Research on microstructures of sub-rapidly solidified AZ61 Magnesium Alloy

AZ61 magnesium alloy foils of 0.5–3.0 mm thick were successfully produced by using sub-rapid solidification technique. Microstructures of conventionally solidified (CS) and sub-rapidly solidified (sub-RS) alloys were examined by optical microscope (OM) and scanning electron microscope (SEM). The results showed that the cellular grain of 1.8–13.5 μm can be obtained during sub-rapid solidification process. Phase compositions and microdistribution of the alloying elements in the foils were analyzed by X-ray diffraction (XRD) and electron probe microanalyzer (EPMA), respectively. The eutectic transformation L → α-Mg + β-Mg₁₇Al₁₂ and microsegregation in conventionally solidified AZ61 alloy were remarkably suppressed in sub-rapid solidification process. As a consequence, the alloying elements Al, Zn, Mn showed much higher solid solubility and the sub-rapid solidification microstructures dominantly consisted of supersaturated α-Mg solid solution. Meanwhile, the β-Mg₁₇Al₁₂ phases located in the α-Mg grain boundaries are largely decreased due to high solidification cooling rate.     

Structural characteristics and elevated temperature mechanical properties of AJ62 Mg alloy

Structure and mechanical properties of the novel casting AJ62 (Mg–6Al–2Sr) alloy developed for elevated temperature applications were studied. The AJ62 alloy was compared to commercial casting AZ91 (Mg–9Al–1Zn) and WE43 (Mg–4Y–3RE) alloys. The structure was examined by scanning electron microscopy, x-ray diffraction and energy dispersive spectrometry. Mechanical properties were characterized by Viskers hardness measurements in the as-cast state and after a long-term heat treatment at 250 °C/150 hours. Compressive mechanical tests were also carried out both at room and elevated temperatures. Compressive creep tests were conducted at a temperature of 250 °C and compressive stresses of 60, 100 and 140 MPa. The structure of the AJ62 alloy consisted of primary α-Mg dendrites and interdendritic nework of the Al₄Sr and massive Al₃Mg₁₃Sr phases. By increasing the cooling rate during solidification from 10 and 120 K/s the average dendrite arm thickness decreased from 18 to 5 μm and the total volume fraction of the interdendritic phases from 20% to 30%. Both factors slightly increased hardness and compressive strength. The room temperature compressive strength and hardness of the alloy solidified at 30 K/s were 298 MPa and 50 HV 5, i.e. similar to those of the as-cast WE43 alloy and lower than those of the AZ91 alloy. At 250 °C the compressive strength of the AJ62 alloy decreased by 50 MPa, whereas those of the AZ91 and WE43 alloys by 100 and 20 MPa, respectively. The creep rate of the AJ62 alloy was higher than that of the WE43 alloy, but significantly lower in comparison with the AZ91 alloy. Different thermal stabilities of the alloys were discussed and related to structural changes during elevated temperature expositions.     

Microstructure and elevated temperature mechanical and creep properties of Mg–4Y–3Nd–0.5Zr alloy in the product form of a large structural casting

In order to save the invaluable heavy rare earth (HRE) elements for important functional applications, a modified version of the WE43 magnesium alloy, Mg–4Y–3Nd–0.5Zr (wt.%), free of the HRE elements, has been designed. As part of the alloy development program, a large complex component of the alloy (net product weight: 80 kg) was made via differential pressure casting. The large component was then subjected to the T6 treatment (solid solution and ageing) following established commercial practice for the T6 treatment of the WE43 alloy. A significant number of samples were prepared from the thickest section (58 mm) of the T6-treated component for both microstructural characterization and detailed property assessment. The alloy showed noticeably higher tensile strengths than did the HRE-containing WE43 alloy over the temperature range of 473–573 K. The creep resistance of the alloy was superior to that of the WE43 alloy at 473 K while being similar at 523 K. The microstructures of the alloy in the as-cast, solution treated and then aged states were characterized. The component-based detailed assessment suggests that the idea of using neodymium (Nd) to replace the HRE elements in the WE43 alloy is promising for structural applications at elevated temperatures.     

