A new route to bulk nanocrystalline materials

Despite their interesting properties, nanostructured materials have found limited use as a result of the cost of preparation and the difficulty in scaling up. Herein, the authors report a technique, friction stir processing (FSP), to refine grain sizes to a nanoscale. Nanocrystalline 7075 Al with an average grain size of 100 nm was successfully obtained using FSP. It may be possible to further control the microstructure of the processed material by changing the processing parameters and the cooling rate. In principle, by applying multiple overlapping passes, it should be possible to produce any desired size thin sheet to nanostructure using this technique. We expect that the FSP technique may pave the way to large-scale structural applications of nanostructured metals and alloys.