Abstract: The present disclosure is related to surfaces having various topographical features and methods of making same. The disclosed features, created on various polycrystalline metallic substrates, may aid in effectively and rapidly reducing or eliminating detrimental effects of microbes. In some embodiments, the surface features may include channels and combinations of angular features such as ledges, ridges, and nodules, which may help adsorption of microbes to the surface, increase the surface chemical activity, and increase the effective surface area to support and/or accelerate the killing or deactivation of microbes. Some embodiments including reducing radii of curvature on channel ledges, intra-grain angular ridges, and angular nodules to accelerate disruption of microbial outer membranes by charge concentration and charge transfer.

Abstract: A configuration of nanoscale metal or metal oxide projections on the surface of a metal substrate is provided. The configuration, because of their nanoscale geometric characteristics, create non-uniform distributions of electrical surface charge, which can rapidly transfer into nearby microbes to reduce or eliminate their pathogenicity. The charge transfer disrupts the microbe outer membrane and inactivates pathogenic processes. One embodiment of a nano surface architecture is provided that is suitable for inactivating viruses or killing bacteria via enhanced charge transfer. A range of nanoprojection spacings, sizes, and shapes are provided. A high shear deformation process to create high-angle grain boundaries and specific grain sizes in metal or alloy substrates suited for nucleating and growing nanoprojections that possess the characteristics needed to deactivate microbes is also provided.

Abstract: Disclosed herein is an integrated combination of materials within a vesicle, comprising a space filling porous or fibrous structure and an engineered nonuniform elastic truss to form an impact mitigating Hybrid Material System (HMS). The macroscale and microscale structures within the HMS can be configured to absorb kinetic energy and reduce the forces transmitted by impacts through the HMS to any surface or body in contact with the HMS.

Abstract: Systems, methods, and apparatuses are provided herein to thermomechanically process a workpiece to increase the strength in terms of hardness and the electrical conductivity of the workpiece. In some embodiments, a shear strain is induced in a workpiece at a temperature or within a range of temperatures, and the workpiece is rotated about its longitudinal axis. Then, another shear strain is induced in the workpiece. In various embodiments, four shear strains are induced in a workpiece, and the workpiece is rotated between shear strains. The shear strains, temperatures, and rotations contribute to the increase in density of dislocations, precipitation growth, and refinement of grain size. The result is a workpiece such as AA1xxx aluminum with an increase in hardness and electrical conductivity.

Abstract: A conductive element of a cable or a wire is formed of a high shear deformation processed aluminum alloy. The aluminum-zirconium alloy exhibits high electrical conductivity and high tensile strength. Methods of forming cables and wires are also further disclosed including the formation of all aluminum alloy cables having high ampacity.

Abstract: Disclosed herein is an integrated combination of materials within a vesicle, comprising a space filling porous or fibrous structure and an engineered nonuniform elastic truss to form an impact mitigating Hybrid Material System (HMS). The macroscale and microscale structures within the HMS can be configured to absorb kinetic energy and reduce the forces transmitted by impacts through the HMS to any surface or body in contact with the HMS.

Abstract: The disclosed invention specifies: 1) a metal or alloy with specific characteristics of its Deformation-induced Volumetric Microstructural Imperfections (DIVMI), 2) a method to measure these imperfections, and 3) a method to control these imperfections in a way that enhances one or more of strength, ductility, and the high cycle fatigue endurance limit of metals and alloys. The invention recognizes that all deformation-processed metals or alloys contain DIVMI and that through Severe Plastic Deformation processing one can minimize the characteristics of DIVMI that limit mechanical properties. Application of the methods to measure and control imperfections allows one to produce metals and alloys with strengths approaching the theoretical limit of strength.

Abstract: An apparatus that continuously processes a metal workpiece without substantially altering its cross section includes a wheel member having an endless circumferential groove, and a stationary constraint die that surrounds the wheel member, covers most of the length of the groove, and forms a passageway with the groove. The passageway has a rectangular shaped cross section. An abutment member projects from the die into the groove and blocks one end of the passageway. The wheel member rotates relative to the die in the direction toward the abutment member. An output channel in the die adjacent the abutment member has substantially the same cross section as the passageway. A metal workpiece is fed through an input channel into the passageway and carried in the groove by frictional drag in the direction towards the abutment member, and is extruded through the output channel without any substantial change in cross section.

Abstract: A method of refining the grain structure and improving the hardness and strength properties of a metal or metal alloy workpiece is disclosed. The workpiece is subjected to forces that corrugate and then straighten the workpiece. These steps are repeated until an ultrafine-grained product having improved hardness and strength is produced.

Abstract: We disclose ultrafine-grained titanium. A coarse-grained titanium billet is subjected to multiple extrusions through a preheated equal channel angular extrusion (ECAE) die, with billet rotation between subsequent extrusions. The resulting billet is cold processed by cold rolling and/or cold extrusion, with optional annealing. The resulting ultrafine-grained titanium has greatly improved mechanical properties and is used to make medical implants.

Abstract: A method of refining the grain structure and improving the hardness and strength properties of a metal or metal alloy workpiece is disclosed. The workpiece is subjected to forces that corrugate and then straighten the workpiece. These steps are repeated until an ultrafine-grained product having improved hardness and strength is produced.