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Q. B.

Nguyen
Y. H. D. Chua
K. S. Tun
Department of Mechanical Engineering,
Effect of Addition of 23
National University of Singapore,
9 Engineering Drive 1,
and Copper Particulates and
Singapore 117576
Heat Treatment on the Tensile
J. Chan Response of AZ61 Magnesium
R. Kwok
Singapore Tecfinologies Kinetics Ltd
Alloy
(ST Kinetics),
In this paper, AZ61 magnesium alloy composites containing nanoalumina and micron-
249 Jaian Boon Lay, sized copper particulates are synthesized using the technique of disintegrated melt depo-
Singapore 619523 sition followed by hot extrusion. The simultaneous addition of nano-Al2Os and copper
particulates led to an overall improvement in both microstructural characteristics in
terms of distribution and morphology of secondary phases and mechanical response of
W. L. E. Wong AZ61. The presence of nanoalumina particulates broke down and dispersed the second-
Sctiooi of f\/leotianical and Systems Engineering, ary phase MgjyA2. The 0.2% yield strength increased from 216MPa to 274 MPa. The
Newcastle university International Singapore, ductility increased from 8.4% to 9.3% in the case of the AZ6I-I.5AI2O3 sample. The
180 Ang Mo Kio Avenue 8, results of aging heat treatment in the case of the AZ61-1.5AI2O3-ICU sample showed sig-
Block P Room 220, nificant improvement in both tensile strength, ductility, and work offracture (54% incre-
Singapore 569830 ment). An attempt is made to correlate the tensile response of composites with their
microstructural characteristics. [DOI: 10.1115/1.4023769]
M. Gupta^
Department of Mechanicai Engineering, Keywords: magnesium, nanocomposite, mechanical behavior, microstructure, solidification
National university of Singapore,
9 Engineering Drivel,
Singapore 117576
e-maii: mpegm@nus.edu.sg

1 Introduction of alloys. The solution to further improve overall properties of


AZ61 is to alloy it with another alloying element and/or nanocer-
In view of the greenhouse effect and the moving trend towards
amic particles to form more stable secondary phases and subse-
a green environment, tremendous efforts have been put in place to
quently do heat treatment to improve tensile strength, ductility,
seek for energy-saving solutions. Lightweight structural materials,
and dimensional stability [3,10-13]. Previous studies have proven
such as magnesium-based materials, have been the focus among
that the addition of Cu particulates into magnesium matrix signifi-
researchers and scientists [1-5]. Magnesium with a density of
cantly increases the hardness and strength properties [1416].
1.74 g/cm^ is probably the best candidate of lightweight engineer-
Addition of alumina nanoparticulates led to a significant increase
ing metals available [6]. The combination of lightweight, good
in ductility of magnesium-based materials [17]. Aging treatment
mechanical properties, good castability, and machinability makes
ranging from 150 C to 225 C for different aging times imparts
magnesium-based materials promising engineering materials in
the best effects on mechanical properties [1,2]. The literature
various applications in automotive, aerospace, electronics, sports,
search, however, shows that no attempt has been done to incorpo-
and consumer products industries [4-7]. However, magnesium-
rate nanoalumina and micron-sized copper particulates into
based materials still need to overcome its current limiting factors,
magnesium alloy AZ61 and to investigate their effects on micro-
such as low ductility, rapid strength loss when used at high service
structural and mechanical characteristics.
temperatures, poor creep, and corrosion resistance [4,6-9]. Thus,
magnesium is seldom used in its pure form but instead often Accordingly, an attempt is made in the present study to add
alloyed with aluminum, zinc, zirconium, silver, calcium, or rare nanoalumina particulates to improve ductility and copper to
earth elements [2,4,10]. Aluminum alloying element improves the enhance microstmctural characteristics, hardness, and strength of
castability and mechanical properties at room temperature. Zinc AZ61 alloy. The choices of these additions, further, are also
enhances mechanical properties and corrosion resistance [10]. As expected to enhance high temperature properties, as established
a result, magnesium-aluminum-zinc (AZ)-based alloys have been before [4]. Aging heat treatment is also carried out on the specific
receiving much attention from researchers around the world samples to improve their microstructure and tensile response. Dis-
[5-8]. AZ61 is one of the promising alloys among the AZ series integrated melt deposition (DMD) technique is used in the present
study to synthesize monolithic and composite materials, and all the
characterization studies were performed on the extruded samples.
'Corresponding author.
Contributed by the Materials Division of ASME for publication in the JOURNAL OF 2 Materials Preparation and Experimental Procedures
ENGINEERJNG MATERIALS AND TECHNOLOGY. Manuscript received January 3, 2012; final
manuscript received June 25, 2012; published online May 6, 2013. Assoc. Editor: In the present study, AZ61 billets (from Magnesium Tokyo,
Yoshlhiro Tomita. Japan) of 60 mm depth and 160 mm diameter were machined from

