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High energy mechanical milling followed by hot-pressing consolidation has been used to produce nanostructured Al–5 wt %Si alloy. X-ray diffraction (XRD), scanning electron microscopy equipped with energy dispersive X-ray detector (SEM-EDX), Vickers hardness, and compression measurements were used to examine the effect of milling duration on microstructure and mechanical properties of the nanostructured consolidated alloys. Crystallite sizes and lattice strains were determined by X-ray peak broadening analysis using the Williamson-Hall (W-H) method. Increasing the milling time reduced the crystallite size, and the minimum crystallite size of about 33 nm was achieved for both consolidated and powdered samples after 50 h of milling. Based on the SEM-EDX observations, the best distribution of silicon into Al matrix was obtained after 20 h of milling and remained unchanged afterwards. Hardness of both consolidated and powder samples increased with milling time, which can be attributed to the reduction of crystallite size and the better distribution of silicon in the aluminum matrix. Similarly, increased milling time increased the yield and compressive strengths of consolidated samples.

Structural and Mechanical Evaluation of a Nanocrystalline Al–5 wt %Si Alloy Produced by Mechanical Alloying