Powder metallurgy of Mg–1%Al–1%Sn alloy reinforced with low content of graphene nanoplatelets (GNPs)

Significance of the Powder Metallurgy Approach and Its Processing Parameters on the Mechanical Behavior of Magnesium-Based Materials

Magnesium-based materials, which are known for their light weight and exceptional strength-to-weight ratio, hold immense promise in the biomedical, automotive, aerospace, and military sectors. However, their inherent limitations, including low wear resistance and poor mechanical properties, have driven the development of magnesium-based metal matrix composites (Mg-MMCs). The pivotal role of powder metallurgy (PM) in fabricating Mg-MMCs was explored, enhancing their mechanical and corrosion resistance characteristics. The mechanical characteristics depend upon the fabrication methodology, composition, processing technique, and reinforcement added to the magnesium. PM is identified as the most efficient due to its ability to produce near-net shape composites with high precision, cost-effectiveness, and minimal waste. Furthermore, PM enables precise control over critical processing parameters, such as compaction pressure, sintering temperature, and particle size, which directly influence the composite's microstructure and properties. This study highlights various reinforcements, mainly carbon nanotubes (CNTs), graphene nanoparticles (GNPs), silicon carbide (SiC), and hydroxyapatite (HAp), and their effects on improving wear, corrosion resistance, and mechanical strength. Among these, CNTs emerge as a standout reinforcement due to their ability to enhance multiple properties when used at optimal weight fractions. Further, this study delves into the interaction between reinforcement types and matrix materials, emphasizing the importance of uniform dispersion in preventing porosity and improving durability. Optimal PM conditions, such as a compaction pressure of 450 MPa, sintering temperatures between 550 and 600 °C, and sintering times of 2 h, are recommended for achieving superior mechanical performance. Emerging trends in reinforcement materials, including nanostructures and bioactive particles, are also discussed, underscoring their potential to widen the application spectrum of Mg-MMCs.

The Effectiveness Mechanisms of Carbon Nanotubes (CNTs) as Reinforcements for Magnesium-Based Composites for Biomedical Applications: A Review

As a smart implant, magnesium (Mg) is highly biocompatible and non-toxic. In addition, the elastic modulus of Mg relative to other biodegradable metals (iron and zinc) is close to the elastic modulus of natural bone, making Mg an attractive alternative to hard tissues. However, high corrosion rates and low strength under load relative to bone are some challenges for the widespread use of Mg in orthopedics. Composite fabrication has proven to be an excellent way to improve the mechanical performance and corrosion control of Mg. As a result, their composites emerge as an innovative biodegradable material. Carbon nanotubes (CNTs) have superb properties like low density, high tensile strength, high strength-to-volume ratio, high thermal conductivity, and relatively good antibacterial properties. Therefore, using CNTs as reinforcements for the Mg matrix has been proposed as an essential option. However, the lack of understanding of the mechanisms of effectiveness in mechanical, corrosion, antibacterial, and cellular fields through the presence of CNTs as Mg matrix reinforcements is a challenge for their application. This review focuses on recent findings on Mg/CNT composites fabricated for biological applications. The literature mentions effective mechanisms for mechanical, corrosion, antimicrobial, and cellular domains with the presence of CNTs as reinforcements for Mg-based nanobiocomposites.

The Effect of Graphene Nanoplatelets Content on the Hardness of Mg6%Zn0.2%Mn Composites

The effect of graphene nanoplatelets (GNPs) content on the hardness of magnesium-based composites was studied. A magnesium-based composite, Mg6%Zn0.2%Mn with graphene nanoplatelets (GNPs), was fabricated via powder metallurgy process at room temperature and compressive pressures of 50kN for 20 minutes, which was then sintered at 500°C for 2 hours. It produced significant grain refinement microstructure. The change in microstructure was examined by 3D microscope analysis, and the hardness value was evaluated using the Vickers microhardness apparatus. This study demonstrated the importance of GNPs reinforcement with zinc and manganese for microhardness analysis in the sintered Mg-based GNPs composites. It also portrayed their influence on grain refinement of the microstructure. The hardness results agreed with the microstructure results, proving that the presence of GNPs increases the hardness of the Mg-based composites.