Impression creep behavior of a cast MRI153 magnesium alloy

Creep behavior of a cast MRI153 magnesium alloy was investigated using impression creep technique. The tests were carried out under constant punching stress in the range of 360–600 MPa at temperatures between 425 and 490 K. Microstructure of the alloy was composed of α(Mg) matrix phase besides Mg₁₇Al₁₂ and Al₂Ca intermetallic compounds. Stress exponent of minimum creep rate, n, was found to vary between 6.45 and 7. Calculation of the activation energy showed a slight decrease with increasing stress such that the creep activation energy of 115.2 kJ/mol under σ_imp/G = 0.030 decreased to 99.5 kJ/mol under σ_imp/G = 0.040. The obtained stress exponent and activation energy data suggested that the pipe diffusion dislocation climb controlled creep as the dominant mechanism during the creep test.     

An investigation on the tribological behavior of AZ91 and AZ91 + 3 wt% RE magnesium alloys at elevated temperatures

The wear behavior of AZ91 and AZ91 + 3 wt% RE magnesium alloys was investigated under a normal load of 20 N at the wear testing temperatures of 25–250 °C and sliding speeds of 0.4 and 1 m s⁻¹. As the sliding speed increased from 0.4 to 1 m s⁻¹ at the wear temperature of 25 °C, the wear rates of AZ91 and AZ91 + 3 wt% RE alloys decreased by about 8% and 60%, respectively. With an increase in the wear temperature to 100 °C, the wear rate of AZ91 alloy was reduced by 58% at a sliding speed of 0.4 m s⁻¹, while the wear rate was sharply increased at a sliding speed of 1 m s⁻¹. At higher wear temperatures, the wear of the AZ91 alloy at both sliding speeds soared as a result of the softening of β-Mg₁₇Al₁₂ phase. However, the wear rate of AZ91 + 3 wt% RE alloy showed a minimum at the wear temperatures of 100 and 200 °C at sliding speeds of 1 and 0.4 m s⁻¹, respectively. Superior wear behavior of AZ91 + 3 wt% RE at the elevated temperatures could be attributed to its higher thermal stability and strength. Furthermore, a rise in sliding speed led to a 55% reduction in the wear rate of AZ91 + 3 wt% RE alloy at the wear temperature of 100 °C due to the formation of stable oxide layers on the wear surface.     

Impression creep behavior of Al–1.9%Ni–1.6%Mn–1%Mg alloy

In the present study, microstructure and creep behavior of an Al–1.9%Ni–1.6%Mn–1%Mg alloy were studied at temperature ranging from 493 to 513 K and under stresses between 420 and 530 MPa. The creep test was carried out by impression creep technique in which a flat ended cylindrical indenter was impressed on the specimens. The results showed that microstructure of the alloy is composed of primary α(Al) phase covered by a mantle of α(Al)+Ni₃Al intermetallic compound. Mn segregated into Al_xMn_yNi_z or Al₆Mn phases distributed inside the matrix phase. It was found that the stress exponent, n, decreases from 5.2 to 3.6 with increasing temperature. Creep activation energies between 115 kJ/mol and 151 kJ/mol were estimated for the alloy and it decreases with rising stress. According to the stress exponent and creep activation energies, the lattice and pipe diffusion- climb controlled dislocation creep were the dominant creep mechanism.     

Development of high-performance quaternary LPSO Mg–Y–Zn–Al alloys by Disintegrated Melt Deposition technique

In the present study, new quaternary MgY_1.65Zn_0.74Al_0.53 and MgY_3.72Zn_1.96Al_0.45 alloys (wt.%) were synthesized employing the Disintegrated Melt Deposition (DMD) casting technique followed by hot extrusion. Microstructural characterization revealed the presence of 14H long-period stacking ordered structure (LPSO) and Mg₄Y₂ZnAl₃ phases aligned along the direction of extrusion in both alloys. Refined grains (⩽5 μm) due to the effect of dynamic recrystallization (DRX) were also observed to co-exist with larger worked grains (⩾20 μm) in the extruded microstructures. Compared to monolithic Mg, significant increase in the microhardness (∼67–88%), tensile yield strength (∼245–290%) and ultimate tensile strength (∼113–144%) were observed in the Mg–Y–Zn–Al alloys. Despite the significant increase in strength of materials, failure strains of both Mg–Y–Zn–Al alloys were comparable to monolithic Mg. Ignition temperatures of both Mg–Y–Zn–Al alloys were found to outperform commercially available AZ31, AZ80 and WE43 (high-temperature) Mg alloys, and the highest ignition temperature of 770 °C was achieved in the MgY_3.72Zn_1.96Al_0.45 alloy.     

