High conductivity magnesium alloy

Abstract

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

1 - 22 . (canceled) 
     
     
         23 . A magnesium-based composite comprising a base metal and a plurality of nanoparticles; said base metal includes at least 70 wt. % magnesium; said nanoparticles have a melting point that is greater than a melting point of said base metal; said nanoparticles constitute at least 0.1 vol. % of said magnesium-based composite; a plurality of said nanoparticles are located within 200 nm of grain boundaries or dislocations in said magnesium-based composite; said magnesium-based composite has a thermal conductivity of greater than 140 W/m-K; said nanoparticles have an average thermal conductivity that is greater than said thermal conductivity of said magnesium-based composite; said nanoparticles cause said magnesium-based composite to have at least a 10% increase in thermal conductivity as compared to said thermal conductivity of said base metal. 
     
     
         24 . The magnesium-based composite as defined in  claim 23 , wherein said insoluble nanoparticles have an average thermal conductivity of greater than 160 W/m-K. 
     
     
         25 . The magnesium-based composite as defined in  claim 23 , wherein said insoluble nanoparticles have an average thermal conductivity of greater than 180 W/m-K. 
     
     
         26 . The magnesium-based composite as defined in  claim 23 , wherein said nanoparticles include a plurality of particles selected from the group consisting of copper, silver, aluminum, beryllium, gold, tungsten, SiC, carbon fibers, carbon nanotubes, graphite, AlN, BN, and Max phase particles. 
     
     
         27 . The magnesium-based composite as defined in  claim 25 , wherein said nanoparticles include a plurality of particles selected from the group consisting of copper, silver, aluminum, beryllium, gold, tungsten, SiC, carbon fibers, graphite, AlN, BN, and Max phase particles. 
     
     
         28 . The magnesium-based composite as defined in  claim 23 , wherein said nanoparticles constitute about 0.1-15 vol. % of said magnesium-based composite. 
     
     
         29 . The magnesium-based composite as defined in  claim 27 , wherein said nanoparticles constitute about 0.1-15 vol. % of said magnesium-based composite. 
     
     
         30 . A method for forming a magnesium-based composite comprising:
 providing a base metal that includes at least 70 wt. % magnesium;   providing a plurality of nanoparticles; said nanoparticles have a melting point that is greater than a melting point of said base metal; said nanoparticles constitute at least 0.1 vol. % of said magnesium-based composite;   heating said base metal until molten;   mixing said plurality of nanoparticles in said molten base metal to form a mixture and to cause said plurality of said nanoparticles to disperse in said mixture; and,   cooling said mixture to form said magnesium-based composite;   wherein said nanoparticles have an average thermal conductivity that is greater than said thermal conductivity of said magnesium-based composite; a plurality of said nanoparticles are located within 200 nm of grain boundaries or dislocations in said magnesium-based composite;   said nanoparticles constitute at least 0.1 vol. % of said magnesium-based composite; said magnesium-based composite has a thermal conductivity of greater than 140 W/m-K; said nanoparticles cause said magnesium-based composite to have at least a 10% increase in thermal conductivity as compared to said thermal conductivity of said base metal.   
     
     
         31 . The method as defined in  claim 30 , wherein said nanoparticles include a plurality of particles selected from the group consisting of copper, silver, aluminum, beryllium, gold, tungsten, SiC, carbon fibers, carbon nanotubes, graphite, AlN, BN, and Max phase particles. 
     
     
         32 . The method as defined in  claim 30 , wherein said step of mixing includes ultrasonic dispersion. 
     
     
         33 . The method as defined in  claim 31 , wherein said step of mixing includes ultrasonic dispersion. 
     
     
         34 . The method as defined in  claim 30 , wherein said insoluble nanoparticles have an average thermal conductivity of greater than 180 W/m-K. 
     
     
         35 . The method as defined in  claim 33 , wherein said insoluble nanoparticles have an average thermal conductivity of greater than 180 W/m-K. 
     
     
         36 . The method as defined in  claim 30 , wherein said nanoparticles constitute about 0.1-15 vol. % of said magnesium-based composite. 
     
     
         37 . The method as defined in  claim 35 , wherein said nanoparticles constitute about 0.1-15 vol. % of said magnesium-based composite.