The microstructure and mechanical properties of Mg-3Al-3RE alloys

The Mg-3Al-3RE alloys (RE, the cerium-rich or the yttrium-rich misch metal) were smelted in a resistance furnace under the protective flux from the Mg-RE master alloys and pure magnesium ingots. The microstructure and mechanical properties of samples prepared by steel mould casting method were investigated.

Refinement of edge-to-edge matching model and its application in the Mg17Al12/alpha-Mg and alpha-Y/alpha-Mg systems

A refined version of the edge-to-edge matching model is described here. In the original model, the matching directions were obtained from the planes with all the atomic centers that were exactly in the plane, or the distance from the atomic center to the plane which was less than the atomic radius. The direction-matching pairs were the match of straight rows-straight rows and zigzag rows-zigzag rows. In the refined model, the matching directions were obtained from the planes with all the atomic centers that were exactly in the plane.

Electrochemical corrosion behavior of Mg-5Al-0.4Mn-xNd in NaCl solution

The electrochemical corrosion behavior of Mg-5Al-0.4Mn-xNd (x = 0, 1, 2 and 4 wt.%) alloys in 3.5% NaCl solution was investigated. The corrosion behavior of the alloys was assessed by open circuit potential measure, potentiodynamic polarization, and electrochemical impedance spectroscopy. The electrochemical results show the intermetallic precipitates with Nd behave as less noble cathodes in micro-galvanic corrosion and suppress the cathodic process. During corrosion, Al2O3 and Nd2O3, in proper ratio, is incorporated into the corrosion film, and enhances the corrosion resistance.

Micro/nanoreservoirs for controlled release of active species in smart functional coatings

This work reports one possible way to develop new functional coatings used to increase the life time of metallic structures. The functionalities selected and attributed to model coatings in the frame of this work were corrosion protection, self-sensing and prevention of fouling (antifouling). The way used to confer those functionalities to coatings was based on the encapsulation of active compounds (corrosion inhibitors, pH indicators and biocides) in micro and nanocontainers followed by their incorporation into the coating matrices. To confer active corrosion protection, one corrosion inhibitor (2-mercaptobenzothiazole, MBT) was encapsulated in two different containers, firstly in silica nanocapsules (SiNC) and in polyurea microcapsules (PU-MC). The incorporation of both containers in different models coatings shows a significant improvement in the corrosion protection of aluminum alloy 2024 (AA2024). Following the same approach, SiNC and PU-MC were also used for the encapsulation of phenolphthalein (one well known pH indicator) to introduce sensing properties in polymeric coatings. SiNC and PU-MC containing phenolphthalein acted as corrosion sensor, showing a pink coloration due to the beginning of cathodic reaction, resulting in a pH increase identified by those capsules. Their sensing performance was proved in suspension and when integrated in coatings for aluminium alloy 2024 and magnesium alloy AZ31. In a similar way, the biocide activity (antifouling) was assigned to two polymeric matrices using SiNC for encapsulation of one biocide (Dichloro-2-octyl-2H-isothiazol-3-one, DCOIT) and also SiNC-MBT was tested as biocide. The antifouling activity of those two encapsulated compounds was assessed through inhibition and consequent decrease in the bioluminescence of modified E. coli. That effect was verified in suspension and when incorporated in coatings for AISI 1008 carbon steel. The developed micro and nanocontainers presented the desired performance, allowing the introduction of new functionalities to model coatings, showing potential to be used as functional additives in the next generation of multifunctional coatings.

Development of the sheared edge in the trimming of steel and light metal sheet, part 1 - experimental observations

Trimming experiments were conducted on sheet metals including two drawing steels, an aluminum alloy and a magnesium alloy, using a specially designed die in a mechanical press. The punch-die clearance was varied and data obtained on the rollover and burr height as a function of the clearance. Samples were also partially trimmed to examine crack initiation, the generation of the fracture surface profile and mechanism of burr formation. The results showed that while the burr height and rollover depth generally increased with increasing clearance for all examined materials, there were differences in the fracture surface profile shape, the burr shape, and the mechanism of burr formation, between the two steels and the two light alloys. The major cause of these differences appeared to be the rate of crack propagation through the sheet material.

Effect of composition on the texture and deformation behaviour of wrought Mg alloys

The microstructure and mechanical response of three extruded magnesium alloys, Mg-3Al-1Zn (AZ31), Mg-1.5Mn (Ml) and Mg-lMn-0.4RE (ME10) are examined. The tensile yield strength of ME10 was nearly half that of AZ31 and Ml. The tensile elongations were 6%, 11% and 19% for Ml, AZ31 and ME10, respectively. This range of properties is large and is attributed to the unique extrusion texture produced in ME10, and the high density of fine particles in Ml.

