Accelerating discovery and manufacturing of nanocrystalline high-entropy alloys as next-generation structural materials

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Metals are a major workhorse of our society. In many critical applications, they are irreplaceable. For example, aerospace engine components are made of metals, as they need to operate in high-temperature and high-stress environments for long durations. Today, the rapid development of modern industry is calling for next-generation structural materials that can withstand even more demanding conditions. This requires superior material properties and manufacturing processes. Hence, developing advanced materials and manufacturing is critical to strengthening Canada's competitive position in today's world economy. Having expertise in metals and manufacturing, my research group at the University of Toronto aims to use novel experimental methods to create new metallic materials with optimized properties that cannot be obtained using conventional techniques, especially for aerospace and other critical applications. ******With this long-term vision, our group will develop and manufacture nanocrystalline (nc) high-entropy alloys (HEAs) as next-generation structural materials. Nc (or nano-grained) metals exhibit remarkably high strength and are very attractive in structural applications, but they are unstable at even modest temperatures, rendering them unsuitable for high-temperature processing and applications. Recently, as an evolving field of physical metallurgy, HEAs exhibit excellent mechanical properties and thermal stability. This proposal outlines a new methodology: designing nc-HEAs at small scales by microfabrication and nanomechanical testing, followed by producing nc-HEAs at large scales using an additive manufacturing (3D printing) approach. Our group will seek to answer the following scientific question: What chemical compositions yield the best thermal and mechanical stability of nc-HEAs? The engineering goal is to produce nc-HEA components in bulk by additive manufacturing. ******The initial benefits of my proposed research will be in-depth knowledge of new alloys and manufacturing. The long-term benefits will be that manufacturers consume much less of expensive raw materials and energy, reduce waste of materials, and use lighter but stronger materials in airplanes, permitting lower fuel consumption and CO2 emissions. For broader impacts, the research methodology would trigger a chain reaction of new research and applications in other related disciplines, such as in the energy and environmental sectors.******Using the proposed expenditure, I will train two doctoral students and approximately ten undergraduate students. Providing trainees great opportunities to work on state-of-the-art equipment and critical scientific questions, my research group will also provide unique training opportunities for next-generation researchers and engineers in these fields and strengthen Canada's position amidst global competition for highly qualified personnel (HQP).