Baylor UniversityMechanical Engineering

Research

Materials processing, structure & properties

We investigate how heat, shear, chemistry, defects, and interfaces shape microstructure—and how those structures respond in demanding applications.

01

Solid-Phase & Friction-Based Manufacturing

Shape materials through heat, shear, and pressure—without melting the whole feedstock.

<p>We study friction extrusion, friction stir processing, additive friction stir deposition, and related severe-plastic-deformation routes to connect processing path with microstructure and performance.</p>

Friction extrusionFriction stir processingMicrostructure characterizationMagnesium alloysSteels
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Photograph and sectional schematic of the friction-extrusion setup used to produce an oxide-dispersion-strengthened copper rod
Experimental setup and sectional schematic for friction extrusion of an ODS copper rod from powder.Ma et al., Journal of Manufacturing Processes (2022), Fig. 2 · Source
02

Powder Metallurgy & Dispersion-Strengthened Materials

Turn engineered powders into dense, stable structural materials.

<p>Research examines powder synthesis, consolidation, oxide dispersion, and processing routes that reduce or replace conventional ball milling and long thermomechanical sequences.</p>

Powder synthesisFriction consolidationElectron microscopyODS steelsGARS powders
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Long oxide-dispersion-strengthened copper extrudate with optical and transmission electron micrographs of its microstructure
Three-meter ODS copper extrudate and representative refined microstructure produced from powder.Ma et al., Journal of Manufacturing Processes (2022), Fig. 3 · Source
03

Nuclear & Fusion Structural Materials

Connect microstructural stability with performance under heat and irradiation.

<p>The research record spans FeCrAl alloys, nanostructured ferritic materials, oxide-dispersion-strengthened steels, irradiation effects, and manufacturing challenges for fission and fusion systems.</p>

Irradiation characterizationTEMScatteringFeCrAl alloysODS steels
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Hardness map and EBSD inverse-pole-figure maps across a friction-consolidated oxide-dispersion-strengthened steel puck
Hardness and EBSD grain maps across a friction-consolidated GARS-derived ODS steel puck.Zhang et al., Journal of Nuclear Materials (2022), Fig. 6 · Source
04

Magnesium & Lightweight Alloys

Resolve the deformation mechanisms that govern lightweight metals.

<p>Work on magnesium links slip, twinning, stacking faults, texture, rare-earth additions, and solid-phase processing to strength, ductility, corrosion, and microstructural stability.</p>

In situ TEMCrystal-defect analysisMechanical testingMg-YMg-Gd-Y
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Several friction-extruded ZK60 magnesium alloy tubes made using the ShAPE process
Friction-extruded ZK60 magnesium-alloy tubes produced with PNNL’s ShAPE process.S. Whalen / Pacific Northwest National Laboratory, CC0 · Source
05

Sustainable Metallurgy

Investigate shorter, lower-step routes for producing structural materials.

<p>Verified work includes processing concepts that avoid prolonged ball milling, canning, degassing, or hot rolling. Broader energy and emissions claims remain subject to process-specific life-cycle evidence.</p>

Process-chain comparisonSolid-state processingPowder consolidationODS steelsRecycled and powder feedstocks
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Cross-section and hardness map of a GARS-derived oxide-dispersion-strengthened steel puck made by friction consolidation
Consolidated GARS-derived ODS steel cross-section and hardness distribution from a shortened process route.Zhang et al., Journal of Nuclear Materials (2022), Fig. 5 · Source