A rationale for the strong dependence of mechanical twinning on grain size

In metals that yield as a consequence of mechanical twinning, the yield stress is a function of the grain size in much the same way as it is for dislocation glide. However, the sensitivity to grain size is typically greater. The intent of the present communication is to show that this can be understood, at least in part, in terms of a size effect that accompanies twinning. Some confirmatory data from a magnesium alloy are presented.

Fine grained AZ31 produced by conventional thermo-mechanical processing

The magnesium alloy AZ31 was processed by severe hot rolling and annealing. This processing was optimised to produce recrystallised grain sizes as small as 2.2 μm. The texture of the processed plate was similar to that of the as-received material, with a strong basal alignment in the normal direction. Tensile testing of the fine grained material showed an increase in the strength and elongation compared to the as-received plate. It is  concluded that the improved mechanical properties of the fine grained material results from a refinement in the grain size and the elimination of shear bands that pre-exist in the as-received material.

Simulation of Mg sheet press cell materials

Major characteristics of Magnesium alloy are low density (= 1.8 g/cm³) and excellent recyclability; therefore Mg is considered as one of low environmental loading materials. The low-density materials, such as Mg, are suitable for the transportation system to reduce the emission of Co2, save energy resource and increase the safety for accidents like corrosions. In the place, cellular materials like aluminum foams are also low-density materials and can be controlled the stress-strain relation. Combination of Mg alloy and cellular materials, that is Mg cell, is one of the most excellent materials for transportation system, because of its ultra low density. safeties, and recycle ability. To make the Mg cellular materials. there are some problems to solve. One is how to make them uniformly to supply them as same perfonnance materials. One is how to make them inexpensively. Most of cellular materials are very expensive because of there are many processes or special fabrication system to make them. To solve these problems. we investigated the press cell materials. The press cell material consists sheets pressed as cell shape and wall. Therefore, it is very easy to make cellular materials and control validation of the performance of each foam materials. In this paper, we simulated compression tests of this new type of Mg alloy cellular materials under dynamic loading to investigate the relation between the compression speed and the compression behavior to show the shock absorbing capability of this new foam material. It is very important to understand their mechanical properties relatcd with cell shapes and wall to be applied widely.

Evolution of hot working stress and microstructure of Mg-3Al-1Zn

The deformation behaviour of magnesium alloy AZ31 was examined. The work found that dynamic recrystallisation operates during hot deformation. The influence that different process variables have on this mechanism were quantified. The optimisation of dynamic recrystallisation allows magnesium alloys to be formed into products more easily whilst developing enhanced final properties.

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.

Effects of replication on measured S-N curves of metals

Replication, or repeated tests at the same stress amplitude, is used to provide statistical confidence in life data during the development of S-N curves. This paper discusses the effects of replication on the measurement of S-N curves and presents an alternative to traditional replication methods for the determination of S-N curves, particularly for the development of preliminary S-N curves. Using specimens made out of the extruded bars of a magnesium alloy, it is demonstrated that the S-N curve estimated using the data from non-replication tests is almost same as that from replication tests. The advantage of using non-replication fatigue tests is that it uses fewer specimens, in this instance, only half of that required for 50% replication fatigue test, to achieve the same estimation as that of the replication fatigue tests. Another advantage of using non-replication fatigue tests is that it can detect the non-linearity using limited specimens.

Modelling of bending-dominated forming processes of metal sheets

Theoretical solutions, finite element models, and experimental techniques are developed for three major sheet metal forming operations: bending (pure bending and cyclic bending), die bending, and deep drawing. These have been applied to two different commercial quality cold-rolled steels, one stainless steel, and one magnesium alloy.

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.

Effects of replication on measured S-N curves of metals

Replication, or repeated tests at the same stress amplitude, is used to provide statistical confidence in life data during the development of S-N curves. This paper discusses the effects of replication on the measurement of S-N curves and presents an alternative to traditional replication methods for the determination of S-N curves, particularly for the development of preliminary S-N curves. Using specimens made out of the extruded bars of a magnesium alloy, it is demonstrated that the S-N curve estimated using the data from non-replication tests is almost same as that from replication tests. The advantage of using non-replication fatigue tests is that it uses fewer specimens, in this instance, only half of that required for 50% replication fatigue test, to achieve the same estimation as that of the replication fatigue tests. Another advantage of using non-replication fatigue tests is that it can detect the non-linearity using limited specimens.