About

James T. Burns is an Associate Professor of Materials Science and Engineering at the University of Virginia School of Engineering and Applied Science. His research focuses on the impact of environmental degradation on the mechanical properties of high-performance structural metals. He explores a wide range of material systems, including steel, aluminum, titanium, and nickel-based alloys, produced through traditional and additively manufactured processes. His work is at the intersection of metallurgy, mechanics, and electrochemistry, enabling him to address real-world challenges across various fields such as infrastructure, aerospace, automotive, energy, and biomedical applications. Burns aims to understand the mechanistic factors governing environmental degradation phenomena like fracture mechanics, hydrogen embrittlement, and corrosion. His goal is to inform engineering solutions by linking processing, microstructure, properties, and component performance within a material science framework. His contributions include advancing knowledge on the structural integrity of high-performance alloys under environmental effects, with societal implications for safety and durability in engineering systems.

Research topics

• Materials science
• Metallurgy
• Composite material

Selected publications

• Programmable Phase Selection between Altermagnetic and Noncentrosymmetric Polymorphs of MnTe on InP via Molecular Beam Epitaxy

  ACS Applied Materials & Interfaces · 2026-02-25 · 1 citations

  article

  Phase selecting nearly degenerate crystalline polymorphs during epitaxial growth can be challenging yet critical to targeting physical properties for specific applications. Here, we establish how phase selectivity of altermagnetic and noncentrosymmetric polymorphs of MnTe can be programmed by subtle changes to the surface of lattice-matched InP substrates in molecular beam epitaxy growth. Bulk altermagnetic MnTe is thermodynamically stable in the hexagonal NiAs-structure and is synthesized here on the polar (111)A surface (In-terminated) of InP, while the noncentrosymmetric, cubic ZnS-structure with wide band gap (>3 eV), which epitaxially matches III-V materials, is stabilized on the (111)B surface (P-terminated). Electron microscopy, X-ray photoemission spectroscopy, and reflection high-energy electron diffraction indicate that phase selection is triggered at the interface and proceeds along the growing surface. First-principles calculations suggest that interfacial termination and strain have a significant effect on the interfacial energy; stabilizing the NiAs polymorph on the In-terminated surface and the ZnS structure on the P-terminated surface. Selectively grown, high-quality, phase pure films of both MnTe polymorphs will enable our understanding of the novel properties of these materials, thereby facilitating their use in new applications ranging from spintronics to microelectronic devices.

  PublisherDOI

• Process control of elemental mixing in laser powder bed fusion of dissimilar Al/Zn alloys

  Journal of Manufacturing Processes · 2026-04-02

  article
  PublisherDOI

• Unveiling Atomistic Mechanisms Governing Additive Manufacturing Processability and Mechanical Behavior of a Refractory Complex Concentrated Alloy

  Advanced Functional Materials · 2025-11-10 · 1 citations

  article

  Abstract Extending the concept of complex concentrated alloys (CCAs) to the refractory alloys (solidus temperature over 2000 °C) space potentially facilitates the design of lightweight structural alloys with service temperatures that exceed those of Ni and Co‐based alloys. However, the room and elevated temperature tensile properties of the current refractory‐CCAs (R‐CCAs) are inferior to those of the Ni/Co‐based alloys. Furthermore, the manufacturing scalability of R‐CCAs remains challenging, in that cracks are prevalent in all R‐CCAs when processed using near‐net shape manufacturing processes, such as fusion‐based additive manufacturing (F‐BAM). Still, mechanisms governing the poor F‐BAM processability of R‐CCAs remain unexplored. To this end, this work unveils the atomistic mechanisms underlying F‐BAM process‐induced cracking in a NbTiTaMoHfZrC R‐CCA. The implications of light elements’ presence for intrinsic ductility and grain boundary cohesion, and subsequently for F‐BAM processability and mechanical behavior, are revealed. Leveraging the insights, we accomplish what is, to the best of the knowledge, the first instance of crack‐free F‐BAM processing of any R‐CCA. Additionally, the R‐CCA exhibits over 20% tensile ductility and ≈160 MPa tensile yield strength at 1200 °C. In addition to facilitating the design of lightweight R‐CCAs, findings enable scalable manufacturing of these ultra‐high temperature alloys for structural applications.