Microstructures, mechanical and corrosion properties of graphene nanoplatelet-reinforced zinc matrix composites for implant applications

Zinc (Zn)-based alloys and composites are gaining increasing interest as promising biodegradable implant materials due to their appropriate biodegradation rates and biological functionalities. However, the inadequate mechanical strength and ductility of pure Zn have restricted its application. In this study, Zn matrix composites (ZMCs) reinforced with 0.1-0.4 wt.% graphene nanoplatelets (GNP) fabricated via powder metallurgy were investigated as potential biodegradable implant materials. The microstructures, mechanical properties, and corrosion behaviors of the GNP-reinforced ZMCs were characterized using optical microscopy, scanning electron microscopy combined with energy-dispersive X-ray spectroscopy, Raman spectroscopy, compression testing, and electrochemical and immersion testing in Hanks' balanced salt solution (HBSS). The microstructural study revealed that the GNP was uniformly dispersed in the ZMCs after ball milling and sintering at 420°C for 6 h. The microhardness, compressive yield strength, ultimate compressive strength, and compressive strain of the ZMC-0.2GNP were 69 HV, 123 MPa, 247 MPa, and 23 %, respectively, improvements of ∼ 18 %, 50%, ∼ 28%, and ∼ 15% compared to pure Zn. The corrosion rate of the ZMCs were lower than that of the pure Zn in HBSS, and the ZMC-0.2GNP composite exhibited the lowest corrosion rate of 0.09 mm/y as measured by electrochemical testing. Biocompatibility assessment indicated that the diluted extracts of pure Zn and GNP-reinforced ZMCs with concentrations of 12.5% and 6.25% exhibited no cytotoxicity after cell culturing for up to 5 days, and the diluted extracts of ZMC-0.2 GNP composite revealed more than 90% cell viability after cell culturing of 3 days, showing the satisfying cytocompatibility. STATEMENT OF SIGNIFICANCE: Biodegradable Zn is a promising candidate material for orthopedic implant applications. Nonetheless, the inadequate mechanical strength and ductility of pure Zn limited its clinical application. In this study, Zn matrix composites (ZMCs) reinforced with 0.1-0.4 wt.% graphene nanoplatelets (GNP) were developed via powder metallurgy, and the reinforcing efficacy of GNP on their mechanical properties was investigated. The addition of GNP significantly improved the compressive properties of ZMCs, with the Zn-0.2GNP composite exhibiting the best compressive properties, including 123 MPa compressive yield strength, 247 MPa ultimate compressive strength, and 22.9% compressive strain. Further, the 12.5% concentration extract of the ZMCs exhibited no cytotoxicity after cell culturing for 5 d toward SaOS2 cells.

Manufacturing Techniques for Mg-Based Metal Matrix Composite with Different Reinforcements

Magnesium is among the lightest structural metals available, with the capacity to replace traditional alloys in mass-saving applications while still providing increased stiffness and strength. The inclusion of reinforcing components into the metallic matrix has a substantial impact on stiffness, specific strength, wear behaviour, damping behaviour, and creep properties when compared to typical engineering materials. Due to their outstanding physical and mechanical characteristics along with low density, magnesium metal matrix composites are viable materials for numerous applications. This study discusses how to choose an appropriate technique and its process parameters for synthesising magnesium-based metal matrix composites (MMCs) and gives an overview of the impacts of various reinforcements in magnesium and its alloys, emphasising their benefits and drawbacks. The essential applications of various magnesium-based MMCs are also critically examined in this article. The impact of reinforcement on the microstructure as well as mechanical characteristics are thoroughly examined.

