The size effect of interstitial solutes
In general, the capacity of interstitial sites (both O-sites or T-sites) to accommodate small solutes is somewhat limited, as high concentrations of interstitial solutes tend to cause the formation of precipitated phases18–22. Therefore, we began our investigation with a single solute accommodated in a bcc supercell, i.e., a single-solute model, to determine its favored site for occupancy. In contrast to the T-site, the O-site has a distinctive flat octahedral shape, as shown in Fig. 1c-d. For the six host metal atoms enclosing the O-site, the distance dS, between the center of the O-site and the two closest adjacent host metal atoms is only a/2 (where a denotes the lattice parameter of the host metal), significantly smaller than the distance dL = \(\:a/\sqrt{2}\) between the center and the other four co-planar metal atoms. Consequently, when the octahedral site accommodates a single solute, the two nearest neighboring host metal atoms are displaced markedly away from their original lattice site, as illustrated schematically in Fig. 1d. Due to the limited open volume of octahedral or tetrahedral sites, various degrees of internal stress on the solute thus strongly depends on the interstitial solute size.
With strain considerations as our starting point, we estimated the elastic strain energy for an interstitial solute (atomic radius r) located at octahedral or tetrahedral sites within a bcc lattice (atomic radius R) as a function of r/R, as shown in Fig. 2a. We employed a hybrid empirical interatomic potential as a simplified model to represent the interactions of a single interstitial solute with Nb atoms sitting on their lattice sites (see METHODS for details). This strain consideration, a key component of the overall free energy, supports the prevailing belief that interstitials predominantly reside in the O-sites of a bcc metal23. A cross-over is seen at a critical r/R value (~ 0.46), for the elastic strain energy of interstitial solute residing in the octahedral site versus the tetrahedral site. For interstitial solutes such as C, N, and O, which have r/R values within the range of 0.5 to 0.53, the elastic strain energy in the octahedral site is lower than that of the tetrahedral site, strongly suggesting that these solutes prefer the octahedral site in the Nb lattice, consistent with previous findings14–16.
Figure 2a also demonstrates that in the region where r/R < 0.46, the T-site is more likely to accommodate interstitial solutes than the O-site. Consequently, for much smaller solutes such as H, for which r/R ≈ 0.24, the tetrahedral site is more stable, which is supported by previous studies on H accommodation in TiZrHfNbTa alloys10 as well as in simple bcc metals like Nb and Ta24. Another way to demonstrate the size/strain effect is to place individual oxygen atoms at either octahedral or tetrahedral sites within the Nb lattice, while varying the degree of lattice expansion, (which corresponds to different r/R values, as detailed in the METHODS section). Due to the stress symmetry from neighboring metal atoms, the oxygen solute atom remains confined to its starting site in the Nb lattice without displacement. Figure 2b shows that as the Nb lattice expands (i.e., decreasing r/R), the total energy difference, \(\:{E}_{O-site}-{E}_{T-site}\) gradually diminishes until the lattice expansion factor L0 exceeds a critical value (~ 1.066), at which the total energy of \(\:{E}_{T-site}\) becomes lower than that of \(\:{E}_{O-site}\). Thus, lattice expansion can indeed cause oxygen solutes to transition from octahedral to tetrahedral sites. This analysis, different from the estimate in Fig. 1, was performed based on DFT-derived energies.
Interstitial residing in O-site versus T-site at dilute concentrations
In addition to pure bcc metals, the preferential occupancy of interstitial sites in a concentrated solid solution, i.e., MPEA, is the main focus of the present work. MPEAs typically exhibit a complex local atomic landscape characterized by significant chemical and structural inhomogeneity, including variations in lattice distortions and local chemical environment. These complexities have been shown to affect the mechanical properties of the materials. The predicted interactions between a single interstitial solute and host pure metal atoms (i.e., the simple model in Fig. 2) were subsequently studied in the more structurally complex bcc NbTiZr alloy, again based on energy evaluation using DFT. As depicted in Fig. 3a, our DFT results indicated that when a single interstitial solute was initially introduced into a tetrahedral site within an NbTiZr supercell, it spontaneously moved to the nearest octahedral site upon structural relaxation. Figure 3b illustrates that the host metals surrounding the oxygen solute undergo severe local lattice distortions. The oxygen solute entering the octahedral site, having hopped approximately 0.75 Å, significantly displaces the two closest metal atoms from their original sites. This is a more favorable accommodation because it incurs less strain energy compared to the case of tetrahedral site where four metal atoms need to be pushed apart.