  PublisherDOI

• Effect of Laser Surface Treatment on the Distribution of Beta Phase and Intermetallic Particles and the Surface Integrity of AA5456 Alloy

  Metallurgical and Materials Transactions A · 2025-09-24

  articleOpen accessSenior author

  Abstract AA5456-H116 alloy is widely used in marine environments owing to the combination of mechanical properties and general corrosion resistance. However, precipitation of β phase (Al 3 Mg 2 ) on grain boundaries can occur at modestly elevated temperatures (> 50 °C), resulting in susceptibility to intergranular corrosion (IGC), intergranular stress corrosion cracking (IGSCC), and corrosion fatigue. This work uses electron backscatter diffraction (EBSD) and scanning electron microscopy (SEM) to examine the effect of continuous wave (CW) and defocused continuous wave (DCW) fiber laser surface treatment (LST) on the β phase and constituent intermetallic particles distribution in AA5456. The surface topography and subsurface defect distribution in the LST regions are also investigated; the presence of cracks and porosity was observed. Different CW/DCW processing parameters result in different aspect ratios, subsurface defects, and microstructures; specifically, surface polishing revealed the presence of subsurface defects up to 300 µm in size for CW conditions. Statistical analysis of the constituent particles distribution revealed a reduction in the total volume and size distribution in the LST region. Linear β coverage analysis along grain boundaries in the laser-treated region demonstrated that both CW and DCW LST processes are capable of resolutionizing β particles. Although both CW and DCW LSTs are equally effective in resolutionizing the β particles, DCW outperformed CW in terms of minimizing subsurface defects along with the formation of uniform melt pool distribution.

  PublisherOA PDFDOI

• Identification of Sub-Micrometer Features in Additively Manufactured 17-4ph Stainless Steel

  SSRN Electronic Journal · 2025-01-01

  preprintOpen accessSenior author
  PublisherDOI

• Identification of sub-micrometer features in additively manufactured 17-4PH stainless steel

  Materials Science and Engineering A · 2025-07-15 · 1 citations

  articleSenior author
  PublisherDOI

• Mitigation of Environmental-Assisted Cracking in Martensitic Stainless Steel via ZnNi Plating in Sodium Chloride Solution

  CORROSION · 2025-10-01

  article

  The impact of galvanic coupling on the environmental-assisted cracking (EAC) resistance of a martensitic stainless steel (P675) was evaluated by the introduction of a ZnNi electrodeposit during fracture mechanics testing. The influence of ZnNi galvanic coupling on EAC behavior was studied under both constant stress intensity K (dK/dt = 0 MPa√m/h) and rising K (dK/dt = 4 MPa√m/h) conditions in 0.6 M NaCl. For constant K, the ZnNi anode was galvanically coupled to the steel via a zero-resistance ammeter, and both small and large area ratios of ZnNi to P675 steel were examined across different exposure durations. The results showed that even a small anode-to-cathode area ratio (∼1:1,000) was effective in reducing the crack growth rate, depending on exposure time. Shorter exposure durations (e.g., 90 min) led to reduced crack propagation, whereas longer exposures (up to 800 min) further mitigated EAC under small-area galvanic coupling conditions. This improvement was attributed to the electrochemical potential generated by the galvanic coupling, which remained within the immunity well throughout the immersion time. In contrast, the large area ratio (∼6:1) did not initiate EAC, even when the potential was outside the immunity well. This unexpected suppression of cracking is attributed to Zn2+ ions released from ZnNi, which appear to counteract the electrochemical driving force for crack initiation and propagation. To validate this, ZnNi coatings with small area ratios (∼1:1,000) were directly applied to the P675 steel surface, and fracture mechanics testing was conducted under rising K conditions. The results demonstrated that ZnNi continued to suppress EAC even under increasing crack-driving force, confirming that controlled galvanic coupling can effectively enhance crack resistance in martensitic stainless steel.