Tensile properties of hot rolled Mg–3Sn–1Ca alloy sheets at elevated temperatures

Mechanical behavior of hot rolled Mg–3Sn–1Ca (TX31) magnesium alloy sheets were studied in the temperature range 25–350 °C. The microstructure of the alloy consisted of the eutectic structure of α-Mg + Mg₂Sn and a dispersion of needle-like CaMgSn. The highest room-temperature ductility of 18% was obtained by hot rolling of the cast slabs at 440 °C, followed by annealing at 420 °C. The high temperature tensile deformation of the material was characterized by a decrease in work hardening exponent (n) and an increase in strain rate sensitivity index (m). These variations resulted in respective drops of proof stress and tensile strength from 126.5 MPa and 220 MPa at room temperature to 23.5 MPa and 29 MPa at 350 °C. This was in contrast to the ductility of the alloy which increased from 18% at room temperature to 56% at 350 °C. The observed variations in strength and ductility were ascribed to the activity of non-basal slip systems and dynamic recovery at high temperatures. The TX31 alloy showed lower strength than AZ31 magnesium alloy at low temperatures, while it exhibited superior strength at temperatures higher than 200 °C, mainly due to the presence of thermally stable CaMgSn particles.     

Evaluation of wear characteristics of Al3Tip/Mg composite

The dry sliding wear tests were performed for a novel developed Al₃Ti_p/Mg composite under the ambient temperatures at 25–200 °C and the loads of 25–150 N. The wear rate of the composite increased with increasing the load, but reduced with increasing the ambient temperature. The Al₃Ti_p/Mg composite had relatively lower wear rates than AZ91D alloy under the loads of less than 100 N at 25 °C. At 200 °C, the Al₃Ti_p/Mg composite presented an absolutely higher wear resistance than AZ91D alloy, and the mild-severe wear transition was delayed. These were attributed to Al₃Ti particulates and the mechanical mixing layer formed on the worn surfaces, which hindered the plastic deformation and thermal softening of the matrix. The mechanical mixing layer contained MgO, Fe–Ti–O, Al₃Ti, Mg₁₇Al₁₂ and Mg and thickened with increasing the ambient temperature. The predominant wear mechanisms of the composite were oxidation wear and delamination wear.     

Investigation of the compressive creep behavior of AZ91D magnesium alloy

The creep resistance of AZ91D alloy has been studied in uniaxial compression tests at temperature ranges from 275 °C to 325 °C. The initial microstructure of the alloy consists of α phase and β phase precipitated in the grain boundary. The minimum creep rate dependence on applied stress and the temperature is also analyzed in detail. We find that the stress exponent n is close to the theoretical values (3 or 5) and the activation energy Q for creep varies from 121 kJ/mol to 171 kJ/mol. Creep could be controlled by high-temperature climb and cross-slip of dislocation at different temperatures.     

Preparation and characterization of As-cast and hot-rolled Mg–3Al–0.5Mn–0.5Zn–1MM alloy

Mg–3Al–0.5Mn–0.5Zn–1MM alloy was prepared by metal mould casting method. The as-cast ingot was homogenized and then hot-rolled at 673 K with total thickness reduction of 65%. Microstructure and mechanical properties of the as-cast and hot-rolled samples were investigated. The results showed that the as-cast sample mainly consisted of α-Mg, β-Mg₁₇Al₁₂, Al₁₀Ce₂Mn₇, and Al₁₁RE₃ (RE = La and Ce) phases. The average grain size of the sample homogenized at 673 K was about 240 μm, and it was greatly refined to about 7 μm by dynamic recrystallization for the hot-rolled sample. The ultimate tensile strength and 0.2% yield strength of the hot-rolled sample were 300 MPa and 230 MPa, respectively. They were enhanced by 55% and 400% correspondingly compared with those of the as-cast sample. The improvement of the strengths was attributed to the refined grains, breakup of the precipitates and increase of the dislocation density.     

