Magnesium has been trending of late in automobile, aerospace, defense, sports, electronic and biomedical sectors as it offers an advantage in light-weighting. In aluminum, titanium, and steel dominated aerospace and defense sectors, applications of Mg were banned/restricted until recently due to perceived easy ignition and inability to self-extinguish immediately. Strength is generally inversely related to ductility, weak texture and unrelated to ignition resistance, making it challenging to optimize all four concurrently in a material. We address this challenge by designing a low density (~1.76 g.cm⁻³) in-situ Mg nanocomposite. It is a resultant of a sequence of in-situ reactions during melt processing and extrusion. The in-situ formed Y₂O₃ nanoparticles exhibit coherency with matrix and lead to development of large amount of elastic and plastic strain fields around them. These nanoparticles and secondary phases (Mg₂Ca and Mg₂Y) are responsible for the nanocomposite’s high tensile strength (~343 MPa). A weak texture mediated tensile ductility of 30% and compressive failure strain of 44% is observed. Further, the ignition temperature increased to 1045 °C (near the boiling point of Mg) due to the formation of protective surficial oxide layers aided by the presence of insulating Y₂O₃ nanoparticles, rendering the nanocomposite outperform other traditional commercial Mg-based materials.

This work introduces Mg-4Zn-3Gd-1Ca/2ZnO (wt.%) nanocomposite fabricated using the technique of disintegrated melt deposition and extrusion. Addition of ZnO nanoparticles enhanced the compressive strengths of alloy by ~100 MPa. Nanocomposite samples display high strength and good ductility: 0.2% compressive yield stress of 355 MPa, ultimate compressive stress of 703 MPa and compressive failure strain of 10.6%. The significant enhancement of compressive yield stress is mainly attributed to the grain refinement by adding nanoparticles. The strength levels exceed that of commercial magnesium alloys (i.e. WE43, WE54, ZK60 and ME21) and mild steels (i.e. S275 and S355), making Mg-4Zn-3Gd-1Ca/2ZnO a very promising material for multiple engineering and biomedical applications.

In this study, a new structure is proposed based on the body-centered cubic (BCC) lattice structure by adding a cubic truss in the center of the BCC structure and denoting it TLC (truss–lattice–cube). The different dimensions of the central cube can notably affect the mechanical properties of the lattice structure. With a fixed length (15 mm) of a unit cell, the optimal size for the central cube is determined to be 5 mm. Quasi-static compressive tests are performed on specimens made of polylactic acid (PLA) using additive manufacturing technology. The deformation characteristics of the new structure are analyzed in detail by experiments and numerical simulations. Compared to the BCC structure, the mechanical properties of the TLC structure were significantly improved. The initial flow stress of the TLC increased by 122% at a strain of 0.1; the specific strength enhanced by 293% at a strain of 0.5; and the specific energy absorption improved by 312% at a strain of 0.6. Printing defects in the lattice structure may remarkably damage its mechanical properties. In this work, incorporation of microcracks into the finite element model allows the simulation to capture the influence of printing defects and significantly improve the predictive accuracy of the simulation.