Bulk low-cost interface-defined laminated materials and their method of fabrication

A batch or continuous process for fabricating a low porosity nanolaminate material comprising at least two continuous individual layers comprising at least two different nanomaterials, wherein adjacent layers each have a different nanomaterial composition, the continuous individual layers being numerous enough and thin enough such that at least one property of the low porosity nanolaminate material is mainly determined by an unbroken continuous interface between the adjacent layers and to a lesser degree by properties of the different nanomaterial composition comprising the continuous individual layers, the batch or continuous process comprising the steps of:

• a) selecting the different nanomaterial composition for each continuous individual layer, a sequence of the continuous individual layers, a structure and a chemistry of each unbroken continuous interface between each continuous individual layer, and a desired final layer thickness of each of the continuous individual layers in a direction about perpendicular to a plane of the continuous individual layers, wherein the desired final layer thickness is 1-999 nanometers;
• b) selecting at least two nanopowders each consisting of nanosize particles of different composition;
• c) refining and classifying the at least two nanopowders such that that the nanosize particles are at least 3-10 times smaller than the desired final layer thickness of each continuous individual layer;
• d) forming at least two pastes or slurries by adding a solvent and at least one additive selected from the group consisting of a binder, a lubricant, a dispersing agent, a stabilizer, and a plasticizer to the at least two nanopowders, wherein each paste or slurry each comprises one of the at least two nanopowders;
• e) adjusting a viscosity of each paste or slurry such that low viscosity slurries are capable of being sprayed or spread and such that higher viscosity pastes are capable of being rolled, pressed, or wrapped around a mandrel without deforming in a manner that intermixes the adjacent layers;
• f) fabricating a green nanolaminate from the at least two pastes or slurries by at least one process selected from the group consisting of spraying, spreading, wrapping, rolling, pressing, cutting, and stacking;
• g) repeating the at least one fabrication process until at least one of a desired number of continuous individual layers and the desired final layer thickness of each of the continuous individual layers is obtained;
• h) compacting the green nanolaminate utilizing an additional rolling sequence or an additional pressing sequence;
• i) de-watering, de-gassing, and burning out the green nanolaminate prior to consolidation to remove volatile components;
• j) consolidating the green nanolaminate to form the low porosity nanolaminate material having a desired final thickness utilizing at least one technique selected from the group consisting of atomic templating via cold consolidation, rapid sintering, hot pressing, dynamic compaction, plastic deformation, liquid infiltration, microwave heating, and hot rolling, wherein the green nanolaminate is consolidated to a density that is at least 95% of theoretical density while minimizing porosity and grain growth of the at least two different nanomaterials such that unbroken continuous interfaces are formed between the adjacent layers;
• and
• k) annealing the low porosity nanolaminate material at an elevated temperature sufficient to cause atomic rearrangement such that a desired degree of coherency at the unbroken continuous interfaces is developed.