Micron-sized Powders Research Articles

3D shape and size characterization of micron-sized coal particle with XRCT and SH

The shape and size of solid fuel particles are significant parameters in combustion process, and have attracted broad attentions in simulation and experiment studies. In this study, X-ray computer tomography (XRCT) and spherical harmonics (SH) were introduced and combined to conduct accurate morphology characterization of micron-sized coal powder in three dimensions (3D) with purpose of providing references for morphology characterization, size measurement, and modeling of solid fuel particles. The shape parameters including volume, surface area, sphericity index, specific surface area, enlongation index, and flatness index, and the size parameters including diameter of volume equivalent sphere, three principal dimensions, and sieve size, were obtained with SH expansion. Validation on standard geometries demonstrated the accuracy of the method under the SH degree N ≥ 20, with errors for volume, surface area, and sieve size within 1 %, 3 %, and 2.5 %, respectively. These parameters were analyzed statistically to reveal the morphological characteristics of micron-sized coal powder. The Zingg diagram indicated that nearly 60 % of the coal powder particles are nearly spherical. Comparison among 3D size, 2D size, and sieve size implied that characterizing with 2D size may overestimate the fineness of coal powder. Although there was a variance in the particle size distribution, it was demonstrated that there exists a strong linear relationship between the 3D size, 2D size, and sieve size. The method could serve as a functional auxiliary tool for fuel particle research.

Fabrication of FeSiBCr/wollastonite amorphous soft magnetic powder cores with low loss and high-quality factor

In this paper, the best magnetic properties of FeSiBCr/wollastonite soft magnetic composites were explored by adjusting the content of wollastonite powder and annea- ling temperature. FeSiBCr/wollastonite soft magnetic composites with low loss and high quality factor were successfully prepared by adding micron-sized wollastonite po-wder into amorphous magnetic powder. Wollastonite was used as the insulating coating material of amorphous magnetic powder for the first time, which showed good performance in reducing the loss of magnetic powder. The loss change of FeSiBCr/wollastonite magnetic powder cores was studied by B-H analyzer and loss separation analysis model. The results show that the total loss (Pcv) of FeSiBCr/woll- astonite composite cores is lower than that of the pure FeSiBCr cores. With the incre- ase of wollastonite powder content and annealing temperature, the total loss of FeSiBCr/wollastonite composite powder cores shows a trend of first decreasing and then increasing. The composite powder cores containing 0.8 wt% wollastonite powder was heat treated at 678 K for 1 hour under the protection of nitrogen, and its magnetic properties were the best, with a permeability of 28.93 and a loss of 196.2 mW/cm3( f =1 MHz and Bm =20 mT). Wollastonite is a new coating material, which has a good effect of reducing loss. At the same time, this work also provides a new scheme for reducing the total loss of soft magnetic powder cores.

Preparation of monophasic YAG raw material by multi-stage process

The paper deals with the study of the features of the process of YAG phase formation via the Solid-State Reaction (SSR) method according to the proposed multi-stage scheme, including three stages of various mechanical and thermal processing (pre-milling in a ball mill for 24, 48 and 72 h, as well as firing at 1150 °C, 1250 °C, and 1450 °C with intermediate grinding step). The commercial micrometer-sized Y2O3 and Al2O3 powders were used as starting materials. The phase transformation was monitored by the X-ray diffraction in each synthesis stage. The microstructure and elemental distribution of samples were studied by scanning electron microscopy and energy-dispersive X-ray spectrometry. During the work, we found the dual effects of partially reacted mixture grinding, which can accelerate or slow down the synthesis rate depending on the YAG content in the preceding stage. We have proposed a simple model including the concept of “critical YAG concentration”. When the lower limit of this parameter (over 60 %) is reached, grinding has a negative effect on the further course of the SSR. Carrying out the synthesis according to a three-stage scheme makes it possible to obtain a product with a YAG content above 90 %, regardless of the pre-milling time, and the use of a two-stage synthesis scheme provides a monophasic raw material (99 % of YAG) suitable for further single crystals growth. The increased efficiency of the multi-stage YAG synthesis scheme was demonstrated in comparison with the conventional one-stage obtaining process that yielded only up to 60% of the target phase in the temperature range up to 1500 °C.

