In this paper is discussed the effect of the inoculant mischmetal addition on the microstructure of the magnesium alloy AZ91. The concentration of the inoculant was increased in the samples within the range from 0.1% up to 0.6%. The thermal process was performed with the use of Derivative and Thermal Analysis (DTA). A particular attention was paid to finding the optimal amount of the inoculant, which causes fragmentation of the microstructure. The concentration of each element was verified with use of a spark spectrometer. In addition, the microstructures of every samples were examined with the use of an optical microscope and also was performed an image analysis with a statistical analysis using the NIS–Elements program. The point of those analyses was to examine the differences in the grain diameters of phase αMg and eutectic αMg+γ(Mg17Al12) in the prepared samples as well as the average size of each type of grain by way of measuring their perimeters. This paper is the second part of the introduction into a bigger research on grain refinement of magnesium alloys, especially AZ91. Another purpose of this research is to achieve better microstructure fragmentation of magnesium alloys without the relevant changes of the chemical composition, which should improve the mechanical properties.
The thermochemical treatment applied to improve the surface properties of AZ91 consisted in heating the material in contact with AlSi10Mg powder at 445 oC for 30 min. During heat treatment process the powder was held under pressure to facilitate the diffusion of the alloying elements to the substrate and, accordingly, the formation of a modified layer. Two pressures, 1 MPa and 5 MPa, were tested. The resultant layers, containing hard Mg2Si and Mg17Al12 phases, were examined using an optical microscope and a scanning electron microscope equipped with an energy-dispersive X-ray spectrometer (EDS). The experimental data show that the layer microstructure was dependent on the pressure applied. A thicker, three-zone layer (about 200 μm) was obtained at 1 MPa. At the top, there were Mg2Si phase particles distributed over the Mg17Al12 intermetallic phase matrix. The next zone was a eutectic (Mg17Al12 and a solid solution of Al in Mg) with Mg2Si phase particles embedded in it. Finally, the area closest to the AZ91 substrate was a eutectic not including the Mg2Si phase particles. By contrast, the layer produced at a pressure of 5 MPa had lower thickness of approx. 150 μm and a two-zone structure. Mg2Si phase particles were present in both zones. In the upper zone, Mg2Si phase particles were regularly distributed over the Mg17Al12 intermetallic phase matrix. The lower zone, adjacent to the AZ91, was characterized by a higher volume fraction of Mg2Si phase particles distributed over the matrix composed mainly of Mg17Al12. The alloyed layers enriched with Al and Si had much higher hardness than the AZ91 substrate.
In this study, modification of the AZ91 magnesium alloy surface layer with a CO2 continuous wave operation laser has been taken on. The extent and character of structural changes generated in the surface layer of the material was being assessed on the basis of both macro- and microscopy investigations, and the EDX analysis. Considerable changes in the structure of the AZ91 alloy surface layer and the morphology of phases have been found. The remelting processing was accompanied by a strong refinement of the structure and a more uniform distribution of individual phases. The conducted investigations showed that the remelting zone dimensions are a result of the process parameters, and that they can be controlled by an appropriate combination of basic remelting parameters, i.e. the laser power, the distance from the sample surface, and the scanning rate. The investigations and the obtained results revealed the possibility of an effective modification of the AZ91 magnesium alloy surface layer in the process of remelting carried out with a CO2 laser beam.
This work presents an influence of cooling rate on crystallization process, structure and mechanical properties of MCMgAl12Zn1 cast magnesium alloy. The experiments were performed using the novel Universal Metallurgical Simulator and Analyzer Platform. The apparatus enabled recording the temperature during refrigerate magnesium alloy with three different cooling rates, i.e. 0.6, 1.2 and 2.4°C/s and calculate a first derivative. Based on first derivative results, nucleation temperature, beginning of nucleation of eutectic and solidus temperature were described. It was fund that the formation temperatures of various thermal parameters, mechanical properties (hardness and ultimate compressive strength) and grain size are shifting with an increasing cooling rate.
AM50/Mg2Si composites containing 5.7 wt. % and 9.9 wt. %. of Mg2Si reinforcing phase were prepared successfully by casting method. The microstructure of the cast AM50/Mg2Si magnesium matrix composites was investigated by light microscopy and X-ray diffractometry (XRD). The microstructure of these composites was characterized by the presence of α-phase (a solid solution of aluminium in magnesium), Mg17Al12 (γ-phase), Al8Mn5 and Mg2Si. It was demonstrated that the Mg2Si phase was formed mainly as primary dendrites and eutectic.
