In this study, the nature of the ball-milling mechanism in a ternary materials system (Mg-6Sn-1Na) is investigated for proper mechanical alloying. An identical powder mixture for this material system is exposed to different milling durations for a suitable mixture. First, the platelet structure formation is observed on particles with increasing milling duration, mainly formed in direction of the hexagonal crystal structure of the Mg matrix. Then, the flake structure with texture formation is broken into smaller spherical particles with further ball milling up to 12 h. According to EDS analysis, the secondary phases in the Mg matrix are homogenously distributed with a 12-h milling duration which advises a proper mixture in this material system. The solid solution formation is triggered with an 8-h milling duration according to XRD analysis on 101 reflections. Conventional sintering is performed at 350 °C in 2 h for each sample. In bulk samples, XRD data reveal that secondary phases (Mg₂Sn) with island-like structures are formed on the Mg matrix for a milling duration of up to 8 h. These bigger secondary phases are mainly constituted as Mg₂Sn intermetallic forms, which have a negative effect on physical and mechanical properties due to a mismatch in the grain boundary formation. However, the homogenous distribution of secondary phases with a smaller particle size distribution, acquired with 12 h milling time, provides the highest density, modulus of elasticity, and hardness values for this ternary materials system. The ternary materials produced with the 12-h ball-milling process provide an improvement of about 117% in hardness value compared with the cast form.

In this study, the effects of different sintering methodology on grain formation, density, and hardness of blended leach residue (B‐LR) pellets is investigated. For the first time, the flash sintering (FS) method, an environmentally friendly process, is used to make multiphase ceramic composites using B‐LR under 100 V/mm at 675C. The outcomes of this study revealed that the FS process is faster and more energy‐efficient than the conventional sintering (CS) methods performed at 800°C for 4 h. The formation of abnormal grain growth is prevented by FS in B‐LR material composition after it is exposed to a max power absorption 61.4 mW/mm ³ and whole FS is completed less than 100 s. Besides, FS method does not lead to any melting on grain boundaries due to excessive joule heating, compared with the CS sample. It is noted that FS also provides better density and hardness values for this material system along with compositional integrity in this multiphase system. The significant outcome of this study is reducing lead volatility and emission by decrement on the sintering temperature. Ultimately, this study has planned the practicality of reusage and recycle of this material with green, safe, and eco‐friendly methods.