Lightweight high-strength metal matrix nano-composites (MMNCs) can be used in a wide variety of applications, e.g., aerospace, automotive, and biomedical engineering, owing to their sustainability, increased specific strength/stiffness, enhanced elevated temperature strength, improved wear, or corrosion resistance. A metallic matrix, commonly comprising of light aluminum or magnesium alloys, can be significantly strengthened even by very low weight fractions (~1 wt%) of well-dispersed nanoparticles. This review discusses the recent advancements in the fabrication of metal matrix nanocomposites starting with manufacturing routes and different nanoparticles, intricacies of the underlying physics, and the mechanisms of particle dispersion in a particle-metal composite system. Thereafter, the microstructural influences of the nanoparticles on the composite system are outlined and the theory of the strengthening mechanisms is also explained. Finally, microstructural, mechanical, and tribological properties of the selected MMNCs are discussed as well.

Magnesium alloys suffer from only moderate high-temperature strength and creep resistance. Aluminium-free magnesium alloys for sand casting or alloys containing aluminium with expensive additional alloying elements may be in use, but only microparticle or microfibre-reinforced magnesium alloys really exhibit satisfactory creep strengths at temperatures up to 250°C. Reinforcing magnesium alloys with ceramic nanoparticles could be a solution for preserving a low density while increasing the high-temperature performance. When produced using melting processes, nanoparticle-reinforced magnesium composites are expected to enjoy strengthening due to the grain refinement described in the Hall-Petch relation. When an isotropic distribution of nanoparticles is achieved, the composites are additionally expected to be Orowan-strengthened. In this review, a variety of ceramic materials, such as SiC, Al 2 O 3 , Y 2 O 3 , SiO 2 and carbon nanotubes were investigated for reinforcement. Pure magnesium and various magnesium alloys were chosen as the matrix material and both powder metallurgical and melting processes were used for production of the composites. The mechanical properties of the composites were generally enhanced, compared to an unreinforced alloy; not only at room temperature, but also at elevated temperatures. In some cases an increase in strength in combination with increased ductility was also identified.

An AM60 magnesium alloy nanocomposite reinforced with 1 wt % of AlN nanoparticles was prepared using an ultrasound (US) assisted permanent-mould indirect-chill casting process. Ultrasonically generated cavitation and acoustic streaming promoted de-agglomeration of particle clusters and distributed the particles throughout the melt. Significant grain refinement due to nucleation on the AlN nanoparticles was accompanied by an exceptional improvement in properties: yield strength increased by 103%, ultimate tensile strength by 115%, and ductility by 140%.Although good grain refinement was observed, the large nucleation undercooling of 14 K limits further refinement because nucleation is prevented by the formation of a nucleation-free zone around each grain. To assess the industrial applicability and recyclability of the nanocomposite material in various casting processes, tests were performed to determine the effect of remelting on the microstructure. With each remelting, a small percentage of effective AlN nanoparticles was lost, and some grain growth was observed. However, even after the third remelting, excellent strength and ductility was retained. According to strengthening models, enhanced yield strength is mainly attributed to Hall-Petch strengthening caused by the refined grain size. A small additional contribution to strengthening is attributed to Orowan strengthening.

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