Abstract: A method by which consolidated articles can be produced from nanocrystalline materials to have mechanical properties that can be improved through thermal treatment. The method entails machining a body to produce polycrystalline chips having nanocrystalline microstructures, and then consolidating the chips to form a consolidated article having mechanical properties that exceed that of the body from which the chips were formed. In particular, consolidation of nanocrystalline chips formed by machining a supersaturated solid-solution body causes precipitation of a fine dispersion of precipitates in the consolidated article, with the potential for certain properties to even improve during consolidation or subsequent thermal treatment of the consolidated article.

Abstract: A method for producing articles containing nanocrystalline microstructures, and particularly to a method of controllably producing nanocrystalline chips with a desired shape and size. The method generally entails machining a body with a cutting tool to produce polycrystalline chips having nanocrystalline microstructures while superimposing modulation on the cutting tool so as to move the cutting tool relative to the body being machined and cause instantaneous and periodic separation between the cutting tool and the body at a point of contact between the cutting tool and the body, wherein each separation between the cutting tool and the body yields a chip. In this manner, the shapes and sizes of the chips are determined at least in part by the modulation cycle, and particularly the length of time the cutting tool is engaged with the body being machined.