Journal of Engineering Materials and Technology JULY 2013, Vol. 135 / 031004-1
Copyright 2013 by ASME
Fig. 1 Precasting materiais preparation

a 160-mm-diameterbiUet. Fifty-nanometer alumina particulates and present in the samples. The samples were polished and exposed to
50-/xm-sized copper powder were supplied by Baikowski (Japan) Cu Ka radiation (A = 1.54056 A deg) using a scanning speed of
and Alfa Aesar's company with purity of 99.9%, respectively. 2 deg/min.
Arrays of holes with 10 mm diameter and 50 mm depth were com-
puter numerical control dried in AZ61 blocks to contain nano- 2.3 Microstructure Characterization. Microstructural char-
AI2O3 and Cu powders (see Fig. 1). Firstly, 1.5% volume percentage acterization studies were conducted on metallographically
of 50-nm AI2O3 particulates was added into AZ61. Subsequently, polished extruded samples to investigate morphological character-
three different volume percentages of Cu (1, 2, and 3 vol.%) were istics of grains, reinforcement distribution, and interfacial integ-
added into AZ6I-I.5AI2O3 composite (Table 1). The 40-mm-diame- rity between the matrix and reinforcement. The etchant solution
ter cast ingots were produced using the DMD technique, which is was made using lO-cm' acetic acid, 5-cm^ picric acid, and
fully described elsewhere [16]. The ingots were machined down to 95-cm^ ethyl alcohol to reveal the grain boundaries for micro-
36 mm diameter and hot extmded at 350 C to 8-mm-diameter rods. structural analysis. Field emission scanning electron microscopy
Aging heat treatment was carried out at 150 C for 5 h on the (FESEM)-S4300 equipped with energy dispersive spectroscopy
selected AZ6I-I.5AI2O3-ICU composite [18]. All characterizations, was used. Image analysis using the Scion system was carried out
including density measurement. X-ray, microstructure, coefficient of on the multiple images (0.18 mm x 0.24 mm) to determine the
thermal expansion, microhardness, tensile testing, and fracture morphology of second phases.
study, were carried out on extruded rods in the present study [17].
2.4 Coefficient of Thermal Expansion. The coefficients of
2.1 Density Measurement. Density (p) measurements were thermal expansion (CTE) of monolithic and composite samples
performed in accordance with Archimedes' principle on three ran- were determined by measuring the displacement of the samples as
domly selected polished samples of monolithic AZ61 and AZ61-Cu- a function of temperature in the temperature range 50-400 C
AI2O3 materials taken from the extruded rods. Distilled water was using an automated SETARAM 92-16/18 thermomechanical ana-
used as the immersion fluid. The samples were weighed using an lyzer. The samples with 8 mm diameter and 10 mm height were
A&D ER-182 A electronic balance with an accuracy of 0.0001 g. heated at 5 K/min , and the argon gas flow rate was maintained at
Theoretical densities of materials were calculated, assuming they are 1.21/min^'.
fully dense, to measure the volume percentage of porosity in the end
materials. Rule of mixture was used in both calculations.
2.5 Microhardness. Microhardness measurements were
made on the polished samples. Vickers microhardness was meas-
2.2 X-Ray Diffraction Studies. An automatic Shimadzu ured using a Shimadzu-HMV automatic digital microhardness tes-
LAB-X XRD-6000 diffractometer was used to identify phases ter using 25-gf-indenting load and a dwell time of 15 s.

