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.     

铈镧混合稀土对AZ91D压铸镁合金显微组织和蠕变性能的影响

研究了不同含量Ce/La(x=0,0.1,0.5,1.0)对AZ91D镁合金显微组织及蠕变性能的影响。通过X射线衍射(XRD)、金相显微镜(OM)、扫描电镜(SEM)及能谱分析(EDX)观察与分析表明,压铸AZ91D镁合金中添加Ce/La后,除了α-Mg,β-Mg17Al12相之外,还生成了新的稀土化合物Al11RE3(RE=Ce/La)化合物,并且细化了合金显微组织、提高了合金室温和高温力学性能。生成的Al11RE3(RE=Ce/La)高温热稳定相使AZ91D+xCe/La(x=0,0.1,0.5,1.0)合金在150℃,50MPa下的蠕变抗力优于AZ91D镁合金,1%Ce/La的合金与AZ91D相比,蠕变延伸率低了0.2%,最小蠕变速率从2.30×10-8s-1降低到2.02×10-8s-1。蠕变试样的微观组织结构分析表明:AZ91D合金的蠕变机制主要以晶界滑移方式为主,Al11RE3(RE=Ce/La)热稳定相在晶界处延缓和阻碍了晶界断裂的过程。     

Casting of High-Aluminum-Content Mg Alloys Strip by a Horizontal Twin-Roll Caster

This study was aimed to investigate casting of high-aluminum-content Mg alloys strip by a horizontal twin-roll caster. A horizontal-type twin-roll caster was equipped with a nozzle. This nozzle was movable. The roll size was φ300 × W150, and copper rolls were used. The rolling road was very small. It was possible to cast AZ91D and AZ121 magnesium alloys continuously by a horizontal twin-roll caster. There was gloss and no crack. The thickness of as-cast strip of AZ91D was 4.5 mm and that of AZ121 was 4.6 mm, respectively. In the case that roll velocity was 48 m/min, the thickness of as-cast strip of AZ121 was 2.0 mm. A 2.0-mm-thick strip was able to coil, and the diameter was φ500 mm. The microstructures of the as-cast strip of AZ91D and AZ121 magnesium alloys were observed using light optical microscopy. Isometric dendrite crystals were observed at the as-cast strip. The as-cast strip without facing of AZ91D and AZ121 magnesium alloys were able to hot rolling of 75 pct reduction. The surface of the as-rolled sheet was flat and glossy. The tensile strength of the as rolled was 230 MPa and the elongation of as rolled was 4 pct.     

Creep deformation mechanisms in high-pressure die-cast magnesium-aluminum-base alloys

Creep of die-cast Mg alloys is described as an integral part of their plastic deformation behavior in terms of stress-strain-rate-strain relations. Creep tests yield information on yield stress, work hardening, maximum deformation resistance (minimum creep rate), and work softening. Testing in compression avoids influences by fracture. Data on the alloy AJ52 (5Al, 2Sr) in the temperature range between 135 °C and 190 °C are presented and compared to those for AZ91 and AS21. Die-cast Mg-Al alloys consist of fine grains with a grain boundary region containing intermetallic precipitates. Transmission electron microscopic observations indicate that basal glide is the dominant mechanism of deformation being supplemented by nonbasal glide and twinning to maintain compatiblity between the grains. The deformation resistance can be modeled with a composite approach assuming that the grain boundary region is relatively hard due to precipitation of intermetallic phases. The differences in long-term creep resistance at low stress are explained in terms of different strength and stability of precipitates in the different alloys. This article is based on a presentation made in the symposium entitled “Phase Transformations and Deformation in Magnesium Alloys,” which occurred during the Spring TMS meeting, March 14–17, 2004, in Charlotte, NC, under the auspices of the ASM-MSCTS Phase Transformations Committee.     

