Low cycle fatigue properties of friction stir welded joints of a semi-solid processed AZ91D magnesium alloy

A semi-solid processed (thixomolded) Mg–9Al–1Zn magnesium alloy (AZ91D) was subjected to friction stir welding (FSW), aiming at evaluating the weldability and fatigue property of the FSW joint. Microstructure analysis showed that a recystallized fine-grained microstructure was generated in the nugget zone (NZ) after FSW. The yield strength, ultimate tensile strength, and elongation of the FSW joint were obtained to be 192 MPa, 245 MPa, and 7.6%, respectively. Low-cycle fatigue tests showed that the FSW joint had a fatigue life fairly close to that of the BM, which could be well described by the Basquin and Coffin-Manson equations. Unlike the extruded magnesium alloys, the hysteresis loops of FSW joint of the thixomolded AZ91D alloy were basically symmetrical, while the non-linear or pseudoelastic behavior was still present. The FSW joint was observed to fail in the BM section rather than in the NZ. Fatigue crack initiated basically from the pores at or near the specimen surface, and crack propagation was mainly characterized by fatigue striations along with the presence of secondary cracks.     

Characterization of the fatigue behaviour of the magnesium alloy AZ91D by means of mechanical hysteresis and temperature measurements

Stress-controlled load increase and constant amplitude tests were performed on the cast magnesium alloy AZ91D. Rather small values of the plastic strain amplitude reflect the very localised plastic deformation predominant in the _I-phase. The cyclic deformation and temperature curves of the load increase tests exhibit cyclic yield strength values which allow a good estimation of the endurance limit. Stress amplitudes above the endurance limit lead to cyclic hardening. As compared to the behaviour under monotonic tensile loading, the alloy exhibits cyclic hardening. Microscopic investigations illustrate the different influences of the - and β-phase in respect to crack initiation.     

Thermo-mechanical behaviours of light alloys in comparison to high temperature isothermal behaviours

Abstract

In this article, out-of-phase thermo-mechanical fatigue (TMF) behaviours of light alloys were investigated in comparison to their high temperature low cycle fatigue (LCF) behaviours. For this objective, strain based fatigue tests were performed on the A356 aluminium alloy and on the AZ91 magnesium alloy. Besides, TMF tests were carried out, where both strain and temperature changed. The fatigue lifetime comparison demonstrated that the TMF lifetime was less than that one under LCF loadings at elevated temperatures for both light alloys. The reason was due to severe conditions in TMF tests in comparison to LCF tests. The temperature varied in TMF test but it was constant under LCF loadings. As the other reason, the tensile mean stress occurred under TMF loadings, in comparison to the compressive mean stress under LCF loadings. At high temperatures, the cyclic hardening behaviour occurred in the AZ91 alloy and the A356 alloy had the cyclic softening behaviour.     

Calorimetric analysis of AZ91D magnesium alloy

In order to study the activation energies and microstructure evolution of β-Mg₁₇Al₁₂ and eutectic structure in AZ91D magnesium alloy, calorimetric analyses were carried out using non-isothermal measurements by DSC and scanning electron microscopy (SEM) with EDX. During DSC tests, two peak temperatures of β-Mg₁₇Al₁₂ dissolution/precipitation and eutectic transformation were delayed in the heating/cooling process with the increase of scanning rates due to the occurrence of superheating/supercooling. Activation energies of β-Mg₁₇Al₁₂ dissolution and eutectic transformation were derived using multiple heating rates. Furthermore, the results of SEM and EDX revealed that the size and morphology of eutectic structures in the alloy had a close relationship with the time of β-Mg₁₇Al₁₂ phase dissolution during the heating process. More eutectic structures formed at low scanning rate due to sufficient time for the diffusion of Al in α-Mg regions.     

Simulation and experimental investigation of FSP of AZ91 magnesium alloy

A thermo-mechanical simulation of the friction stir processing (FSP), using the DEFORM 3D software based on Lagrangian implicit, was developed and verified by the experimental results. Simulation can successfully predict the temperature and effective strain distributions. Material flow around the tool pin was examined using the point tracking. It was found that the major part of material flow occurs at the advancing side, and consequently, stirred zone (SZ) stretches toward the advancing side. However, material at the retreating side moves slightly in backward direction. The material deformation and the peak temperature influence on the microstructural characters and can determine the width of SZ. Based on the simulation, effective strain and temperature histories of material around the tool pin were also calculated. The amount of effective strain and peak temperature required for recrystallization at the advancing and retreating sides as well as at the bottom of SZ was determined. Therefore, the width of SZ can be predicted by the simulation.     