  PublisherDOI

• Methods for Regulating Depth of Corrosion Fissures in Simulated Fastener Holes of 7050-T7451 Aluminum Alloy

  CORROSION · 2025-05-01

  article

  This study presents a new test method for inducing controlled corrosion damage within simulated fastener holes of aluminum alloys, aimed at pretreating fatigue test specimens. The method involves insulating the outer surfaces while exposing the fastener hole surface to electrolytes containing 0.66 M NaCl + 0.1 M AlCl3 with varying concentrations of K2S2O8. The evolution of corrosion damage within the fastener hole was examined as a function of exposure duration, electrolyte composition, and volume, as well as the effect of galvanic coupling with an SS316 cathode. Results indicate that fissure depth increases with an increase in K2S2O8 concentration, but does not progress further after 24 h to 48 h of exposure in the chemical, or freely-corroding, exposure test. In contrast, galvanic coupling with an SS316 plate significantly accelerates corrosion, leading to much deeper fissures in a shorter time. The importance of electrolyte replenishment has been explored using electrochemical measurements, revealing the impact of evolving electrolyte chemistry. Beyond its application in specimen pretreatment to study environmentally assisted cracking, this method provides a simple yet effective approach for studying localized corrosion and potentially evaluating mitigation strategies for fastener holes in aerospace structures.

  PublisherDOI

• Surface Nanostructure Control and Thermodynamic Stability Analysis of Femtosecond Laser-Ablated CuCoMn _1.75 NiFe _0.25 Nanoparticles

  Langmuir · 2025-12-11 · 1 citations

  article

  high-entropy alloy (HEA) nanoparticles synthesized by femtosecond laser ablation in ethanol and liquid nitrogen (LN2). Using multimodal electron microscopy and spectroscopy, we examine phase, particle size, defect structure, chemical distribution, and surface composition and relate them to HEA stability. Elemental distributions are uniform in both media, but LN2 produces smaller particles with a narrower size distribution and mainly single- or few-domain interiors, whereas ethanol yields larger particles built from 2-4 nm crystallites with domain aggregation. Edge defects appear in both but energy-dispersive X-ray spectroscopy (EDS) is broadly uniform with local fluctuations in ethanol. X-ray photoelectron spectroscopy (XPS), supported by an attenuation model, indicates an ∼1 nm oxide overlayer that suppresses Mn 2p intensity; correcting for it returns Mn toward the bulk value. UV-NIR and photoluminescent spectra independently support a thin oxide shell. Composition-based thermodynamic descriptors place LN2 closer to bulk mixing parameters, while ethanol raises ΔH_mix and lowers Ω. Cooling simulations are consistent (LN2 ∼ 0.1 μs quench, ethanol ∼1 μs). These results connect solvent-controlled kinetics and thermodynamics to crystalline state and surface chemistry, informing surface control of HEA nanoparticles.

  PublisherDOI

• The role of hydrogen-metal interactions in hydrogen environmentally assisted cracking susceptibility in additively manufactured 17-4 PH stainless steel

  Materials Science and Engineering A · 2025-02-04 · 3 citations

  article
  PublisherDOI

Frequent coauthors

• Zachary D. Harris

  University of Virginia

  55 shared

• David Raynor

  Royal Botanic Garden Edinburgh

  36 shared

• Gordon DesBrisay

  36 shared

• David Wilson

  Quanterix (United States)

  36 shared

• Michel Faure

  Mitchell Library

  36 shared

• Michael Barfoot

  Brock University

  36 shared

• Anne Skoczylas

  36 shared

• David Brown

  Royal College of Physicians

  36 shared

Awards & honors

• HH Uhlig Award, NACE International (outstanding educator in…
• Engineering Excellence Award, NASA Engineering Safety Center…
• UVA PRI Society Recognition for Teaching Excellence 2019
• AFOSR-Young Investigator Research Grant 2016
• UVA’s 2024 Research Achievement Awards