Preparation of Silicon Carbide Powder from Amorphous Silica and Investigation of Synthesis Mechanism

An innovative process for preparing silicon carbide (SiC) from acid leaching residue of ferronickel slag through a carbon–thermal reduction process was proposed in this study. The results indicate that the acid leaching residue is an ideal silicon source for SiC preparation according to its high amorphous silica content of 84.20% and fine particle size of d50 = 29.16 μm. Compared with carbon black, activated carbon, and graphite, coke is the more appropriate carbon source for SiC preparation. A micron-size SiC powder with grade of 88.90% and an average particle size (d50) of 44.68 μm can be obtained under the following conditions: the mass ratio of coke to leaching residue as 1.2:1, in an air atmosphere, reducing at 1600 °C for 3 h, following by decarbonizing at 700 °C for 4 h. The XRD, SEM and FTIR analyses show that the prepared powder is 3C-SiC and belongs to the β-SiC crystal type. Based on thermodynamic analysis and micromorphology observation, it can be concluded that with amorphous silica as the silicon source, the carbon–thermal synthesis of SiC powder follows both the solid–solid reaction mechanism and the gas–solid mechanism. The SiC created through solid–solid reaction is primarily nucleated in situ on amorphous SiO2, with a size close to that of the original acid-leaching slag, while the SiC generated according to the gas–solid mechanism mainly nucleates heterogeneously on the surface of carbon particles, resulting in a smaller particle size and mostly adhering to the surface of solid–solid nucleated SiC particles. This study provides a feasible method for the effective utilization of amorphous silica, which is also significant for the efficient consumption of the vast acid leaching residue.

Thermal enhancement of the oxidation layer of micron-sized aluminum powder and its anti-oxidation performance

Micron-sized aluminum powder, with its typical core-shell structure, exhibits oxidation behavior upon slow heating in an oxidative atmosphere that is related to the particle size of the aluminum powder. A particle size-dependent thermal response mechanism for micron-sized aluminum powder is established: a "shell-breaking eruption" thermal response mechanism. The oxide layer is thermally enhanced, and the anti-oxidation reaction behavior mechanism of the enhanced samples is studied. Aluminum powder samples, heated slowly to specific temperatures to obtain changes in the oxide layer structure, are analyzed using a thermal analyzer to compare the slow heating response behavior of aluminum powder before and after the oxidation layer changes. It was found that after thermal enhancement of the aluminum powder oxidation layer, which changed from amorphous to γ-phase and whose thickness increased to twice the original thickness, the slow oxidation process of micron-sized aluminum powder was inhibited, and the aluminum powder was completely deactivated in the slow heating response.

Reaction mechanism of micron-sized aluminum powders in O2 and CO2 gradually heated environment

The behavior of aluminum powders in specific oxidized environment is different from each other obviously. Thermal behaviors of micron-sized aluminum powders in different oxygenated and gradually heating environments were discussed in order to find out the oxidation mechanism. Particular attention is paid to the reaction mechanism of oxygen and carbon dioxide atmosphere. Thermogravimetric analysis and related characterization methods are used and the results demonstrated that under the certain condition, reaction process of micron-sized aluminum powders can be divided into four stages. General routes for the oxidation of micron-sized aluminum in general heating system are the same, however, itis different among the extent of reaction at the third stage in different kinds of oxidizing gas atmospheres. Gas phased products were detected during the main reaction stage under carbon dioxide by combining thermal analysis and mass spectrometry which contributes to the rupture of alumina shell and further reaction of micron-sized aluminum powders. Consequently, rapider and more complete reaction process was achieved. The increasing thickness of original alumina shell can restrict the reaction rate of aluminum powders harder at the same time.

Studies on activity and oxide shell thickness of micron-sized Mg-Al alloy powder

The empirical formula of average oxide thickness of atomized micron-sized aluminum - magnesium alloy powder was proposed. At the same time, the influence of particle size and the ratio of magnesium on samples’ activity was studied. The phase composition, morphology, and oxidation process of the alloy powders were studied by x-ray diffraction, scanning electron microscope/energy-dispersive x-ray, respectively. Study on the change of powder activity was achieved by standard gas volumn method. The results show that the oxide thickness of the atomized micron-sized aluminum - magnesium alloy powder is positively correlated with the particle size, and the activity decreases with the increase of the particle size and the magnesium content.

