Interrupted creep behaviour of Mg alloys developed for powertrain applications

A conventional magnesium alloy, AZ91D, and two creep resistant magnesium alloys, developed for powertrain applications, MRI 153M and MRI 230D, are prepared by high pressure die casting. These alloys are tested for their creep behaviour in the continuous manner, as is the Current practice, and in the interrupted manner, which represents the real life Situation more closely. It is observed that the interrupted creep tests give rise to a primary creep appearing at the beginning of each cycle resulting in a higher average strain rate than that encountered in the continuous creep tests. Further, the shorter the cycle time, higher is the average strain rate in the interrupted creep tests. A higher average strain rate will give rise to a higher strain over the same period. This is attributed to the recovery taking place during the cooling and heating between two cycles. The effect of additional precipitation during interrupted creep tests depends on the nature of the precipitates. The additional precipitation of beta phase during the cooling and heating between two cycles increases the steady state strain rate in the AZ91D and MRI 153M alloys. whereas the additional precipitation of C36 phase during the cooling and heating between two cycles decreases the steady state strain rate in the MRI 230D alloy. (C) 2009 Elsevier B.V. All rights reserved.

Microstructures and mechanical properties of as-cast Mg–5Al–0.4Mn–xNd (x=0, 1, 2 and 4) alloys

Mg-5Al-0.4Mn-xNd (x=0, 1, 2 and 4wt.%) alloys were prepared by metal mould casting method. The microstructures and mechanical properties were investigated. The results demonstrated that Al11Nd3 phase was formed and mainly aggregated along the grain boundaries with the addition of Nd. Meanwhile, the grain sizes were greatly reduced with the increasing Nd content.

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.

Effects of spark discharge on the anodic coatings on magnesium alloy

Spark discharge was the representative phenomenon of Micro-arc oxidation (MAO) method distinguished from other electrochemical oxidation methods. Under the spark discharge treatment, characteristics of the anodic layer were significantly changed. To investigate the influences of the spark discharge, a piece of magnesium alloy AZ91D specimen was partly treated by MAO method in alkaline silicate solution. And the microstructure, element distributions as well as the surface potential distributions of the specimen were studied by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and scanning Kelvin probe (SKP) technique. As a result of intensive spark discharge treatment, porous external layer with dense internal layer were formed on Mg alloy surface. At the same time, the depositions of OH- and SiO32- ions were accelerated, which resulted in the enrichment of element oxygen and silicon at the spark discharge region. Moreover, due to the compact internal layer, the intensive spark discharge region exhibited more positive potentials with respect to other regions, which meant this region could restrain the ejection of electron and provide effective protection to the substrate. In addition, it was found that oxygen played a vital role in determining the intensity and size of sparks, and abundant oxygen resulted in intensive and larger sparks. (c) 2005 Elsevier B.V. All rights reserved.

Collagen type-I leads to in vivo matrix mineralization and secondary stabilization of Mg-Zr-Ca alloy implants

Biodegradable magnesium-zirconia-calcium (Mg-Zr-Ca) alloy implants were coated with Collagen type-I (Coll-I) and assessed for their rate and efficacy of bone mineralization and implant stabilization. The phases, microstructure and mechanical properties of these alloys were analyzed using X-ray diffraction (XRD), optical microscopy and compression test, respectively, and the corrosion behavior was established by their hydrogen production rate in simulated body fluid (SBF). Coll-I extracted from rat tail, and characterized using fourier transform infrared (FT-IR) spectroscopy, was used for dip-coating the Mg-based alloys. The coated alloys were implanted into the femur bones of male New Zealand white rabbits. In vivo bone formation around the implants was quantified by measuring the bone mineral content/density (BMC/BMD) using dual-energy X-ray absorptiometry (DXA). Osseointegration of the implant and new bone mineralization was visualized by histological and immunohistochemical analysis. Upon surface coating with Coll-I, these alloys demonstrated high surface energy showing enhanced performance as an implant material that is suitable for rapid and efficient new bone tissue induction with optimal mineral content and cellular properties. The results demonstrate that Coll-I coated Mg-Zr-Ca alloys have a tendency to form superior trabecular bone structure with better osteoinduction around the implants and higher implant secondary stabilization, through the phenomenon of contact osteogenesis, compared to the control and uncoated ones in shorter periods of implantation. Hence, Coll-I surface coating of Mg-Zr-Ca alloys is a promising method for expediting new bone formation in vivo and enhancing osseointegration in load bearing implant applications.