Numerical simulations of cyclic behaviors in light alloys under isothermal and thermo-mechanical fatigue loadings

In this article, numerical simulations of cyclic behaviors in light alloys are conducted under isothermal and thermo-mechanical fatigue loadings. For this purpose, an aluminum alloy (A356) which is widely used in cylinder heads and a magnesium alloy (AZ91) which can be applicable in cylinder heads are considered to study their stress–strain hysteresis loops. Two plasticity approaches including the Chaboche’s hardening model and the Nagode’s spring-slider model are applied to simulate cyclic behaviors. To validate obtained results, strain-controlled fatigue tests are performed under low cycle and thermo-mechanical fatigue loadings. Numerical results demonstrate a good agreement with experimental data at the mid-life cycle of fatigue tests in light alloys. Calibrated material constants based on low cycle fatigue tests at various temperatures are applied to models to estimate the thermo-mechanical behavior of light alloys. The reason is to reduce costs and the testing time by performing isothermal fatigue experiments at higher strain rates.     

Cyclic hardening/softening behaviour in AZ31B magnesium alloy based on infrared thermography

The work-hardening/softening behaviour of AZ31B magnesium alloy during high cycle fatigue was investigated. The superficial temperature evolution during fatigue tests was used as a criterion for the different levels of work-hardening/softening. The microstructures under different cycles were observed by transmission electron microscope. Tensile test (with post-fatigue) was conducted to quantify the work-hardening/softening behaviour which showed that high dislocation density after cyclic loading lead to high tensile strength. The temperature evolution of the specimens with different levels of work-hardening/softening during tensile tests is related to the microstructures; the results indicated that the temperature rise of the specimen with high density dislocation was lower. Microstructures after tensile tests showed that high dislocation density after cyclic loading would lead to high twinning density.     

Thermomechanical Processing and Superplasticity of AZ91 Magnesium Alloy

The effect of extrusion on grain refinement has been studied in the AZ91 cast ingots. It is found that grain sizesmaller than 10μm can be obtained by the extrusion processing. Vickers hardness measurements were also carriedout to evaluate the effect of these processes on the room temperature mechanical properties. The experimentalresults of high temperature tensile tests revealed that the stress was inversely proportional to the square of the grainsize and that the activation energy for superplastic flow was higher than that for grain boundary diffusion.     

Fatigue behaviour of cast magnesium alloy AZ91 microstructurally modified by friction stir processing

Friction stir processing (FSP) was applied to cast magnesium alloy AZ91-F to modify the as-cast microstructure, and the effect of FSP on fatigue behaviour was discussed based on microstructural consideration, crack initiation, crack growth behaviour, and fracture surface analysis. Fully reversed axial fatigue tests have been performed using as-cast, T5-aged and their FSPed specimens (as-cast/FSP and T5/FSP). It was found that both FSPed specimens exhibited significantly higher fatigue strength than the as-cast and T5-aged specimens. FSP resulted in the break-up of coarse as-cast microstructure, grain refinement of the matrix, finely dispersed precipitates and increase of hardness, thereby both the crack initiation resistance and the crack growth resistance were considerably enhanced compared with the as-cast and T5-aged specimens, resulting in the improved fatigue strengths of the FSPed specimens.     

Texture modification and mechanical properties of AZ31 magnesium alloy sheet subjected to equal channel angular bending

Analysis of the recently proposed equal channel angular bending(ECAB)process is provided on thin hotrolled AZ31 magnesium alloy sheets.In particular,effects of deformation temperature and strain path on the texture evolution and mechanical properties are systematically investigated under single pass ECAB at various temperatures and multi-pass ECAB process that involves changes in strain paths.It is found that simultaneous activation of multiple twinning types is successfully introduced during ECAB,which results in obvious tilted component of basal texture.Attributed to the domination of extension twins,weaker basal textures are detected after both single pass ECAB at 150℃and three cross passes ECAB at 200℃.After annealing,the basal texture is further weakened via twin-related recrystallization and the annealed microstructure is featured with mixture of basal and non-basal orientated grains.Additionally,the effect of grain orientation on the mode of plastic deformation and the roles of grain orientation and grain boundary on the local strain accommodation are coherently studied.This study reveals that over 60%increase of uniform elongation with marginal reduction of tensile strength less than 5%can be achieved for single pass ECAB at 150℃and three cross passes ECAB at 200℃,which is the result of larger fraction of grains favored with extension twinning and better local strain accommodation.     

