Mechanical serial block face scanning electron microscopy (SBFSEM) has emerged as a means of obtaining three dimensional (3D) electron images over volumes much larger than possible by focused ion beam (FIB) serial sectioning and at higher spatial resolution than achievable with conventional X-ray computed tomography (CT). Such high resolution 3D electron images can be employed for precisely determining the shape, volume fraction, distribution and connectivity of important microstructural features. While soft (fixed or frozen) biological samples are particularly well suited for nanoscale sectioning using an ultramicrotome, the technique can also produce excellent 3D images at electron microscope resolution in a time and resource-efficient manner for engineering materials. Currently, a lack of appreciation of the capabilities of ultramicrotomy and the operational challenges associated with minimising artefacts for different materials is limiting its wider application to engineering materials. Consequently, this paper outlines the current state of the art for SBFSEM examining in detail how damage is introduced during slicing and highlighting strategies for minimising such damage. A particular focus of the study is the acquisition of 3D images for a variety of metallic and coated systems.

22Cr-5Ni duplex stainless steel (DSS) was aged at 748 K (475 °C) and the microstructure development correlated to changes in mechanical properties and fracture behavior. Tensile testing of aged microstructures confirmed the occurrence of 748 K (475 °C) embrittlement, which was accompanied by an increase of strength and hardness and loss of toughness. Aging caused spinodal decomposition of the ferrite phase, consisting of Cr-enriched α″ and Fe-rich α′ and the formation of a large number of R-phase precipitates, with sizes between 50 and 400 nm. Fracture surface analyses revealed a gradual change of the fracture mode from ductile to brittle delamination fracture, associated with slip incompatibility between ferrite and austenite. Ferrite became highly brittle after 255 hours of aging, mainly due to the presence of precipitates, while austenite was ductile and accommodated most plastic strain. The fracture mechanism as a function of 748 K (475 °C) embrittlement is discussed in light of microstructure development.

During solidification of metallic materials, heterogeneous nucleation occurs on substrates, either endogenous or exogenous. The potency of the substrates for nucleation is mainly dependent upon the atomic arrangements on the substrate surface, which are affected by the lattice misfit between the substrate and the nucleated solid, the surface roughness at atomic scale, and the chemical interaction between the substrates and the melt. Extensive examinations on metal/substrate (M/S) interfaces at atomic scale by the state-of-the-art aberration (Cs) corrected STEM and associated EDS and EELS have shown that alloying elements in liquid melts tend to segregate at the interfaces, leading to the formation of various 2-dimensional compounds (2DCs) or 2-dimensional solutions (2DSs), depending upon segregation behavior of the elements. For instance, Al₃Ti 2DC and Ti₂Zr 2DC at the Al/TiB₂ interface, Y₂O₃ 2DC at the Mg/MgO interface, and a Si-rich 2DS layer at Al-Si/TiB₂ interface have been identified. Such interfacial segregations significantly affect nucleation potency of the substrates, resulting in either promoting or impeding the heterogeneous nucleation process during solidification. In this paper, we present an overview of the current studies of interfacial segregation behavior, the structure and chemistry of interfaces, and their impacts on the subsequent heterogeneous nucleation and grain initiation processes. Our focus is on the advances made in the understanding of the mechanisms for nucleation and grain refinement. It is demonstrated that it is feasible to manipulate heterogeneous nucleation by modifying nucleation potency of a substrate through deliberate interfacial segregation of desirable elements, achieving effective control of the grain structure of cast metallic materials.

Three dimensional (3D) ultra-structural imaging is an important tool for unraveling the organizational structure of individual chromosomes at various stages of the cell cycle. Performing hitherto uninvestigated ultra-structural analysis of the human genome at prophase, we used serial block-face scanning electron microscopy (SBFSEM) to understand chromosomal architectural organization within 3D nuclear space. Acquired images allowed us to segment, reconstruct, and extract quantitative 3D structural information about the prophase nucleus and the preserved, intact individual chromosomes within it. Our data demonstrate that each chromosome can be identified with its homolog and classified into respective cytogenetic groups. Thereby, we present the first 3D karyotype built from the compact axial structure seen on the core of all prophase chromosomes. The chromosomes display parallel-aligned sister chromatids with familiar chromosome morphologies with no crossovers. Furthermore, the spatial positions of all 46 chromosomes revealed a pattern showing a gene density-based correlation and a neighborhood map of individual chromosomes based on their relative spatial positioning. A comprehensive picture of 3D chromosomal organization at the nanometer level in a single human lymphocyte cell is presented.

Serial block-face scanning electron microscopy (SBFSEM) has been used to investigate the three-dimensional (3D) structure of a cured waterborne paint containing TiO₂ pigment particles, and the surrounding environment of the TiO₂ pigment particles in the cured paint film was also discussed. The 3D spatial distribution of the particles in the paint film and their degree of dispersion were clearly revealed. More than 55% of the measured TiO₂ particles have volumes between 1.0 × 10⁶ nm³ and 1.0 × 10⁷ nm³. From the obtained 3D images, we proposed that there are three different types of voids in the measured cured waterborne paint film: voids that exist in the cured paint themselves, voids produced by particle shedding, and voids produced by quasi-liquid phase evaporation during measurement. Among these, the latter two types of voids are artefacts caused during SBFSEM measurement which provide evidence to support that the pigment particles in the cured paint/coating films are surrounding by quasi-liquid environment rather than dry solid environment. The error caused by particle shedding to the statistical calculation of the TiO₂ particles was corrected in our analysis. The resulting 3D structure of the paint, especially the different voids are important for further systematic research, and are critical for understanding the real environment of the pigment particles in the cured paint films.