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Tailoring the physical properties of complex materials for targetedapplications requires optimizing the microstructure and crystalline defectsthat influence electrical and thermal transport, and mechanical properties.Laser surface remelting can be used to modify the sub-surface microstructure ofbulk materials and hence manipulate their properties locally. Here, weintroduce an approach to perform remelting in a reactive nitrogen atmosphere,in order to form nitrides and induce segregation of nitrogen to structuraldefects. These defects arise from the fast solidification of the full-HeuslerFe2VAl compound that is a promising thermoelectric material. Advanced scanningelectron microscopy, including electron channelling contrast imaging andthree-dimensional electron backscatter diffraction, is complemented by atomprobe tomography to study the distribution of crystalline defects and theirlocal chemical composition. We reveal a high density of dislocations, which arestable due to their character as geometrically necessary dislocations. At thesedislocations and low-angle grain boundaries, we observe segregation of nitrogenand vanadium, which can be enhanced by repeated remelting in nitrogenatmosphere. We propose that this approach can be generalized to other additivemanufacturing processes to promote local segregation and precipitation states,thereby manipulating physical properties.

In-situ nitriding of Fe2VAl during laser surface remelting to manipulate microstructure and crystalline defects