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Two nanostructured aluminum powder alloys (supersaturated Al4.5Cu prepared by mechanical alloying, and Al3.0Fe0.42Cu0.37Mn rich in precipitates and prepared by rapid solidification via gas atomization) were consolidated into bulk material under various processing conditions via hot extrusion. The microstructural modifications and mechanical properties of the consolidated alloys as a function of the extrusion conditions were investigated and are discussed here. The effect of pre-existing precipitates from nonsupersaturated alloy is shown to be more effective for controlling grain growth during consolidation. The increase in the extrusion load, with a concomitant increase in the extrusion rate and decrease in temperature, is shown to lead to microstructural modifications. The differences in mechanical properties measured by compressive tests are also discussed in association with the extrusion parameters. Furthermore, suggestions are given for rationalizing the extrusion rate and temperature for the consolidation of nanostructured aluminum powder alloys via hot extrusion.

Samples of a 2Mg-Fe (at.%) mixture were produced by high energy ball-milling (HEBM) with ball to powder ratio = 20:1, in an argon gas atmosphere, in 190 ml vials (sample-1) to produce powders and in 300 ml vials (sample-2) to produce plates. Both samples were cold-pressed into preforms. The preforms were then extruded at 300°C at a ram speed of 1mm/min., with the following extrusion ratios: sample-1 at 3/1 to ensure porosity and sample-2 at 5/1 to increase the adhesion of the plates. The resulting bulks from samples 1 and 2 were hydrogenated for 24h in a reactor under 15 bar of H2to produce the Mg2FeH6complex hydride, and at 11 bar of H2to produce both the complex hydride and MgH2hydride. In addition, sample-1 was severely temperature-hydrogen cycled to verify its microstructural stability and the influence of grain size on the sorption properties. XRD patterns showed Mg(hc), Fe(ccc) and Mg2FeH6in both samples, and sample-2 also contained MgH2and MgO (attributed to processing contamination). DSC results demonstrated that the initial desorption temperature of sample-1 was lower than that of sample-2. However, sample-2 showed faster desorption kinetics, presenting a desorption peak about 73°C below that of sample-1. This could be attributed to the activation/catalyst effect of the MgH2hydride. The improvement in sorption properties was attributed mainly to porosity and to the type of employed catalysts.