Mechanical properties of Mg-based materials fabricated by mechanical milling and spark plasma sintering

In this work, magnesium powders of different grain sizes were synthesized by mechanical milling for periods ranging from 0.5 to 30 h. Subsequent to milling, powders were consolidated by spark plasma sintering at 550 ℃ for 10 min. Before and after sintering, microstructural changes were investigated by analytical methods including X-ray diffraction (XRD), X-ray spectrometer, optical and electron microscopy. Analyses showed that nanocrystalline sizes were achieved by mechanical milling for milling times exceeding 5 h. Additionally, it was recognized that grain growth occurred during sintering, but to a limited extent. Mechanical test results displayed reasonable improvements in both compressive yield strength and hardness values with increasing milling times up to 5 h, where these reached their maximum values (245.5 MPa and 75.9 HV). The enhancement in these properties with increased milling time up to 5 h was attributed to both the extent of grain refinement and the formation of MgO together with incorporation of Fe particles, originating from the milling process, into the matrix. On the other hand, a substantial decrease in yield strength and hardness values in the samples milled in excess of 5 h were recorded, which in turn was related to the accompanying decline in bulk density of the samples. Microstructural analysis of the deformed samples revealed that grain size reduction suppressed twin formation, which elucidates the enhancement in ductility with decreasing grain size.