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Using nanoscale electrical-discharge-induced rapid Joule heating, we developed a method for ultrafast shape change and joining of small-volume materials. Shape change is dominated by surface-tension-driven convection in the transient liquid melt, giving an extremely high strain rate of ~106 s–1. In addition, the heat can be dissipated in small volumes within a few microseconds through thermal conduction, quenching the melt back to the solid state with cooling rates up to 108 K·s-1. We demonstrate that this approach can be utilized for the ultrafast welding of small-volume crystalline Mo (a refractory metal) and amorphous Cu49Zr51 without introducing obvious microstructural changes, distinguishing the process from bulk welding.
This work was supported by the grants from NSFC (Nos. 50925104, 51231005 and 51321003) and 973 (Program of China) (Nos. 2010CB631003, 2012CB619402). We also appreciate the support from the 111 Project of China (No. B06025). Both E. M. and J. L. carried out this work under an adjunct professorship at XJTU. J. L. acknowledges support by NSF (No. DMR- 1120901). E. M. was supported at JHU by US-NSF (No. DMR-0904188).