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Metal matrix composites (MMCs) are emerging as advanced engineering materials for application in aerospace, defence, automotive and consumer industries (sports goods etc.). In MMCs, a metallic base material is reinforced with ceramic fiber, whisker or particulate in order to achieve a combination of properties not attainable by either constituent individually. Aluminium or its alloy is favoured as metallic matrix material because of its low density, easy fabricability and good engineering properties. In general, the benefits of aluminium metal matrix composites (AMCs) over unreinforced aluminium alloy are increased specific stiffness, improved wear resistance and decreased coefficient of thermal expansion. The conventional reinforcement materials for AMCs are SiC and AI2O3. In the present work, boron carbide (B4C) particles of average size 40μm were chosen as reinforcement because of its higher hardness (very close to diamond) than the conventional reinforcement like SiC, AI2O3 etc. and of its density (2.52 g cm"3) very close to Al alloy matrix. In addition, due to high neutron capture cross-section of 10B isotope, composites containing B4C particle reinforcement have the potential for use in nuclear reactors as neutron shielding and control rod material. Al-5%Mg alloy was chosen as matrix alloy to utilize the beneficial role of Mg in improving wettability between B4C particles and the alloy melt. (Al-5%Mg)-B4C composites containing 10 and 20 vol% B4C particles were fabricated. For the purpose of inter-comparison, unreinforced Al-5%Mg alloy was also prepared and characterized. The Stir Cast technique, commonly utilized for preparation of Al-SiC, was adapted in this investigation.The Composites thus prepared was subsequently hot extruded with the objective of homogenization and healing minor casting defects. Finally the unreinforced alloy and its composites were characterized in terms of their microstructure, mechanical and thermo-physical properties, sliding wear behaviour and neutron absorption characteristics. The microstructures of the composites were evaluated by both optical microscope and scanning electron microscope (SEM). The micrographs revealed a relatively uniform distribution of B4C particles and good interfacial integrity between matrix and B4C particles. The hot hardness in the range of 25°C to 500°C and indentation creep data in the range of 300°C to 400°C show that hot hardness and creep resistance of Al-Mg alloy is enhanced by the presence of B4C particles. Measurement of coefficient of thermal expansion (CTE) of composites and unreinforced alloy upto 450°C showed that CTE values decrease with increase in volume fraction of reinforcement. Compression tests at strain rates, 0.1, 10 and 100 s-1 in the temperature range 25 - 450 °C showed that the flow stress values of composites were, in general, greater than those of unreinforced alloy at all strain rates. These tests also depicted that the compressive strength increases with increase in volume fraction of reinforcements. True stress values of composites and unreinforced alloy has been found to be a strong function of temperature and strain rate. The kinetic analysis of elevated temperature plasticity of composites revealed higher stress exponent values compared to unreinforced alloy. Similarly, apparent activation energy values for hot deformation of composites were found to be higher than that of self-diffusion in Al-Mg alloy. Tensile test data revealed that the modulus and 0.2% proof stress of composites increase with increase in volume fraction of the reinforcements. Composites containing 10%BUC showed higher ultimate tensile strength values (UTS) compared to unreinforced alloy. However, composites with 20%B4C showed lower UTS compared to that of the unreinforced alloy. This could be attributed to increased level of stress concentration and high level of plastic constraint imposed by the reinforcing jparticles or due to the presence solidification-induced defects (pores and B4C agglomerates ). Sliding wear characteristics were evaluated at a speed of 1 m/s and at loads ranging from 0.5 to 3.5kg using a pin-on-disc set up. Results show that wear resistance of Al-5%Mg increases with the addition of B4C particles. Significant improvement in wear resistance of Al-5%Mg is achieved with the addition of 20% B4C particles. SEM examination of worn surfaces showed no pull-out of reinforcing particles even at the highest load of 3.5 kg, thus confirming good interfacial bonding between dispersed B4C particles and Al alloy matrix. The neutron radiography data proved that (Al-5%Mg)-B4C composites possess good neutron absorbing characteristics. From the experimental data evaluated in the "study, it may be concluded that (Al-5%Mg)-B4C composites could be a candidate material for neutron shielding and control rod application. The enhanced elevated temperature-strength and favourable neutron absorption characteristics of these composites are strong points in favour of this material.