Modification of AZ91?Mg Alloys for High Temperature Applications

The good specific strength and specific modulus of magnesium alloys had drawn the attention of the automotive manufacturers for use in fuel efficient vehicles. Among the cast magnesium alloys, AZ91 (Mg?C9Al?C1Zn) is the most sought alloy because of its good casting properties. However, this alloy loses its strength and creep resistance properties above 120?°C due to softening of the ?? phase (Mg₁₇Al₁₂). Hence, this alloy cannot be used for making heavier engine components (power train), which require the thermal stability up to about 250?°C. The paper discusses the approach of modifying the AZ91 alloy by minor alloying additions to improve the high temperature withstanding capability without significantly affecting its casting properties. Additions of Ca to AZ91 alloy to the levels of about 0.4?wt% increased the ambient and high temperature strength of the base alloy. Additions of other minor alloying elements such as Sb, Pb, rare earths etc. can also increase the high temperature capability of the AZ91 by further modifying the ?? phase structure. The paper overviews the work carried out by the authors on the role of different alloying additions on the microstructure and mechanical properties of AZ91 magnesium alloys.     

Electron-beam welding behavior in Mg-Al-based alloys

The electron-beam welding (EBW) behaviors of pure Mg and the AZ31, AZ61, and AZ91 Mg alloys are examined in this study, in terms of fusion-zone characteristics, grain structures, texture evolution, and joint efficiency. With increasing A1 content, the Mg-based materials were found to be more easily fusion welded. The AZ91 alloy could be welded using a beam power of 2200 W and a weld speed of 16 mm/s, resulting in a weld depth of 29 mm with a fusion-zone aspect ratio of 8.2. The grains inside the fusion zone were nearly equiaxed in shape and ∼10 μm in size, due to the rapid cooling rate. Extended partial melting zones were observed in alloys with high solute contents, such as AZ61 and AZ91. The postweld tensile strength of the Mg alloys could recover back to ∼80 to 110 pct of the original strength. The texture in the fusion zone was traced by X-ray diffraction (XRD) and electron-backscattered diffraction (EBSD). The grain orientations inside the rapidly solidified electron-beam-welded fusion zones are still rather diversely distributed. The α ₁-, α ₂-, and α ₃-axes of some grains tend to align at 90 or 30 deg with respect to welding direction, and the c-axis tends to align along the plate normal direction. The influence from surface tension on the weld top-surface appearance and weld depth was not pronounced for the current four Mg materials. Instead, differences in the solidus temperatures and thermal conductivity should be the primary factors.     

Warm-temperature tensile ductility in Al−Mg alloys

Several binary and ternary Al alloys containing from 2.8 to 5.5 wt pct Mg were tested in tension at elevated temperatures (200°C to 500°C) over a range of strain rates (10⁻⁴ to 2.0 s⁻¹). Tensile ductilities of up to 325 pct were obtained in binary Al−Mg alloys with coarse grains deformed in the solute-drag creep regime. Under test conditions in which solute-drag creep controls deformation, Mg in concentrations from 2.8 to 5.5 wt pct neither affects tensile ductility nor influences strain-rate sensitivity or flow stress significantly. Strength is shown to increase with increasing Mg concentration, however, in the power-law-break down regime. The solute-drag creep process, which leads to superplastic-like elongations, is shown to have no observable grain-size dependence in a binary Al−Mg material. Ternary alloying additions of Mn and Zr are shown to decrease the strain-rate sensitivity during solute-drag creep, negatively influencing ductility. An important cause of reduced ductility in the ternary alloys during creep deformation is found to be a transition from necking-controlled failure in the binary alloys to cavitation-controlled failure in the ternary alloys investigated. An increase in ternary element concentration, which can increase the relative volume percentage of proeutectic products, increases cavitation.     