Solid-state production of uniform metal powders for additive manufacturing by ultrasonic vibration machining

This work presents a new technique to generate uniform and micron-sized metal powders for additive manufacturing. By collecting discrete chips resulting from ultrasonic vibration machining, we demonstrate the feasibility of all solid-state production consistent powders with tight dimensional tolerance, the ability to control powder geometry, and good efficiency. The technique offers a new route for sustainable and low-cost manufacturing of high-quality metal powders. The powder generation mechanism is analyzed with a special tool path design to ensure consistent dimensions over multiple cuts. An analytical model to predict the dimensions of produced powders under different cutting parameters is introduced. Aluminum and brass powders of different dimensions are produced, and the overall shear ratio that governs the deformation during the machining process is calibrated with the experimental results. The morphology consistency of produced powders is investigated over multiple hours of production, illuminating the role of tool wear on final powder shape. A high-efficiency powder collection system and a scalable solution for parallel production are proposed for the introduced technique. Additive manufacturing experiments (laser powder bed fusion) are conducted using produced A356 aluminum powders, demonstrating the printability of produced powders in additive manufacturing. The microhardness of the printed parts for five different process parameters is measured to be 45% higher than the raw material on average.

Thermal Plasma Spheroidization and Characterization of Stainless Steel Powders Using Direct Current Plasma Technology

The production of spherical powders has recently registered a boost due to the need to fabricate new printing materials for Additive Manufacturing applications, from polymers and resins to metals and ceramics. Among these materials, stainless steels powders play a leading role, since they are widely used in industry and everyday life; indeed, micron-sized spherical stainless steel powders have specific characteristics and are considered as one of the best candidates for Additive Manufacturing systems and for application in a wide range of sectors. In this paper, stainless steel 316 L powders were used to explore and identify the best process parameters of a thermal plasma process able to produce spherical powders for Additive Manufacturing applications. X-ray Diffraction, Scanning Electron Microscopy, Particle Size Distribution and Flowability analysis were performed to characterize reagents and products. Powders with a high circularity (>0.8) and improved flowability (<30 s/50 g) were successfully obtained. The collected results were compared with data available from the literature to identify the potential use of the spherical produced powders.

From biomass to batteries: the contribution of silicon–carbon composites prepared from high-nitrogen egg whites and micron-sized silica powder to lithium-ion battery performance

This research uses egg white proteins as a carbon source to create silicon/nitrogen-doped composites, addressing silicon electrode volume expansion in lithium-ion batteries.

Towards chitosan-amorphous calcium phosphate nanocomposite: Co-precipitation induced by spray drying

This article reports the successful one-step synthesis of two micron-sized composite powders consisting of chitosan and amorphous calcium phosphate. These composite materials are prepared by spray drying of a solution containing chitosan and calcium phosphate precursors. The co-precipitation of chitosan and calcium phosphate precursors during the process induces a highly homogeneous distribution of the phases. The mineral phase identified as spherical nanoparticles dispersed in chitosan showed no chemical bonding with the polymer. As demonstrated by electron microscopy, small angle X-ray scattering and spectroscopies, variation in chitosan concentrations significantly influences the size and spatial distribution of the mineral phase. These results present a promising approach for the preparation of chitosan/amorphous calcium phosphate composite powders with controlled and tunable properties with potential applications in the field of biomaterial engineering such as bone substitutes.

Microstructure and properties of Ni-Ti based gradient laser cladding layer of Ti6Al4V alloy by laser powder bed fusion

An economical gradient layer was successfully prepared on Ti6Al4V alloy produced by laser powder bed fusion (L-PBF) using only composition design, gravity segregation, and laser cladding of micrometer-sized Ni powder, nanoscale SiC and Y2O3 powders. The microstructure of the layer was systematically studied to analyze the reasons for its improved wear and corrosion resistance. The results indicated that the cladding layer comprised top, middle, lower, and bottom layers. The main phases in top layer were Ti2Ni and β-Ti. Whereas the middle layer is composed of two regions, one with a similar structure to the top layer, and the other is the nickel-enriched area denoted as NEAm where the main phases were Ti2Ni, TiNi, and amorphous. The main phase of the lower layer was TiNi. Owing to the close distance between the bottom layer and the substrate, there was a significant increase of Ti in the bottom layer, and so the bottom layer and the top layer contained the same main phases. The soft phase of TiNi in lower layer would prevent the propagation of cracks that may occur in the top layer. The solidification and formation process of the gradient structure of the cladding layer was analyzed with Scheil model, and the simulation results were consistent with the experimental results. A nanocomposite system consisting of Ti3Si, α-Ti, and β-Ti was found for the first time in this study. The relationship between Ti3Si and α-Ti was coherent, and the relationship between α-Ti and β-Ti satisfied the Burgers orientation relationship. The mechanism of the nanocomposite system generation was that Si was enriched at the grain boundaries after the formation of Ti2Ni, where Ti and Si combined to form Ti3Si, and then Ti3Si was used as nucleating particles to form β-Ti/α-Ti. The α-Ti and β-Ti in the fusion line area at the bottom layer also satisfied the Burgers coherent relationship, indicating excellent bonding strength between cladding layer and substrate. A large number of solute atoms in the solid solution, pinning of second-phase particles, and the amorphous were the fundamental reasons for the substantial improvement in hardness and wear resistance. A small amount of Ni in the top layer increased the polarization of the cathodic reaction, keeping the corrosion current low. In addition, numerous dispersed fine phases in the top layer increased the resistance of charge transfer at the phase interfaces, which was the fundamental reason for the improved corrosion resistance.

