Shape memory alloys (SMAs) are functional materials that are being applied in practically all industries, from aerospace to biomedical sectors, and at present the scientific and technologic communities are looking to gain the advantages offered by the new processing technologies of additive manufacturing (AM). However, the use of AM to produce functional materials, like SMAs, constitutes a real challenge due to the particularly well controlled microstructure required to exhibit the functional property of shape memory. In the present work, the design of the complete AM processing route, from powder atomization to laser powder bed fusion for AM and hot isostatic pressing (HIP), is approached for Cu–Al–Ni SMAs. The microstructure of the different processing states is characterized in relationship with the processing parameters. The thermal martensitic transformation, responsible for the functional properties, is analyzed in a comparative way for each one of the different processed samples. The present results demonstrate that a final post–processing thermal treatment to control the microstructure is crucial to obtain the expected functional properties. Finally, it is demonstrated that using the designed processing route of laser powder bed fusion followed by a post–processing HIP and a final specific thermal treatment, a satisfactory shape memory behavior can be obtained in Cu–Al–Ni SMAs, paving the road for further applications.

Superelastic behavior at nano-scale has been studied along cycling in Cu-Al-Ni shape memory alloy micropillars. Arrays of square micropillars were produced by focused ion beam milling, on slides of [001] oriented Cu-Al-Ni single crystals. Superelastic behavior of micropillars, due to the stress-induced martensitic transformation, has been studied by nano-compression tests during thousand cycles, and its evolution has been followed along cycling. Each pillar has undergone more than thousand cycles without any detrimental evolution. Moreover, we demonstrate that after thousand cycles they exhibit a perfectly reproducible and completely recoverable superelastic behavior.

In situ neutron diffraction is used to study the strain relaxation on a single crystal and other powdered Cu-Al-Ni shape memory alloys (SMAs) around martensitic transformation temperatures. This work is focused on the analysis of the strain evolution along the temperature memory effect appearing in these alloys after partial thermal transformations. A careful study of the influence of partial cycling on the neutron diffraction spectra in the martensitic phase is presented. Two different effects are observed, the d-spacing position shift and the narrowing of various diffraction peaks, along uncompleted transformation cycles during the thermal reverse martensitic transformation. These changes are associated with the relaxation of the mechanical stresses elastically stored around the martensitic variants, due to the different self-accommodating conditions after uncompleted transformations. The evolution of the stresses is measured through the strain relaxation, which is accessible by neutron diffraction. The observed effects and the measured strain relaxations are in agreement with the predictions of the model proposed to explain this behavior in previous calorimetric studies. In addition, the thermal expansion coefficients of both martensite and austenite phases were measured. The neutron experiments have allowed a complete description of the strains during martensitic transformation, and the obtained conclusions can be extrapolated to other SMA systems.

Shape‐memory alloys (SMAs) are the most stretchable metallic materials thanks to their superelastic behavior associated with the stress‐induced martensitic transformation. This property makes SMAs of potential interest for flexible and wearable electronic technologies, provided that their properties will be retained at small scale. Nanocompression experiments on Cu‐Al‐Be SMA single crystals demonstrate that micro‐ and nanopillars, between 2 µm and 260 nm in diameter, exhibit a reproducible superelastic behavior fully recoverable up to 8% strain, even at the nanoscale. Additionally, these micro‐/nanopillars exhibit a size effect on the critical stress for superelasticity, which dramatically increases for pillars smaller than ≈1 µm in diameter, scaling with a power law of exponent n = −2. The observed size effect agrees with a theoretical model of homogeneous nucleation of martensite at small scale and the universality of this scaling power law for Cu‐based SMAs is proposed. These results open new directions for using SMAs as stretchable conductors and actuating devices in flexible and wearable technologies.