Mg-based alloys form a variety of interesting structures including stable and metastable crystalline, stable and metastable quasicrystalline, nanocrystalline and amorphous phases. Many of these phases can be made to coexist by suitable processing leading to an interesting combination of properties. Non-equilibrium processing in combination with suitable heat treatments can be used to control the scale and dispersion of these phases. Further thrust to Mg-based alloys is expected through the development of Mg-based bulk metallic glasses. Magnesium matrix composites are also gaining in prominence. The thesis has been divided into theoretical and experimental parts. The theoretical part focuses on understanding the structure of quasicrystals, rational approximants and related structures. The experimental work involves synthesis, non-equilibrium processing and characterization of specific Mg-based alloys. The structure of quasicrystals and related structures can be understood by working in three dimensions or by projection from higher dimensions. The projection formalism is used to generate quasicrystals and rational approximants in 2D and 3D. Approximants to the Penrose lattice are generated with directions of approximation oriented 90° and 72° apart. Rational approximants to the icosahedral quasilattice are generated and the systematics of lattice-centring in these approximants analysed. Two-dimensional quasiperiodic lattice with 5-fold symmetry, which is periodic along the third dimension, is generated as an approximant to the icosahedral lattice. Approximants are also considered wherein quasiperiodicity is retained along one or two directions. The concept of average lattices can be used to understand diverse structures including vacancy ordered phases (VOP) and orthorhombic approximants to the decagonal phase. VOP which lack incommensurate length scales should be considered as quasiperiodic superlattice (QPSL) approximants rather than as conventional rational approximants and hence have the average lattice scheme built into them. The average lattice approach is further used to unify Kuo’s and Anantharaman's models for orthorhombic approximants to the decagonal quasicrystal. A modified version of Anantharaman's model is also presented. Using the twinned icosahedron model, Robinson and Taylor approximants to the decagonal quasicrystal are generated by the twinning of Mackay and Little approximants to the icosahedral quasicrystal. An indexing scheme based on this model is developed which inherits the merits of the twinned icosahedron model. Further, using cluster of four icosahedra, in a distorted tetrahedral configuration, symmetries of the hexagonal phases, which are related to quasicrystals, are generated. Frank's ratio is brought out as a unifying thread connecting diverse kinds of structures including VOP and hexagonal phases related to quasicrystals, which have pseudocubic symmetry. Experimental work involves the synthesis and characterization of alloys in four systems: a) Mg-Zn-Y, b) Mg-Zn-La, c) Al-Mg-Cu and d) Mg-Cu-Y. Induction melting is used to prepare the alloys and melt-spinning is used as the primary non-equilibrium processing route. The focus in the Mg-Zn-RE systems is in the as cast condition while in the Al-Mg-Cu system it is in the melt-spun condition. Characterization techniques used are XRD, SEM and TEM. In the Mg-Zn-Y system face-centred icosahedral (FC1) phase with quasilattice parameter of 5.21 A is found to coexist with related crystalline phases in the Mg4Zn94Y2 and Mg23Zn5gY9 alloys. A series of crystalline phases with superlattice ordering are seen in the Mg-Zn-Y and Mg-Zn-La systems. These phases with a variety of ordering, many of which display interesting patterns of streaking in the SAD pattern, are related to one-another and to the FCI QC found in the Mg-Zn-Y system. No quasicrystal could be observed in the two alloys investigated in the Mg-Zn-La system with La = 5 and 8 %. Conventional rational approximants were conspicuous by there absence in both the rare-earth containing systems. This is understood in terms of the absence of large clusters in these systems. High Y alloys display a tendency to form nanocrystals in the as-cast condition and amorphous regions are observed in the as-cast alloys with Y > 20 %. Hence, high Y alloys are anticipated to be bulk glass formers. Melt-spinning of the alloys in both the RE containing systems lead to the formation of nanocrystalline regions. The e/a ratio plays an important role in the formation of phases in the Mg-Zn-Y system. An e/a ratio near 2.08 has a stabilising effect on a variety of phases including the FCI quasicrystal, ternary phases related to the quasicrystal and binary phases like YZn12 and Y2Zn17. Formation of quasicrystals in the Al-Mg binary and Mg-Al-Cu ternary seem to be very sensitive to processing conditions and were not observed in the present investigation in the melt-spun alloys. However, β-Al3Mg2 and Mg32(Al,Cu)49 phases with large lattice parameters, which are related to quasicrystals, are observed in as-cast and melt-spun conditions. The Mg32(Al,Cu)49 phase brings out the similarity between this system and the Mg-Al-Zn system. The glass formability of the alloys in the Al-Mg binary and in the Mg-Al-Cu ternary is limited. Except for the formation of amorphous phase in some regions, the alloys were crystalline even when melt-spun at 2800 rpm. The ability to form nanocrystals is also limited in this system as compared to the Mg-Zn-RE systems. Often melt-spun alloys showed a wide range of grain sizes coexisting together.