Developing of Lead/Polyurethane Micro/Nano Composite for Nuclear Shielding Novel Supplies: γ-Spectroscopy and FLUKA Simulation Techniques.

In this work, the effect of adding Pb nano/microparticles in polyurethane foams to improve thermo-physical and mechanical properties were investigated. Moreover, an attempt has been made to modify the micron-sized lead metal powder into nanostructured Pb powder using a high-energy ball mill. Two types of fillers were used, the first is Pb in micro scale and the second is Pb in nano scale. A lead/polyurethane nanocomposite is made using the in-situ polymerization process. The different characterization techniques describe the state of the dispersion of fillers in foam. The effects of these additions in the foam were evaluated, Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray diffraction (XRD) have all been used to analyze the morphology and dispersion of lead in polyurethane. The findings demonstrate that lead is uniformly distributed throughout the polyurethane matrix. The compression test demonstrates that the inclusion of lead weakens the compression strength of the nanocomposites in comparison to that of pure polyurethane. The TGA study shows that the enhanced thermal stability is a result of the inclusion of fillers, especially nanofillers. The shielding efficiency has been studied, MAC, LAC, HVL, MFP and Zeff were determined either experimentally or by Monte Carlo calculations. The nuclear radiation shielding properties were simulated by the FLUKA code for the photon energy range of 0.0001-100 MeV.

Study on the protective performance of high-performance multi-scale (SiCh-p+B4Cp)/5083Al ceramic array armor with excellent ballistic properties

Ceramic array armor suffers from insufficient constrained capability of ceramic units in the embedded armor structure, leading to weak interfacial bonding at ceramic unit connections, significantly reducing the overall ballistic performance. In this study, centimeter-sized SiC hexagonal prisms and micrometer-sized B4C powders were used as reinforcing materials. A high-strength, high-toughness, and multiscale array (SiCh-p + B4Cp)/5083Al armor with strong interfacial bonding was prepared using pressure infiltration technique. The (SiCh-p + B4Cp)/5083Al armor was combined with ultra-high molecular weight polyethylene and 6252 armor steel to form an integrated armor system. To investigate the effect of constrained material on its ballistic performance, the array structures with epoxy and 5083Al as constrained material were prepared for comparison. Ballistic performance tests were conducted using 12.7 mm Armor-Piercing Incendiary (API). The damage mechanisms of the armor structure were studied through finite element simulation and a combination of macroscopic and microscopic analyses. The results demonstrate excellent overall ballistic performance of the (SiCh-p + B4Cp)/5083Al armor system. The high-strength and high-toughness 55 vol%B4Cp/5083Al composite material exhibits strong interfacial bonding with SiCh-p, providing robust support to the SiCh-p. The armor back deformation was reduced by 50 %, and the ceramic layer dissipated more than 70 % of projectile kinetic energy, The materials prepared in this study exhibit significant potential in ballistic performance.