Tabie 1 Resuits of DiVID deposition yield and CTE measurements

Composition AZ61 (wt%) AI2O3 (Wt %) Cu (wt %) Deposition yield (%) CTE (/jm/mK)

AZ61 100.0 0.0 0.0 96.92 25.1


AZ61-1.5A1,O, 96.8 3.2 0.0 94.36 24.8
AZ61-1.5Al,O3-lCu 92.2 3.1 4.7 91.35 24.5
AZ61-1.5Al2Ov2Cu 88.0 3.0 9.0 96.55 24.3
AZ61-1.5Al,Ov3Cu 84.0 2.9 13.1 91.39 24.1
AZ6I-I.5A2O3-ICU-HT 24.6

031004-2 / Vol. 135, JULY 2013 Transactions of the ASME


Table 2 Results of XRD analysis: number of matched peaks size was gradually decreased with an increase in the amount of
copper. Heat treatment further rened grains of the AZ61-
Composition^hase Mg ]M[gl7Ali2 Mg2Cu AlCuMg Cu I.5AI2O3-ICU sample (Table 3).
Microstructural studies conducted on the extruded samples
AZ61 11 4
revealed reasonably uniform distribution of the secondary phases
AZ6I-I.5AI2O3 10 3
AZ6I-I.5AI2O3-ICU 10 3 3 2
in the AZ61 matrix (Fig. 2). This can be attributed to: (i) minimal
AZ6I-I.5AI2O3-2CU 10 3 3 2 1 agglomeration of reinforcements during melting of matrix [14];
AZ6I-I.5AI2O3-3CU 10 3 3 2 1 (ii) minimal gravity-associated segregation due to judicious selec-
AZ61-1.5Al2OvlCu-HT 10 3 3 2 tion of stirring parameters [15,16]; and (iii) the effect of nano-
AI2O3 hard particulates in dispersing second phases [17]. The
overall characteristics of these secondary phases were quantified
by image analysis and shown in Table 4. It is observed that nee-
2.6 Tensile Testing. The smooth bar tensile properties of the dlelike secondary phase was broken down to round-shaped sec-
extruded samples were determined in accordance with American ondary phase in the case of the AZ6I-I.5AI2O3 sample (Fig. 2).
Society for Testing and Materials test method E8M-05 using a The effect of nanoalumina in breaking down and dispersing the
MTS 810 tensile testing machine with a crosshead speed set at secondary phase Mgi7Ali2 of magnesium alloys, which lead to
0.254 mm/min on round tension test specimens of 5 mm diameter higher ductility, was observed earlier [17]. The volume of second-
and 25 mm gauge length. A MTS extensometer was used for strain ary phases increased significantly with the increase in amount of
recording. Cu. It is clearly seen that average aspect ratio of AZ61-1.5 AI2O3-
2Cu and AZ6I-I.5AI2O3-3CU samples are much higher compared
2.7 Fracture Behavior. Fracture surfaces of the tensile sam- to other samples, as much more needle shape and sharp comer
ples were characterized using FESEM-S4300 in order to provide shape of secondary phases can be visibly observed. The sharp cor-
insight into fracture mechanisms operating under tensile loading. ner secondary phases act as stress concentration sites, leading to
crack initiation, which eventually causes lower ductility. Accord-
ing to the microstructural observation coupled with the quantita-
3 Results and Discussion tive results of microstructural characteristics of secondary phases
of the aged sample, it was concluded that more homogeneous dis-
3.1 DMD Yield and Macrostructural Observation. Syn- tribution of secondary phases was observed compared to that prior
thesis of AZ61 with nano-Al203 and Cu particulates composites to heat treatment. Larger amount with smaller and round size of
was successfully accomplished by DMD technique with good dep- secondary phases were obtained. These are factors contributing to
osition yields, as shown in Table 1. Macrostmctural observation enhanced strength and ductility of aged samples [17,19].
on the deposited ingots revealed no detectable reaction between
the graphite crucible and melts, minimal oxidation of the melts, The experimental results of density and porosity measurements
and absence of blowholes and macropores. Subsequently, the suc- in Table 3 indicated that nearly dense materials were obtained by
cessful extrusion with smooth plastic flow indicated that the extru- DMD method coupled with hot extrusion. These results are con-
sion parameters were adequate [4]. The extruded rods showed a sistent with the observations made using optical microscopy and
smooth and shiny surface without any cracks. The observation is FESEM (Fig. 2). Presence of minimal porosity can be attributed
consistent with previous findings made on Mg-based composites to: (i) good compatibility between the AZ61 matrix and reinforce-
synthesized using the DMD method [1417]. ment, leading to the absence of voids and debonded regions usu-
Macroscopic observation of the heat-treated samples, particu- ally associated with ceramic reinforcements [15] and (ii) judicious
larly the machined tensile specimens, indicated no evidence of selection of experimental parameters during primary and second-
surface oxidation or presence of cracks. This can be attributed to ary processing [16].
the protective environment used during aging treatment.

