Ultrastrong spinodoid alloys enabled by electrochemical dealloying and refilling.

We present an extreme case of composition-modulated nanomaterial formed by selective etching (dealloying) and electrochemical refilling. The product is a coarse-grain polycrystal consisting of two interwoven nanophases, with identical crystal structures and a cube-on-cube relationship, separated by smoothly curved semicoherent interfaces with high-density misfit dislocations. This material resembles spinodal alloys structurally, but its synthesis and composition modulation are spinodal-independent. Our Cu/Au "spinodoid" alloy demonstrates superior mechanical properties such as near-theoretical strength and single-phase-like behavior, owing to its fine composition modulation, large-scale coherence of crystal lattice, and smoothly shaped three-dimensional (3D) interface morphology. As a unique extension of spinodal alloy, the spinodoid alloy reported here reveals a number of possibilities to modulate the material's structure and composition down to the nanoscale, such that further improved properties unmatchable by conventional materials can be achieved.

Light, strong, and stable nanoporous aluminum with native oxide shell.

Aluminum (Al) metal is highly reactive but has excellent corrosion resistance because of the formation of a self-healing passive oxide layer on the surface. Here, we report that this native aluminum oxide shell can also stabilize and strengthen porous Al when the ligament (strut) size is decreased to the submicron or nanometer scale. The nanoporous Al with native oxide shell, which is a nanoporous Al-Al2O3 core-shell composite self-organized in a galvanic replacement reaction, is nonflammable under ambient conditions and stable against coarsening near melting temperatures. This material is stronger than conventional foams of similar density consisting of pure Al or Al-based composites, and also lighter and stronger than most nanoporous metals reported previously. Its light weight, high strength, and excellent stability warrant the explorations of functional and structural applications of this material, if more efficient and scalable synthesis processes are developed in the future.