Effect of Y, Sr, and Nd additions on the microstructure and microfracture mechanism of squeeze-cast AZ91-X magnesium alloys

This study aims to investigate the effects of Y, Sr, and Nd additions on the microstructure and microfracture mechanism of the four squeeze-cast magnesium alloys based on the commercial AZ91 alloy. Microstructural observation, in situ fracture tests, and fractographic observation were conducted on the alloys to clarify the microfracture process. Microstructural analyses indicated that grain refinement could be achieved by small additions of alloying elements, although the discontinuously precipitated Mg₁₇Al₁₂ phases still existed on grain boundaries. From in situ fracture observation of an AZ91-Sr alloy, it was seen that coarse needle-shaped compound particles and Mg₁₇Al₁₂ phases located on the grain boundary provided easy intergranular fracture sites under low stress intensity factor levels, resulting in the drop in toughness. On the other hand, the AZ91-Y and AZ91-Nd alloys showed improved fracture toughness, since deformation and fracture paths proceeded into grains rather than to grain boundaries, as the planar slip bands and twinnings actively developed inside the grains. These findings suggested, on the basis of the well-developed planar slip bands and twinnings, that the small addition of Y or Nd was very effective in improving fracture toughness.     

Resistance-Spot-Welded AZ31 Magnesium Alloys: Part I. Dependence of Fusion Zone Microstructures on Second-Phase Particles

A comparison of microstructural features in resistance spot welds of two AZ31 magnesium (Mg) alloys, AZ31-SA (from supplier A) and AZ31-SB (from supplier B), with the same sheet thickness and welding conditions, was performed via optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). These alloys have similar chemical composition but different sizes of second-phase particles due to manufacturing process differences. Both columnar and equiaxed dendritic structures were observed in the weld fusion zones of these AZ31 SA and SB alloys. However, columnar dendritic grains were well developed and the width of the columnar dendritic zone (CDZ) was much larger in the SB alloy. In contrast, columnar grains were restricted within narrow strip regions, and equiaxed grains were promoted in the SA alloy. Microstructural examination showed that the as-received Mg alloys contained two sizes of Al₈Mn₅ second-phase particles. Submicron Al₈Mn₅ particles of 0.09 to 0.4 μm in length occured in both SA and SB alloys; however, larger Al₈Mn₅ particles of 4 to 10 μm in length were observed only in the SA alloy. The welding process did not have a great effect on the populations of Al₈Mn₅ particles in these AZ31 welds. The earlier columnar-equiaxed transition (CET) is believed to be related to the pre-existence of the coarse Al₈Mn₅ intermetallic phases in the SA alloy as an inoculant of α-Mg heterogeneous nucleation. This was revealed by the presence of Al₈Mn₅ particles at the origin of some equiaxed dendrites. Finally, the columnar grains of the SB alloy, which did not contain coarse second-phase particles, were efficiently restrained and equiaxed grains were found to be promoted by adding 10 μm-long Mn particles into the fusion zone during resistance spot welding (RSW).     

Solidification Microstructure and Mechanical Properties of Cast Magnesium-Aluminum-Tin Alloys

The solidification microstructure and mechanical properties of as-cast Mg-Al-Sn alloys have been investigated using computational thermodynamics and experiments. The as-cast microstructure of Mg-Al-Sn alloys consists of α-Mg, Mg₁₇Al₁₂, and Mg₂Sn phases. The amount of Mg₁₇Al₁₂ and Mg₂Sn phases formed increases with increasing Al and Sn content and shows good agreement between the experimental results and the Scheil solidification calculations. Generally, the yield strength of as-cast alloys increases with Al and Sn content, whereas the ductility decreases. This study has confirmed an early development of Mg-7Al-2Sn alloy for structural applications and has led to a promising new Mg-7Al-5Sn alloy with significantly improved strength and ductility comparable with commercial AZ91 alloy.     

