Method for making magnesium-based composite material and equipment for making the same

Abstract

A method for fabricating a magnesium-based composite material, the method includes the steps of: (a) providing a large amount of magnesium-based powder and a large amount of nanoscale reinforcements; (b) uniformly mixing the magnesium-based powder and the nanoscale reinforcements to form a mixture; and (c) compacting the mixture at a high velocity in a protective gas to achieve the magnesium-based composite material. High velocity compaction equipment for fabricating the magnesium-based composite material includes a sealing chamber, a gas pumping device, a mold, and a hammer. The gas pumping device is connected to the sealing chamber. The mold is disposed in the sealing chamber with an aperture formed on the top thereof. The hammer is disposed in the sealing chamber and above the mold, and moving along longitudinal thereof at a controllable ramming speed.

1 . A method for fabricating a magnesium-based composite material, the method comprising the steps of:
 (a) providing a large amount of magnesium-based powder and a large amount of nanoscale reinforcements;   (b) uniformly mixing the magnesium-based powder and the nanoscale reinforcements to form a mixture; and   (c) compacting the mixture at a high velocity in a protective gas to achieve the magnesium-based composite material.   
     
     
         2 . The method as claimed in  claim 1 , wherein the material of the magnesium-based powder is one of pure magnesium and magnesium-based alloys. 
     
     
         3 . The method as claimed in  claim 2 , wherein components of the magnesium-based alloy comprises magnesium and other elements selected from a group consisting of zinc, manganese, aluminum, thorium, lithium, silver, calcium, and any combination thereof. 
     
     
         4 . The method as claimed in  claim 3 , wherein a weight ratio of the magnesium to the other elements in the magnesium-based alloy is more than 4:1. 
     
     
         5 . The method as claimed in  claim 2 , wherein the diameter of particles of the magnesium-based powder is less than about 74 microns. 
     
     
         6 . The method as claimed in  claim 1 , wherein the nanoscale reinforcements are made up of carbon nanotubes, carbon nanofibers, silicon carbide nano-particles, alumina (Al 2 O 3 ) nano-particles, titanium carbide (TiC) nano-particles, and any combination thereof. 
     
     
         7 . The method as claimed in  claim 6 , wherein the diameter of the nanoscale reinforcements is in the approximate range from 1 nanometer to 10 microns. 
     
     
         8 . The method as claimed in  claim 1 , wherein a weight percentage of the nanoscale reinforcements in the mixture is in the approximate range from 0.01% to 30%. 
     
     
         9 . The method as claimed in  claim 1 , wherein step (c) is performed in a high velocity compaction equipment and comprises substeps of:
 (c1) disposing the mixture in a mold of the high velocity compaction equipment in a protective gas;   (c2) lightly pressing the mixture in the mold through an aperture thereon by a hammer; and   (c3) repeatedly compacting the mixture in the mold through the aperture thereon by the hammer at a high speed to achieve the magnesium-based composite material.   
     
     
         10 . The method as claimed in  claim 1 , wherein step (b) is executed in a ball mill with a protective gas filled therein. 
     
     
         11 . The method as claimed in  claim 10 , wherein a milling time is in the approximate range from 0.5 to 24 hours, and a milling speed is in the approximate range from 100 to 300 rotations per minute. 
     
     
         12 . The method as claimed in  claim 1 , wherein an additional step (d) of sintering the magnesium-based composite material in protective gas is further provided after the step (c). 
     
     
         13 . The method as claimed in  claim 12 , wherein the magnesium-based composite material is sintered in a furnace, and the sintering temperature is in the approximate range from 400° C. to 680° C., and the sintering time is in the approximate range from 0.5 to 1 hour. 
     
     
         14 . The method as claimed in  claim 1 , wherein the protective gas in step (c) is nitrogen (N 2 ) and/or a noble gas. 
     
     
         15 . A high velocity compaction equipment for fabricating the magnesium-based composite material comprising:
 a sealing chamber,   a gas pumping device disposed outside the sealing chamber and connected thereto,   a mold disposed in the sealing chamber with an aperture formed on a top thereof, and   a hammer disposed in the sealing chamber and above the mold, and the hammer moving along longitudinal thereof at a controllable ramming speed.   
     
     
         16 . The high velocity compaction equipment as claimed in  claim 15 , wherein a cross section of the hammer has the same size as the aperture of the mold. 
     
     
         17 . The high velocity compaction equipment as claimed in  claim 15 , wherein the ramming speed of the hammer is in the approximate range from 2 to 30 meters per second. 
     
     
         18 . The high velocity compaction equipment as claimed in  claim 15 , wherein a weight of the hammer is in the approximate range from 5 to 1200 kilograms.