Temperature-dependent dynamics and dislocation behavior in nanoscale machining of FeCoNiCrAl high-entropy alloys: Molecular dynamics simulation

Abstract

This study investigates the impact of machining parameters on forces, thermal dynamics, dislocation behavior, and crystalline structure changes in FeCoNiCrAl high-entropy alloys during nanoscale material removal using molecular dynamics (MD) simulations. Utilizing Embedded Atom Method (EAM) and Tersoff interaction potentials, simulations were performed at cryogenic (73 K) and room (293 K) temperatures. Novel findings reveal that at 73 K, cutting velocities below 200 m/s produced the highest forces along the [001] direction, whereas at 200 m/s, the peak force shifted to [100]. Increasing velocity decreased the force along [001], while [100] exhibited an inverse relationship. At 293 K, the force remained highest along [001] across all velocities. Notably, forces at 73 K were 1.82, 1.79, and 1.58 times higher than at 293 K for velocities of 100, 200, and 300 m/s, respectively. Dislocation density, particularly 1/6<112> (Shockley) dislocations, peaked under all machining conditions, with a slight initial decrease at 293 K before a significant drop with higher cutting speeds. At 293 K and a cutting speed of 100 m/s, dislocation densities for depths of 5, 10, 15, and 20 Å were approximately 1.04, 1.54, 1.17, and 1.14 times greater than those at 73 K, respectively.