Microstructural and Mechanical Properties Characterization of Graphene Oxide-Reinforced Ti-Matrix Composites

The 0.1–0.7 wt.% graphene oxide (GO)-reinforced Ti-matrix composites (TMCs) were prepared by the hot-pressed sintering method. The effects of GO content on the mechanical properties of TMCs were investigated. The microstructure of TMCs was analyzed. The results show that the microstructure of Ti and TMCs is equiaxed α. The average grain size of TMCs decreases with GO increasing. GO can react with Ti to form TiC at high temperatures. Meanwhile, GO is also presented in the matrix. The hardness of TMCs is higher than that of pure Ti. The maximum hardness is 320 HV, which is 43% higher than that of pure Ti. The yield strength of Ti-0.5 wt.% GO sintered at 1373 K is 1324 MPa, 77% more than pure Ti. The strengthening mechanism of TMCs is the fine-grained strengthening and the reinforcement that bear the stress from the matrix. The friction coefficient of Ti-0.3 wt.% GO sintered at 1373 K comes up to 0.50, which is reduced by 0.2 compared with pure Ti.

Recent advances in 2D graphene reinforced metal matrix composites

The unique combination of excellent mechanical and functional properties makes graphene an ideal component for high-performance 'smart' composites, which are sensitive to thermal, optical, electrical and mechanical excitations, hence being potential in application of a range of sensors. It has confirmed that the addition of graphene into metal matrix can significantly enhance the mechanical property and deliver surprising functional properties. Thus, graphene reinforced metal matrix composites (GMMCs) have long been regarded as potential prospects of nanotechnology applications. Recently, researchers mainly focused on: (i) solving the interfacial issues and realizing controllable alignment of graphene in metal matrix to achieve optimal performance; (ii) reasonable designing of the microstructures basing on usage requirement and then fabricating via efficient technique. Thus, it is necessary to figure out key roles of microstructure in fabrication process, mechanical and multi-functional properties. This review consists of four parts: (i) fabrication process. The fabrication processes are firstly divided into three kinds basing on the different bonding nature between graphene and metal matrix. (ii) Mechanical property. The microstructural characteristics of metal matrix accompanying by the incorporation of graphene and their vital effects on mechanical properties of GMMCs are systematically summarized. (iii) Functional property. The crucial effects of microstructure on electrical and thermal properties are summarized. (iv) Prospect applications and future challenges. Application and challenges basing on the research status are discussed to provide useful directions for future exploration in related fields. All these four parts are discussed with a focus on key role of microstructure characteristics, which is instructive for the microstructures design and fabrication process optimization during academic researches and potential commercial applications.

Mechanical Characterization of Graphene Nanoplatelets-Reinforced Mg-3Sn Alloy Synthesized by Powder Metallurgy

The present study investigated the effects of alloying and nano-reinforcement on the mechanical properties (microhardness, tensile strength, and compressive strength) of Mg-based alloys and composites. Pure Mg, Mg-3Sn alloy, and Mg-3Sn + 0.2 GNP alloy-nanocomposite were synthesized by powder metallurgy followed by hot extrusion. The microstructural characteristics of the bulk extruded samples were explored using X-ray diffraction, field-emission scanning electron microscopy, and optical microscopy and their mechanical properties were compared. The microhardness, tensile strength, and compressive strength of the Mg-3Sn alloy improved when compared to those of monolithic Mg sample and further improvements were displayed by Mg-3Sn + 0.2 GNP alloy-nanocomposite. No significant change in the compressive strain to failure was observed in both the alloy and the alloy-nanocomposite with respect to that of the pure Mg sample. However, an enhanced tensile strain to failure was displayed by both the alloy and the alloy-nanocomposite.

