Grain refinement of Mg-Al(-Mn) alloys by SiC additions

The addition of SiC particles effectively grain refined a range of Mg-Al alloys. The greatest reductions in grain size were found for the alloys with lower Al contents. The presence of Mg2Si in the microstructure after that SiC addition, and consideration of phase equilibria suggested that the SiC transforms to Al4C3, and this is the actual nucleant. The addition of Mn poisoned the grain refining effect of the SiC addition, probably due to the formation of less potent Al-Mn-carbides. (c) 2006 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Iron-related porosity in Al-Si-(Cu) foundry alloys

An experimental program has been undertaken to explore the effect of iron concentration on porosity levels in Al-Si alloy sand castings. The effect of iron concentrations above, below and equal to the critical iron content for alloys with either 5 or 9% Si and either 0, 1 or 3% Cu has been determined. Increasing iron concentrations were found to increase porosity in all alloys except the copper-containing Al-5% Si alloys which displayed a porosity minimum at the critical iron content. Porosity was observed to be higher in the Al-9% Si castings than the Al-5% Si castings. Differences in the primary phase volume fraction and morphology may explain this observation. The results of this experimental work do not support the existing published theories that have been proposed to explain the effect the iron on porosity. An alternative theory is therefore developed. (c) 2006 Elsevier B.V. All rights reserved.

The effect of aluminium content on the mechanical properties and microstructure of die cast binary magnesium-aluminium alloys

This paper investigates the relationship between mechanical properties and microstructure in high pressure die cast binary Mg-Al alloys. As-cast test bars produced using high pressure die casting have been tested in tension in order to determine the properties for castings produced using this technique. It has been shown that increasing aluminium levels results in increases in yield strength and a decrease in ductility for these alloys. Higher aluminium levels also result in a decrease in creep rate at 150 degrees C. It has also been shown that an increase in aluminium levels results in an increase in the volume fraction of eutectic Mg17Al12 in the microstructure.

Anodizing treatments for magnesium alloys and their effecton corrosion resistance in various environments

This paper reviews various aspects of anodizing of magnesium alloys, such as the basics, processes, properties and applications. It systematically summarises the existing fundamental studies and technical developments of anodizing of magnesium alloys, and concludes that new anodizing processes based on electrolytic plasma anodizing that convert the surface of a magnesium alloy into a hard ceramic coating in an electrolytic bath using high energy electric discharges can offer improved wear and corrosion resistance. These new anodized coatings are often claimed to perform better than the traditional ones obtained through older anodizing processes, such as DOW17 or HAE. The new anodizing techniques are chromate free and hence environment friendly. It is expected that more cost-effective, environment-friendly and non-toxic anodizing techniques will be developed and applied to magnesium alloy components in the future.

Effect of manganese on grain refinement of Mg-Al based alloys

Manganese is a grain refiner for high purity Mg-3%Al, Mg-6%Al, Mg-9%Al, and commercial AZ31 (Mg-3%Al-1%Zn) alloys when introduced in the form of an Al-60%Mn master alloy splatter but the use of pure Mn flakes and ALTAB (TM) Mn75 tablets shows no grain refinement. Long time holding of the melt at 730 degrees C leads to an increase in grain size. The mechanism is attributed to the presence of all epsilon-AlMn phase (hexagonal close-packed) in the master alloy splatter. (c) 2006 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Eutectic grain size and strontium concentration in hypoeutectic aluminium-silicon alloys

Recently it has been shown that modification with strontium causes an increase in the size of eutectic grains. The eutectic grain size increases because there are fewer nucleation events, possibly due to the poisoning of phosphorus-based nuclei that are active in the unmodified alloy. The current paper investigates the effect of strontium concentration on the eutectic grain size. In the aluminium-10 wt.% silicon alloy used in this research, for fixed casting conditions, the eutectic grain size increases as the strontium concentration increases up to approximately 150ppm, beyond which the grain size is relatively stable. This critical strontium concentration is likely to differ depending on the composition of the base alloy, including the concentration of minor elements and impurities. It is concluded that processing and in-service properties of strontium modified aluminium-silicon castings are likely to be more stable if a minimum critical strontium concentration is exceeded. If operating below this critical strontium concentration exceptional control over composition and casting conditions is required. (c) 2005 Elsevier B.V. All rights reserved.