Effect of Sb on the microstructure and mechanical properties of AZ91 magnesium alloy

Effects of Sb addition on the microstructure, mechanical properties, and fracture behaviors of AZ91 magnesium alloy, as well as the sensitivity to section thickness of the structure and mechanical properties, have been studied. The results show that when Sb is added into the AZ91 alloy, the grain is refined, the Mg₁₇Al₁₂ phase is refined and granulated, and a new Mg₃Sb₂ phase is formed and becomes coarse needle-shaped as Sb content increases. The room-temperature tensile strength, elongation, and impact toughness increase first, and then decrease with increasing Sb content. The study on sensitivity to section thickness shows that, when composition is constant, the room-temperature tensile strength and elongation increase with the reduction of section thickness; when section thickness is constant, the room-temperature tensile strength and elongation increase first, and then decrease with increasing Sb content. Additionally, the Sb addition improves the tensile strength of the AZ91 alloy at 100 °C and 150 °C. The room-temperature tensile and impact fractographs of the AZ91 alloy show intergranular fracture. With increasing Sb content, the tearing deformation zones on the both fractographs enlarge at first, and then diminish, which is consistent with the change of tensile strength, elongation, and impact toughness increasing first, and then reducing with increasing Sb content.     

Effect of Sb on the microstructure and mechanical properties of AZ91 magnesium alloy

Effects of Sb addition on the microstructure, mechanical properties, and fracture behaviors of AZ91 magnesium alloy, as well as the sensitivity to section thickness of the structure and mechanical properties, have been studied. The results show that when Sb is added into the AZ91 alloy, the grain is refined, the Mg₁₇Al₁₂ phase is refined and granulated, and a new Mg₃Sb₂ phase is formed and becomes coarse needle-shaped as Sb content increases. The room-temperature tensile strength, elongation, and impact toughness increase first, and then decrease with increasing Sb content. The study on sensitivity to section thickness shows that, when composition is constant, the room-temperature tensile strength and elongation increase with the reduction of section thickness; when section thickness is constant, the room-temperature tensile strength and elongation increase first, and then decrease with increasing Sb content. Additionally, the Sb addition improves the tensile strength of the AZ91 alloy at 100°C and 150°C. The room-temperature tensile and impact fractographs of the AZ91 alloy show intergranular fracture. With increasing Sb content, the tearing deformation zones on the both fractographs enlarge at first, and then diminish, which is consistent with the change of tensile strength, elongation, and impact toughness increasing first, and then reducing with increasing Sb content.     

Mechanism of detrimental effects of carbon content on cleavage fracture toughness of low-alloy steel

The variation in fracture toughness of low-alloy base steels and weld steels with carbon contents of 0.08 and 0.21 wt pct was investigated using notched and precracked specimens tested at low temperatures. The attention is focused on the mechanism associated with detrimental effects on cleavage fracture toughness resulting from increasing carbon content. Analyses reveal that, in the case of constant ferrite grain sizes with increasing carbon content, the yield stress σ _y increases and the local fracture stress σ _f remains constant for notched specimens. For precracked specimens, the σ _y increases, whereas the σ _f decreases. In both cases, the ratio σ _f /σ _y decreases; this ratio is one of the principal factors inducing the deterioration in the cleavage fracture toughness of the higher carbon steels. Analyses also reveal that the critical strain for initiating a crack nucleus, which decreases with increasing carbon content and impurity elements, appears to be another principal factor that has a negative effect on the fracture toughness in both notched and precracked specimens. The results of the fracture toughness measured for weld metal with various grain sizes further support the predominant effect of grain size on the toughness of notched specimens.     

Effects of precipitates on grain size and mechanical properties of AZ31-x% Nd magnesium alloy

The effects of precipitates on grain size and mechanical properties of as-cast AZ3 1-x%Nd magnesium alloy were investi- gated, and the affecting mechanism was also discussed. The results indicated that Al2Nd phase, AlllNd3 phase and a few AI-Mn-Nd-Fe phase were furmed when adding 0.38 wt.%-1.46 wt.% Nd into AZ31 melt, coarse AI2Nd transformed into Al11Nd3 gradually with the increasing of Nd content. Due to structure and size transformation and content increasing of AI-Nd phase, the grain size of AZ31-x% Nd alloy increased firstly, and then decreased with the increment of Nd content. After reaching a minimum value, once again it rose up, provided that Nd content was further increased. The tensile property reached its optimal value when the adding amount of Nd content was 1.05 wl.%, however, adding excessive amount of Nd deteriorated both ultimate strength and elongation ofAZ31 alloy.     