Universal approach for developing reprocessable and reprintable plant oil-based resins for digital light processing 3D printing

Recently, researchers have shown great interest in the development of biobased and reprintable 3D printing materials for sustainable 3D printing. Herein, a method for developing plant oil (PO)-based digital light processing (DLP) printing resins that are both reprocessable and reprintable is proposed. Biobased UV-curable monomers (POPITs) containing dynamic hindered urea bonds (HUBs) from POs were synthesized via the thiol-ene click reaction. A range of DLP printing resins (POPIT-I) with high biobased content (52.6%–58.1%) were prepared by blending POPITs with the biobased dilute monomer isobornyl acrylate. These resins demonstrated good mechanical and thermal properties (e.g., tensile strength: 45.1–49.5 MPa and Tg: 74–92 °C), as well as high DLP printing quality. Reprocessable DLP printing was employed to fabricate large-volume parts through the dissociation and reorganization of HUBs, thereby reducing printing difficulty and printing time. Additionally, a powder blending and modification method was used to recycle and reprint printed materials. The printing materials, including printed green parts and discarded supporting materials, were milled into micron-sized powders and then blended with POPIT-I to prepare the powder blending resins. The milled powders in the powder blending resins were further modified by 2-(tert-butylamino) ethyl methacrylate to prepare reprinting resins. This process resulted in the grafting of C = C onto the powder surface, which eliminated heterogeneity between the powders and POPIT-I. The mechanical and thermal properties of the reprinting resins were comparable with those of POPIT-I even after three rounds of recycling. Furthermore, the reprinting method reported here is applicable to other dynamic covalent bond-based 3D printing systems.

Detailed investigation on the insulation and permeability characteristics of rigid polyurethane foam loaded with micron-sized Turkey feather powder depending on the free volume change

This study brokes new ground to understand the insulation and permeability performances of rigid polyurethane foams (RPUFs) containing the different contents of micron-sized turkey feather powders (TFPs) depending on the free volume change for the first time. The effects of TFPs loading on the RPUFs were investigated by the examination of their structural and chemical features (particle size and ATR-FTIR analyses), free volume property (PALS analysis), insulation features (thermal conductivity and sound absorption tests), permeability performance (air and water vapor permeability tests) and cellular topology (SEM). PALS analysis results revealed that the addition of TFPs into the foams led to the sharp decrease in all free volume parameters since TFPs caused the formation of the disordered cells by occupying the holes in the matrix. Furthermore, both thermal conductivity and acoustic performance of the resulting foams get worse when compared to unfilled RPUF. This results were attributed to the formation of thinner and weaker cells during polymerization, reduction in the amount of CO2 inside the cells, enhancement in the solid-phase level in the matrix due to the increasing of volumetric density. Additionally, the foam samples with high content of TFPs showed considerably lower air and water vapor permeabilities when compared to neat RPUFs due to the dominant hydrophobic character of the keratin and reduction in the degree of vacancies in the matrix. SEM analysis also revealed that TFPs showed good compatibility with RPUF, but the distorted and irregular shaped cellular morphology was obtained at high contents.

Microstructural and thermal evaluation of the formation of tin–tellurium (Sn[sbnd]Te) alloy by ball milling process

A mechanically induced phase transition in tin‑tellurium (SnTe) system and its dependence on the milling time of the masses of metastable SnTe phase(s) produced during ball milling have been investigated. The synthesis approach involves top-down ball milling of elemental Sn and Te powders in an argon environment with a milling time of 1 to 5 h at a low ball milling speed of 300 RPM. The SnTe solid solution forms as particles, resulting in large masses due to the ball milling operation. Ball milling of initial micron-sized powders of Sn and Te resulted in a homogenized nano-sized powder mixture. This mechanical mixture of Sn and Te powders exhibiting intermediate phases with a crystal structure similar to that of elemental Sn and Te were detected in the ball-milled mixtures at various milling times, which resulted in a stable phase that ultimately transformed into a SnTe solid solution. Morphological and structural modifications at different stages of ball milling were investigated through X-ray diffraction, field emission scanning electron microscopy, transmission electron microscopy, differential scanning calorimetry, dynamic light scattering, density measurement, and surface analysis. Subsequently, dense pellets were fabricated by spark plasma sintering from synthesized SnTe solid-solution powders produced by ball milling for 5 h. The sintered samples showed excellent structural integrity with densities of up to 6.35 g/cm3. It is to be noted that the formation of large quantities of uniform SnTe powder alloy produced by ball milling is reported for the first time in this study. These findings could be extended in the future to prepare bulk quantities of many solid solutions of the elements of the same periodic group.

Study of the Aid Effect of CuO-TiO2-Nb2O5 on the Dielectric and Structural Properties of Alumina Ceramics.