AZ91D室温环境棘轮及其低周疲劳行为

通过AZ91D室温环境应力控制下的低周疲劳试验,对铸造镁合金棘轮及其低周疲劳行为进行了研究,讨论了室温环境下材料的应力循环特性、棘轮行为、塑性应变范围、全应变范围等疲劳参量随载荷水平和加载历史的变化规律,同时基于平均应力修正对材料的应力-寿命曲线进行了讨论。研究结果表明:AZ91D在室温环境下的应力循环呈循环硬化,材料的棘轮行为和塑性应变范围、全应变范围等疲劳参量依赖于载荷水平和加载历史,另外考虑平均应力修正后的应力-寿命曲线预测效果有明显改观。     

Effects of SiCp size and volume fraction on the high cycle fatigue behavior of AZ91D magnesium alloy composites

High cycle fatigue tests (i.e., stress-controlled, axial) were conducted on monolithic AZ91D and AZ91D magnesinm alloy composites processed via squeeze casting and extrusion to contain either 15 gm or 52 gm size SiC particles, at both the 20% and 25% volume fraction reinforcement level. The effects of changes in SiC particle size and volume fraction on the high cycle fatigue behavior have been determined. In addition, the number of cracked particles on the fatigue fracture surfaces, as well as the level of damage beneath the fatigue fracture surfaces were quantified in order to determine the effects of particle size on the evolution of damage during fatigue and during overload failure. Commercial purity Mg specimens containing a large grain size were also tested in fatigue for comparison with the alloy and composite data.     

Influence of elevated temperatures on the cyclic deformation behaviour of the magnesium die-cast alloys AZ91D and MRI 230D

The magnesium alloys AZ91D and MRI 230D were investigated in form of die-cast specimens with a cast skin. The fine-grained microstructure consists of a dendritic magnesium solid solution and interdentritic precipitates. The cyclic deformation behaviour was characterised in stress-controlled load increase tests and constant amplitude tests by means of mechanical stress–strain hysteresis measurements at room temperature and at T = 150 °C. The MRI alloy leads to higher plastic strain amplitudes and nevertheless higher lifetimes for both temperatures. Load increase tests allow a reliable short-time estimation of the endurance limit under both, room and elevated temperatures. With the physically based fatigue life calculation method “PHYBAL” the lifetime of the magnesium alloys can be calculated on the basis of cyclic deformation data determined in one load increase test and two constant amplitude tests in excellent agreement with the conventionally determined S–N curve.     

The effect of PVD coatings on the corrosion behaviour of AZ91 magnesium alloy

In this study, multilayered AlN (AlN + AlN + AlN) and AlN + TiN were coated on AZ91 magnesium alloy using physical vapour deposition (PVD) technique of DC magnetron sputtering, and the influence of the coatings on the corrosion behaviour of the AZ91 alloy was examined. A PVD system for coating processes, a potentiostat for electrochemical corrosion tests, X-ray difractometer for compositional analysis of the coatings, and scanning electron microscopy for surface examinations were used. It was determined that PVD coatings deposited on AZ91 magnesium alloy increased the corrosion resistance of the alloy, and AlN + AlN + AlN coating increased the corrosion resistance much more than AlN + TiN coating. However, it was observed that, in the coating layers, small structural defects e.g., pores, pinholes, cracks that could arise from the coating process or substrate and get the ability of protection from corrosion worsened were present.     

High cyclic fatigue characteristics of gravity cast AZ91 magnesium alloy subjected to transverse load

High cycle fatigue behavior of magnesium AZ91 alloy under transverse loading ambience is reported. An electro dynamic shaker system was used to apply transverse load on the specimen fabricated according to ASTM standard. The S–N curve for this novel test method for the alloy was generated and compared with the existing fatigue data. This assumes significance in the terrain of commercial applications, where the design of critical components is subjected to repeated transverse loads. Fatigue cracks were initiated at the pores in most of the samples. Considering the pores as the initial cracks, using linear fracture mechanics, critical stress intensity amplitude (K_cr) was estimated. Structure – fatigue property correlation was investigated by metallographic (optical and SEM) examination.     

