Formation of fine Mg2Si phase in Mg–Si alloy via solid-state sintering using high energy ball milling

This study aims to investigate the formation of the fine Mg2Si phase in the Mg–Si alloy system with varying amounts of silicon (1, 2, and 6 wt% of silicon) via solid-state sintering using powders after high energy ball milling. This investigation is focused on developing alloys with unique properties utilizing powder metallurgy process for different automotive parts such as instrument panel beams, transfer cases, manual transmission cases, valve/cam covers, steering components and various housings and brackets. These investigations revealed that during the sintering process magnesium atoms react with silicon atoms and form a precipitate of an intermetallic compound of magnesium and silicon Mg2Si. X-ray diffraction (XRD) was carried out to confirm the formation of the crystalline phase Mg2Si and to calculate crystallite sizes of Mg and Mg2Si in different compositions. SEM micrographs and energy dispersive spectroscopy (EDS) of the samples show a uniform microstructure and similar distribution of the Mg2Si phase throughout the alloy with grain size varying from 3 to 10 μm. The structural and mechanical integrity of the prepared samples, bulk density, apparent porosity, and Vickers hardness were also measured. •Formation of fine Mg2Si phase via powder metallurgy process without using a modifier.•The Mg2Si phase has been confirmed by Rietveld refined X-ray diffraction profile.•Optimization of green density at different loads of pure magnesium powder, ball mill, and without ball mill condition.•The morphology of Mg2Si phase is affected by increases the wt. % of silicon in Mg–Si composites.•Enhancement of the mechanical property by reducing the cost of synthesis.