Construction of extrusion limit diagram for AZ31 magnesium alloy by FE simulation

The maximum speed at which magnesium can be extruded is considerably slower than that of many common aluminium extrusion alloys. This affects both the economies of production and the final mechanical behaviour. The present work quantifies the limiting extrusion speeds and ratios of magnesium alloy AZ31 as a function of billet temperature. This is done by combining hot compression test results, FE simulations and extrusion trials. Hot working stress–strain curves displayed a distinct dynamic recrystallisation peak. These data were used as a “look-up” table for the FE simulations in which the cracking limit was assumed to occur when the surface temperature reaches the incipient melting point. The maximum extrusion ratio predicted using FE analysis dropped from 90 to 40 when the extrusion ram speed was raised from 5 to 50 mm/s. The predicted limits agree well with the occurrence of cracking in both a laboratory and a commercial extrusion trial.

The origin of "Rare Earth" texture development in extruded Mg-based alloys and its effect on tensile ductility

The extrusion behaviour, texture and tensile ductility of five binary Mg-based alloys have been examined and compared to pure Mg. The five alloying additions examined were Al, Sn, Ca, La and Gd. When these alloys are compared at equivalent grain size, the La- and Gd-containing alloys show the best ductilities. This has been attributed to a weaker extrusion texture. These two alloying additions, La and Gd, were found to also produce a new texture peak with View the MathML source parallel to the extrusion direction. This “rare earth texture” component was found to be suppressed at high extrusion temperatures. It is proposed that the View the MathML source texture component arises from oriented nucleation at shear bands.

Atom probe tomography of solute distributions in mg-based alloys

Atom probe tomography (APT) has been carried out on three magnesium-based alloys: M1 (Mg-1 wt pct Mn), AZ31(Mg-3 pct Al-1 pct Zn), and ME10 (Mg-1 pct Mn- 0.4 pct misch metal). The aims of this experiment were to measure the composition of the matrix and to investigate solute clustering in the matrix of the three different alloys. For AZ31, the matrix composition was variable but close to the bulk composition. For ME10 and M1, the matrix was depleted in alloying additions, with the remainder residing in precipitates. Most alloying additions were found to exhibit clustering to some extent, with misch metal having the strongest partitioning behavior to clusters. Solute clusters did not appear to affect mechanical twinning. It has been proposed that the clustering behavior of misch metal contributes to its ability to modify the recrystallization texture.

Performance of wrought aluminium and magnesium alloy tubes in three-point bending

This present work examines the load carrying capacity, energy absorption and fracture characteristics of wrought magnesium and aluminium alloy tubes in three-point bending. Magnesium alloy AZ31, and aluminium alloys 6063 and 7075, were extruded into cylindrical tubes of both equivalent thickness and mass. A strong thickness effect was present meaning that the AZ31 tube had significantly higher load and energy absorption performance than an equivalent mass 6063 tube, albeit not as high as the 7075 tube. Hinge formation and maximum load was delayed for the magnesium alloy, meaning that a high energy absorption rate persisted to higher deformation displacements than the aluminium alloys. It was also found that fracture during deformation was dependent on the indenter diameter, tube thickness and lower support separation.

Potentiostatic control of ionic liquid surface film formation on ZE41 magnesium alloy

The generation of potentially corrosion-resistant films on light metal alloys of magnesium have been investigated. Magnesium alloy, ZE41 [Mg−Zn−Rare Earth (RE)-Zr, nominal composition 4 wt % Zn, 1.7 wt % RE (Ce), 0.6 wt % Zr, remaining balance, Mg], was exposed under potentiostatic control to the ionic liquid trihexyl(tetradecyl)phosphonium diphenylphosphate, denoted [P_6,6,6,14][DPP]. During exposure to this IL, a bias potential, shifted from open circuit, was applied to the ZE41 surface. Electrochemical impedance spectroscopy (EIS) and chronoamperometry (CA) were used to monitor the evolution of film formation on the metal surface during exposure. The EIS data indicate that, of the four bias potentials examined, applying a potential of −200 mV versus OCP during the exposure period resulted in surface films of greatest resistance. Both EIS measurements and scanning electron microscopy (SEM) imaging indicate that these surfaces are substantially different to those formed without potential bias. Time of flight-secondary ion mass spectrometry (ToF-SIMS) elemental mapping of the films was utilized to ascertain the distribution of the ionic liquid cationic and anionic species relative to the microstructural surface features of ZE41 and indicated a more uniform distribution compared with the surface following exposure in the absence of a bias potential. Immersion of the treated ZE41 specimens in a chloride contaminated salt solution clearly indicated that the ionic liquid generated surface films offered significant protection against pitting corrosion, although the intermetallics were still insufficiently protected by the IL and hence favored intergranular corrosion processes.

