Healing metallic materials involves high temperatures and large energy inputs. This work demonstrates rapid, effective, low‐energy, and room‐temperature healing of metallic materials by using electrochemistry and polymer‐coated cellular nickel to mimic the transport‐mediated healing of bone. The polymer coating enables selective healing only at the fracture site, electrochemical reactions transport metal ions from a metal source to fractured areas, and the cellular structure of the metal allows facile ion transport to healing sites and effective recovery of strength and toughness when the cellular metal is subjected to three types of damage (scission fracture, tensile failure, and plastic deformation). Using this strategy, samples fractured in tension and by scission recover 100% of their tensile strength in as little as 10 and 4 h of healing. The healing process is stochastic, thus a statistical method is used to quantify and predict the likelihood of achieving target healing strengths based on energy input. This electrochemistry‐based approach enables the first demonstration of room‐temperature healing of structural metallic materials and requires several orders of magnitude less energy than many previously reported metal healing techniques.
Repairing fractured metals to extend their useful lifetimes advances sustainability and mitigates carbon emissions from metal mining and processing. While high‐temperature techniques are being used to repair metals, the increasing ubiquity of digital manufacturing and “unweldable” alloys, as well as the integration of metals with polymers and electronics, call for radically different repair approaches. Herein, a framework for effective room‐temperature repair of fractured metals using an area‐selective nickel electrodeposition process refered to as electrochemical healing is presented. Based on a model that links geometric, mechanical, and electrochemical parameters to the recovery of tensile strength, this framework enables 100% recovery of tensile strength in nickel, low‐carbon steel, two “unweldable” aluminum alloys, and a 3D‐printed difficult‐to‐weld shellular structure using a single common electrolyte. Through a distinct energy‐dissipation mechanism, this framework also enables up to 136% recovery of toughness in an aluminum alloy. To facilitate practical adoption, this work reveals scaling laws for the energetic, financial, and time costs of healing, and demonstrates the restoration of a functional level of strength in a fractured standard steel wrench. Empowered with this framework, room‐temperature electrochemical healing can open exciting possibilities for the effective, scalable repair of metals in diverse applications.
more » « less- NSF-PAR ID:
- 10419014
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Materials
- Volume:
- 35
- Issue:
- 24
- ISSN:
- 0935-9648
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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