  Nanocrystalline metal alloys show great potential as structural materials,
but are often only available in small volumes such as thin films or powders.
However, recent research has suggested that dopant segregation and grain
boundary structural transitions between states known as complexions can
dramatically alter grain size stability and potentially enable activated
sintering. In this study, we explore strategic consolidation routes for
mechanically alloyed Cu-4 at.% Zr powders to capture the effects of amorphous
complexion formation on the densification of bulk nanostructured metals. We
observed an increase in density of the consolidated samples which coincides
with the formation of amorphous intergranular films. At the same time, the
grain size is reasonably stable after exposure to these temperatures. As a
result, we are able to produce a bulk nano-grained metal with a grain size of
57 nm and a density of 99.8%, which shows an impressive balance of small grain
size and high density using simple consolidation techniques.
