Novel Methods to Produce Nanocrystalline Materials

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Nanocrystalline materials are desired in many applications due to their ability to provide superior mechanical properties coupled with improved wear and corrosion resistance. In this Phase I effort, the ability to develop a number of nanocrystalline materials using pulsed reactive electrodes (PRE) either in the form of a rod, wire, or in some cases braided wires submerged in a reactive or nonreactive dielectric fluid, is demonstrated. Control over the processing parameters can result in nanometer size powders with tailored size, shape and morphology that can be characterized. The technique can be adapted for producing carbides, nitrides, borides or oxides. The follow-on Phase II effort will probably focus on adding reactive gases that flow alongside the electrode in a specially designed holder and a technique for consolidation of the nanocrystalline materials into shapes ranging from sheets, using high shear compaction, to plates and other intricate shapes. Extensive testing of these compacted shapes for strength, corrosion and high temperature behavior is also planned in the Phase II effort. Methods for scaling up this technique to produce commercial quantities of nano-crystalline powders for use in numerous applications will be considered. Production of nanocrystalline powders can result in a quantum jump in structural materials technology. Alloys and nanocomposites thus produced should facilitate applications in numerous electrical, magnetic, and packaging applications. Other uses include crucibles, nozzles, smart materials, sensors, and several structural components.