Corrosion fatigue of die-cast and extruded magnesium alloys

To study the fatigue life of die-cast and extruded AZ91D, AM50 and AZ31 magnesium alloys, corrosion fatigue tests were carried out using a rotating beam type fatigue machine. Corrosive environment (3.5% NaCl) significantly decreases fatigue life of alloys, especially for extruded alloys. The fatigue data at high stresses were analyzed using fitting equations. Extruded alloys show a higher sensitivity to the action of NaCl solution in comparison with die-cast alloys; however, their corrosion fatigue life is longer than that of die-cast alloys. Corrosion fatigue behavior of Mg alloys correlates with their mechanochemical behavior. The latter was studied by the polarization measurements of the dissolution rate of strained alloys. TEM observations confirmed that the maximums on the curves of Mg dissolution rate dependence on the strain in NaCl solution appeared at the work-hardening stages due to the creation and destruction of dislocation pile-ups.     

Warm-temperature tensile ductility in Al-Mg alloys

Several binary and ternary Al alloys containing from 2.8 to 5.5 wt pct Mg were tested in tension at elevated temperatures (200 °C to 500 °C) over a range of strain rates (10⁻⁴ to 2.0 s⁻¹). Tensile ductilies of up to 325 pct were obtained in binary Al-Mg alloys with coarse grains deformed in the solute-drag creep regime. Under test conditions in which solute-drag creep controls deformation, Mg in concentrations from 2.8 to 5.5 wt pct neither affects tensile ductility nor influences strain-rate sensitivity or flow stress significantly. Strength is shown to increase with increasing Mg concentration, however, in the power-law-breakdown regime. The solute-drag creep process, which leads to superplastic-like elongations, is shown to have no observable grain-size dependence in a binary Al-Mg material. Ternary alloying additions of Mn and Zr are shown to decrease the strain-rate sensitivity during solute-drag creep, negatively influencing ductility. An important cause of reduced ductility in the ternary alloys during creep deformation is found to be a transition from necking-controlled failure in the binary alloys to cavitation-controlled failure in the ternary alloys investigated. An increase in ternary element concentration, which can increase the relative volume percentage of proeutectic products, increases cavitation.     

Structure and Corrosion Resistance of Microarc Oxidation Coatings on AZ91D Magnesium Alloy

Magnesium alloys are widely used as shells of 3C (computer, mobile phone and consumer electronics) equipments for its impressive mechanical and physical properties, such as low density, good resistance to electromagnetic radiation, suitable for high pressure diecasting and easily recycling, etc. But poor corrosion resistance confines its extensively application. In this paper, protective coatings was successfully prepared on AZ91D magnesium alloys by micro-arc oxidation (MAO) and painting process. Microstructures and phases of MAO coatings were invesgated with scanning electron microscope (SEM) and X-Ray diffractometer. Mechanical properties of MAO coating, such as adhesive force and corrosion resistance, were also tested. Results showed that MAO coatings were a good base for painting process. MAO coatings with paint have good adhesive properties to base metal and excellent corrosion resistance. Micro-arc oxidation with painting process is a good kind of surface treatment to improve the corrosion resistance of mobile phone shell made of AZ91D magnesium alloys.     

Creep processes in magnesium alloys and their composites

A comparison is made between the creep characteristics of two squeeze-cast magnesium alloys (AZ 91 and QE 22) reinforced with 20 vol pct Al₂O₃ short fibers and the unreinforced AZ 91 and QE 22 matrix alloys. The results show the creep resistance of the reinforced materials is considerably improved by comparison with the unreinforced matrix alloys. It is suggested that creep strengthening in these short-fiber composites arises primarily from the existence of a threshold stress and the effect of load transfer. By testing samples to failure, it is demonstrated that the unreinforced and reinforced materials exhibit similar times to failure at the higher stress levels. A detailed microstructural investigation by transmission electron microscopy (TEM) reveals no substantial changes in matrix microstructure due to the presence of the reinforcement. This suggests that direct composite strengthening dominates over indirect effects. This article is based on a presentation made in the symposium entitled “Defect Properties and Mechanical Behavior of HCP Metals and Alloys” at the TMS Annual Meeting, February 11–15, 2001, in New Orleans, Louisiana, under the auspices of the following ASM committees: Materials Science Critical Technology Sector, Structural Materials Division, Electronic, Magnetic & Photonic Materials Division, Chemistry & Physics of Materials Committee, Joint Nuclear Materials Committee, and Titanium Committee.     

