Materials and methods for producing metal nanocomposites, and metal nanocomposites obtained therefrom

Abstract

Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.

What is claimed is: 
     
         1 . A method of making a metal nanocomposite, said method comprising:
 (a) providing a precursor composition comprising metal-containing microparticles and nanoparticles, wherein said nanoparticles are chemically and/or physically disposed on surfaces of said microparticles;   (b) consolidating said precursor composition into an intermediate composition comprising said metal-containing microparticles and said nanoparticles, wherein said nanoparticles are consolidated in a three-dimensional architecture throughout said intermediate composition; and   (c) processing said intermediate composition to convert said intermediate composition into a metal nanocomposite.   
     
     
         2 . The method of  claim 1 , wherein said precursor composition is in powder form. 
     
     
         3 . The method of  claim 1 , wherein said intermediate composition is in ingot form. 
     
     
         4 . The method of  claim 1 , wherein said microparticles contain an element selected from the group consisting of Al, Mg, Ni, Fe, Cu, Ti, V, Si, and combinations thereof. 
     
     
         5 . The method of  claim 1 , wherein said nanoparticles contain a compound selected from the group consisting of metals, ceramics, cermets, intermetallic alloys, oxides, carbides, nitrides, borides, polymers, carbon, and combinations thereof. 
     
     
         6 . The method of  claim 1 , wherein step (b) includes pressing, binding, sintering, or a combination thereof. 
     
     
         7 . The method of  claim 1 , wherein step (c) includes pressing, sintering, mixing, dispersing, friction stir welding, extrusion, binding, melting, semi-solid melting, capacitive discharge sintering, casting, or a combination thereof. 
     
     
         8 . The method of  claim 1 , wherein said metal nanocomposite has a cast microstructure. 
     
     
         9 . The method of  claim 1 , wherein said metal-containing microparticles and said nanoparticles are each dispersed throughout said metal nanocomposite. 
     
     
         10 . The method of  claim 1 , wherein said metal nanocomposite has a layered configuration including at least a first layer comprising said nanoparticles and at least a second layer comprising said metal-matrix phase.