Materials Science Forum Vols. 638-642

Abstract: A cellular automaton (CA) model has been developed for simulating the microstructure evolution and dendrite morphology of cast magnesium alloys. The growth kinetics of dendrite tips is determined by the difference between local equilibrium composition and local actual composition obtained by solving the solute transport equation. Two sets of meshes, a hexagonal mesh and an orthogonal mesh, are used in the model to perform the simulation. The hexagonal mesh is used to perform CA calculation to reflect the texture of Mg alloy dendrites, and the orthogonal mesh is used to solve the solute transport equations. The model was applied to simulate single dendrite evolution and columnar dendrites growth of AZ91D Mg alloy, as well as multi-grain growth of Mg-10Gd-2Y-0.5Zr (wt%) Mg alloy. Permanent mold step-shaped castings of the two Mg alloys were poured and metallographic examinations were carried out for validating the present model. The simulation results agree well with metallographic results. The model can be applied to simulate the microstructure evolution and dendrite morphology of magnesium alloys.

Abstract: Machined AZ31 alloy chips were consolidated by hot-pressing and then hot-extrusion at 300 °C, and their workability was evaluated. The consolidated sample has a fully dense microstructure with fine equiaxed grains. The　compression and backward extrusion tests reveal that the consolidated AZ31 chips have a good workability at above 200°C.　It is said that the recycled AZ31 alloy by hot-extrusion of the chips is suitable for forging materials and the process is useful for the recycling of Mg chips.

Abstract: Inhomogeneous deformation in a magnesium alloy with long-period stacking order (LPSO) phase has been investigated using high-precision markers drawn by electron beam lithography. Mg alloys containing Zn and rare earth elements such as Y have a characteristic microstructure including the LPSO phase and the usual hcp matrix phase. The mechanical performance of this alloy is remarkably enhanced by warm-extrusion. The microstructure developed by such extrusion consists of elongated grains with fine-lamellae of LPSO phase and fine-grained matrix of hcp phase. In order to clarify the details of inhomogeneous deformation which should relate with the superior mechanical properties in this alloy, high-precision marking method using electron beam lithography has been employed. By using the method, local displacement due to tensile deformation in the Mg alloy was directly measured.

Abstract: Specimens of rectangular and circular cross section of a Mg-9Al binary alloy have been tensile tested and the cross section of undeformed specimens examined using scanning electron microscopy. The rectangular cross sections showed three scales in the cellular intermetallics network: coarse at the core, fine at the surface and very fine at the corners, whereas the circular ones showed only two, coarse at the core and fine at the surface. The specimens of rectangular cross section exhibited higher yield strength in comparison to the circular ones. Possible reasons for the observed increased strength of the rectangular sections are discussed.

Abstract: The deformation behaviour of magnesium single crystals under plane strain conditions has been examined using molecular dynamics modelling. The simulations were based on an existing atomic potential for magnesium taken from the literature. A strain of 10% was applied at rates of 3x109s-1 and 3x107s-1. The simulations predicted the formation of mechanical twins that accommodated extension in the c-axis direction of the hexagonal unit cell. However, the predicted twin is not of the same kind found in magnesium, but is that commonly observed in titanium. It is believed that further analysis of the physical properties predicted by this interatomic potential will shed more light on the atomic processes controlling twinning in Magnesium alloys. It also highlights the need for improvements to the interatomic potential such that more accurate deformation behaviour can be attained.

Abstract: Application of magnesium alloys potentially plays a key role in weight reduction of automotive and aerospace components. Majority of magnesium components are manufactured via the high-pressure die-casting (HPDC) or permanent-mold casting (PMC) processes. In general, castability of magnesium alloys is comparable to aluminum alloys. However, unique defects related to the high susceptibility of magnesium to rapidly solidify, dissolve hydrogen or form oxides potentially contribute to material failure. In this research, AE42 magnesium alloy castings were manufactured via the PMC process. Formation of fold defects in regions of high melt turbulence was observed on the macro-scale as visible surface flow-lines. Microstructural analysis revealed that folds in the AE42 alloy we related to the rapid solidification and short alloy freezing range. Further, segregation of Al2RE intermetallics at the metal front hindered proper fusion of merging metal fronts.