Carbon Nanotubes (CNTs)-Reinforced Magnesium-Based Matrix Composites: A Comprehensive Review

In recent years considerable attention has been attracted to magnesium because of its light weight, high specific strength, and ease of recycling. Because of the growing demand for lightweight materials in aerospace, medical and automotive industries, magnesium-based metal matrix nanocomposites (MMNCs) reinforced with ceramic nanometer-sized particles, graphene nanoplatelets (GNPs) or carbon nanotubes (CNTs) were developed. CNTs have excellent material characteristics like low density, high tensile strength, high ratio of surface-to-volume, and high thermal conductivity that makes them attractive to use as reinforcements to fabricate high-performance, and high-strength metal-matrix composites (MMCs). Reinforcing magnesium (Mg) using small amounts of CNTs can improve the mechanical and physical properties in the fabricated lightweight and high-performance nanocomposite. Nevertheless, the incorporation of CNTs into a Mg-based matrix faces some challenges, and a uniform distribution is dependent on the parameters of the fabricating process. The characteristics of a CNTs reinforced composite are related to the uniform distribution, weight percent, and length of the CNTs, as well as the interfacial bonding and alignment between CNTs reinforcement and the Mg-based matrix. In this review article, the recent findings in the fabricating methods, characterization of the composite's properties, and application of Mg-based composites reinforced with CNTs are studied. These include the strategies of fabricating CNT-reinforced Mg-based composites, mechanical responses, and corrosion behaviors. The present review aims to investigate and conclude the most relevant studies conducted in the field of Mg/CNTs composites. Strategies to conquer complicated challenges are suggested and potential fields of Mg/CNTs composites as upcoming structural material regarding functional requirements in aerospace, medical and automotive industries are particularly presented.

Recent Developments in Magnesium Metal-Matrix Composites for Biomedical Applications: A Review

Recently, there is a growing interest in developing magnesium (Mg) based degradable biomaterial. Although corrosion is a concern for Mg, other physical properties, such as low density and Young's modulus, combined with good biocompatibility, lead to significant research and development in this area. To address the issues of corrosion and low yield strength of pure Mg, several approaches have been adopted, such as, composite preparation with suitable bioactive reinforcements, alloying, or surface modifications. This review specifically focuses on recent developments in Mg-based metal matrix composites (MMCs) for biomedical applications. Much effort has gone into finding suitable bioactive, bioresorbable reinforcements and processing techniques that can improve upon existing materials. In summary, this review provides a comprehensive overview of existing Mg-based composite preparation and their mechanical and corrosion properties and biological responses and future perspectives on the development of Mg-based composite biomaterials.

Effect of Fabrication Parameters on the Performance of 0.5 wt.% Graphene Nanoplates-Reinforced Aluminum Composites

Aluminum composites reinforced by graphene nanoplates(GNP) with a mass fraction of 0.5% (0.5 wt.% GNP/Al) were fabricated using cold pressing and hot pressing. An orthogonal test was used to optimize the fabrication parameters. Ball milling time, ball milling speed, and ultrasonic time have the largest influence on the uniformity of the graphene in the composites. Afterwards, the microstructure, interfacial properties, and fracture morphology of the composites obtained with different parameters were further analyzed. The results show that ball milling time and ball milling speed have obvious influences on the mechanical properties of the composite. In this paper, when the ball milling speed is 300 r/min and the ball milling time is 6 h, the dispersion uniformity of graphene in the 0.5 wt.% GNP/Al composite is the best, the agglomeration is the lowest, and the mechanical properties of the composites are the best, among which the tensile strength is 156.8 MPa, 56.6% higher than that of pure aluminum fabricated by the same process (100.1 MPa), and the elongation is 19.9%, 39.8% lower than that of pure aluminum (33.1%).