Creep processes in magnesium alloys and their composites

A comparison is made between the creep characteristics of two squeeze-cast magnesium alloys (AZ 91 and QE 22) reinforced with 20 vol pct Al₂O₃ short fibers and the unreinforced AZ 91 and QE 22 matrix alloys. The results show the creep resistance of the reinforced materials is considerably improved by comparison with the unreinforced matrix alloys. It is suggested that creep strengthening in these short-fiber composites arises primarily from the existence of a threshold stress and the effect of load transfer. By testing samples to failure, it is demonstrated that the unreinforced and reinforced materials exhibit similar times to failure at the higher stress levels. A detailed microstructural investigation by transmission electron microscopy (TEM) reveals no substantial changes in matrix microstructure due to the presence of the reinforcement. This suggests that direct composite strengthening dominates over indirect effects. This article is based on a presentation made in the symposium entitled “Defect Properties and Mechanical Behavior of HCP Metals and Alloys” at the TMS Annual Meeting, February 11–15, 2001, in New Orleans, Louisiana, under the auspices of the following ASM committees: Materials Science Critical Technology Sector, Structural Materials Division, Electronic, Magnetic & Photonic Materials Division, Chemistry & Physics of Materials Committee, Joint Nuclear Materials Committee, and Titanium Committee.     

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.     

Nitride Nanoparticle Addition to Beneficially Reinforce Hybrid Magnesium Alloys

This study is aimed at understanding the function of two nitride nanoparticles regarding altering the mechanical properties of hybrid magnesium alloys in relation to nanoparticle-matrix reactivity. Nitride nanoparticles were selected for reinforcement purposes due to the affinity between magnesium and nitrogen (in parallel with the well-known magnesium-oxygen affinity). AZ91/ZK60A and AZ31/AZ91 hybrid magnesium alloys were reinforced with AlN and Si₃N₄ nanoparticles (respectively) using solidification processing followed by hot extrusion. Each nitride nanocomposite exhibited higher tensile strength than the corresponding monolithic hybrid alloy. However, AZ91/ZK60A/AlN exhibited slightly lower tensile ductility than AZ91/ZK60A, while AZ31/AZ91/Si₃N₄ exhibited higher tensile ductility than AZ31/AZ91. The formation of high strain zones (HSZs) (from particle surfaces inclusive) during tensile deformation as a significant mechanism supporting ductility enhancement was addressed. AZ91/ZK60A/AlN exhibited lower and higher compressive strength and ductility (respectively) compared to AZ91/ZK60A, while AZ31/AZ91/Si₃N₄ exhibited higher and unchanged compressive strength and ductility (respectively) compared to AZ31/AZ91. Nanograin formation (recrystallization) during room temperature compressive deformation (as a toughening mechanism) in relation to nanoparticle-stimulated nucleation (NSN) ability was also discussed. The beneficial (as well as comparative) effects of the respective nitride nanoparticle on each hybrid alloy are studied in this article.     

Impression Creep Behavior of an Mg–Zn–RE Alloy at Elevated Temperatures

Mg–Zn–RE alloys are promising candidates for automotive and aerospace applications as, among magnesium alloys, they have better corrosion and creep resistance abilities at elevated temperatures. This study evaluates the high-temperature creep behavior of ZE41 magnesium alloy, belonging to the Mg–Zn–RE family, using impression test. Impression tests were performed under a constant temperature and stress with a flat-ended cylindrical punch. Power law and Eyring relationships were used to analyze the creep mechanism. By applying the power-law relationship, it was found that the creep exponent decreased from 7.5 to 4 in the temperature range of 493 K to 593 K. Activation energy increased from 78.5 to 107.1 kJ/mol in the applied stress range of 350 to 500 MPa (normalized stress: 0.024 ≤ σ_imp/G ≥ 0.034). Using the Eyring relationship, a single activation energy of 25 kJ/mol for the entire stress and temperature range was obtained. Based on the creep exponent and activation energy, it is proposed that pipe-diffusion-controlled dislocation climb is the dominant mechanism, but grain boundary sliding also contributes at higher stresses.