Correlating the microstructure of the die-chill skin and the corrosion properties for a hot-chamber die-cast AZ91D magnesium alloy

The corrosion of a hot-chamber die-cast AZ91D thin plate (1.4 mm in thickness) was investigated in terms of its microstructure, to elucidate the role of die-chill skin in corrosion. The die-chill skin was composed of a thin layer of chill zone and a thick layer of an interdendritic Al-rich α-Mg/Al₁₂Mg₁₇ β-phase particle/α-Mg grain composite microstructures. The chill zone (4±1 μm in thickness) had fine columnar and equiaxed grains and contained a distribution of submicron Mg-Al-Zn intermetallic particles. Beneath the chill zone, Al₁₂Mg₁₇ β particles were irregularly shaped but did not have an interdendritic network morphology. Furthermore, Al-rich α phase (also known as eutectic α) was in the interdendritic network, which occupied a higher volume fraction than the β phase in the die-skin layer. Corrosion characteristics were studied via constant-immersion and electrochemical tests. Although previous studies have ascribed the fine microstructure to good corrosion resistance for the AZ91D alloy, the present study showed severe corrosion of the sample with a die skin in chloride solution. Moreover, the sample without the die skin on the surface corroded more slowly. The inferior corrosion performance of the die skin was considered to be related to the high volume fraction of the interdendritic network of Al-rich α phase contained in the die skin, owing to the high cooling rate during solidification. The Al-rich α phase does not increase the corrosion resistance of the AZ91D alloy.     

A metallographic study of porosity and fracture behavior in relation to the tensile properties in 319.2 end chill castings

A metallographic study of the porosity and fracture behavior in unidirectionally solidified end chill castings of 319.2 aluminum alloy (Al-6.2 pct Si-3.8 pct Cu-0.5 pct Fe-0.14 pct Mn-0.06 pct Mg-0.073 pct Ti) was carried out using optical microscopy and scanning electron microscopy (SEM) to determine their relationship with the tensile properties. The parameters varied in the production of these castings were the hydrogen (∼0.1 and ∼0.37 mL/100 g Al), modifier (0 and 300 ppm Sr), and grain refiner (0 and 0.02 wt pct Ti) concentrations, as well as the solidification time, which increased with increasing distance from the end chill bottom of the casting, giving dendrite arm spacings (DASs) ranging from ∼15 to ∼95 /im. Image analysis and energy dispersive X-ray (EDX) analysis were employed for quantification of porosity/microstructural constituents and fracture surface analysis (phase identification), respectively. The results showed that the local solidification time(viz. DAS) significantly influences the ductility at low hydrogen levels; at higher levels, however, hydro-gen has a more pronounced effect (porosity related) on the drop in ductility. Porosity is mainly observed in the form of elongated pores along the grain boundaries, with Sr increasing the porosity volume percent and grain refining increasing the probability for pore branching. The beneficial effect of Sr modification, however, improves the alloy ductility. Fracture of the Si, β-Al₅FeSi, α- Al₁₅(Fe,Mn)₃Si₂, and Al₂Cu phases takes place within the phase particles rather than at the particle/Al matrix interface. Sensitivity of tensile properties to DAS allows for the use of the latter as an indicator of the expected properties of the alloy.     

Effect of Mg and Sr additions on the formation of intermetallics in Al-6 Wt pct Si-3.5 Wt pct Cu-(0.45) to (0.8) Wt pct Fe 319-type alloys

Al-Si alloys are materials that have been developed over the years to meet the increasing demands of the automotive industry for smaller, lighter-weight, high-performance components. An important alloy in this respect is the 319 alloy, wherein silicon and copper are the main alloying elements, and magnesium is often added in automotive versions of the alloy for strengthening purposes. The mechanical properties are also ameliorated by modifying the eutectic silicon structure (strontium being commonly employed) and by reducing the harmful effect of the β-Al₅FeSi iron intermetallic present in the cast structure. Magnesium is also found to refine the silicon structure. The present study was undertaken to investigate the individual and combined roles of Mg and Sr on the morphologies of Si, Mg₂Si, and the iron and copper intermetallics likely to form during the solidification of 319-type alloys at very slow (close to equilibrium) cooling rates. The results show that magnesium leads to the precipitation of Al₈Mg₃FeSi₆, Mg₂Si, and Al₅Mg₈Cu₂Si₆ intermetallics. With a strontium addition, dissolution of a large proportion of the needle-like β-Al₅FeSi intermetallic in the aluminum matrix takes place; no transformation of this phase into any other intermetallics (including the Al₁₅(Fe,Mn)₃Si₂ phase) is observed. When both Mg and Sr are added, the diminution of the β-Al₅FeSi phase is enhanced, through both its dissolution in the aluminum matrix as well as its transformation into Al₈Mg₃FeSi₆. The reactions and phases obtained have been analyzed using thermal analysis, optical microscopy, image analysis, and electron microprobe analysis (EMPA) coupled with energydispersive X-ray (EDX) analysis.     