The aim of this work is to study the structural, dielectric, and mechanical properties of aluminum oxide ceramics with the triple sintering additive 4CuO-TiO2-2Nb2O5. With an increase in sintering temperature from 1050 to 1500 °C, the average grain size and the microhardness value at a load of 100 N (HV0.1) increased with increasing density. It has been shown that at a sintering temperature of 1300 °C, the addition of a 4CuO-TiO2-2Nb2O5 additive increases the low-frequency permittivity (2-500 Hz) in alumina ceramic by more than an order of magnitude due to the presence of a quadruple perovskite phase. At the same time, the density of such ceramics reached 89% of the theoretical density of α-Al2O3, and the microhardness value HV0.1 was 1344. It was observed that the introduction of 5 wt.% 4CuO-TiO2-2Nb2O5 in the raw mixture remarkably increases values of shrinkage and density of sintered ceramics. Overall, the results of this work confirmed that introducing the 4CuO-TiO2-2Nb2O5 sintering additive in the standard solid-phase ceramics route can significantly reduce the processing temperature of alumina ceramics, even when micron-sized powders are used as a starting material. The obtained samples demonstrated the potential of α-Al2O3 with the triple additive in such applications as electronics, microwave technology, and nuclear power engineering.

Microstructural formation and evolution of near-eutectic Al2O3–ZrO2 powders prepared by a rapid cooling technique: An exploration on coupled eutectic growth range

Regulation of eutectic compositions is a difficult challenge due to the limited formation range of this microstructure. Al2O3–ZrO2 powders were successfully prepared through a modified high-temperature melt-assisted air atomization technique. Micron-sized raw powders of α-Al2O3 and m-ZrO2 were used to regulate the temperature of system and the composition of final products. The high-temperature melt of 3500 K (3227 °C) was obtained based on the exothermic reaction between Al and O2, which was subsequently atomized and quenched to form composite powders. The phase composition and microstructure of the as-prepared powders were characterized by X-Ray diffraction and scanning electron microscopy. Eutectic colonies with nanolamellae (62–79 nm) were observed in the as-prepared Al2O3-(28–58 mol%) ZrO2 powders, with growth rates ranging from 1.9 to 2.8 mm s−1. Importantly, the powders with ZrO2 contents of 38 mol% and 42 mol% showed complete eutectic microstructures without primary dendrites, which indicated an extended coupled growth range deviating by ∼4.9 mol% from the eutectic composition (CE). The microstructural formation mechanism was discussed based on solidification behavior analysis. Furthermore, the evolution of the microstructure and phase in Al2O3-42 mol% ZrO2 powders was investigated. This work aims to develop a novel strategy for preparing oxide powders with eutectic structures and provide a reference for the composition regulation of eutectics.

Microstructural and Mechanical Behavior Investigations of Nb-Reinforced Mg–Sn–Al–Zn–Mn Matrix Magnesium Composites

This research focuses on the fabrication and characterization of TAZ532-xNb composites, employing high-purity, micron-sized powders of Mg, Sn, Al, Zn, Mn, and Nb as the raw materials. These powders were subjected to a paraffin coating process aimed at mitigating oxidation. The formation of composites was achieved via hot pressing and was followed by surface preparation and analysis using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). An X-ray diffraction (XRD) study was conducted to identify the microstructural phases. Quantitative assessments including the theoretical density, actual density, and relative density were computed, and their fluctuations in relation to the increasing Nb reinforcement ratio were scrutinized. Furthermore, the mechanical attributes of the composites, such as hardness and tensile strength, were assessed via experimental procedures. The absence of oxygen-related peaks in the XRD patterns endorsed the successful execution of the paraffin coating technique and protective gas atmosphere during sintering. The detection of α-Mg, Mg2Sn, MgZn, Mg17Al12, and Nb phases within the Nb-reinforced composite patterns authenticated the formation of the intended phases. Notably, the relative density values of the composites surpassed 95%, indicating efficient sintering. SEM results disclosed a densely packed microstructure, with Nb reinforcement particles evenly distributed along the grain boundaries, devoid of particle clustering or significant grain growth. These composites manifested exceptional wetting characteristics, which can be attributed to the employment of Mg alloy as the matrix material. EDS data confirmed the proportions of Nb within the composites, aligning with the quantities incorporated during fabrication. The composites showcased an increase in microhardness values with the escalating Nb reinforcement ratio, credited to the harder constitution of Nb particles in comparison to the matrix alloy. Concurrently, tensile strength showed a significant improvement with the increment in Nb reinforcement, while elongation values peaked at a specific Nb reinforcement level. The positive evolution of tensile strength properties was ascribed to the escalated Nb reinforcement ratio, grain size, and consequent higher sample densities.