| Summary: | In this study, the nature of the ball-milling mechanism in a ternary materials system (Mg-6Sn-1Na) is investigated for proper mechanical alloying. An identical powder mixture for this material system is exposed to different milling durations for a suitable mixture. First, the platelet structure formation is observed on particles with increasing milling duration, mainly formed in <200> direction of the hexagonal crystal structure of the Mg matrix. Then, the flake structure with texture formation is broken into smaller spherical particles with further ball milling up to 12 h. According to EDS analysis, the secondary phases in the Mg matrix are homogenously distributed with a 12-h milling duration which advises a proper mixture in this material system. The solid solution formation is triggered with an 8-h milling duration according to XRD analysis on 101 reflections. Conventional sintering is performed at 350 °C in 2 h for each sample. In bulk samples, XRD data reveal that secondary phases (Mg<sub>2</sub>Sn) with island-like structures are formed on the Mg matrix for a milling duration of up to 8 h. These bigger secondary phases are mainly constituted as Mg<sub>2</sub>Sn intermetallic forms, which have a negative effect on physical and mechanical properties due to a mismatch in the grain boundary formation. However, the homogenous distribution of secondary phases with a smaller particle size distribution, acquired with 12 h milling time, provides the highest density, modulus of elasticity, and hardness values for this ternary materials system. The ternary materials produced with the 12-h ball-milling process provide an improvement of about 117% in hardness value compared with the cast form.
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