     

Effect of Al and Gd Solutes on the Strain Rate Sensitivity of Magnesium Alloys

Pure magnesium and two binary alloys, Mg-1 wt pct Al and Mg-1.4 wt pct Gd, have been prepared with comparable grain sizes and textures. The alloys have been tensile tested at various strain rates and temperatures to examine the strain rate sensitivity (SRS). It has been found that Mg and Mg-Al show increasing SRS with increasing deformation temperatures. The Mg-Gd alloy showed decreasing SRS with increasing deformation temperatures and exhibited a negative SRS at 200 °C and 250 °C. Above these temperatures, the SRS returned to a positive value. The elongation to fracture was not effected by the SRS, and it has been concluded that for the alloys and conditions examined, the influences of mechanical twinning and dynamic recrystallization dominate the elongation behavior, rather than the SRS.     

Processing,microstructure, and mechanical behavior of cast magnesium metal matrix composites

Magnesium metal matrix composites (MMCs) have been receiving attention in recent years as an attractive choice for aerospace and automotive applications because of their low density and superior specific properties. This article presents a liquid mixing and casting process that can be used to produce SiC particulate-reinforced magnesium metal matrix composites via conventional foundry processes. Microstructural features, such as SiC particle distribution, grain refinement, and particle/matrix interfacial reactions of the cast magnesium matrix composites, are investigated, and the effects of solidification-process parameters and matrix alloys (pure Mg and Mg-9 pct Al-1 pct Zn alloy AZ91) on the microstructure are established. The results of this work suggest that in the solidification processing of MMCs, it is important to optimize the process parameters both to avoid excessive interfacial reactions and simultaneously achieve wetting, so that a good particle distribution and interfacial bonding are obtained. The tensile properties, strain hardening, and fracture behavior of the AZ91/SiC composites are also studied and the results are compared with those of the unreinforced AZ91 alloy. The strengthening mechanisms for AZ91/SiC composite, based on the proposed SiC particle/matrix interaction during deformation, are used to explain the increased yield strength and elastic modulus of the composite over the magnesium matrix alloy. The low ductility found in the composites is due to the early appearance of localized damages, such as particle cracking, matrix cracking, and occasionally interface debonding, in the fracture process of the composite.     

稀土元素铈对镁合金AZ91D显微组织和力学性能的影响

利用光学显微镜、X射线衍射和扫描电镜等分析研究含铈镁合金AZ91D（0．25％Ce、0．7％Ce、0．95％Ce）的显微组织,并对其力学性能进行了测试,同时与不含铈镁合金AZ91D进行了比较。结果表明,加入一定量Ce后的镁合金AZ91D形成杆状化合物Al4Ce,被推移到生长界面,阻碍枝晶的自由生长,从而细化合金显微组织;Ce能提高镁合金AZ91D抗拉强度和硬度,而对其屈服强度和延伸率影响不大;加入0．7％Ce的AZ91D镁合金晶粒细化效果和综合力学性能比较理想。     

铈对铸造镁合金AZ91D显微组织与力学性能的影响

利用光学金相显微镜OM和XRD分析了分别加入0．1％，0．3％，0．5％，0．7％和1．0％Ce的AZ91D合金显微组织和相组成，测试了室温力学性能和硬度。结果表明，加入一定量Ce后的AZ91D合金形成杆状化合物Al4Ce，被推移到生长界面，阻碍枝晶的自由生长，从而细化合金显微组织；Ce能提高AZ91D合金室温抗拉强度和硬度，而对其屈服强度和延伸率影响不大；加入0．7％Ce的AZ91D合金晶粒细化效果好，其综合力学性能比较理想。