A Review on Casting Magnesium Alloys: Modification of Commercial Alloys and Development of New Alloys

doi:10.1016/j.jmst.2016.07.001

Abstract

Abstract:

The research and development status of casting magnesium alloys including the commercial casting alloys and the new types casting alloys are reviewed, with more attention to microstructure and mechanical properties of modified-AZ91, AM60 and WE43 alloys with various additions, and new types of low cost casting alloys and high strength casting alloys. The modification and/or refinement of Mg₂Si phase in Mg-Al-Si based casting alloys by various additions are discussed and new purifying technologies for casting magnesium alloys are introduced to improve the performance. The modified AZ81 alloy with reduced impurities is found to have the tensile strength of 280 ± 6 MPa and elongation of 16% ± 0.7%. The fatigue strength of AZ91D alloy could be obviously improved by addition of Ce and Nd. The Mg-16Gd-2Ag-0.3Zr alloy exhibits very high tensile and yield strengths (UTS: 423 MPa and YS: 328 MPa); however, its elongation still needs to be improved.

Key words: Casting magnesium alloys, Microstructure, Mechanical properties, Corrosion, Purification, Alloying elements

Pan Fusheng,Yang Mingbo,Chen Xianhua. A Review on Casting Magnesium Alloys: Modification of Commercial Alloys and Development of New Alloys[J]. J. Mater. Sci. Technol., 2016, 32(12): 1211-1221.

Figures/Tables 22

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Compositions (wt%)	Casting processes	Tensile properties -------------			Fatigue properties (MPa)	References
Compositions (wt%)	Casting processes	UTS (MPa)	YS (MPa)	δ (%)	Fatigue properties (MPa)	References
AZ91 + 1.0Ce	HPDC	248	158	6.8	116 (10⁷ cycles)	Yang et al.^[6]
AZ91 + 2.0Ce	HPDC	227	144	6.1	106 (10⁷ cycles)	Yang et al.^[6]
AZ91 + 1.0Nd	HPDC	258	164	5.6	85 (10⁷ cycles)	Yang and Li^[8]
AZ91 + 1.5Nd	HPDC	241	154	5.0	79 (10⁷ cycles)	Yang and Li^[8]
AZ91 + 0.5Y	HPDC	270	162	10.0	-	Zhang et al. ^[9]
AZ91 + 0.8Y	HPDC	272	161	11.0	-	Zhang et al. ^[9]
AZ91 + 0.032B	PM	226	110	4.8	-	Suresh et al.^[10]
AZ91 + 0.04B	PM	229	113	4.9	-	Suresh et al.^[10]
AZ91 + 1.0Bi	PM	250	166	4.6	-	Yuan et al.^[11]
AZ91 + 0.4Sb	PM	264	177	4.5	-
AZ91 + 1.0Bi+0.4Sb	PM	269	178	3.3	-
AZ91 + 0.8Pr	HPDC	228	137	6.8	-	Cui et al.^[13]
AZ91 + 1.2Pr	HPDC	222	128	6.2	-	Cui et al.^[13]
AZ91 + 1.0Ca+0.5Sr	HPDC	250	-	3.5	-	Hirai et al.^[14]
AZ91 + 0.5Ti	PM	170	140	4.0	-	Candan et al.^[15]
AZ91 + 1.0Y+1.0Ca	HPDC	232	168	3.7	-	Wang et al.^[16]
AZ91 + 1.0Y+1.5Ca	HPDC	241	183	3.2	-	Wang et al.^[16]
AZ91 + 0.2Si+0.2Sb	HPDC	231	135	5.8	-	Srinivasan et al.^[25]
AZ91 + 0.5Si+0.2Sb	HPDC	224	126	3.7	-	Srinivasan et al.^[25]