A demanda por aumento da eficiência energética vem obrigando empresas e centros de pesquisa a desenvolver e utilizar novos materiais buscando a redução de peso. Entre esses materiais, destacam-se as ligas de magnésio, com aproximadamente dois terços da densidade do alumínio e a melhor relação peso/resistência entre os metais. Porém, a utilização do magnésio em altas temperaturas tem suas limitações, devido à baixa resistência a fluência e a formação do precipitado -Mg17Al12 que tem baixo ponto de fusão, tornando as ligas de magnésio mais suscetíveis aos efeitos de deslizamento nos contornos de grãos. Algumas ligas de magnésio contendo elementos terras raras foram desenvolvidas para melhorar a resistência a fluência. O trabalho em questão visa analisar o comportamento da liga Mg6Al3La1Ca, correlacionando os parâmetros de solidificação com as propriedades mecânicas: dureza, alongamento específico, limite de escoamento e limite de resistência à tração. Para isso, foram solidificados unidirecionalmente, com atmosfera de argônio, três lingotes da liga Mg6Al3La1Ca a partir de sobreaquecimento de 780°C, 715°C e 650°C. O resfriamento dos lingotes ocorreu no forno e por resfriamento forçado. Os resultados obtidos de limite de resistência à tração, limite de escoamento e dureza tem uma relação direta com a temperatura de vazamento onde os melhores resultados foram obtidos com as temperaturas mais elevadas. Portanto, conclui-se que na temperatura de 780°C com resfriamento forçado foram obtidas as melhores propriedades mecânicas. / The demand for increased energy efficiency is forcing companies and research centers to develop and use new materials aimed at reducing weight. Among these materials, there is magnesium alloys, because it has about two-thirds of the density of aluminum and the best weight/resistance between the metals. However, the use of magnesium at elevated temperatures has its limitations due to low resistance to creep; the formation of -Mg17Al12 precipitate which has a low melting point makes the magnesium alloy more susceptible to slip around the grains. Some magnesium alloys containing rare earth elements have been developed to improve resistance to creep. The work in question is to analyze the behavior the Mg6Al3La1Ca alloy, correlating the parameters of solidification with the mechanical properties: hardness, specific elongation, limits yield strength and tensile strength. For that, three ingots of the alloy Mg6Al3La1Ca were solidified unidirectionally using argon atmosphere with overheating of 780°C, 715°C and 650°C. The cooling of ingots occurred in the furnace and by forced cooling. The results of limit tensile strength, yield strength and hardness have a direct relation with the pouring temperature where the best results were obtained with higher temperatures. Therefore, it is concluded that the best mechanical properties were obtained at temperature of 780°C with forced cooling.

