Lianyi Chen

Processing and properties of magnesium containing a dense uniform dispersion of nanoparticles

Magnesium is a light metal, with a density two-thirds that of aluminium, is abundant on Earth and is biocompatible; it thus has the potential to improve energy efficiency and system performance in aerospace, automobile, defence, mobile electronics and biomedical applications. However, conventional synthesis and processing methods (alloying and thermomechanical processing) have reached certain limits in further improving the properties of magnesium and other metals. Ceramic particles have been introduced into metal matrices to improve the strength of the metals, but unfortunately, ceramic microparticles severely degrade the plasticity and machinability of metals, and nanoparticles, although they have the potential to improve strength while maintaining or even improving the plasticity of metals, are difficult to disperse uniformly in metal matrices. Here we show that a dense uniform dispersion of silicon carbide nanoparticles (14 per cent by volume) in magnesium can be achieved through a nanoparticle self-stabilization mechanism in molten metal. An enhancement of strength, stiffness, plasticity and high-temperature stability is simultaneously achieved, delivering a higher specific yield strength and higher specific modulus than almost all structural metals.

Theoretical study and pathways for nanoparticle capture during solidification of metal melt

Nanocomposites can provide exciting physical, chemical, and mechanical properties for numerous applications. The solidification processing method has great potential for economical fabrication of bulk nanocomposites, especially for those with crystalline materials as the matrix, such as metal matrix nanocomposites (MMNCs). However, it is extremely difficult to effectively capture nanoparticles (less than 100 nm) into the solidification fronts during solidification. It is thus very important to initiate a theoretical study to examine the physics that governs the interactions between nanoparticles and the solidification front, and to provide enabling pathways for effective nanoparticle capture during solidification. The aim of this paper is to establish a theoretical framework for the fundamental understanding of nanoparticle capture during solidification of metal melt in order to obtain bulk MMNCs. A thermodynamically favorable condition is set as the starting point for further theoretical analysis of the three-party model system, namely a nanoparticle-metal-melt-solidification front. Three key interaction potentials, the interfacial energy at short range (0.2-0.4 nm), the van der Waals potential (especially at a longer range beyond 0.4 nm and up to ∼10 nm) and the Brownian potential, were studied. Three possible pathways for nanoparticle capture were thus devised: viscous capture, Brownian capture and spontaneous capture. Spontaneous capture is proposed as the most favorable for nanoparticle capture during solidification of metal melt. The theoretical model of nanoparticle capture from this study will serve as a powerful tool for future experimental studies to realize exciting functionalities offered by bulk MMNCs.

Rapid control of phase growth by nanoparticles

Effective control of phase growth under harsh conditions (such as high temperature, highly conductive liquids or high growth rate), where surfactants are unstable or ineffective, is still a long-standing challenge. Here we show a general approach for rapid control of diffusional growth through nanoparticle self-assembly on the fast-growing phase during cooling. After phase nucleation, the nanoparticles spontaneously assemble, within a few milliseconds, as a thin coating on the growing phase to block/limit diffusion, resulting in a uniformly dispersed phase orders of magnitude smaller than samples without nanoparticles. The effectiveness of this approach is demonstrated in both inorganic (immiscible alloy and eutectic alloy) and organic materials. Our approach overcomes the microstructure refinement limit set by the fast phase growth during cooling and breaks the inherent limitations of surfactants for growth control. Considering the growing availability of numerous types and sizes of nanoparticles, the nanoparticle-enabled growth control will find broad applications.

Assembly of metals and nanoparticles into novel nanocomposite superstructures

Controlled assembly of nanoscale objects into superstructures is of tremendous interests. Many approaches have been developed to fabricate organic-nanoparticle superstructures. However, effective fabrication of inorganic-nanoparticle superstructures (such as nanoparticles linked by metals) remains a difficult challenge. Here we show a novel, general method to assemble metals and nanoparticles rationally into nanocomposite superstructures. Novel metal-nanoparticle superstructures are achieved by self-assembly of liquid metals and nanoparticles in immiscible liquids driven by reduction of free energy. Superstructures with various architectures, such as metal-core/nanoparticle-shell, nanocomposite-core/nanoparticle-shell, network of metal-linked core/shell nanostructures, and network of metal-linked nanoparticles, were successfully fabricated by simply tuning the volume ratio between nanoparticles and liquid metals. Our approach provides a simple, general way for fabrication of numerous metal-nanoparticle superstructures and enables a rational design of these novel superstructures with desired architectures for exciting applications.