3.2 Microstructural Characterization. Table 2 shows the 3.3 Coefficient of Thermal Expansion. The results of CTE
X-ray diffraction phase analysis of all samples. The secondary in Table 1 show that the presence of nano-Al2O3 particulates and
phase Mgi7Ali2 was formed in both monolithic and composite the progressive addition of Cu particulates alloying element
samples. Secondary phases Mg2Cu and MgAlCu were formed in decreased the average CTE values of monolithic AZ61. The
addition to the Mgi7Al|2 phase in micron-Cu-containing samples. results suggest an appropriate integration of AZ61 magnesium
No elemental copper peaks were detected in the case of AZ31- alloy with nano-Al2O3 particulates and Cu particulates alloying
I.5AI2O3-ICU nanocomposites. Copper peaks, however, were element, which have low CTE values (7.4 x 10^ K"' and
detected for samples containing 2 and 3 vol.% of copper. 17.4 X 10 K~' for alumina and copper, respectively) and the
The results of microstructural characterization revealed pres- ability of the reinforcements to effectively constraint the expan-
ence of nearly equiaxed grains in both monolithic and composite sion of the matrix, as demonstrated in prior studies [10,14].
samples. Secondary phases were predominantly located at grain The decreasing values in CTE can also be attributed to the pres-
boundaries. Scion software was used to analyze grain size and ence of Cu-based phases, such as Mg2Cu and AlCuMg, which
grain aspect ratio. The results revealed that presence of nanoalu- suggest that the composites are more dimensionally stable as a
mina and/or copper particulates reduced the grain size of magne- function of temperature than the monolithic AZ61. The results are
sium alloy AZ61 marginally. The results also indicated that grain consistent with similar findings made by investigators on other

Table 3 Results of density and porosity measurements

Composition Theo, density (g/ctn^) Exp. dertsity (g/cm^) Porosity (%) Grain size (/im) Aspect ratio

AZ61 1.800 1.799 0.008 0.04 3.43 0.05 1.62


AZ6I-I.5AI2O3 1.832 1.831 0.001 0.07 2.56 0.03 1.48
AZ6I-I.5AI2O3-ICU 1.904 1.903 0.006 0.06 2.33 0.02 1.31
AZ6I-I.5AI2O3-2CU 1.975 1.974 0.002 0.03 2.16 0.04 1.23
2.046 2.046 0.002 0.03 1.97 0.02 1.15
AZ6I-I.5AI2O3-ICU-HT 1.904 1.903 0.003 0.03 1.51 0.01 1.06

