Synthesis and microstructure of bulk nanocrystalline copper

Abstract

The synthesis of bulk nanocrystalline copper (NC-Cu) by powder metallurgy is presented, from compaction of nanocrystalline powders to sintering and differential extrusion. At each step of the process, the microstructure is characterized using X-ray diffraction (XRD) analysis, field-emission gun scanning electron microscopy (FEG-SEM), and transmission electron microscopy (TEM). Particular attention is given to the concept of grain size in nanostructured materials and the comparison of results from the different characterization techniques. The fully dense material has a grain size of 100 nm with a microstructure best described in terms of the distribution of high-angle grain boundaries (GBs), twin boundaries, and low-angle GBs. Dislocations occur in half the grains and at most of the twin boundaries. The GBs are shown to be crystalline, and no evidence is found for amorphous interfacial regions. It is proposed that the grain size be defined only in terms of high-angle GBs, excluding low-angle GBs, for the discussion of mechanical properties. In this respect, the microstructure is compared with the NC-Cu material produced by other synthesis techniques. Powder metallurgy (P/M) processing is revealed as an alternative for the production of large-size submicrocrystalline and NC materials.