Development of Hierarchical Magnesium Composites Using Hybrid Microwave Sintering

In this work, hierarchical magnesium based composites with a micro-architecture comprising reinforcing constituent that is a composite in itself were fabricated using powder metallurgy route including microwave assisted rapid sintering technique and hot extrusion. Different level-I composite particles comprises sub-micron pure aluminum (Al) matrix containing Al2O3 particles of different length scale (from micrometer to nanometer size). Microstructural characterization of the hierarchical composites revealed reasonably uniform distribution of level-I composite particles and significant grain refinement compared to monolithic Mg. Hierarchical composite configurations exhibited different mechanical performance as a function of Al2O3 length scale. Among the different hierarchical formulations synthesized, the hierarchical configuration with level-I composition comprising Al and nano-Al2O3 (0.05 mu m) exhibited the highest improvement in tensile yield strength (0.2% YS), ultimate tensile strength (UTS), tensile failure strain (FS), compressive yield strength (0.2% CYS) and ultimate compressive strength (UCS) (+96%, +80%, +42%, +80%, and +83%) as compared to monolithic Mg. An attempt has been made in the present study to correlate the effect of different length scales of Al2O3 particulates on the microstructural and mechanical response of magnesium.