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    Size-Dependent Phase Selection during Thermomechanical Nanomolding

    Yupeng Wu1,*, Yangyang Pan1,*, Hui Fang1,*, Guoxing Han1, Naijia Liu2, Arindam Raj2, Sungwoo Sohn2, Zhiping Xu3, Yi-Xiang Yang2 et al.

    You Li1, Ning Li4,‡, Jan Schroers2,§, and Ze Liu1,5,6,†

    • 1Department of Engineering Mechanics, School of Civil Engineering, Wuhan University, Wuhan, Hubei 430072, China
    • 2Department of Mechanical Engineering and Materials Science, Yale University, New Haven, Connecticut 06511, United States
    • 3Applied Mechanics Laboratory, Department of Engineering Mechanics, Tsinghua University, Beijing, 100084, China
    • 4State Key Laboratory of Material Processing and Die and Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
    • 5State Key Laboratory of Water Resources and Hydropower Engineering Science, Wuhan University, Wuhan 430072, China
    • 6The Institute of Technological Sciences, Wuhan University, Wuhan, 430072 China

    • *These authors contributed equally to this work.
    • †Contact author: ze.liu@whu.edu.cn
    • ‡Contact author: hslining@hust.edu.cn
    • §Contact author: jan.schroers@yale.edu

    Phys. Rev. Lett. 136, 146201 – Published 10 April, 2026

    DOI: https://doi.org/10.1103/qr4t-smkg

    Abstract

    Selectively realizing metastable phases is challenging, despite their vast number, due to the interplay of kinetics and thermodynamics, which has to be realized through processing conditions. Here, we demonstrate selective and controlled realization of metastable phases through size confinement effects. This is realized during diffusion-controlled filling of nanocavities. By nanomolding AuSi alloy and performing crystal structure and elemental analysis of molded alloy nanowires, we observe three different phase states, i.e., hybrid nanophase, bamboo-shaped, and uniform alloy phases, corresponding to different nanowire sizes. The surprising uniform alloy phase for nanowires with diameter below ∼20  nm exhibits perfect single crystalline structure with uniform distribution of Au and Si compositions. A phase state-energy map is constructed to rationalize the findings by considering the competition between mixing enthalpy, configuration entropy, strain energy and interfacial energy. Our Letter demonstrates the universal applicability of nanomolding in fabricating metal-metal and metal-nonmetal metastable phases. In contrast to state-of-the-art rapid cooling techniques, this strategy is simple and practical, thereby enabling precise selection of novel materials with tailored functionalities.

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