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Journal of Materials Science & Technology 32 (2016) 1211–1221

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Journal of Materials Science & Technology


j o u r n a l h o m e p a g e : w w w. j m s t . o r g

A Review on Casting Magnesium Alloys: Modification of Commercial


Alloys and Development of New Alloys
Fusheng Pan 1,2,*, Mingbo Yang 1,3, Xianhua Chen 1,*
1
National Engineering Research Center for Magnesium Alloys (CCMg), Chongqing University, Chongqing 400044, China
2 Chongqing Academy of Science and Technology (CAST), Chongqing 401123, China
3 College of Material Science and Engineering, Chongqing University of Technology, Chongqing 400050, China

A R T I C L E I N F O
The research and development status of casting magnesium alloys including the commercial casting alloys
Article history: and the new types casting alloys are reviewed, with more attention to microstructure and mechanical
Received 19 March 2016 properties of modified-AZ91, AM60 and WE43 alloys with various additions, and new types of low cost
Received in revised form casting alloys and high strength casting alloys. The modification and/or refinement of Mg2Si phase in
28 April 2016 Mg–Al–Si based casting alloys by various additions are discussed and new purifying technologies for casting
Accepted 1 June 2016 magnesium alloys are introduced to improve the performance. The modified AZ81 alloy with reduced
Available online 4 July 2016 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–
Key words: 0.3Zr alloy exhibits very high tensile and yield strengths (UTS: 423 MPa and YS: 328 MPa); however, its
Casting magnesium alloys
elongation still needs to be improved.
Microstructure
Copyright © 2016, The editorial office of Journal of Materials Science & Technology. Published by
Mechanical properties
Corrosion
Elsevier Limited.
Purification
Alloying elements

1. Introduction the development of low cost, high strength and/or creep-resistant


casting magnesium alloys, have been obtained.
It is well known that the applications of magnesium alloys are
significantly potential in automobile, aircraft, aerospace, and 3C in- 2. Modification of Commercial Casting Magnesium Alloys
dustries because of their low density, high specific strength, good
castability and better damping capacity and so on. Compared with At present, the commercial casting magnesium alloys are mainly
wrought magnesium alloys, casting magnesium alloys have clear classified into Mg–Al and Mg–RE based alloys. The former mainly
economical advantages for mass production of components due to includes AZ91, AM50 and AM60 alloys, and the latter mainly consist
their shorter processing cycle and assembly costs[1–3]. Therefore, of WE43 and WE54 alloys[1]. The aging hardenability of these Mg–
casting magnesium alloys obtain more incremental use. To date, Al based alloys, such as AM60 alloy, is relatively poor; therefore, these
almost 90% of total application products for magnesium alloys involve alloys are commonly prepared by high pressure die casting (HPDC)
casting processes. However, the applications of casting magne- with relatively high cooling rate. Oppositely, other commercial cast
sium alloys are still limited. One of the main reasons is that the magnesium alloys, including WE43 and WE54 alloys, can be cast
mechanical properties at room and elevated temperatures for the by sand casting (SC) process with a low cooling rate, and then the
commercial casting magnesium alloys are still unsatisfactory as com- mechanical properties are further improved by solution and aging
pared with Al alloys. Consequently, the development of casting treatments. At the same time, low pressure casting (LPC) and per-
magnesium alloys with high performance have received much global manent mold gravity casting (PM) also are used to fabricate the parts
attention in recent years and many positive results, especially on of Mg–Al and Mg–RE based magnesium alloys.
the modification of the commercial casting magnesium alloys and
2.1. Modification of commercial Mg–Al based alloys

It is well known that the possible application of AZ91 and AM60


* Corresponding authors. alloys is still restricted due to some problems. For example, the two
E-mail addresses: fspan@cqu.edu.cn (F. Pan); xhchen@cqu.edu.cn (X. Chen). alloys are unsuitable for manufacturing parts operating at

http://dx.doi.org/10.1016/j.jmst.2016.07.001
1005-0302/Copyright © 2016, The editorial office of Journal of Materials Science & Technology. Published by Elsevier Limited.
1212 F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221

Table 1
As-cast RT mechanical properties of modified-AZ91 alloys with various additions

Compositions (wt%) Casting processes Tensile properties Fatigue properties References


(MPa)
UTS (MPa) YS (MPa) δ (%)

