Nanostructure assisted casting of thermally stable, ultrafine grained, nanocrystalline metals

Abstract

Provided herein are nanocrystalline materials comprising, e.g., a matrix including one or more metals; and nanostructures dispersed in the matrix, wherein the matrix is polycrystalline and includes grains having an average size of about 1μm or less. Also provided herein are manufacturing methods of a nanocrystalline materials.

What is claimed is: 
     
         1 . A nanocrystalline material comprising:
 a matrix including one or more metals; and   nanostructures dispersed in the matrix, wherein the matrix is polycrystalline and includes grains having an average size of about 1 μm or less.   
     
     
         2 . The nanocrystalline material of  claim 1 , wherein the average size of the grains is about 600 nm or less. 
     
     
         3 . The nanocrystalline material of any of  claim 1 , wherein the average size of the grains is about 400 nm or less. 
     
     
         4 . The nanocrystalline material of any of  claim 1 , wherein the nanostructures are dispersed in the matrix at a volume fraction of about 5% or greater of the nanocrystalline material. 
     
     
         5 . The nanocrystalline material of  claim 4 , wherein the volume fraction of the nanostructures in the nanocrystalline material is about 10% or greater. 
     
     
         6 . The nanocrystalline material of  claim 4 , wherein the volume fraction of the nanostructures in the nanocrystalline material is about 15% or greater. 
     
     
         7 . The nanocrystalline material of  claim 1 , wherein the matrix includes copper, and the nanostructures include a transition metal or a transition metal carbide. 
     
     
         8 . The nanocrystalline material of  claim 1 , wherein the matrix includes zinc, and the nanostructures include a transition metal or a transition metal carbide. 
     
     
         9 . The nanocrystalline material of  claim 1 , wherein the matrix includes aluminum, and the nanostructures include a transition metal carbide or a transition metal boride. 
     
     
         10 . A manufacturing method of a nanocrystalline material, comprising:
 heating a matrix material including one or more metals to form a melt;   loading a mixture including a salt and nanostructures over a surface of the melt, such that the salt is heated to form a molten salt including the nanostructures dispersed therein;   agitating the melt to incorporate the nanostructures from the molten salt into the melt; and   cooling the melt including the nanostructures dispersed therein to form a master material.   
     
     
         11 . The manufacturing method of  claim 10 , further comprising subjecting the master material to casting to form a metal part. 
     
     
         12 . The manufacturing method of  claim 11 , wherein subjecting the master material to casting includes heating the master material to form a master material melt, delivering the master material melt to a mold defining a hollow space with a requisite shape, and cooling and solidifying the master material melt to form the metal part including the nanocrystalline material and having the requisite shape. 
     
     
         13 . The manufacturing method of  claim 12 , wherein cooling the master material melt is performed at a rate of less than about 100 K/s. 
     
     
         14 . A manufacturing method of a nanocrystalline material, comprising:
 mixing a powder of a matrix material and reinforcing nanostructures to form a powder mixture;   compacting the powder mixture to form a preform;   heating the preform under compression to form a melt including the nanostructures dispersed therein; and   cooling the melt including the nanostructures dispersed therein to form a master material.   
     
     
         15 . The manufacturing method of  claim 14 , further comprising subjecting the master material to casting to form a metal part. 
     
     
         16 . The manufacturing method of  claim 15 , wherein subjecting the master material to casting includes heating the master material to form a master material melt, delivering the master material melt to a mold defining a hollow space with a requisite shape, and cooling and solidifying the master material melt to form the metal part including the nanocrystalline material and having the requisite shape. 
     
     
         17 . The manufacturing method of  claim 16 , wherein cooling the master material melt is performed at a rate of less than about 100 K/s.