A demanda por aumento da eficiência energética vem obrigando empresas e centros de pesquisa a desenvolver e utilizar novos materiais buscando a redução de peso. Entre esses materiais, destacam-se as ligas de magnésio, com aproximadamente dois terços da densidade do alumínio e a melhor relação peso/resistência entre os metais. Porém, a utilização do magnésio em altas temperaturas tem suas limitações, devido à baixa resistência a fluência e a formação do precipitado -Mg17Al12 que tem baixo ponto de fusão, tornando as ligas de magnésio mais suscetíveis aos efeitos de deslizamento nos contornos de grãos. Algumas ligas de magnésio contendo elementos terras raras foram desenvolvidas para melhorar a resistência a fluência. O trabalho em questão visa analisar o comportamento da liga Mg6Al3La1Ca, correlacionando os parâmetros de solidificação com as propriedades mecânicas: dureza, alongamento específico, limite de escoamento e limite de resistência à tração. Para isso, foram solidificados unidirecionalmente, com atmosfera de argônio, três lingotes da liga Mg6Al3La1Ca a partir de sobreaquecimento de 780°C, 715°C e 650°C. O resfriamento dos lingotes ocorreu no forno e por resfriamento forçado. Os resultados obtidos de limite de resistência à tração, limite de escoamento e dureza tem uma relação direta com a temperatura de vazamento onde os melhores resultados foram obtidos com as temperaturas mais elevadas. Portanto, conclui-se que na temperatura de 780°C com resfriamento forçado foram obtidas as melhores propriedades mecânicas. / The demand for increased energy efficiency is forcing companies and research centers to develop and use new materials aimed at reducing weight. Among these materials, there is magnesium alloys, because it has about two-thirds of the density of aluminum and the best weight/resistance between the metals. However, the use of magnesium at elevated temperatures has its limitations due to low resistance to creep; the formation of -Mg17Al12 precipitate which has a low melting point makes the magnesium alloy more susceptible to slip around the grains. Some magnesium alloys containing rare earth elements have been developed to improve resistance to creep. The work in question is to analyze the behavior the Mg6Al3La1Ca alloy, correlating the parameters of solidification with the mechanical properties: hardness, specific elongation, limits yield strength and tensile strength. For that, three ingots of the alloy Mg6Al3La1Ca were solidified unidirectionally using argon atmosphere with overheating of 780°C, 715°C and 650°C. The cooling of ingots occurred in the furnace and by forced cooling. The results of limit tensile strength, yield strength and hardness have a direct relation with the pouring temperature where the best results were obtained with higher temperatures. Therefore, it is concluded that the best mechanical properties were obtained at temperature of 780°C with forced cooling.

A demanda por aumento da eficiência energética vem obrigando empresas e centros de pesquisa a desenvolver e utilizar novos materiais buscando a redução de peso. Entre esses materiais, destacam-se as ligas de magnésio, com aproximadamente dois terços da densidade do alumínio e a melhor relação peso/resistência entre os metais. Porém, a utilização do magnésio em altas temperaturas tem suas limitações, devido à baixa resistência a fluência e a formação do precipitado -Mg17Al12 que tem baixo ponto de fusão, tornando as ligas de magnésio mais suscetíveis aos efeitos de deslizamento nos contornos de grãos. Algumas ligas de magnésio contendo elementos terras raras foram desenvolvidas para melhorar a resistência a fluência. O trabalho em questão visa analisar o comportamento da liga Mg6Al3La1Ca, correlacionando os parâmetros de solidificação com as propriedades mecânicas: dureza, alongamento específico, limite de escoamento e limite de resistência à tração. Para isso, foram solidificados unidirecionalmente, com atmosfera de argônio, três lingotes da liga Mg6Al3La1Ca a partir de sobreaquecimento de 780°C, 715°C e 650°C. O resfriamento dos lingotes ocorreu no forno e por resfriamento forçado. Os resultados obtidos de limite de resistência à tração, limite de escoamento e dureza tem uma relação direta com a temperatura de vazamento onde os melhores resultados foram obtidos com as temperaturas mais elevadas. Portanto, conclui-se que na temperatura de 780°C com resfriamento forçado foram obtidas as melhores propriedades mecânicas. / The demand for increased energy efficiency is forcing companies and research centers to develop and use new materials aimed at reducing weight. Among these materials, there is magnesium alloys, because it has about two-thirds of the density of aluminum and the best weight/resistance between the metals. However, the use of magnesium at elevated temperatures has its limitations due to low resistance to creep; the formation of -Mg17Al12 precipitate which has a low melting point makes the magnesium alloy more susceptible to slip around the grains. Some magnesium alloys containing rare earth elements have been developed to improve resistance to creep. The work in question is to analyze the behavior the Mg6Al3La1Ca alloy, correlating the parameters of solidification with the mechanical properties: hardness, specific elongation, limits yield strength and tensile strength. For that, three ingots of the alloy Mg6Al3La1Ca were solidified unidirectionally using argon atmosphere with overheating of 780°C, 715°C and 650°C. The cooling of ingots occurred in the furnace and by forced cooling. The results of limit tensile strength, yield strength and hardness have a direct relation with the pouring temperature where the best results were obtained with higher temperatures. Therefore, it is concluded that the best mechanical properties were obtained at temperature of 780°C with forced cooling.