Abstract: The creep behavior of two series of magnesium alloys, Mg-4Al based alloys with strontium addition and binary Mg-Nd alloys, has been studied. Results show that the high creep properties achieved by the Mg-Nd alloys are attributed to the precipitation of tiny dispersed β’ particles, which form and effectively restrict the dislocation slipping and climb during creep deformation. In terms of values of the stress exponent and apparent activation energy gained from systematic creep tests, the mechanism responsible for creep deformation of the Mg-Nd alloys is inferred as dislocation climb, which is supported by TEM observations performed on the Mg-2Nd alloy after creep test. For the Mg-4Al based alloys, however, microstructural observations reveal that the significant improvement on creep properties caused by Sr addition is accounted for the formation of an interphase network consisting of Al4Sr and a Mg-Al-Sr ternary compound distributing at grain boundaries. The breakage of the interphase network after extrusion results in a sharp drop of creep properties, indicating the creep deformation of the alloy is controlled mainly by grain boundary sliding, which is in contradiction to the mechanism for creep of the alloys inferred by the classical criterions based on the values of stress exponent and apparent activation energy.

Abstract: Compressive creep behavior of hot-rolled (40%) Mg-Y and Mg-Y-Zn alloys are investigated at 480 ~ 650 K. Creep strength is substantially improved by the simultaneous addition of yttrium and zinc. The minimum creep rate of Mg-0.9mol%Y-0.04mol%Zn (WZ301) alloy decreases to 1/10 lower than that of Mg-1.1mol%Y (W4) alloy at 650 K. Activation energy for creep in W4 and WZ301 alloys are more than 200 kJ/mol at the temperature range of 480 ~ 550 K. These values are higher than the activation energy for self-diffusion coefficient in magnesium (135 kJ/mol). Many stacking faults (planar defects, PDs) are only observed on the basal planes of the matrix in Mg-Y-Zn ternary alloys. Stacking fault energy is considered to decrease by the multiple-addition of yttrium and zinc. The size and density of these planar defects depend on solute content, aging condition. TEM observation has been revealed that the decreasing of the stacking fault energy affects the distribution of dislocations during creep. Many a-dislocations on basal planes are extended significantly. Dislocation motion is restricted significantly by both of these two types of stacking faults (planar type and extended dislocations).

Abstract: This paper describes the twin roll casting technology of magnesium alloys that contains relatively high weight ratio of aluminum, such as AM60, AZ91 and AZ121. The cast magnesium alloy sheets were hot-rolled in an elevated temperature to investigate the appropriate hot-rolling conditions for producing high-quality strip using a purpose-built strip-casting mill. The influences of such process parameters as materials of roll, casting temperature, and roll speed are ascertained. A simple method of predicting the convection heat transfer coefficient between casting rolls and molten metal is introduced. The microstructure of the manufactured wrought alloy sheets was observed to investigate the effects of the hot-rolling and heat-treatment conditions on crystal growth in the cast products. It is found that manufacturing thin magnesium alloy sheet was possible at a roll speed of 110m/min by a vertical type roll caster. The grain size of the manufactured wrought magnesium alloys sheet was less than 30 micrometers due to rapid solidification in the proposed process.

Abstract: A new ECAP process method called rotary-die ECAP (RD-ECAP) was developed to form fine-grained bulk materials such as aluminium alloys, magnesium alloys, aluminium composites, and titanium, all of which can be processed under conditions of 573-773K, at an approximately 0.9-2.4 mm/s punch speed of 300MPa or lower. By the RD-ECAP method, ECAP processing of up to 2 passes can be done without sample removal and samples processed over 30 cycles were obtained.