Ultrasonic-Assisted Synthesis of Surface-Clean TiB2 Nanoparticles and Their Improved Dispersion and Capture in Al-Matrix Nanocomposites

Metal-matrix nanocomposites (MMNCs) have great potential for a wide range of applications. To provide high performance, effective nanoparticle (NP) dispersion in the liquid and NP capture within the metal grains during solidification is essential. In this work, we present the novel synthesis and structural characterization of surface-clean titanium diboride (TiB2) NPs with an average particle size of 20 nm, by ultrasonic-assisted reduction of fluorotitanate and fluoroboride salts in molten aluminum. The high-intensity ultrasonic field restricts NP growth. Using a master nanocomposite approach, the as-prepared TiB2 NPs are effectively incorporated into A206 alloys during solidification processing because of their clean surface, showing partial capture and significant grain refinement.

Effect of fabrication and processing technology on the biodegradability of magnesium nanocomposites.

Magnesium and its alloys have gained significant attention recently as potential alternatives for biodegradable materials due to their unique biodegradability, biocompatibility, and mechanical properties. However, magnesium alloys tend to have high corrosion rates in biological liquids, thus presenting a potential problem if a magnesium implant/device needs to maintain mechanical integrity for a sufficient period under practical physiological conditions. In this study, hydroxyapatite nanoparticles were used to form magnesium based metal matrix nanocomposites (MMNC) through two processes: friction stir processing (FSP) and a two-state nanoprocessing (TSnP) combining liquid state ultrasonic processing and solid state FSP. In addition, laser surface melting (LSM) was carried out for further surface treatment. In vitro immersion tests indicated that the corrosion rate of MMNC decreased by 52% compared with pure Mg through FSP. Potentiodynamic polarization tests showed that the corrosion current of MMNC decreased by 71% and 30%, respectively, by TSnP and LSM when compared with pure Mg or untreated counterparts. This study suggests that fabrication of MMNC and further processing through FSP and LSM can robustly enhance the corrosion resistance of magnesium, which will boost its potential for biological applications.

Controlling Phase Growth During Solidification by Nanoparticles

Controlling phase growth during solidification is essential to obtain desirable structures and properties in metallic materials by casting. However, only limited ways are available for controlling the growth of phases during solidification. Here, we report a general approach to control the growth of phase domains during solidification by adsorption of nanoparticles on the growing interface. The effectiveness of the approach is demonstrated in an Sn–Al alloy. With nanoparticle-enabled growth control, the size of the primary Al phase is reduced substantially and the dendrite growth is restricted. This work potentially provides an effective way to control the structure of alloys during solidification.

Nanoparticle-induced unusual melting and solidification behaviours of metals

Effective control of melting and solidification behaviours of materials is significant for numerous applications. It has been a long-standing challenge to increase the melted zone (MZ) depth while shrinking the heat-affected zone (HAZ) size during local melting and solidification of materials. In this paper, nanoparticle-induced unusual melting and solidification behaviours of metals are reported that effectively solve this long-time dilemma. By introduction of Al2O3 nanoparticles, the MZ depth of Ni is increased by 68%, while the corresponding HAZ size is decreased by 67% in laser melting at a pulse energy of 0.18 mJ. The addition of SiC nanoparticles shows similar results. The discovery of the unusual melting and solidification of materials that contain nanoparticles will not only have impacts on existing melting and solidification manufacturing processes, such as laser welding and additive manufacturing, but also on other applications such as pharmaceutical processing and energy storage.

Achieving Uniform Distribution and Dispersion of a High Percentage Nanoparticles in Mg18Sn Matrix by Solidification Processing

It is extremely difficult to incorporate and disperse nanoparticles (NPs), especially for a high percentage, into metal matrix during solidification processing to achieve crucial property enhancement in metal matrix nanocomposites (MMNCs), mainly due to the strong tendency of NP aggregation. Thus, the significant property enhancement expected by the addition of a high percentage of NPs is rarely achieved in solidification processing of bulk MMNCs. Here we show that an unprecedented uniform distribution of 5 vol.% SiC NPs in Mgl8Sn alloy matrix is obtained by solidification processing. The resulting Mg18Sn matrix nanocomposites exhibits a very high microhardness value of 150 kg/mm2. The results reported in this work shed light on a potential pathway for production of ultrahigh performance metallic nanocomposites.

Large-scale solution synthesis of α-AlF3·3H2O nanorods under low supersaturation conditions and their conversion to porous β-AlF3 nanorods

We report for the first time the multi-gram scale solution growth of α-aluminium fluoride trihydrate (α-AlF3·3H2O) nanorods (NRs) under low supersaturation conditions, and their conversion to porous β-AlF3 NRs. Electron microscopy analysis shows that the NRs yielded from the optimized conditions have an average length of 1.9 μm and diameter of 223 nm. Nanoparticle morphology can also be achieved by tuning the supersaturation through several experimental parameters such as [Al3+] and [HF]/[Al3+] and H2O/2-propanol vol. ratio. Moderate thermal treatment of the as-synthesized α-AlF3·3H2O NRs in air atmosphere (5 h at 500 °C) results in pure β-AlF3 porous NRs, which may be useful as catalysts.