Tensile and Fracture Properties of Cast and Forged Composite Synthesized by Addition of Al-Si Alloy to Magnesium

Cast Mg-Al-Si composites synthesized by addition of Al-Si alloy containing 10, 15, and 20 wt pct of Si, in molten magnesium, to generate particles of Mg₂Si by reaction between silicon and magnesium during stir casting has opened up the possibility to control the size of these particles. The microstructure of the cast composite consists of relatively dark polyhedral phase of Mg₂Si and bright phase of β-Al₁₂Mg₁₇ along the boundary between dendrites of α-Mg solid solution. After hot forging at 350 °C, the microstructure has changed to relatively smaller sizes of β-Al₁₂Mg₁₇ and Mg₂Si particles apart from larger grains surrounded by smaller grains due to dynamic recovery and recrystallization. Some of the Mg₂Si particles crack during forging. In both the cast and forged composite, the Brinell hardness increases rapidly with increasing volume fraction of Mg₂Si, but the hardness is higher in forged composites by about 100 BHN. Yield strength in cast composites improves over that of the cast alloy, but there is a marginal increase in yield strength with increasing Mg₂Si content. In forged composites, there is significant improvement in yield strength with increasing Mg₂Si particles and also over those observed in their cast counterpart. In cast composites, ultimate tensile strength (UTS) decreases with increasing Mg₂Si content possibly due to increased casting defects such as porosity and segregation, which increases with increasing Mg₂Si content and may counteract the strengthening effect of Mg₂Si content. However, in forged composite, UTS increases with increasing Mg₂Si content until 5.25 vol pct due to elimination of segregation and lowering of porosity, but at higher Mg₂Si content of 7 vol pct, UTS decreases, possibly due to extensive cracking of Mg₂Si particles. On forging, the ductility decreases in forged alloy and composites possibly due to the remaining strain and the forged microstructure. The initiation fracture toughness, J _IC , decreases drastically in cast composites from that of Mg-9 wt pct. alloy designated as MA alloy due to the presence Mg₂Si particles. Thereafter, J _IC does not appear to be very sensitive to the increasing presence of Mg₂Si particles. There is drastic reduction of J _IC on forging of the alloy, which was attributed to the remaining strain and forged microstructure, and it is further lowered in the composites because of cracking of Mg₂Si particles. The ratio of the tearing modulus to the elastic modulus in cast composites shows a lower ratio, which decreases with increasing Mg₂Si content. The ratio decreases comparatively more on forging of cast MA alloy than those observed in forged composites.     

Fatigue and Tensile Behavior of Cast,Hot-Rolled,and Severely Plastically Deformed AZ31 Magnesium Alloy

The work focuses on experimental examination of the fatigue behavior of magnesium alloy AZ31 produced by three different procedures: squeeze casting (SC), hot rolling (HR), and equal-channel angular pressing (ECAP). The microstructures produced were studied by light and transmission electron microscopy (TEM). Squeeze-cast AZ31 had low porosity and coarse grains, while hot-rolled material showed microstructure with grain size of 3 to 20 μm. The finest grain structure with the average grain size of about 1 to 2 μm was found in the material pressed 4 times at 200 °C using the ECAP technique, route B _c . It was shown that low- and high-cycle fatigue behavior under symmetric loading at room temperature and with loading frequency of 20 Hz is strongly dependent on the technique employed in producing the alloy. The ECAP was shown to improve the fatigue life of the material in the low-cycle region over that of the squeeze-cast material. However, the fatigue life of AZ31 after ECAP was slightly lower than that of the hot-rolled material. In the high-cycle region, the hot-rolled material and the material that underwent ECAP exhibit the same fatigue strength, which is superior to that of the squeeze-cast alloy. Fatigue crack initiation and the character of fracture were examined by means of scanning electron microscopy. This article is based on a presentation made in the symposium entitled “Ultrafine-Grained Materials: from Basics to Application,” which occurred September 25–27, 2006 in Kloster Irsee, Germany.