Journal of Engineering Materials and Technology JULY2013, Vol. 135 / 031004-3


Fig. 2 Representative FESEM micrographs showing distribution of intermetallic phases

Table 4 Results of second phase characteristics

Second phase characteristic

Composition Amount (vol.9 Diameter (/im) Aspect ratio Interparticulate spacing (/jm)"

AZ61 2.54 0.13 1.16 0.02 1.30 5.29


AZ6I-I.5AI2O3 3.26 0.22 1.05 0.05 1.17 4.10
AZ6I-I.5AI2O3-ICU 12.43 0.31 1.23 0.02 2.09 1.86
AZ6I-I.5AI2O3-2CU 19.62 0.38 1.26 0.01 2.28 1.26
AZ6I-I.5AI2O3-3CU 24.17 0.32 1.29 0.01 2.77 1.04
AZ61 -1.5 AI2O3-1 Cu-HT 12.75 0.35 1.19 0.03 1.91 1.76

"Interparticulate spacing, = df \/'n./Af 1 j ; d is diameter and/is volume fraction of secondary phases [19].

Table 5 Results of tensile and microhardness properties

Composition Hardness (Hv) 0.2 YS (MPa) UTS (MPa) Failure strain (%) WoF (MJ/m^)

AZ6I 80.3 1.1 216 4 307 4 8.4 1.3 24.9 4.3


AZ6I-I.5AI2O3 103 1.9 237 9 334 8 9.3 1.3 30.1 3.7
AZ6I-I.5AI2O3-ICU 107 1.0 237 9 332 7 6.1 0.6 19.8 1.8
AZ6I-I.5AI2O3-2CU 1121.6 252 7 332 5 3.0 0.8 9.9 2.5
AZ6I-I.5AI2O3-3CU 116.8 1.1 274 4 339 8 2.1 0.5 7.6 1.8
AZ6I-I.5AI2O3-ICU-HT 119.6 1.0 258 2 332 3 9.2 0.3 30.5 1.2

031004-4 / Vol. 135, JULY 2013 Transactions of the ASME


l2O3 ceramic particulates [17] and (ii) greater constraints
on localized matrix deformation during indentation due to the
increased presence of intermetallic phases and smaller grain size
(see Tables 3 and 4) [14]. This is consistent with earlier observa-
tions made on Mg-Cu and AZ3IB-AI2O3 formulations [16,17].
l-AZISl An increment in hardness value in the case of the heat-treated
2-AZ61+1.5A1203 sample, AZ6I-I.5AI2O3-ICU-HT, compared to the nonheat-
3-AZ61+l..'A120+lCa treated one, AZ6I-I.5AI2O3-ICU, was also observed. This can be
4.AZ61+1.5At2O+2Cn attributed to slightly higher volume of well-distributed, smaller,
.5.AZl+1.5AI203+3Ql and more spherical secondary phases coupled with homogene-
6.AZ61+l,5A1203+lOl(IID ously distributed, relatively smaller grains [2,11].

3.5 Tensile Characteristics. Results of room temperature


Strain (%) tensile properties of monolithic and composite samples are shown
in Table 5. Addition of nanoalumina and/or micron copper partic-
Fig. 3 Stress-strain curves of samples at room temperature ulates led to a significant improvement in 0.2% yield strength and
ultimate strength of AZ61 (Fig. 3). The yield strength and ultimate
strength increased from 216 MPa to 274 MPa and from 307 MPa
magnesium-based formulations containing different types of rein- to 339 MPa, respectively. Ductility increased from 8.4% to 9.3%
forcements and in different length scales [9,14,16]. in the case of the AZ6I-I.5AI2O3 composite sample. However,
subsequent addition of micron-sized copper led to a reduction in
3.4 Hardness. Table 5 shows the results of microhardness ductility. Aging heat treatment led to simultaneous enhancement
measurements. The results revealed a significant increase in aver- of both strength and ductility of the AZ6I-I.5AI2O3-ICU compos-
age microhardness with the presence of nanoalumina and an ite sample. An overall assessment in terms of work of fracture
increasing amount of micron-sized copper particulates. The indicated a 54% increment in the case of the aged sample, AZ61-
increase in hardness of composites can be attributed primarily to: I.5AI2O3-ICU-HT (30.5 MJ/m') compared to that of the nonaged
(i) an increase in the presence of harder intermetallic phases and sample (19.8 MJ/m^).

