Microstructural progression of shear-induced mixing in a CuNi alloy

Abstract Shear deformation has been highlighted in multiple research efforts for its ability to impart novel microstructures that demonstrate improvements in mechanical properties. When used to process and densify powdered material, these shear-based consolidation techniques are commonly referred to as friction consolidation (FC). In this paper, the microstructural evolution from compacted Cu and Ni powders to a consolidated Cu0.5Ni0.5 alloy is examined. Various stages of porosity reduction and preferential deformation are shown. Deformation was observed to accumulate preferentially in the more ductile material early in the process, leading to the formation of a tortuous microstructural zone. Porosity reduction was extensive, decreasing from ~65% in the pre-compacted state to ~1% in the fully consolidated alloy. The final consolidated alloy showed roughly a 2× hardness improvement over the unalloyed, compacted material. Unique aspects of this work include demonstration of use of FC processing to produce an equiaxed, sub-micrometer grain size in samples within a 0.5 to 2 min processing time. The results point to future opportunities to implement shear deformation during powder densification to expand the range of property outcomes in bulk materials.