In the present investigation, surface coatings employing laser surface alloying (LSA) and plasma electrolytic oxidation (PEO) processes have been prepared on Mg alloys. The coatings have been investigated for corrosion and wear behaviour. Two important Mg alloys based on Mg–Al system were selected namely, MRI 230D and AM50 as substrates. LSA coatings have been prepared employing Al and Al2O3 as precursors using different laser scan speeds. PEO coatings were prepared in standard silicate and phosphate based electrolytes employing unipolar, pulsed DC. Hybrid coatings using a combination of the two processes were also produced and investigated for corrosion and wear behaviour. Hybrid coatings of LSA followed by PEO (LSA+PEO) were investigated for effectiveness of sealing the cracks in the LSA coatings by subsequent PEO process and consequent improvement in the corrosion resistance. Hybrid coatings of PEO followed by LSA (PEO+LSA) were prepared with an objective of sealing the pores in the PEO coating LSA treatment. In an attempt to produce more compact PEO coatings, electrolyte containing montmorillonite clay additives was employed for the PEO process of AM50 Mg alloy. The coatings were produced employing different current densities and the effect of current density on the microstructure and corrosion behaviour of coating was investigated. Electrochemical corrosion tests of uncoated and coated alloys were carried out in 3.5 wt.% (0.6M)NaCl, neutral pH, solution with an exposed area of 0.5 cm2 for a time duration of 18.5 h. For the PEO coatings with clay additives, corrosion tests were conducted additionally in 0.5 wt.% (0.08 M) NaCl, neutral pH, solution for a time duration of 226.1 h. Wear behaviour of LSA coatings was analyzed by employing a pin on disc tribo–tester conforming to ASTM G–99 standard at ambient conditions with ground EN32 steel disc of hardness Rc 58 as the counterface. Tests were conducted under dry sliding conditions for a sliding distance of 1.0 km at a sliding velocity of 0.837 m/s employing normal loads of 10, 20, 30 and 40 N. Friction and wear behavior of PEO and PEO+LSA coatings were analyzed at ambient conditions by employing a ball−on−flat linearly oscillating tribometer conforming to ASTM G–133 standard. AISI 52100 steel ball of diameter 6 mm was employed as the friction partner. Wear tests were conducted under dry sliding conditions for a total sliding distance of 100 m at normal loads of 2 N and 5 N with oscillating amplitude of 10 mm and mean sliding speed of 5 mm/s. LSA coatings could not improve the corrosion resistance of MRI 230D Mg alloy. This was attributed to the presence of cracks in the LSA coating, which resulted in the accelerated galvanic corrosion of the substrate. LSA coatings improved the wear resistance at all loads. The improved wear resistance was attributed to β (Mg17Al12) phase and Al2O3 particles in the coating which increased the hardness of the LSA layer. No trend in corrosion and wear resistance with laser scan speed was observed for LSA coatings. PEO coatings improved the corrosion resistance of the MRI 230D Mg alloy significantly. The improved corrosion resistance was attributed to the enhanced barrier protection provided by dense barrier layer formed at the substrate/coating interface and to the insoluble phase constituents in the coatings. PEO coating was effective in improving the wear resistance at low loads/contact pressures. At higher loads, the coating underwent micro–fracture as a result of the porosity in the coatings. Hybrid coatings of LSA followed by PEO (LSA+PEO) in silicate based electrolyte improved the corrosion resistance of LSA coatings. However, the corrosion resistance was not improved to the extent of PEO coatings on as–cast alloy as a result of cracks in the primary coatings, which were not fully sealed by the plasma conversion products. No trend in corrosion resistance with laser scan speed was observed for LSA+PEOcoatings. In hybrid coatings of PEO followed by LSA (PEO+LSA), primary PEO coating was completely melted and mixed with applied precursor to form a single composite LSA layer. The corrosion resistance of the hybrid coatings was observed to be lower than that of the as–cast alloy. The presence of solidification cracks reduced the barrier properties and resulted in the accelerated galvanic corrosion of the substrate similar to LSA coatings. Hybrid (PEO+LSA) coatings exhibited improved wear resistance as compared to as–cast alloy at lower loads as a result of increase in the hardness