Achieving uniformly distributed reinforcement particles in a dense matrix is crucial for enhancing the mechanical properties of nanocomposites. This study focuses on fabricating Mg-SiC nanocomposites with a high-volume fraction of SiC particles (10 vol.%) using cold isostatic pressing (CIP). The objective is to obtain a fully dense material with a uniform dispersion of nanoparticles. The SiC particle size impact on the compressibility and density distribution of milled Mg-SiC nanocomposites is studied through the elastoplastic Modified Drucker-Prager Cap (MDPC) model and finite element method (FEM) simulations. The findings demonstrate significant variations in the size and dispersion of SiC particles within the Mg matrix. Specifically, the Mg-SiC nanocomposite with 10% submicron-scale SiC content (M10Sµ) exhibits superior compressibility, higher relative density, increased element volume (EVOL), and more consistent density distribution compared to the composite containing 10% nanoscale SiC (M10Sn) following CIP simulation. Under 700 MPa, M10Sµ shows improvements in both computational and experimental results for volume reduction percentage, 2.31% and 2.81%, respectively, and relative density, 4.14% and 3.73%, respectively, compared to M10Sn. The relative density and volume reduction outcomes are in qualitative alignment with experimental findings, emphasizing the significance of particle size in optimizing nanocomposite characteristics.

Improving the ductile deformation behavior of Mg-SiC nanocomposites without compromising strength is critical to enhancing their mechanical properties. Mg-SiC nanocomposites are produced through mechanical milling, cold isostatic pressing, sintering, and hot extrusion processes. This study investigates the uniaxial stress–strain response and deformation behavior of the Mg-SiC nanocomposite compared to pure Mg samples with and without the milling process. The deformation behavior was investigated by two-dimensional (2D) digital image correlation (DIC) at two macroscopic and microscopic scales, employing light micrographs and in situ loading samples, respectively, in the scanning electron microscope. Compared to the pure Mg samples, the mechanical test results demonstrated a significant improvement in strength (80 MPa) and fracture strain (23.5%) of the Mg-SiC nanocomposite. The three-dimensional (3D) representative volume element (RVE) model revealed the particle dispersion effect on the mechanical properties of the nanocomposite. The RVE results demonstrate ductile deformation behavior in the sample with homogenous dispersion of SiC particles compared with the heterogeneous dispersion of SiC particles in Mg-SiC nanocomposite. The results demonstrated a good agreement between DIC and RVE predictions for Mg-SiC nanocomposites across macro- and microscales.