Effect of Ni Reinforcement on AZ31 Mg Alloy and Development of MMCs using Friction Stir Processing

Abstract

In this study, magnesium matrix composites (MMCs) were successfully fabricated by reinforcing AZ31 magnesium alloy with nickel particles through friction stir processing (FSP) route. The incorporation of Ni significantly enhanced the mechanical performance of the base alloy, resulting in up to 25% improvement in ultimate tensile strength and 55% increase in hardness, while retaining superior ductility compared to other-reinforced composites. The composites fabricated with 15% Ni content and four processing passes exhibited the most uniform particle distribution, grain refinement, and optimized strength–ductility balance. The absence of intermetallic formation and the homogenous dispersion of Ni particles contributed to improved load transfer and resistance to deformation. These results demonstrate a promising route to tailor the mechanical behavior of lightweight Mg alloys for advanced structural applications in automotive and aerospace sectors. This study demonstrates a practical and scalable approach to engineer high-performance, lightweight Mg-based composites for aerospace and automotive applications, marking a significant step forward from conventional MMC reinforcement strategies. © 2025 Elsevier B.V., All rights reserved.