Scalable synthesis of a bulk nanocrystalline material with a multitude of divergent properties through traditional manufacturing process

A long-standing endeavor for materials scientists is to develop structural materials with a multitude of extreme properties. Toward this, nanocrystalline materials have enhanced mechanical strength and unique deformation mechanisms that provide potential for various structural applications. However, for the production of structural materials to be more viable, the scalability of nanocrystalline materials to bulk scale, utilizing industrially based practices that are reliable and stable, is as critical as some of the unique properties of such materials. The work presented here highlights an important step forward in the developmental process of nanocrystalline-based structural materials with a multitude of optimized properties and scalability for various engineering applica-tions. By utilizing common thermo-mechanical processing routes such as hot isostatic pressing (HIP) in combi-nation with open die forging on alloys that form extremely stable nanostructures, a single, fully dense 7.5 lbs (3.42 kg) ingot of nanocrystalline copper tantalum (Cu-Ta) was produced. Microstructural evolution during processing as well as the comparative mechanical response is reported. This work builds on the tremendous progress that has been made in the field of nanostructured materials in the last two decades to produce volumes of material that can be measured in centimeters and kilograms rather than microns and milligrams.