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The synthesis of Magnesium based alloy AZ31 using Magnesia Packed Sintering (MPS), an innovative approach in powder metallurgy is focused here. It is aimed to exclude the usage of protective gases for preventing oxidation and to optimize the process parameters. This method uses magnesia powder packed around the green compact inside a steel container to avoid oxidation and burning. This approach of sintering is developed as an alternative method for atmospheric protection. This method can be applied to fabricate magnesium based alloys and composites. Taguchi method integrated with GRA is employed for parameter optimization. Experiments are conducted based on L9 orthogonal array to analyse the effect of compaction pressure(675,700,725MPa),sintering temperature(450,500,540°C)and holding time(60,90,120 minutes).The GRG of output responses like compressive strength, micro hardness is analysed using ANOVA. Micro structural analysis is done using Scanning Electron Microscopy (SEM). Tests of confirmation with optimized parameters shown improvement in strength and hardness.Energy Dispersive X- ray Spectroscopy analysis is carried out to confirm the presence of Al, Zn, Mn in the sintered compact to ensure AZ31 composition. The phase analysis is done using X-ray Diffraction(XRD). The results proved that the new process is effective.

Synthesis of AZ31 alloy by magnesia packed sintering