Novel Magnesium Nanocomposite for Wire-Arc Directed Energy Deposition

Area of Science:

• Materials Science
• Additive Manufacturing
• Biomedical Engineering

Background:

• Magnesium alloys are crucial for lightweight construction and degradable implants due to their properties.
• Additive manufacturing offers new possibilities for magnesium alloy applications.
• Processing magnesium alloys via additive manufacturing is challenging due to their reactivity.

Purpose of the Study:

• To develop a magnesium-based nanocomposite wire suitable for additive manufacturing.
• To investigate the mechanical properties and microstructure of additively manufactured magnesium alloy samples.
• To overcome processing challenges associated with magnesium alloys in additive manufacturing.

Main Methods:

• Fabrication of a magnesium-based nanocomposite wire (AM60 with AlN nanoparticles and calcium) using a high-shear process.
• Extrusion of the composite material into wires for feedstock.
• Wire-arc directed energy deposition to build samples.
• Examination of mechanical properties and microstructure.

Main Results:

• Successfully produced a magnesium-based nanocomposite wire.
• Achieved a yield strength of 131 MPa in the welding direction and perpendicular to it.
• Observed a reduction in ductility due to calcium and nanoparticle addition.

Conclusions:

• The developed magnesium nanocomposite wire is viable for additive manufacturing.
• The process enhances yield strength, making it suitable for demanding applications.
• Further optimization may be needed to balance strength and ductility.