Evaluation of coatings for mg alloys for biomedical applications

The aim of this work was to assess a number of coatings developed for Mg for biomedical applications. The Mg substrates were high-purity (HP) Mg and ME10, an alloy recently developed for improved extrudability. The research utilized the new fishing-line specimen configuration to allow direct comparison to our recent in vivo and in vitro measurements. The in vitro measurements were immersion tests of fishing-line specimens immersed in Nor's solution at 37 °C. Tests of substantial duration are needed because the corrosion rates of uncoated samples are low. Nor's solution is the designation given to Hank's solution through which CO2 is bubbled at a partial pressure of 0.009 atm. In this solution, pH is maintained constant by the interaction of CO2 and the bicarbonate ions in the solution. This is the same buffer as that which maintains the pH of blood. Coatings examined were: (i) an anodization using a bio-friendly alkaline electrolyte consisting of phosphate, borate, and metasilicate, (ii) octyltrimethoxysilane (OSi), (iii) 1,2-bis[triethoxysilyl]ethane (BTSE), (iv) anodization+OSi, and (v) anodization + BTSE. The performance of coated samples was comparable to or better than that of the uncoated samples, and there was a substantially better performance for the ME10 samples after anodization+OSi. Reasons for the various performances are discussed.

Corrosion behaviour of a pressure die cast magnesium alloy

High pressure die casting is the most important production method for casting magnesium alloy components, and uniformity of appearance is an important criterion for acceptance of a component by customers. This paper investigates the influence of uniformity in surface appearance of diecast AZ91D plates on their corrosion behaviour. Through immersion, hydrogen collection and weight loss measurements it was found that corrosion is more likely to occur on the areas of the plate that appear to be darker, leading to a non-uniformly corroded surface. Microstructural analysis showed that the non-uniformity in appearance is related to a difference in the morphology and distribution of porosity across the surface of a diecast AZ91D plate. The darker areas of the surface are high in porosity which breaks the continuity of the beta-phase network and provides shortcut paths for corrosion from the surface to the interior of the casting. The brighter shiny areas of the surface are much less porous, with isolated pores being confined by corrosion resistant beta-precipitates thus reducing the corrosion rate.

Influence of the beta phase on the corrosion performance of anodised coatings on magnesium-aluminium alloys

The effect of the beta phase in Mg-Al alloys on the corrosion performance of an anodised coating was studied. It was found that the corrosion resistance of the anodised coating was closely associated with the corrosion performance of the substrate alloy. In particular, Mg alloys with a dual phase microstructure of alpha + beta with intermediate aluminium contents (namely 5%, 10% and 22% Al) after anodisation had the highest corrosion rate and the worst corrosion resistance provide by the anodised coating. The poor performance of an anodised coating was attributed partly to lower corrosion resistance of the substrate alloy and partly to the higher porosity of the anodised coating. (c) 2004 Elsevier Ltd. All rights reserved.

Effect of aging on yield stress and corrosion resistance of die cast magnesium alloy

Corrosion resistance is an important property that could be affected by the ageing process. In order to investigate whether aging affects the corrosion resistance, corrosion rate and yield strength of diecast magnesium alloy AZ91D were measured and analysed after ageing. It was found that the dependence of the corrosion rate on ageing time can be ascribed to the changes in microstructure of the alloy and chemical composition of its matrix. Precipitation of the P phase (Mg17Al12) occurred along the grain boundaries during the initial ageing stages, resulting in a decreasing corrosion rate and an inceasing yield strength. In the later stages, the decreasing aluminium content in the alpha matrix made it more active, causing an increase in the corrosion rate. The decrease in aluminium content in the matrix also leads to a decrease in yield strength.