Graphene Family Nanomaterial Reinforced Magnesium-Based Matrix Composites for Biomedical Application: A Comprehensive Review

Together with the enhancement of the load-bearing implant process for bone substitution and reproduction, an increasing requirement was observed concerning biodegradable magnesium and its alloys with lighter density and outstanding characteristics. Regardless of the current great potential of Mg utilization currently, the broader use of Mg alloys continues to be constrained by several natural causes, such as low resistance of corrosion, inadequate mechanical integrity during the healing process, and poor antibacterial performance. In this perspective, Mg-based composite encapsulated within graphene family nanomaterials (GFNs) such as graphene (Gr), graphene oxide (GO), graphene nanoplatelets (GNPs), and reduced graphene oxide (rGO) as reinforcement agents present great antibacterial activity, as well as cellular response and depicted numerous benefits for biomedical use. Magnesium matrix nanocomposites reinforced with GFNs possess enhanced mechanical properties and high corrosion resistance (low concentration graphene). It is worth noting that numerous elements including the production technique of the Mg-based composite containing GFNs and the size, distribution, and amounts of GFNs in the Mg-based matrix have a crucial role in their properties and applications. Then, the antibacterial mechanisms of GFN-based composite are briefly described. Subsequently, the antibacterial and strengthening mechanisms of GFN-embedded Mg-based composites are briefly described. This review article is designed to wrap up and explore the most pertinent research performed in the direction of Mg-based composites encapsulated within GFNs. Feasible upcoming investigation directions in the field of GFN-embedded Mg-based composites are discussed in detail.

Magnesium matrix nanocomposites for orthopedic applications: A review from mechanical, corrosion, and biological perspectives

Magnesium (Mg) and some of its alloys have attracted extensive interests for biomedical applications as they exhibit biodegradability and low elastic modulus that is closer to natural bones than the currently used metallic implant materials such as titanium (Ti) and its alloys, stainless steels, and cobalt-chromium (Co-Cr) alloys. However, the rapid degradation of Mg alloys and loss of their mechanical integrity before sufficient bone healing impede their clinical application. Our literature review shows that magnesium matrix nanocomposites (MMNCs) reinforced with nanoparticles possess enhanced strength, high corrosion resistance, and good biocompatibility. This article provides a detailed analysis of the effects of nanoparticle reinforcements on the mechanical properties, corrosion behavior, and biocompatibility of MMNCs as promising biodegradable implant materials. The governing equations to quantitatively predict the mechanical properties and underlying synergistic strengthening mechanisms in MMNCs are elucidated. The potential, recent advances, challenges and future research directions in relation to nanoparticles reinforced MMNCs are highlighted. STATEMENT OF SIGNIFICANCE: Critically reviewing magnesium metal matrix nanocomposites (MMNCs) for the biomedical application. Clear definitions of strengthening mechanisms using reinforcement particle in the magnesium matrix, as there were controversial in governing equations of strengthening parameters. Providing better understanding of the effect of particle size, volume fraction, interfacial bonding, and uniform dispersion of reinforcement particles on MMNCs.

Development of Novel AlSi10Mg Based Nanocomposites: Microstructure, Thermal and Mechanical Properties

Al matrix nanocomposites are interestingly employed in the automotive, military, aerospace and electronics packaging industries. In this study, Graphene Nanoplatelets (GNPs) reinforced AlSi10Mg nanocomposites were produced via powder metallurgy. The effect of GNPs content on density, microstructure and mechanical characteristics of the AlSi10Mg/GNPs nanocomposites was investigated systematically. To this aim, AlSi10Mg/GNPs nanocomposites reinforced with 0.5, 1.0 and 2.0 wt.% of GNPs were produced by wet mixing method following by hot compaction at 600 °C. To evaluate the effect of GNPs on mechanical properties of the as-fabricated nanocomposite, Vickers hardness and tensile properties of composites analyzed at room temperature. According to the results, it was found that the fabrication of AlSi10Mg/GNPs nanocomposites is faced with several challenges such as agglomeration and non-uniform dispersion of GNPs that should be addressed to achieve the desirable thermal and mechanical properties. For instance, surprisingly, it is revealed that the mechanical and thermal properties of nanocomposites were deteriorated in the presence of a high quantity of GNPs (>1.0 wt.%), which can be attributed to the GNPs agglomeration and accordingly introduction of internal porosity in the nanocomposite. The relatively low fraction of GNPs can uniformly be dispersed in the matrix and improve the performance of the nanocomposite.

