Evaluation of Magnalium Alloy Developed by the Powder Metallurgy Process: Processing and Metallurgical Characteristics

The conventional powder metallurgy process is a promising method to develop magnalium alloy using sintering without any hot deformation and liquid metallurgy. Moreover, metallurgical and microstructural properties of magnalium alloy have not been systematically investigated and are less considered for the lightweight high-strength structural applications. In this experimental work, the Mg and Al powder mix for x-Mg–Al-Ni–Sn (x = 4–6%) was mixed initially by ball milling and then by compaction and sintering process. Synthesized magnalium alloy was successfully investigated according to the improved density, micro-indentation hardness, excellent compressive strength and microstructural evaluation. Experimental results reveal that for x = 6% Mg–Magnalium alloy density of the component reaches 2.59 g/cm3, micro-indentation hardness has the maximum value of 302.9 HV at some Mg interfaces and 211.8 HV on average with compressive strength of 24.6 MPa. Also, based on this study, microstructural characteristics showed an excellent bonding with proper mixing of included particulates and Al–Mg interfaces.