Simulation of galvanic corrosion of magnesium coupled to a steel fastener in NaCl solution

The galvanic corrosion of magnesium alloy AZ91D coupled to a steel fastener was studied using a boundary element method (BEM) model and experimental measurements. The BEM model used the measured polarization curves as boundary conditions. The experimental program involved measuring the total corrosion rate as a function of distance from the interface of the magnesium in the form of a sheet containing a mild steel circular insert (5 to 30 mm in diameter). The measured total corrosion rate was interpreted as due to galvanic corrosion plus self corrosion. For a typical case, the self corrosion was estimated typically to be similar to 230 mm/y for an area surrounding the interface and to a distance of about I cm from the interface. Scanning Kelvin Probe Force Microscopy (SKPFM) revealed microgalvanic cells with potential differences of approximately 100 mV across the AZ91D surface. These microgalvanic cells may influence the relative contributions of galvanic and self corrosion to the total corrosion of AZ91D.

Corrosion of magnesium alloys in commercial engine coolants

A number of magnesium alloys show promise as engine block materials. However, a critical issue for the automotive industry is corrosion of the engine block by the coolant and this could limit the use of magnesium engine blocks. This work assesses the corrosion performance of conventional magnesium alloy AZ91D and a recently developed engine block magnesium alloy AM-SC1 in several commercial coolants. Immersion testing, hydrogen evolution measurement, galvanic current monitoring and the standard ASTM D1384 test were employed to reveal the corrosion performance of the magnesium alloys subjected to the coolants. The results show that the tested commercial coolants are corrosive to the magnesium alloys in terms of general and galvanic corrosion. The two magnesium alloys exhibited slightly different corrosion resistance to the coolants with AZ91D being more corrosion resistant than AM-SC1. The corrosivity varied from coolant to coolant. Generally speaking. an oraganic-acid based long life coolant was less corrosive to the magnesium alloys than a traditional coolant. Among the studied commercial coolants. Toyota long, life coolant appeared to be the most promising one. In addition. it was found that potassium fluoride effectively inhibited corrosion of the magnesium alloys in the studied commercial coolants. Both general and galvanic corrosion rates were significantly decreased by addition of KF, and there were no evident side effects on the other engine block materials, such as copper, solder. brass. steel and aluminium alloys, in terms of their corrosion performance. The ASTM D 1384 test further confirmed these results and suggested that Toyota long life coolant with 1%wt KF addition is a promising coolant for magnesium engine blocks.

Corrosion behaviour of pure magnesium in a simulated body fluid

The corrosion behaviour of pure magnesium in Hank's simulated body fluid (SBF) was investigated. It was found that the polarization of Mg in the SBF solution was similar to that in a NaCl aqueous solution. However, AC impedance analysis suggested that the detailed dissolution steps involved in the corrosion of Mg in the SBF could be different in terms of their rates or contributions to corrosion damage of Mg. Moreover, the corrosion rate of Mg in the SBF solution was found to be increasing with time and significant hydrogen evolution and alkalization of the SBF solution resulting from corrosion of Mg were measured in the study. The results suggested that after some proper measures are taken to retard corrosion reaction, Mg can be successfully employed as a degradable and absorbable implant material.

The corrosion performance of anodised magnesium alloys

The corrosion performance of anodised magnesium and its alloys, such as commercial purity magnesium (CP-Mg) and high-purity magnesium (HP-Mg) ingots, magnesium alloy ingots of MEZ, ZE41, AM60 and AZ91D and diecast AM60 (AM60-DC) and AZ91D (AZ91D-DC) plates, was evaluated by salt spray and salt immersion testing. The corrosion resistance was in the sequential order: AZ91D approximate to AM60 approximate to MEZ >= AZ91D-DC >= AM60-DC > HP-Mg > ZE41 > CP-Mg. It was concluded the corrosion resistance of an anodised magnesium alloy was determined by the corrosion performance of the substrate alloy due to the porous coating formed on the substrate alloy acting as a simple corrosion barrier. (c) 2006 Elsevier Ltd. All rights reserved.