An Overview of the Recent Developments in Metal Matrix Nanocomposites Reinforced by Graphene

Two-dimensional graphene plateletes with unique mechanical, electrical and thermo-physical properties could attract more attention for their employed as reinforcements in the production of new metal matrix nanocomposites (MMNCs), due to superior characteristics, such as being lightweight, high strength and high performance. Over the last years, due to the rapid advances of nanotechnology, increasing demand for the development of advanced MMNCs for various applications, such as structural engineering and functional device applications, has been generated. The purpose of this work is to review recent research into the development in the powder-based production, property characterization and application of magnesium, aluminum, copper, nickel, titanium and iron matrix nanocomposites reinforced with graphene. These include a comparison between the properties of graphene and another well-known carbonaceous reinforcement (carbon nanotube), following by powder-based processing strategies of MMNCs above, their mechanical and tribological properties and their electrical and thermal conductivities. The effects of graphene distribution in the metal matrices and the types of interfacial bonding are also discussed. Fundamentals and the structure–property relationship of such novel nanocomposites have also been discussed and reported.

Bioinspired, Graphene/Al2O3 Doubly Reinforced Aluminum Composites with High Strength and Toughness

Nacre, commonly referred to as nature's armor, has served as a blueprint for engineering stronger and tougher bioinspired materials. Nature organizes a brick-and-mortar-like architecture in nacre, with hard bricks of aragonite sandwiched with soft biopolymer layers. However, cloning nacre's entire reinforcing mechanisms in engineered materials remains a challenge. In this study, we employed hybrid graphene/Al₂O₃ platelets with surface nanointerlocks as hard bricks for primary load bearer and mechanical interlocking, along with aluminum laminates as soft mortar for load distribution and energy dissipation, to replicate nacre's architecture and reinforcing effects in aluminum composites. Compared with aluminum, the bioinspired, graphene/Al₂O₃ doubly reinforced aluminum composite demonstrated an exceptional, joint improvement in hardness (210%), strength (223%), stiffness (78%), and toughness (30%), which are even superior over nacre. This design strategy and model material system should guide the synthesis of bioinspired materials to achieve exceptionally high strength and toughness.

Effect of Pre-Oxidation Treatment of Nano-SiC Particulates on Microstructure and Mechanical Properties of SiC/Mg-8Al-1Sn Composites Fabricated by Powder Metallurgy Combined with Hot Extrusion

Nano-SiC particulates (n-SiC_p) reinforced Mg-8Al-1Sn (AT81) composites with different pre-oxidation parameters were fabricated by powder metallurgy (P/M) process combined with hot extrusion. The effects of pre-oxidization treatment of n-SiC_p on the microstructure and tensile properties of 0.5 vol % n-SiC_p/AT81 composites were investigated accordingly. The distribution of n-SiC_p with different pre-oxidation parameters was homogeneous in the composites. Moreover, it was found that a thin MgAl₂O₄ layer formed at the interface when the n-SiC_p were pre-oxidized at 1073 K for 2 h, while the MgAl₂O₄ layer became much thicker with pre-oxidization temperature increasing to 1273 K for 2 h. After an appropriate pre-oxidization treatment of n-SiC_p at 1073 K for 2 h, the as-extruded 0.5 vol % n-SiC_p/AT81 composites exhibited an enhanced strength. It was found that the yield strength (YS) and ultimate tensile strength (UTS) increased from 168 MPa and 311 MPa to 255 MPa and 393 MPa compared with the as-extruded AT81 alloy, reflecting 51.8% and 26.4% increments, respectively. The improvement of mechanical properties should be mainly attributed to the grain refinement and homogeneous distribution of n-SiC_p in the composites. Moreover, a well-bonded interface and the formation of an appropriate amount of interfacial product (MgAl₂O₄) benefited the material's mechanical properties.