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A Comprehensive Study of Diffusion Bonding of Mg AZ31 to Al 5754, Al 6061 and Al 7039 Alloys

In the present study, microstructural and mechanical properties of diffusion bonding of AZ31–Mg with Al 5754, Al 6061, and Al 7039 alloys were compared under same conditions. The vacuum diffusion processes were performed at a temperature of 440 °C, the pressure of 29 MPa, and a vacuum of 1?×?10^?4 torr for 60 min. The microstructural characterizations were investigated using optical microscopy and scanning electron microscopy equipped with EDS analysis and linear scanner. The XRD analysis was performed to study phase figures near the interface zone. The results revealed the formation of brittle intermetallic compounds like Al₁₂Mg₁₇, Al₃Mg₂, and their other combinations at bonding interfaces of all samples. Additionally, the hardness of Al alloys seemed to play a key role in increasing diffusion rate of magnesium atoms toward the aluminum atoms, with Al 6061 alloy having the highest diffusion rate. It consequently led to an increase in diffusion rate and thus formation of a strong diffusion bonding between magnesium and aluminum alloys. The highest strength was about 42 MPa for the diffusion bonding between Mg AZ31 and Al 6061. Further investigations on surfaces indicated that the brittle phases especially Al₃Mg₂ caused brittle fracturing.     

Effect of Ca and Rare Earth Elements on Impression Creep Properties of AZ91 Magnesium Alloy

Creep properties of AZ91 magnesium alloy and AZRC91 (AZ91 + 1 wt pct RE + 1.2 wt pct Ca) alloy were investigated using the impression creep method. It was shown that the creep properties of AZ91 alloy are significantly improved by adding Ca and rare earth (RE) elements. The improvement in creep resistance is mainly attributed to the reduction in the amount and continuity of eutectic β(Mg₁₇Al₁₂) phase as well as the formation of new Al₁₁RE₃ and Al₂Ca intermetallic compounds at interdendritic regions. It was found that the stress exponent of minimum creep rate, n, varies between 5.69 and 6 for AZ91 alloy and varies between 5.81 and 6.46 for AZRC91 alloy. Activation energies of 120.9 ± 8.9 kJ/mol and 100.6 ± 7.1 kJ/mol were obtained for AZ91 and AZRC91 alloys, respectively. It was shown that the lattice and pipe-diffusion-controlled dislocation climb are the dominant creep mechanisms for AZ91 and AZRC91 alloys, respectively. The constitutive equations, correlating the minimum creep rate with temperature and stress, were also developed for both alloys.     

Role of Mg in the stress corrosion cracking of an Al-Mg alloy

The corrosion and stress corrosion cracking (SCC) susceptibility of an Al-Mg alloy, AA5083, has been shown to depend on the precipitation of the Mg-rich β phase, (Al₃Mg₂), but not the enrichment of elemental Mg at grain boundaries to an enrichment ratio of 1.4. These results were determined by measuring the progress of Mg enrichment at grain boundaries, for increasing thermal-treatment times, using auger electron spectroscopy (AES) of grain boundaries exposed by fracture within the spectrometer and by analytical electron microscopy (AEM) of thin foils. The progress of the β phase precipitation was followed by AEM and scanning electron microscopy (SEM), for the same thermal-treatment times. The lack of a Mg-segregation effect on SCC was demonstrated by results obtained with X-ray photoelectron spectroscopy (XPS) analysis of Mg-implanted Al following in-situ electrochemical tests and SCC tests, while the dominance of β phase precipitation was demonstrated by electrochemical analysis and SCC testing. Crack-growth tests of alloy AA5083 demonstrated faster cracking at potentials anodic to the open circuit potential (OCP) with no increase at potentials cathodic to the OCP.     

Microstructural evaluation of Ti-6-22-22 alloy

In this study, the microstructure of Ti-6-22-22 alloy as a function of aging time and temperature was examined and related to its fracture behavior. Fracture primarily occurred along prior β grain boundaries, but the morphology of the fracture surfaces varied from very smooth to rough and dimpled with increasing fracture toughness. Changes in the density of acicular α, silicides, and ordering in α were found to influence the fracture toughness. Ordering in the α phase was found to reduce fracture toughness significantly, while an increased density of acicular α reduced the toughness only slightly. The amount of partitioning of alloying elements was not found to correlate directly with toughness.