Investigation of the tensile and fatigue properties of cast magnesium alloys, created by the heated mold continuous casting process (HMC), was conducted. The mechanical properties of the Mg-HMC alloys were overall higher than those for the Mg alloys, made by the conventional gravity casting process (GC), and especially excellent mechanical properties were obtained for the Mg97Y2Zn1 -HMC alloy. This was because of the fine-grained structure composed of the -Mg phases with the interdendritic LPSO phase. Such mechanical properties were similar levels to those for conventional cast aluminum alloy (Al84.7Si10.5Cu2.5Fe1.3Zn1 alloys: ADC12), made by the GC process. Moreover, the tensile properties (UTS and f ) and fatigue properties of the Mg97Y2Zn1 -HMC alloy were about 1.5 times higher than that for the commercial Mg90Al9Zn1 -GC alloy (AZ91). The high correlation rate between tensile properties and fatigue strength (endurance limit: l ) was obtained. With newly proposed etching technique, the residual stress in the Mg97Y2Zn1 alloy could be revealed, and it appeared that the high internal stress was severely accumulated in and around the long-period stacking-order phases (LPSO). This was made during the solidification process due to the different shrinkage rate between α-Mg and LPSO. In this etching technique, microcracks were observed on the sample surface, and amount of micro-cracks (density) could be a parameter to determine the severity of the internal stress, i.e., a large amount to micro-cracks is caused by the high internal stress.
The results of some mechanical properties of four Mg-5Al-xRE-0.4Mn (x = 1 – 5) alloys are presented. The microstructure of experimental alloys consisted of an α-Mg phase and an α+γ semi-divorced eutectic, Al11RE3 phase and an Al10RE2Mn7 intermetallic compound. For gravity casting in metal mould alloys, Brinell hardness, impact strength, tensile and compression properties at ambient temperature were determined. The performed mechanical tests allowed the author to determine the proportional influence of the mass fraction of rare earth elements in the alloys on their tensile strength, yield strength, compression strength and Brinell hardness. The impact strength of the alloys slightly decreases with a rise in the rare earth elements mass fraction.
To the main advantages of magnesium alloys belongs their low density, and just because of such property the alloys are used in aviation and rocket structures, and in all other applications, where mass of products have significant importance for conditions of their operation. To additional advantages of the magnesium alloys belongs good corrosion resistance, par with or even surpassing aluminum alloys. Magnesium is the lightest of all the engineering metals, having a density of 1.74 g/cm3 . It is 35% lighter than aluminum (2.7 g/cm3 ) and over four times lighter than steel (7.86 g/cm3 ). The Mg-Li alloys belong to a light-weight metallic structural materials having mass density of 1.35-1.65 g/cm3 , what means they are two times lighter than aluminum alloys. Such value of mass density means that density of these alloys is comparable with density of plastics used as structural materials, and therefore Mg–Li alloys belong to the lightest of all metal alloys. In the present paper are discussed melting and crystallization processes of ultra-light weight MgLi12,5 alloys recorded with use of ATND methods. Investigated magnesium alloy was produced in Krakow Foundry Research Institute on experimental stand to melting and casting of ultra-light weight alloys. Obtained test results in form of recorded curves from ATND methods have enabled determination of characteristic temperatures of phase transitions of the investigated alloy.
The Mg-RE alloys are attractive, constructional materials, especially for aircraft and automotive industry, thanks to combination of low density, good mechanical properties, also at elevated temperature, and good castability and machinability. Present paper contains results of fatigue resistance test carried out on Elektron 21 magnesium alloy, followed by microstructural and fractographical investigation of material after test. The as-cast material has been heat treated according to two different procedures. The fatigue resistance test has been conducted with 106 cycles of uniaxial, sine wave form stress between 9 MPa and 90 MPa. Fractures of specimens, which ruptured during the test, have been investigated with scanning electron microscope. The microstructure of specimens has been investigated with light microscopy. Detrimental effect of casting defects, as inclusions and porosity, on fatigue resistance has been proved. Also the influence of heat treatment's parameters has been described.
