Diffusion bonding and oxygen utilisation for Ti₂NiO_x formation was found to successfully heal the cracks. SPS enhances mechanical properties, superelasticity at higher temperatures, and two-way shape memory strain during thermomechanical cycling. This work provides an alternative solution for healing cracks in L-PBF parts, enabling the sustainable reuse of cracked materials. By implementing SPS, this approach effectively addresses hot cracking limitations, expanding the application potential of L-PBF NiTi parts while improving their functional and mechanical properties.

Boron containing MoSi₂ is a promising material for applications at high temperature, but the oxidation mechanism is still unclear. In this work, the high temperature (1100 °C) oxidation of B doped MoSi₂ in synthetic air has been investigated. A (boro)silicate layer is formed on the surface of the alloy, which features a mixture of amorphous SiO₂ and cristobalite. After an initial transient period, the oxidation kinetics follows a parabolic growth rate law. The growth rate constant of the oxide layer is enhanced by the boron in the alloy by 90 % per at.% B. The increase in growth rate is associated with boron mitigating the formation of cristobalite thereby promoting the formation of amorphous SiO₂.

To prevent premature triggering of the healing reaction in Mo-Si containing self-healing thermal barrier coating system, an oxygen impenetrable shell (α-Al₂O₃) around the sacrificial healing particles (MoSi₂) is desired. Here an encapsulation method is presented through selective oxidation of Al in Mo(Al_xSi_1-x)₂ particles. Healing particles of Mo(Al_xSi_1-x)₂ is designed in terms of alumina shell thickness, particle size and fraction Al dissolved. By replacing Si by Al in MoSi₂ up to the maximum solubility (x = 0.65) a strong crack healing ability is maintained (relative volume expansion ≥ 40 %). The formed exclusive α-Al₂O₃, featuring a two-layered structure, results from a counter-diffusion process along the grain boundaries, and its oxidation kinetics fits well with the 3D diffusion-Jander model. After 16 h exposure in gaseous ambient with a pO₂ of 5 × 10^-10 atm. at 1100 °C, a closed and dense shell of α-Al₂O₃ is formed with a thickness of about 1.3 µm. The oxide shell produced under this condition provided healing particles with significantly improved stability upon exposure to high pO₂ of 0.2 atm. at 1100 °C for 50 h. The particles after exposure feature an inner core of MoSi₂ with Al completely consumed and an oxide shell of α-Al₂O₃.

In the research of cancer cell invasion and metastasis, recreation of physiologically relevant and faithful three-dimensional (3D) tumor models that recapitulate spatial architecture, spatiotemporal control of cell communication and signaling pathways, and integration of extracellular cues remains an open challenge. Here, a programmable multifunctional 3D cancer cell invasion microbuckets-hydrogel (Mb-H) platform is developed by integrating various function-variable microbuckets and extracellular matrix (ECM)-like hydrogels. Based on this Mb-H micro platform, the aggregation of multi-cancer cells is well controlled to form cancer cell spheroids, and the guiding relationship of single-cell migration and collective cell migration during the epithelial-mesenchymal transition (EMT) of cancer cell invasion are demonstrated. By programming and precisely assembling multiple functions in one system, the Mb-H platform with spatial-temporal controlled release of cytokine transforming growth factor beta (TGF-β) and various functionalized Mb-H platforms with intelligent adjustment of cell-matrix interactions are engineered to coordinate the 3D invasive migration of cancer cell spheroids. This programmable and adaptable 3D cancer cell invasion micro platform takes a new step toward mimicking the dynamically changing (localized) tumor microenvironment and exhibits wide potential applications in cancer research, bio-fabrication, cell signaling, and drug screening.