Influence of focusing thermal effect upon AZ91D magnesium alloy weld during vacuum electron beam welding

The influence of focusing thermal effect upon the weld shape, microstructure and alloying elements distribution in the welded joints during vacuum electron beam welding on AZ91D magnesium alloy was studied. The results show that the focus state affects the offset of DOF, and further significantly affects the actual welding heat input in the process of vacuum electron beam welding. The sharp focusing state is characterized with higher welding energy density, but the welding energy density of defocusing state is lower. Therefore, the welding process with sharp focusing state and smaller calculation welding heat input can obtain the same weld penetration as the welding process is the conditions of defocusing state and larger calculation welding heat input. And the welding process of sharp focusing state and smaller calculation welding heat input can induce more strongly burning loss of Mg element than the conditions of defocusing state and larger calculation welding heat input. Then, which will affect the distribution of alloy elements in weld seam.     

The surface chemistry of 3-mercaptopropyltrimethoxysilane films deposited on magnesium alloy AZ91

Magnesium and its alloys have desirable physical and mechanical properties for a number of applications. Unfortunately, these materials are highly susceptible to corrosion, particularly in the presence of aqueous solutions. The purpose of this study is to develop a uniform, non-toxic surface treatment to enhance the corrosion resistance of magnesium alloys. This paper reports the influence of the coating bath parameters and alloy microstructure on the deposition of 3-mercaptopropyltrimethoxysilane (MPTS) coatings on magnesium alloy AZ91. The surface chemistry at the magnesium/MPTS interface has also been explored. The results indicate that the deposition of MPTS onto AZ91 was influenced by both the pH and MPTS concentration in the coating bath. Furthermore, scanning electron microscopy results showed that the MPTS film deposited uniformly on all phases of the magnesium alloy surface. X-ray photoelectron spectroscopy studies revealed that at the magnesium/MPTS interface, the molecules bond to the surface through the thiol group in an acid-base interaction with the Mg(OH)₂ layer, whereas in the bulk of the film, the molecules are randomly oriented.     

Experimental and numerical evaluations of stress relaxation in A356 aluminium alloy subjected to out-of-phase thermomechanical cyclic loadings

Abstract

In this study, the stress relaxation has been measured experimentally and has been also calculated numerically by the finite element method in the A356·0 aluminium–silicon–magnesium alloy, under out-of-phase thermomechanical cyclic loadings. To get this objective, strain based thermomechanical fatigue tests were performed on cylindrical specimens, at an out-of-phase condition. In this loading condition, when the temperature was maximum, the mechanical strain was compressive and vice versa. These fatigue experiments were repeated at various dwell times, in which the temperature was held at the maximum temperature. This hold time was considered as 5, 30, 60 and 180 s and then the stress relaxation was measured during the mid-life cycle of each test. Besides, the finite element analysis was also conducted on the material to simulate the stress relaxation numerically. A two-layer visco-plastic model was applied to simulate the high temperature cyclic behavior of the material. Finite element results showed a good agreement with experimental results, which were obtained from thermomechanical fatigue tests on the A356·0 aluminium alloy. The two-layer visco-plastic model could properly predict the stress relaxation at elevated temperatures, during various dwell times.     

In situ observation of ageing process and new morphologies of continuous precipitates in AZ91 magnesium alloy

An in situ observation of the precipitating process of γ-Mg₁₇Al₁₂ phase in die-cast AZ91 magnesium alloy, was carried out with a transmission electron microscope equipped with a heating stage maintained at 473 K for 8 h. In addition to the thin plate-shaped continuous precipitates, continuous precipitates with rod-shaped and the Potter orientation relationship were observed and analyzed with transmission electron microscopy including high-resolution transmission electron microscopy techniques. It was also observed firstly that there exist plate-shaped continuous precipitates with the Pitsch-Schrader orientation relationship in the die-cast AZ91 magnesium alloy.     

Cyclic deformation and lifetime of Alloy 617B during isothermal low cycle fatigue

Isothermal low cycle fatigue tests are carried out on the nickel-base Alloy 617B in the solution-annealed, stabilized and long-term aged conditions at temperatures between room temperature and 900 °C. In addition, fatigue microcrack growth is measured using the replica technique. Transmission electron microscopy studies suggest that the observed differences in cyclic hardening between the different heat treatments result from the precipitation of fine carbides. Scanning electron microscope observations indicate a change in fracture mode for the solution-annealed and long-term aged material with temperature. The Chaboche model is able to describe the time and temperature dependent cyclic plasticity of the three material conditions. The measured lifetimes and crack growth rates can be described using a fracture mechanics based lifetime model. However, the data for room temperature and for temperatures above 400 °C fall into two different scatter bands due to differences in crack growth rates.