due to β (Mg17Al12) phase and oxide/ceramic particles in the hybrid layer. At higher loads, hybrid coatings exhibited higher wear rate as compared to as–cast alloy and PEO coatings. This was attributed to three–body abrasive wear as a result of dislodged hard oxide/ceramic particles in the wear tracks. No trend in corrosion and wear resistance with laser scan speed was observed for PEO+LSA coatings. PEO coatings on AM50 Mg alloy by employing clay additives in the electrolyte resulted in the reactive uptake of clay particles producing a predominantly amorphous coating at low current density. Clay additives were effective in improving the compactness of the coating at lower current density. At higher current densities, the porosity of the coatings increased. The clay particles got re–constituted producing increasing amount of crystalline phases with increase in current density. Long term impedance measurements showed that clay addition as well as increased current density employed for the PEO process was not effective in improving the corrosion resistance of the coatings. At low current density, even though the coating with clay additives was more compact, it was deficient in MgO and consisted predominantly of an amorphous phase, which underwent fast dissolution in electrolyte thereby resulting in an early loss of barrier properties. At higher current densities, even though the coatings consisted of increased amount of MgO and crystalline phases, which resist dissolution in the electrolyte, the increased porosity and defective barrier layer resulted in easy permeation of the electrolyte into the substrate/coating interface, which resulted in much earlier loss of barrier properties and inferior corrosion resistance.

This thesis deals with the characterization of electrochemical corrosion properties of magnesium alloys as promising materials for biomedical applications. The wrought alloys AZ31 and AZ61 were used and exposed to corrosive environments of Hanks solutions (SBF) to simulate environmental conditions in living organisms. For the evaluation of the surfaces was used scanning electron microscopy (SEM) with elemental analysis measured by energy-dispersive spectroscopy (EDS). Short-term (5 min) and long-term (72 h) corrosion tests were conducted in order to optimize the measurement methodology and obtain corrosion parameters - especially corrosion potential (Ekor), corrosion current density (ikor) and polarisation resistance (RP). To evaluation of the short-term tests were by potentiodynamic tests, namely the linear polarization (LP) test. Long-term tests were measured by electrochemical impedance spectroscopy (EIS). Effects of the composition of the alloys (AZ31 and AZ61), surface treatment (grinding and polishing) and the composition of the solution (SBF without Ca, Mg, and with Ca, Mg) were compared. Complex corrosion behaviour in time was characterized and corrosion mechanisms were discussed.

This thesis dealt with thermal stability of magnesium alloy AZ91 prepared by severe plastic deformation, which leeds to fine grained structure. This structure is characterised by its inherent instability and this thesis tries to find out the value of critical temperature and rate of this instability, which manifests as grain coarsening.

The aim of this master’s thesis is electrochemical characteristics evaluation of magnesium alloys. The theoretical part describes the properties of magnesium and its alloys and their corrosion characteristics. In the experimental part are presented results of corrosion resistance measurement of two types of wrought magnesium alloys. It was AZ31 and AZ61 magnesium alloys, which were measured in Hank’s solutions with addition of ions Ca2+ and Mg2+ (SBF+) and without addition of the ions (SBF). The solution temperature during the measurement was 37 ± 1 °C. The experiments were used electrochemical impedance spectroscopy (EIS) and potentiodynamic tests using linear polarization (LP). EIS measurements were done in times of 5 minutes, 1, 2, 4, 8, 12, 24, 48, 72, 96 and 168 hours. Potentiodynamic tests were only short-term and they started after 5 minutes of stabilization. Both methods were used for measuring the electrochemical characteristics of polished and ground surface of the samples. The most important measurement results were polarization resistance, corrosion potential and corrosion current density. The electrochemical measurements are used to estimate the chemical composition influence and alloy’s structure of the corrosion resistance.