The effect of potential bias on the formation of ionic liquid generated surface films on Mg alloys

An electrochemical approach to the formation of a protective surface film on Mg alloys immersed in the ionic liquid (IL), trihexyl(tetradecyl)phosphonium–bis 2,4,4-trimethylpentylphosphinate, was investigated in this work. Initially, cyclic voltammetry was used with the Mg alloy being cycled from OCP to more anodic potentials. EIS data indicate that, under these circumstances, an optimum level of protection was achieved at intermediate potentials (e.g., 0 or 0.25 V versus Ag/AgCl). In the second part of this paper, a small constant bias was applied to the Mg alloy immersed in the IL for extended periods using a novel cell design. This electrochemical cell allowed us to monitor in situ surface film formation on the metal surface as well as the subsequent corrosion behaviour of the metal in a corrosive medium. This apparatus was used to investigate the evolution of the surface film on an AZ31 magnesium alloy under a potential bias (between ±100 mV versus open circuit) applied for over 24 h, and the film evolution was monitored using electrochemical impedance spectroscopy (EIS). A film resistance was determined from the EIS data and it was shown that this increased substantially during the first few hours (independent of the bias potential used) with a subsequent decrease upon longer exposure of the surface to the IL. Preliminary characterization of the film formed on the Mg alloy surface using ToF-SIMS indicates that a multilayer surface exists with a phosphorous rich outer layer and a native oxide/hydroxide film underlying this. The corrosion performance of a treated AZ31 specimen when exposed to 0.1 M NaCl aqueous solution showed considerable improvement, consistent with electrochemical data.

Exploiting low levels of rare earth addition in Mg extrusion alloys

The present work examines the extrusion and mechanical properties of MExlOO alloys, which contain levels of rare earth alloying additions up to 0.4 wt%. It is shown that these alloys can display the high extrudability of alloy Ml with strengths nearing those of AZ31. Most importantly, the grades display high room temperature ductility; values of total tensile elongation as high as 30% have been observed. These benefits derive from a combination of grain refinement and texture weakening.

Corrosion inhibition of 7000 series aluminium alloys with cerium diphenyl phosphate

Cerium diphenyl phosphate (Ce(dpp)3) has previously been shown to be a strong corrosion inhibitor for aluminium-copper magnesium alloy AA2024-T3 and AA7075 in chloride solutions. Surface characterisation including SEM and ToF-SIMS coupled with electrochemical impedance spectroscopy (EIS) measurements are used to propose a mechanism of corrosion inhibition which appears to involve the formation of a complex oxide film of aluminium and cerium also incorporating the organophosphate component. The formation of a thin complex film consisting of hydrolysis products of the Ce(dpp)3 compound and aluminium oxide is proposed to lead to the observed inhibition. SEM analysis shows that some intermetallics favour the creation of thicker deposits predominantly containing cerium oxide compounds.

Effect of Zn concentration and grain size on prismatic slip in Mg-Zn binary alloys

Mg-Zn binary alloys with concentrations between 0 and 2.8wt% Zn have been prepared and processed via hot rolling and annealing to produce specimens with a strong basal texture and a range of grain sizes. These have been deformed in tension, a condition in which the deformation is dominated by prismatic slip. This data has been used to assess the Hall-Petch parameter as a function of Zn concentration for deformation dominated by prismatic slip. Pure magnesium showed non-linear Hall-Petch behaviour at large grain sizes, and this is compared to the values for prismatic slip measured on single crystals. The differences between critical resolved shear stress measurements made through single crystal, polycrystal and mathematical modelling techniques are also discussed.

Microstructural development and mechanical properties in wrought Mg-Zn-RE alloys

Magnesium-zinc alloys with and without rare earth metals were examined. Particles form when rare earth metals are present and these affect the development of the internal structures in the alloys. Finer, more numerous and more uniformly distributed particles result in alloys with the best combination of high strength and ductility.

A physically based phenomenological model for deformation twinning in magnesium alloy

A partial differential equation is developed that captures the evolution of key characteristics of tensile twinning in magnesium base alloys. The objective is to provide a framework for ascertaining the effects of hardening – due to grain refinement, precipitation and dislocation substructure – on twin volume fraction, thickness and length. The model is developed with the help of observations made on alloy AZ31. It is shown that it is necessary to consider the nucleation of twins at locations where neighbouring twins impinge on the grain boundary. The model provides a reasonable approximation for the role of grain size on twinning. It predicts a period of low apparent work hardening following yielding and shows that this should be more extensive for finer grain sizes, in agreement with experiment. Finally, some predictions are made on the effect of changing the resistance to twinning.