AZ61 - I.5ALO3-2CU ^

Fig. 4 Fractographs of samples showing microcracks, plastic deformation, and shear


feature

Journal of Engineering Materials and Technology JULY2013, Vol. 135 / 031004-5


The significant increase in 0.2% yield strength and ultimate ten- (2) Presence of nanoalumina breaks and disperses the
sile strength of monolithic AZ61 due to addition of nanoalumina Mgi7Ali2 phase and increases strengths and ductility of
particulates and/or micron copper particulates can be primarily AZ61.
attributed to: (i) grain refinement (see Table 3) [15]; (ii) presence (3) Addition of Cu particulates leads to formation of Mg2Cu
of reasonably distributed harder particulates/intermetallics phases and MgAlCu secondary phases in matrix. The increasing
(Fig. 2) [14]; (iii) Orowan strengthening due to a significantly
presence of copper in AZ6I-I.5AI2O3 samples led to a rea-
reduced interparticulate spacing of intermetallics phases (see Ta-
sonable improvement in hardness and 0.2% yield strength,
ble 4) [19]; (iv) the effective load transfer between matrix and sec-
while the ductility was compromised.
ondary phases [16]; and (v) the formation of internal stresses due
(4) Aging heat treatment enhanced microstmcture and tensile
to different thermal expansion behavior between secondary phases
and the matrix [9]. Upon aging heat treatment, there was an incre- response in terms of 0.2% yield strength and ductility of an
ment in 0.2% yield strength compared to that of the nonaged sam- AZ6I-I.5AI2O3-ICU sample.
ple. Precipitation took place during the aging treatment and (5) Fracture behavior of AZ61, AZ6I-I.5AI2O3-ICU, and
resulted in a higher amount of secondary phases (see Fig. 2 and AZ6I-I.5AI2O3-ICU-HT samples showed evidence of a
Table 4). Presence of homogenously distributed round and smaller mixed-mode fracture with limited presence of microcracks,
grains was another factor that contributed to the increment of evidence of plastic deformation, and shear band feature,
0.2% yield strength [11,17,20]. while AZ6I-I.5AI2O3-2CU and AZ6I-I.5AI2O3-3CU sam-
ples exhibited significant presence of microcracks and lim-
Table 5 also shows the increase in ductility of AZ61 when nano- ited evidence of plastic deformation.
alumina particulates were added. An increase from 8.4% to 9.3% in
failure strain in the case of the AZ6I-I.5AI2O3 sample was
observed when compared to the AZ61 sample. The increase in
ductility can primarily be attributed to: (a) grain refinement (see
Table 1) [9]; (b) presence and reasonably good distribution of inter- Acknowledgment
metallics [20]; and (c) reduction in size and roundness of second The authors would like to acknowledge National University
phases (see Table 4 and Fig. 2) [17]. An increment of 51% in fail- of Singapore and Agency for Science, Technology and
ure strain was also observed in the case of the aged sample, AZ61- Research (ASTAR) Grant 092 137 0015 (WBS# R-265-000-
I.5AI2O3-ICU-HT. The failure strain increased from 6.1% for the 321-305).
nonaged sample to 9.2% for the aged sample. This can be mainly
attributed to reduction in aspect ratio of secondary phases and
decrease in size and aspect ratio of the matrix grains [1,2,11,12]. References
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I.5AI2O3, and AZ6I-I.5AI2O3-CU formulations. 1411-1416.

031004-6 / Vol. 135, JULY 2013 Transactions of the ASME


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