The effect of grain refinement and cooling rate on the hot tearing of wrought aluminium alloys

Using modifications to the Rappaz-Drezet-Gremaud hot tearing model, and using empirical equations developed for grain size and dendrite arm spacing (DAS) on the addition of grain refiner for a range of cooling rates, the effect of grain refinement and cooling rate on hot tearing susceptibility has been analysed. It was found that grain refinement decreased the grain size and made the grain morphology more globular. Therefore refining the grain size of an equiaxed dendritic grain decreased the hot tearing susceptibility. However, when the alloy was grain refined such that globular grain morphologies where obtained, further grain refinement increased the hot tearing susceptibility. Increasing the cooling decreased the grain size and made the grain morphology more dendritic and therefore increased the likelihood of hot tearing. The effect was particularly strong for equiaxed dendritic grain morphologies; hence grain refinement is increasingly important at high cooling rates to obtain more globular grain morphologies to reduce the hot tearing susceptibility.

Synthesis and structure characterization of chromium oxide prepared by solid thermal decomposition reaction

Mesoporous chromium oxide (Cr2O3) nanocrystals were first synthesized by the thermal decomposition reaction of Cr(NO3)(3)(circle)9H(2)O using citric acid monohydrate (CA) as the mesoporous template agent. The texture and chemistry of chromium oxide nanocrystals were characterized by N-2 adsorption-desorption isotherms, FTIR, X-ray diffraction (XRD), UV-vis, and thermoanalytical methods. It was shown that the hydrate water and CA are the crucial factors in influencing the formation of mesoporous Cr2O3 nanocrystals in the mixture system. The decomposition of CA results in the formation of a mesoporous structure with wormlike pores. The hydrate water of the mixture provides surface hydroxyls that act as binders, making the nanocrystals aggregate. The pore structures and phases of chromium oxide are affected by the ratio of precursor-to-CA, thermal temperature, and time.

Interactions between iron, manganese, and the Al-Si eutectic in hypoeutectic Al-Si alloys

Sand-cast plates were used to determine the effect of iron and manganese concentrations on porosity levels in Al-9 pet Si-0.5 pet Mg alloys. Iron increased porosity levels. Manganese additions increased porosity levels in alloys with 0.1 pet Fe, but reduced porosity in alloys with 0.6 and I pet Fe. Thermal analysis and quenching were undertaken to determine the effect of iron and manganese on the solidification of the Al-Si eutectic. At high iron levels, the presence of large beta-Al5FeSi was found to reduce the number of eutectic nucleation events and increase the eutectic grain size. The preferential formation of alpha-Al15Mn3Si2 upon addition of manganese reversed these effects. It is proposed that this interaction is due to beta-Al5FeSi and the Al-Si eutectic having common nuclei. Porosity levels are proposed to be controlled by the eutectic grain size and the size of the iron-bearing intermetallic particles rather than the specific intermetallic phase that forms.

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.

Effects of combined additions of Sr and AlTiB grain refiners in hypoeutectic Al-Si foundry alloys

Strontium is the most widely used and a very effective element for modifying the morphology of eutectic silicon, while Ti and B are commonly present in the commercial grain refiners used for Al-Si alloys. Systematic studies on the effects of combined additions of Sr and different AlTiB grain refiners on the Al + Si eutectic and primary aluminium solidification have been performed. While slight coarsening of both eutectic Si and primary aluminium grains occurs during holding, no obvious interactions are observed between Sr and AlTiB grain refiners when the addition level of grain refiners is low. As a result, a well-modified and grain refined structure was obtained. However, strong negative interactions between Sr and Al1.5Ti1.5B3 were observed as the addition level of the grain refiner increases. It was found that these interactions have a much more profound impact on the eutectic solidification than the primary Al solidification. The melt treated with combined additions of Sr and Al1.5Ti1.5B still shows good grain refinement efficiency even after losing its modification completely. The mechanism responsible for such negative interactions is further discussed. (c) 2006 Elsevier B.V. All rights reserved.