Interface-controlled in-situ synthesis of nanostructures in molten metals for mass manufacturing

Abstract

Provided herein are manufacturing methods of a metal matrix nanocomposite, comprising: providing a molten metal including a first reactant; providing a molten salt, including a second set of reactants and a diluting salt, over a surface of the molten metal; and maintaining the molten salt and the molten metal at a temperature sufficient to react the first reactant and the second set of reactants, such that nanostructures with controlled small sizes are formed adjacent to an interface between the molten salt and the molten metal, and are incorporated into the molten metal for mass manufacturing of metal matrix nanocomposite.

1 . A manufacturing method of a metal matrix nanocomposite, comprising:
 providing a molten metal including a first reactant;   providing a molten salt, including a second set of reactants and a diluting salt, over a surface of the molten metal; and   maintaining the molten salt and the molten metal at a temperature sufficient to react the first reactant and the second set of reactants, such that nanostructures are formed adjacent to an interface between the molten salt and the molten metal, and are incorporated into the molten metal.   
     
     
         2 . The manufacturing method of  claim 1 , wherein one or more of a concentration of the first reactant, a concentration of the second set of reactants, the temperature, and a time of reaction is set or adjusted according to a target size of the nanostructures. 
     
     
         3 . The manufacturing method of  claim 1 , wherein the manufacturing method provides for mass production. 
     
     
         4 . The manufacturing method of  claim 1 , wherein providing the molten metal includes heating one or more metals to form the molten metal. 
     
     
         5 . The manufacturing method of  claim 1 , wherein the first reactant is a metal or an alloying element. 
     
     
         6 . The manufacturing method of  claim 1 , wherein providing the molten metal includes heating the first reactant to form the molten metal. 
     
     
         7 . The manufacturing method of  claim 1 , wherein the second set of reactants includes a metal-containing salt. 
     
     
         8 . The manufacturing method of  claim 7 , wherein the metal-containing salt is a metal-containing halide salt. 
     
     
         9 . The manufacturing method of  claim 7 , wherein the second set of reactants also includes a boron-containing salt. 
     
     
         10 . The manufacturing method of  claim 7 , wherein the second set of reactants also includes a carbon source. 
     
     
         11 . The manufacturing method of  claim 7 , wherein the second set of reactants also includes a silicon-containing salt. 
     
     
         12 . The manufacturing method of  claim 1 , wherein the second set of reactants includes a metal-containing oxide. 
     
     
         13 . The manufacturing method of  claim 12 , wherein the second set of reactants also includes a carbon source. 
     
     
         14 . The manufacturing method of  claim 1 , wherein providing the molten salt includes combining the second set of reactants with the diluting salt. 
     
     
         15 . The manufacturing method of  claim 14 , wherein the diluting salt includes a halide salt or a mixture of halide salts. 
     
     
         16 . The manufacturing method of  claim 14 , wherein the diluting salt includes one or more chloride salts, one or more fluoride salts, or a mixture thereof. 
     
     
         17 . The manufacturing method of  claim 1 , further comprising agitating the molten metal. 
     
     
         18 . The manufacturing method of  claim 1 , further comprising cooling the molten metal including the nanostructures incorporated therein to form the metal matrix nanocomposite. 
     
     
         19 . The manufacturing method of  claim 18 , wherein the nanostructures have an average size in a range of about 1 nm to about 500 nm. 
     
     
         20 . The manufacturing method of  claim 18 , wherein a distribution of sizes of the nanostructures is characterized by a standard deviation, relative to an average size, that is up to about 50% of the average size. 
     
     
         21 . The manufacturing method of  claim 18 , wherein the metal matrix nanocomposite includes the nanostructures at a volume percentage in a range of about 0.5% or greater and up to about 30%. 
     
     
         22 . A metal matrix nanocomposite formed by the method of  claim 1 .