A novel, alloy-agnostic, nanofunctionalization process has been utilized to produce metal matrix composites (MMCs) via additive manufacturing, providing new geometric freedom for MMC design. MMCs were produced with the addition of tungsten carbide nanoparticles to commercially available AlSi10Mg alloy powder. Tungsten carbide was chosen due to the potential for coherent crystallographic phases that were identified utilizing a lattice-matching approach to promote wetting and increase dislocation interactions. Structures were produced with evenly distributed strengthening phases leading to tensile strengths >385 MPa and a 50% decrease in wear rate over the commercially available AlSi10Mg alloy at only 1 vol% loading of tungsten carbide.

When properly designed at ultra-low density, hollow metallic microlattices can fully recover from compressive strains in excess of 50%, while dissipating a considerable portion of the elastic strain energy. This article investigates the physical mechanisms responsible for energy loss upon compressive cycling, and attributes the most significant contribution to a unique form of structural damping, whereby elastic local buckling of individual bars releases energy upon loading. Subsequently, a simple mechanical model is presented to capture the relationship between lattice geometry and structural damping. The model is used to optimize the microlattice geometry for maximum damping performance. The conclusions show that hollow metallic microlattices exhibit exceptionally large values of the damping figure of merit, (Young's modulus)1/3(loss coefficient)/(density), but this performance requires very low relative densities (<1%), thus limiting the amount of energy that can be dissipated.

Recent advances in multiscale manufacturing enable fabrication of hollow-truss based lattices with dimensional control spanning seven orders of magnitude in length scale (from ∼50 nm to ∼10 cm), thus enabling the exploitation of nano-scale strengthening mechanisms in a macroscale cellular material. This article develops mechanical models for the compressive strength of hollow microlattices and validates them with a selection of experimental measurements on nickel microlattices over a wide relative density range (0.01–10%). The limitations of beam-theory-based analytical approaches for ultralight designs are emphasized, and suitable numerical (finite elements) models are presented. Subsequently, a novel computational platform is utilized to efficiently scan the entire design space and produce maps for optimally strong designs. The results indicate that a strong compressive response can be obtained by stubby lattice designs at relatively high densities (∼10%) or by selectively thickening the nodes at ultra-low densities.

The metastable solid solubility extension of CoO in ZnO (wurtzite) was investigated in precursor-derived powders as well as in thin films grown on sapphire substrates by pulsed laser deposition. A maximum solubility of 30% Co2+ in ZnO was achieved in the powders. Transmission electron microscopy (TEM) of the films revealed them to have grown epitaxially and retained up to nearly 40% CoO in solid solution, but some Co2+ precipitated as rock-salt. The temperature dependence of the metastable solubility limit in the ZnO–CoO system was assessed and is discussed in terms of the relevant thermodynamic factors. The magnetic properties of n-type conductive Zn0.79Co0.2Al0.01Ofilms were studied, yielding evidence of a ferromagnetic phase with a TC of 25 K and a second, magnetically ordered, phase with positive exchange and arguably a TC of ∼250 K. Connections between the properties and microstructural observations in high resolution TEM are proposed.

The metastable-to-equilibrium phase evolution over a wide range of compositions in the TiO2-YO3/2-ZrO2 system was investigated. The competing phases are all derivatives of the fluorite structure and compositions within the fluorite and pyrochlore fields exhibit technologically interesting ionic and mixed ionic-electronic conductivity. Powders of various compositions were synthesized by precursor routes, pyrolyzed and subsequently heat-treated in a stepwise manner at progressively higher temperatures to explore the sequence of phase evolution. Extended solid solutions with amorphous, fluorite and ordered pyrochlore structures were produced over significant composition ranges within the ternary. The study also sheds new light on the correct form of the phase equilibria at 1300°C.