Magnesium alloy with 5 wt% Al, 0.35 wt% Mn and 5 wt% rare earth elements (RE) was prepared and gravity cast into a sand mould. Microstructure investigations were conducted. Analyses of the Mg-Al-RE alloy microstructure were carried out by light microscopy, scanning electron microscopy and the XRD technique. In the as-cast condition, the alloy was composed of α-Mg, Al11RE3 and Al10RE2Mn7 intermetallic phases. Additionally, due to non-equilibrium solidification conditions, an Al2RE intermetallic phase was revealed.
In this work, the effect of the microstructure on corrosion behavior of selected Mg- and Al-based as cast alloys, was evaluated. The electrochemical examinations were carried out, and then a morphology of corrosion products formed due to local polarization on materials surface, was analyzed. It was documented that the presence of Mg2Si phase plays an important role in the corrosion course of Mg-based alloy. A selective etching was observed in sites of Mg2Si precipitates having “Chinese script”- like morphology. Analogous situation was found for Al-based alloy, where the key role was played by cathodic θ-CuAl2 phase.
The study involved using the liquid-solid compound casting process to fabricate a lightweight ZE41/AlSi12 bimetallic material. ZE41 melt heated to 660 oC was poured onto a solid AlSi12 insert placed in a steel mold. The mold with the insert inside was preheated to 300 oC. The microstructure of the bonding zone between the alloys was examined using optical microscopy and scanning electron microscopy. The chemical composition was determined through linear and point analyses with an energy-dispersive X-ray spectroscope (EDS). The bonding zone between the magnesium and aluminum alloys was about 250 μm thick. The results indicate that the microstructure of the bonding zone changes throughout its thickness. The structural constituents of the bonding zone are: a thin layer of a solid solution of Al and Zn in Mg and particles of Mg-Zn-RE intermetallic phases (adjacent to the ZE41 alloy), a eutectic region (Mg17(Al,Zn)12 intermetallic phase and a solid solution of Al and Zn in Mg), a thin region containing fine, white particles, probably Al-RE intermetallic phases, a region with Mg2Si particles distributed over the eutectic matrix, and a region with Mg2Si particles distributed over the Mg-Al intermetallic phases matrix (adjacent to the AlSi12 alloy). The microstructural analysis performed in the length direction reveals that, for the process parameters tested, the bonding zone forming between the alloys was continuous. Low porosity was observed locally near the ZE41 alloy. The shear strength of the AZ91/AlSi17 joint varied from 51.3 to 56.1 MPa.
The article presents tests results of metalforming of magnesium alloy AZ61. Materials for tests were ingots sized 40×90 mm from magnesium alloy marked with symbol AZ61. Before the shaping process the ingots underwent heat treatment. As a result of conduction of the deformation processes there were rods achieved with diameter of 8 mm. There were axisymmetrical compression tests conducted on the samples taken from rods in temperature range from RT to 350ºC in order to determine the plasticity and formability of the alloy AZ61. Static tensile test was conducted in room temperature (RT), in 300ºC and in 350ºC. With the use of light and electron microscopy techniques the changes which occurred in the microstructure of AZ61alloy in initial condition and after plastic deformation (classic extrusion, KoBo method extrusion) were described. The deformation of alloy AZ61 using the KoBo method contributes to an increase in strength and plastic properties. The effect of superplastic flow was found at a temperature of 350ºC, where a 300% increase in plastic properties – elongation value was obtained. The analysis of the microstructure showed a significant grain size reduction in the microstructure of alloy AZ61 after deformation by the KoBo method and after an axisymmetric compression test, where grains of an average diameter of d = 13 µm were obtained.
Mg-0.5Si-xSn (x=0.95, 2.9, 5.02wt.%) alloys were cast and extruded at 593K (320 o C) with an extrusion ratio of 25. The microstructure and mechanical properties of as-cast and extruded test alloys were investigated by OM, SEM, XRD and tensile tests. The experimental results indicate that the microstructure of the Mg-0.5Si-xSn alloys consists of primary α-Mg dendrites and an interdendritic eutectic containing α-Mg, Mg2Si and Mg2Sn. There is no coarse primary Mg2Si phase in the test alloys due to low Si content. With the increase in the Sn content, the Mg2Si phase was refined. The shape of Mg2Si phase was changed from branch to short bar, and the size of them were reduced. The ultimate tensile strength and yield strength of Mg-0.52Si-2.9Sn alloy at the temperature of 473K (200 o C) reach 133MPa and 112MPa respectively. Refined eutectic Mg2Si phase and dispersed Mg2Sn phase with good elevated temperature stability are beneficial to improve the elevated temperature performance of the alloys. However, with the excess addition of Sn, large block-like Mg2Sn appears around the grain boundary leading to lower mechanical properties.
