Abstract: Reactive sintering of Al-Mg powder mixtures containing 5, 10, 15, and 20 wt.% Mg was used to synthesize lightweight composites reinforced with in-situ formed Al3Mg2 and Al12Mg17 intermetallics. Detailed microstructural investigation and phase analysis were employed to examine the phases in the composites formed at 400 and 450 ℃. The creation of particles with the Al12Mg17 cores encapsulated by the Al3Mg2 phase, which was further covered by a continuous aluminum matrix, was observed in the composites synthesized at 400 ℃. If the composites were held at 450 ℃, the liquid phase appeared at the Al-Mg interface, and as a result, a two-phase mixture was formed. It was the eutectic composed of the Al3Mg2 intermetallic compound and a solid solution of magnesium in aluminum (Al). The introduction of magnesium particles into the aluminum matrix resulted in a decrease in the density of composites, but there was no significant difference in the density of composites sintered at different temperatures. The mechanical behavior of the composites was examined using microhardness and hardness measurements and a room-temperature compression test. The result of using different cooling speeds, with the furnace and quenching in water, was the refining of the grains in the Al3Mg2 + (Al) eutectic, resulting in an increase in microhardness. The increase in hardness of the composites was related to the amount of particles introduced. Sintering at 450 ℃ and the cooling method influenced the hardness and compressive strength of the composites, which were higher by 10% and 13%, respectively, compared to composites sintered at 400 ℃. Tribological tests showed that introducing more and more magnesium particles into the aluminum matrix, followed by reactive sintering, increased the wear resistance. On the other hand, the sintering temperature and cooling conditions had little effect on the wear resistance of the Al-Mg composites.
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