Effect of different annealing atmospheres on crystallization and corrosion resistance of Al86Ni9La5 amorphous alloy

The effect of different annealing atmospheres (H₂, air, Ar and N₂) on precipitated phases, corrosion resistance and hardness of Al₈₆Ni₉La₅ amorphous alloy was investigated using X-ray diffraction (XRD), transmission electron microscopy (TEM), differential scanning calorimetry (DSC), thermogravimetry (TG), electrochemistry experiment and microhardness tester. During annealing at 523 K, the primary crystallized fcc-Al is independent on the annealing atmospheres. During annealing at 584 K, the final crystalline phases, i.e. fcc-Al + Al₁₁La₃ + Al₃Ni, are also independent on the different annealing atmospheres. However, during annealing at 523 K, H₂ and air can promote the eutectic crystallization process, and induce the formation of metastable Al₃Ni₂ phase. The promoting effect of different annealing atmospheres is in the order of H₂ > air > Ar > N₂. The microhardness and corrosion resistance in the 3.5 wt.% NaCl solution are improved by annealing in H₂ and air atmospheres. The property promotion caused by annealing process can be ascribed to the formation of nanocrystalline phases, which is possibly helpful to develop the alloy's application in the seawater environment.     

Effects of ECAE temperature and billet orientation on the microstructure,texture evolution and mechanical properties of a Mg–Zn–Y–Zr alloy

Single-pass equal channel angular extrusion (ECAE) experiments of an extruded Mg–Zn–Y–Zr alloy with an intense initial basal texture were performed in two inter-perpendicular billet orientations and at 473 and 623 K. The study was aimed to determine the effects of ECAE temperature and billet orientation on the microstructure, texture evolution and mechanical properties of the ECAEed alloy. It was found that the grain refinement achieved through the single-pass ECAE in the Orient-I billet orientation (the normal direction (ND) of the extruded plate parallel with the ECAE exit direction) was more effective than that in the Orient-II billet orientation (the ND of the extruded plate perpendicular to the ECAE exit direction). The average grain sizes after ECAE at 473 K were much smaller than those after ECAE at 623 K. The pole figures of the alloy ECAEed at 473 K showed that most of the basal planes in the Orient-I and Orient-II samples were inclined about 40° and 35°, respectively, with respect to the longitudinal direction of the ECAE extrudate. However, for the alloy ECAEed at 623 K, most of the basal planes were parallel with the longitudinal direction of the ECAE extrudate. It was remarkable that the yield strengths of the alloy ECAEed at 473 K were lower than those at 623 K. The peculiar relationship between ECAE temperature and the mechanical properties of the alloy was ascribed to the texture evolution during ECAE.     

Mechanical characterization and corrosion behavior of newly designed Sn and Y added AZ91 alloy

This paper deals the effect of Sn and Y additions on the microstructure, mechanical and corrosion properties of AZ91 alloy. It is found that by the addition of Sn, the formation and growth of discontinuous precipitate get suppressed and new intermetallic Mg₂Sn phase is formed. In the case of Y addition together with Sn, the grain size gets refined, the volume of Mg₁₇Al₁₂ gets decreased and new intermetallic Al₂Y phase is observed. Improved room and high temperature tensile properties are obtained in as-cast and aged Sn and Y added AZ91 alloy. However, maximum properties are obtained for the alloy having combined addition of 0.5 wt.% Sn and 0.9 wt.% Y. Improved corrosion resistance is also noticed with the addition of Sn and Y elements.     

Dry sliding wear behaviour of Mg–10Gd–3Y–0.4Zr alloy

In present work, the wear behaviour of a Mg–10Gd–3Y–0.4Zr alloy during dry sliding has been investigated. The experiments were carried out using Ball-on-Flat type wear apparatus against an AISI 52100 type bearing steel ball counterface in a load range of 3–15 N, sliding speed range of 0.03–0.24 m/s, temperature range of 298–473 K and at a constant sliding distance of 400 m. Analyses of the wear tracks, worn surfaces and wear debris of the Mg–10Gd–3Y–0.4Zr alloy were carried out using scanning electron microscope. As a comparison, the wear properties of common AC8A aluminium alloy under the same condition also presented. The results indicated that the Mg–10Gd–3Y–0.4Zr alloy exhibited low wear rate compared with cast+T6 AC8A aluminium alloy under the same condition. The wear rate of as-cast Mg–10Gd–3Y–0.4Zr alloy was lower than that of cast+T6 Mg–10Gd–3Y–0.4Zr alloy. The Mg₂₄(Gd, Y)₅ eutectic compound of as-cast Mg–10Gd–3Y–0.4Zr alloy could resist the material flow during friction and wear, and affected its wear rate. At high sliding speed, the retained wear debris was the major constituent of producing the severely deformed layers along the sliding direction. The trapped wear debris acted as a protective layer and reduced the wear rate.     