Contemporary materials engineering requires the use of materials characterised by high mechanical properties, as these precisely properties determine the choice of material for parts of machinery and equipment. Owing to these properties it is possible to reduce the weight and, consequently, the consumption of both material and energy. Trying to meet these expectations, the designers are increasingly looking for solutions in the application of magnesium alloys as materials offering a very beneficial strength-to-weight ratio. However, besides alloying elements, the properties are to a great extent shaped by the solidification conditions and related structure. The process of structure formation depends on the choice of casting method forced by the specific properties of casting or by the specific intended use of final product. The article presents a comparison of AZ91 magnesium alloys processed by different casting technologies. A short characteristic was offered for materials processed by the traditional semi-continuous casting process, which uses the solidification rates comprised in a range of 5 - 20⁰C/s, and for materials made in the process of Rapid Solidification, where the solidification rate can reach 106 ⁰C/s. As a result of the casting process, a feedstock in the form of billets and thin strips was obtained and was subjected next to the process of plastic forming. The article presents the results of structural analysis of the final product. The mechanical properties of the ø7 mm extruded rods were also evaluated and compared.
The Ca50Mg20Zn12Cu18 was assessed with different methods in order to characterize its basic characteristics, and to determine whether the amorphous alloy of such composition would be applicable as an implant material. The XRD analysis was conducted to conclude the structure of the initial material. The Ca50Mg20Zn12Cu18 ingot sample demonstrates crystalline structure containing two main intermetallic phases, however as-cast plates show features of an amorphous material, revealing the characteristic amorphous halo on the x-ray patterns. It was confirmed by the scanning electron microscopy method and fracture images revealing chevron pattern morphology with shell type fracture. Corrosion resistance, was studied using the potentiostatic analysis. The amorphous samples show higher resistance than the crystalline one. Post corrosion surface of the Ca50Mg20Zn12Cu18 alloy exhibits high concentration of magnesium and calcium hydroxides, forming the globular structures in large aggregates of spherical units.
The results of studies on the use of modern two cored wires injection method for production of nodular graphite cast iron with use of unique implementation of drum ladle as a treatment/ transport and casting ladle instead vertical treatment ladle was described. The injection of length of Ø 9mm wires, cored: in FeSi + Mg nodulariser mixture and inoculant master alloy is a treatment method which can be used to produce iron melted in coreless induction furnace. This paper describes the results of using this method for possibility production of ductile iron under specific industrial conditions. In this case was taken ductile iron with material designation: EN-GJS-450- 10 Grade according PN-EN 1563:2000. Microstructure of 28 trials was controlled on internally used sample which has been correlated with standard sample before. The paper presents typical metallic matrix and graphite characteristic. Additionally, mechanical properties were checked in one experiment. Because of further possibility treatment temperature reduction only the rough magnesium recovery and cost of this new method are given.
The results of studies on the use of modern two cored wires injection method for production of ferritic nodular cast iron (ductile iron) with use of unique implementation of drum ladle as a treatment / transport and casting ladle instead vertical treatment ladle was described. The injection of length of Ø 9mm wires, cored: in FeSi + Mg nodulariser mixture and inoculant master alloy is a treatment method which can be used to produce iron melted in coreless induction furnace. This paper describes the results and analysis of using this method for optimal production of ductile iron under specific industrial conditions. It means, that length of nodulariser wire plus treatment and pouring temperatures were optimized. In this case, was taken ductile iron with material designation: EN-GJS-SiMo40-6 Grade according EN 16124:2010 E. Microstructure of great number of trials was controlled on internally used sample which has been correlated with standard sample before. The paper presents typical ferritic metallic matrix and nodular graphite. Additionally, mechanical properties were checked in some experiments. Mean values of magnesium recovery and cost of this new method from optimized process parameters were calculated as well.