Reactive Solid-State Shear Processing for Designing Multifunctional Materials

Reactive processing traditionally relies on high-temperature routes where thermodynamic equilibrium governs phase formation and microstructure evolution. In contrast, solid-state shear-based processing provides a non-equilibrium pathway for synthesizing advanced materials through intense plastic deformation, localized heating, and rapid interfacial mixing. In this work, we present a generalized framework for reactive solid-state shear processing using friction-based consolidation as a scalable manufacturing approach. The severe shear deformation promotes fragmentation of reactant phases, atomic-scale mixing, and reaction pathways that are difficult to achieve through conventional processing methods.

The approach is demonstrated across multiple material systems including Al–SmCo₅ magnetic composites, Al–Fe₃O₄ nanothermite systems, Ni–Cu alloys, graphene-reinforced aluminum, Mg–eggshell bio-derived composites, and Al–Cu alloys. Advanced characterization reveals hierarchical microstructures, nanoscale reaction products, and refined grain structures resulting from the combined effects of severe deformation and localized reactions. These microstructural features enable tunable mechanical, magnetic, and functional properties.

The results highlight reactive solid-state shear processing as a versatile and scalable platform for manufacturing multifunctional materials through controlled non-equilibrium pathways.