To conduct a systematic survey that makes better statistical sense in reflecting the varying local atomic environment, we randomly inserted single O, (or C, or N) into different tetrahedral or octahedral sites in the NbTiZr supercell. For each solute species, 54 independent events were studied, and the atomic displacements of the interstitials were extracted during energy minimization. As shown in Fig. 4a, all O, N, and C atoms initially residing in octahedral sites exhibited very small average atomic displacements (0.09 Å for O/N and 0.08 Å for C), arising from the lattice distortion due to the varying local atomic environment. In contrast, atoms initially residing in tetrahedral sites displayed relatively larger atomic displacements (~ 0.75 Å for O, ~ 0.74 Å for N, and ~ 0.76 Å for C), which is close to the distance between an octahedral site and its adjacent tetrahedral site in the NbTiZr lattice (illustrated in Fig. 3b). Upon relaxation, all individual N, C, and O solutes in tetrahedral sites were found to be unstable (i.e., 0% of them remained in their original sites, as listed in Fig. 4b). These results imply that in NbTiZr alloys, individual small solutes tend to reside in octahedral sites rather than in tetrahedral sites, consistent with the general view that interstitial solutes prefer octahedral sites in bcc pure metals14, 15.
Our findings may seem to contradict a previous study12, which claimed that O and N solutes occupy tetrahedral and octahedral sites with equal probability in the TiZrHfNb alloy. Upon communicating with the authors12, we learned that their conclusion was based on the observation that similar energies were reached when the two cases were compared, with solutes initially inserted in octahedral versus tetrahedral sites. However, they neglected to monitor the actual positions of the solute atoms after the relaxation. In the relaxed sample, actually, all solutes initially present in tetrahedral sites have relocated to octahedral sites to lower energy. That change in preferred solute residence was in fact the reason that no statistically meaningful energy difference was found between the two cases (the two eventually evolve into the same configuration).
Local atomic environment around interstitial solutes
Despite the relatively small atomic sizes of C, O, and N solutes compared to the host metals, they are still significantly larger than the open volumes of octahedral or tetrahedral sites in the NbTiZr lattice. To accommodate these small solutes, severe lattice distortions occur around the octahedral sites to release the internal lattice stresses caused by the extrusion of solutes into the host metal. Details of the lattice distortion calculations are provided in the METHODS section. Figure 5a illustrates that the larger the solute size (atomic size: O < N < C), the greater the lattice distortions (Δd) imposed on the surrounding host atoms, with average lattice distortions for O, N, and C being 0.273, 0.286, and 0.288 Å, respectively.
Figure 5b statistically shows the distribution of bond lengths of these small solutes with their adjacent host metal atoms. The bond lengths can be classified into two categories (i.e., dS and dL ), as labeled in Fig. 1d. For each type of solute (i.e., O, C, or N), the converged dS and dL were obtained by statistically averaging 108 and 216 independent bond lengths, respectively. Initially, in the case of octahedral sites without lattice relaxation, dS and dL are 1.70 Å (corresponding to \(\:{d}_{S}=a/2\)) and 2.39 Å (corresponding to \(\:{d}_{L}=a/\surd\:2\)), respectively. However, these bond lengths undergo significant changes after stress relaxation. Specifically, the average dS values for O-, N-, and C-related bonds are 2.11, 2.09, and 2.12 Å, respectively, increasing by 0.41, 0.39, and 0.42 Å from their initial dS. Conversely, the average dL values for O-, N-, and C-related bonds are 2.21, 2.18, and 2.20 Å, respectively, yielding bond shortenings of 0.18, 0.21, and 0.19 Å. As shown in Fig. 5b, the average dS remains shorter than dL.