Microstructural characteristics and mechanical properties of non-combustive Mg–9Al–Zn–Ca magnesium alloy friction stir welded joints

Non-combustive Mg–9Al–Zn–Ca magnesium alloy was friction stir welded with rotation speeds ranging from 500 to 1250 rpm at a constant welding speed of 200 mm/min. Defect-free joints were successfully produced at rotation speeds of 750 and 1000 rpm. The as-received hot extruded material consisted of equiaxed α-Mg grains with β-Mg₁₇Al₁₂ and Al₂Ca compounds distributed along the grain boundaries. Friction stir welding produced much refined α-Mg grains accompanied by the dissolution of the eutectic β-Mg₁₇Al₁₂ phase, while Al₂Ca phase was dispersed homogeneously into the Mg matrix. An increase in rotation speed increased the α-Mg grain size but not significantly, while microstructure in the heat affected zone was almost not changed compared with the base material. The hardness tests showed uniform distributed and slightly increased harness in the stir zone. Results of transverse tensile tests indicated that the defect-free joints fractured at the base material, while longitudinal tensile tests showed that the strength of the defect-free welds was improved due to microstructural refinement and uniform distribution of intermetallic compounds.     

Influence of nano-alumina and sub-micron copper on mechanical properties of magnesium alloy AZ31

Magnesium composites of AZ31–Al₂O₃–Cu formulations were produced using the disintegrated melt deposition technique following by hot extrusion. Microstructural characterization showed reasonable distribution of secondary phases up to 1 vol.% of copper. A tendency to form clustered agglomeration and longer shape of secondary phases was observed when the amount of copper was increased to 1.5 vol.%. Mechanical tests indicated remarkable improvements in 0.2%YS, UTS and microhardness when nano-alumina and sub-micron copper were added into AZ31. The ductility was increased up to 9.3% in the case of AZ31–1.5Al₂O₃–1.0Cu sample and significantly reduced (5.5%) when the amount of copper was increased to 1.5 vol.%. Heat treated sample of AZ31–1.5Al₂O₃–1.0Cu showed overall improvement in both tensile strength and ductility. The results suggest that the judicious selection of composition and heat treatment has the capability to enhance overall tensile response of Mg–Al₂O₃–Cu nanocomposites.     

Laser-tungsten inert gas hybrid welding of dissimilar metals AZ31B Mg alloys to Zn coated steel

Laser-tungsten inert gas (TIG) hybrid welding has been developed for joining Mg alloys to Zn coated steel in a lap joint configuration. The joint could not be produced in laser or arc welding only, while acceptable joints without obvious defects were obtained with a relatively wide processing window in the hybrid process. Two reaction layers were observed to form at the interface and were identified as Mg–Zn eutectic structure (α-Mg + MgZn) and Fe₃Al phase by TEM analysis. In some cases, Al₆Mn phase also formed adjacent to the Fe–Al reaction layer. The tensile-shear strength attained the maximum value of 68 MPa, representing 52.3% joint efficiency relative to Mg base metal. The element Al from AZ31B Mg alloys diffused to the liquid/solid interface and then reacted with the elements from steel, such as Fe and Mn, contributing to the metallurgical bonding at the interface. The weak bonding between Mg–Zn reaction layer and newly formed Fe–Al layer resulted in the interfacial failure.     

Influence of the combined addition of Y and Nd on the microstructure and mechanical properties of Mg–Li alloy

Y and Nd are simultaneously added into Mg–5Li–3Al–2Zn alloy. It is found that there exist the phases of α-Mg, AlLi, Al₁₁Nd₃ and Al₂Y in the alloys. When the contents of Y and Nd are 1.2% and 0.8%, respectively, the grain is the finest with an average size of 30 μm, and the tensile strength of the alloy reaches 231 MPa, the elongation reaches 16%. When the ratio of Y to Nd is 1.2:0.8, there is a synergistic strengthening effect.     

Creep deformation and crack growth rates of a super α2 titanium aluminide alloy

The influences of stress and temperature on creep deformation behavior and the creep crack growth rates of the super α₂ Ti₃Al alloy were investigated with respect to its safe application at high temperatures. In a temperature range of 1033–1093 K at low applied stress levels, the stress exponent was equal to 1.5. At an intermediate stress range (10^?3 < σ/E < 3 × 10^?3), a stress exponent of 3.3 was observed. As the applied stress was increased, the stress exponent changed from 3.3 to 4.4. The high temperature crack growth rate of the Ti₃Al alloy can be correlated with stress intensity factor K rather than C1 at 1033 K due to environmental embrittlement.