Synthesis and characteristics evaluation of magnesium alloy (AZ91) nanocomposite developed with ZrO2 via liquid state stir cast process

With a high strength-to-weight ratio, the AZ91 grade magnesium alloy is essential in various engineering applications like automotive, aerospace, marine, and defence. The main drawback of magnesium casting has oxidation results in agglomeration, slag formation, and voids. The present investigation of the liquid state vacuum stir cast process under an inert atmosphere was utilized to prepare AZ91 alloy nanocomposites with 0, 3, 6, 9, and 12 wt% of nano-zirconium dioxide (ZrO2) particles. The microstructure elemental composition of the developed composites was subjected to SEM/EDS analysis. The effect of ZrO2 nanoparticles on the composite's physical, mechanical, wear, and corrosion properties was studied. The composite's actual density obeys the mixture's rule and is found to be lightweight compared to conventional materials. The composite contained 9 wt% of ZrO2 and showed the maximum micro Vickers hardness number (96.71 +/- 1.05 HV), ultimate tensile (281 +/- 1.1 MPa), and impact strength (20.61 J). The higher content of ZrO2 offered good wear resistance (value) under 40 N at 1 m/sec sliding speed compared to unreinforced cast AZ91 alloy and facilitated higher corrosion resistance of 3.23 mm/year.