Compositions (wt%)	Casting processes	Tensile properties -------------			Fatigue properties (MPa)	References
Compositions (wt%)	Casting processes	UTS (MPa)	YS (MPa)	δ (%)	Fatigue properties (MPa)	References
AZ91 + 1.0Ce	HPDC	248	158	6.8	116 (10⁷ cycles)	Yang et al.^[6]
AZ91 + 2.0Ce	HPDC	227	144	6.1	106 (10⁷ cycles)	Yang et al.^[6]
AZ91 + 1.0Nd	HPDC	258	164	5.6	85 (10⁷ cycles)	Yang and Li^[8]
AZ91 + 1.5Nd	HPDC	241	154	5.0	79 (10⁷ cycles)	Yang and Li^[8]
AZ91 + 0.5Y	HPDC	270	162	10.0	-	Zhang et al. ^[9]
AZ91 + 0.8Y	HPDC	272	161	11.0	-	Zhang et al. ^[9]
AZ91 + 0.032B	PM	226	110	4.8	-	Suresh et al.^[10]
AZ91 + 0.04B	PM	229	113	4.9	-	Suresh et al.^[10]
AZ91 + 1.0Bi	PM	250	166	4.6	-	Yuan et al.^[11]
AZ91 + 0.4Sb	PM	264	177	4.5	-
AZ91 + 1.0Bi+0.4Sb	PM	269	178	3.3	-
AZ91 + 0.8Pr	HPDC	228	137	6.8	-	Cui et al.^[13]
AZ91 + 1.2Pr	HPDC	222	128	6.2	-	Cui et al.^[13]
AZ91 + 1.0Ca+0.5Sr	HPDC	250	-	3.5	-	Hirai et al.^[14]
AZ91 + 0.5Ti	PM	170	140	4.0	-	Candan et al.^[15]
AZ91 + 1.0Y+1.0Ca	HPDC	232	168	3.7	-	Wang et al.^[16]
AZ91 + 1.0Y+1.5Ca	HPDC	241	183	3.2	-	Wang et al.^[16]
AZ91 + 0.2Si+0.2Sb	HPDC	231	135	5.8	-	Srinivasan et al.^[25]
AZ91 + 0.5Si+0.2Sb	HPDC	224	126	3.7	-	Srinivasan et al.^[25]

Compositions (wt%)	Casting processes	UTS (MPa)	YS (MPa)	δ (%)	References
AM60 + 0.2Ti	PM	284	-	11.2	He et al.^[39]
AM60 + 0.4Ti	PM	276	-	9.8	He et al.^[39]
AM60 + 0.5Sn	Squeeze casting	182	-	10.0	Sevik et al.^[40]
AM60 + 4.0Sn	Squeeze casting	212	-	8.1	Sevik et al.^[40]
AM60 + 1Sn+0.3Ti	Squeeze casting	190	115	9.3	Acikgoz et al.^[41]
AM60 + 1Sn+0.3Ti+0.5Ag	Squeeze casting	250	123	9.0
AM60 + 1Sn+0.3Ti+1.0Ag	Squeeze casting	265	128	8.8
AM60 + 1.8Si+0.32Ca	PM	182	-	8.5	Wang et al.^[43]
AM60 + 0.9Y	PM	192	62	12.6	Su et al.^[44]
AM60 + 0.9Nd	PM	230	127	14.0	Mao et al.^[46]
AM60 + 0.15B	PM	160	-	5.7	Wang et al.^[47]
AM60 + 1.6RE	PM	170	-	6.2
AM60 + 0.15B+1.6RE	PM	185	-	6.0

Compositions (wt%)	Casting processes	UTS (MPa)	YS (MPa)	δ (%)	References
AM60 + 0.2Ti	PM	284	-	11.2	He et al.^[39]
AM60 + 0.4Ti	PM	276	-	9.8	He et al.^[39]
AM60 + 0.5Sn	Squeeze casting	182	-	10.0	Sevik et al.^[40]
AM60 + 4.0Sn	Squeeze casting	212	-	8.1	Sevik et al.^[40]
AM60 + 1Sn+0.3Ti	Squeeze casting	190	115	9.3	Acikgoz et al.^[41]
AM60 + 1Sn+0.3Ti+0.5Ag	Squeeze casting	250	123	9.0
AM60 + 1Sn+0.3Ti+1.0Ag	Squeeze casting	265	128	8.8
AM60 + 1.8Si+0.32Ca	PM	182	-	8.5	Wang et al.^[43]
AM60 + 0.9Y	PM	192	62	12.6	Su et al.^[44]
AM60 + 0.9Nd	PM	230	127	14.0	Mao et al.^[46]
AM60 + 0.15B	PM	160	-	5.7	Wang et al.^[47]
AM60 + 1.6RE	PM	170	-	6.2
AM60 + 0.15B+1.6RE	PM	185	-	6.0

Compositions (wt%)	Test conditions	UTS (MPa)	YS (MPa)	δ (%)	References
Mg-4.0Y-2.4Nd-0.2Zn-0.4Zr	PM-T6	345	196	7.3	Fu et al.^[53]
Mg-4.0Y-2.0Nd-1Gd-0.4Zr	PM-T6	330	265	6.5	Su et al.^[54]
Mg-4.2Y-2.5Nd-1Gd-0.6Zr	PM-T6	284	222	2.4	Kang et al.^[55]
Mg-4.2Y-2.5Nd-1Gd-0.2Zn-0.6Zr	PM-T6	298	240	4.6	Kang et al.^[55]
Mg-4.0Y-2.8Nd-0.2Zn-0.4Zr	PM-as-cast	205 ± 8	162 ± 7	5.0 ± 0.4	Pan's group in CCMg
Mg-4.0Y-2.8Nd-0.2Zn-0.4Zr	PM-T6	304 ± 8	225 ± 5	6.4 ± 0.3	Pan's group in CCMg