Manufacturing of near net shape bulk nanostructured materials

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The major interest in nanomaterials, i.e. materials with a grain size distribution ranging from 1 to 100 nm, resides in the novel mechanical and chemical properties achievable compared to their micron-scale counterparts: superior static and dynamic mechanical strength, superplasticity, high strain rate flowability, enhanced corrosion and wear resistance. The possible gain in properties obtainable with nanomaterials creates an enthousiams in all technological sectors. The actual challenge preventing their utilization at large is the availability of processes to fabricate flawless large-scale bulk components at a competitive price. The near-net shape processing route enables significant material and processing cost reduction and reduces the possibility of introducing critical flaws during post-consolidation operations, which would help contributing to their commercialization and implementation. However, the engineering of near-net shape processing of nanomaterials is at its infancy and further understanding of the material's behavior and optimization of the processing conditions remains to be done. The present research proposal is therefore aimed at studying three processes to fabricate near net-shape bulk nanostructured materials: spark plasma sinter rolling, freeforming using electrospark welding and controlled short circuit metal inert gas welding. The two former processing routes will developed bulk nanostructured Al systems targeting the transportation industry, while the later will focus on nanocomposites for wear applications. This project will yield commercially viable processes capable of producing large-scale bulk nanostructured materials in geometries and at cost affordable to the industries.