Figure 5c shows the atomic fraction of Nb, Ti, or Zr in the nearest neighbor shell of interstitial solutes N, C, and O by extracting the local atomic information of the 10% of samples with the lowest interstitial formation energies. All N, C, and O solutes exhibit strong chemical affinities with Ti. This chemical affinity between small solutes and the host metals has also been found in previous studies12, 25–27. Interestingly, as the solute size increases (atomic size: O < N < C), the chemical affinity with Zr decreases while the affinity with Nb increases. This chemical affinity trend arises because, to fit into the open volume of the octahedral sites and release lattice stresses, the larger host metal Zr prefers to stay with the smaller solutes.
The case of highly concentrated interstitial solutes
A crucial question is under what conditions small solutes undergo an unusual switch from octahedral (O-site) to tetrahedral (T-site) occupancy. Earlier, we have shown that in bcc metals with dilute interstitial solute concentrations, the O-site is more favorable because it is less costly in energy for the O-site solute to push two nearest metal atoms away from their lattice positions. However, when the solutes are highly concentrated, the metal atoms become largely constrained by the surrounding interstitial solutes, as illustrated in Fig. 6a. This suppressed displacement would hamper effective release of elastic strain. To support this hypothesis, Fig. 6b illustrates the elastic strain energy for two small solutes (atomic radius r) located at O-sites or T-sites within a bcc Nb lattice (atomic radius R) as a function of r/R. A quantitative estimate of the strain energy is detailed in the METHODS section. Interestingly, the elastic strain energies of O-sites and T-sites exhibit a cross-over similar to the single-solute case (see Fig. 2a), but the critical r/R value in this high solute concentration case is shifted up to ~ 0.24. Notably, when the two O (or N, or C) solutes are located at T-sites, the elastic strain energy is significantly lower than at O-sites (see Fig. 6b). This is because the strain energy cost for an octahedral interstitial solute to displace the two neighboring metal atoms increases significantly at high solute concentrations, eventually becoming comparable to or exceeding that of T-sites. This causes an inversion in the strain energy levels for solutes residing in T-sites versus O-sites, leading to a gradual transition of interstitial solutes from O-sites to T-sites at elevated solute concentrations.
As such, our theoretical model posits that it is the confinement of host metal atoms by adjacent interstitial solutes that causes a shift in the preference from O-sites to T-sites (see illustration in Fig. 6a). These collective interactions will become more pronounced with increasing oxygen content and spatial heterogeneity of oxygen distribution. This explains the observation in recent experimental work17, which demonstrated that the distribution of oxygen is inhomogeneous within the (NbTiZr)86O12C1N1 alloy and the oxygen-enriched regions generally accommodate more tetrahedral interstitials. To verify the effect of oxygen concentration and heterogeneity in NbTiZr alloys, we employed DFT approaches. Among ten independent NbTiZr supercells, oxygen atoms with a range of concentrations and spatial heterogeneity were randomly incorporated into both T-sites and O-sites (see METHODS for details). We then counted the portion of interstitial solutes that remained at tetrahedral versus octahedral sites after structural relaxation. The parameter of oxygen heterogeneity, η, describes local regions enriched with oxygen compared to the whole sample (illustrated in Fig. 7a). The smallest value of η = 1 indicates homogeneous distribution, while larger η values indicate higher heterogeneity.
As depicted in Fig. 7b, oxygen solutes predominantly occupy O-sites when their concentration and heterogeneity are relatively small. Strikingly, the tendency to occupy T-sites gradually increases with rising oxygen concentration and heterogeneity, eventually exceeding the preference for O-sites. For instance, at an already high average oxygen concentration (e.g., 18 at.%), local regions with even higher oxygen concentrations show a stronger preference for the T-sites (Fig. 7b). This trend is consistent with the rationale illustrated in Fig. 6, where the strain energy required for an octahedral interstitial to displace neighboring metal atoms increases significantly with more interstitials in the neighborhood, becoming comparable to or exceeding that required for tetrahedral interstitials. As a result, O-sites become disfavored compared to the more spacious T-sites. A transition from O-sites to T-sites is even more likely when oxygen distribution becomes inhomogeneous, in which would render local regions even more crowded with oxygen interstitials.