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)
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)
AZ91 + 0.5Y HPDC 270 162 10.0 – Zhang et al. [9]
AZ91 + 0.8Y HPDC 272 161 11.0 –
AZ91 + 0.032B PM 226 110 4.8 – Suresh et al.[10]
AZ91 + 0.04B PM 229 113 4.9 –
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 –
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 –
AZ91 + 0.2Si+0.2Sb HPDC 231 135 5.8 – Srinivasan et al.[25]
AZ91 + 0.5Si+0.2Sb HPDC 224 126 3.7 –

temperatures higher than 120 °C[3,4]. In addition, the strength and of AM60 alloy. It is found that the tensile strength of 280 MPa and
ductility of the commercial AZ91 and AM60 alloys do not simul- elongation of 11% could be obtained for the AM60–0.2Ti alloy[39].
taneously satisfy the requirement of some important parts[5]. For Although a lot of modified-AZ91 and AM60 casting magne-
example, AZ91 alloy’s strength is relatively high; however, the duc- sium alloys with various additions have been developed in recent
tility of the alloy is not so good due to the high Al content. Although years, these works mainly focus on the tensile properties, strength-
AM60 alloy has a high ductility, its strength is relatively poor. In the ening mechanism and/or corrosion resistance. The investigation on
past decade, many studies on the effects of alloying elements on the fatigue properties of the modified-AZ91 and AM60 alloys with
microstructure and mechanical of AZ91 and AM60 alloys have been various additions is still limited. It is well known that casting mag-
carried out[6–51]. Tables 1 and 2 summarize the as-cast room tem- nesium alloys are mainly used to produce the automobile parts, such
perature (RT) mechanical properties for some modified-AZ91 and as transmission case, engine cradle and wheel hub. Since these me-
AM60 alloys with various additions, respectively. As shown in Table 1, chanically loaded automobile components are often subjected to
various alloying and/or micro-alloying elements, such as Ce, Nd, Y, cyclic stresses, it is very necessary to further investigate the cyclic
Si, Ca, Ti, B, Sr, Sb, Bi, Pr and so on, have been chosen to further deformation behavior of these modified-AZ91 and AM60 alloys with
improve the mechanical properties of AZ91 alloy[6–38]. Among these various additions. Yang et al.[6–8] and Qin et al.[35] found that the
alloying and micro-alloying elements, Ce, Nd, Y, Bi and Sb ele- fatigue strength of AZ91D alloy could be increased by about 20 MPa
ments are found to be effective for the further enhancement in the and 10 MPa with Ce and Nd additions (Figs. 1 and 2), respectively.
tensile properties of AZ91 alloy. With the addition of yttrium, the Xu et al.[36] investigated the high cycle fatigue properties of AZ91D
AZ91D alloy is found to have good mechanical properties with alloy with 1 wt%RE addition, and found that the mean fatigue
the tensile strength of 270 MPa and elongation of 11%[8]. For the strength of the modified-alloy reaches 70 MPa at the number of
modified-AM60 alloys, various alloying and/or micro-alloying el- cycles to failure, 3.8 × 105 (Fig. 3).
ements, such as Ca, Sn, Y, Si, Ti, Ag, Nd, B, RE, Sr, Ce and so on, have
been chosen to further enhance the mechanical properties of AM60 2.2. Modification of commercial Mg–RE based alloys
alloys[5,39–51]. As shown in Table 2, among these alloying and micro-
alloying elements, Ti, Nd, Sn and Ce elements are found to be WE43 and WE54 are typical commercial Mg–RE based
relatively effective in further enhancing the mechanical properties cast alloys[52–57]. It is well known that WE43 alloy has typical

Table 2
As-cast RT tensile properties of modified-AM60 alloys with various additions

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
AM60 + 0.5Sn Squeeze casting 182 – 10.0 Sevik et al.[40]
AM60 + 4.0Sn Squeeze casting 212 – 8.1
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
F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221 1213

Fig. 1. Fatigue strength of AZ91D–Ce alloys[35].


Fig. 3. Fatigue curve for AZ91D–1wt%RE alloy[36].

composition ranges of Mg–(3.7–4.3)Y–(2.4–4.4)RE–(0.4–1.0)Zr (wt%), 2.3. Modification of other casting magnesium alloys
where RE elements consist of Nd and about 1.0 wt% of heavy rare
earth (HRE) elements including Yb, Er, Dy and Gd. Because the During the past decade, the investigations on the modification
HRE elements often lead to in-homogeneous composition[58] and of other casting magnesium alloys mainly focus on Mg–Al–Si based
the reserves of each of those HRE elements are very limited alloys, with more attention on the modification and/or refine-
in the world, the modification of the commercial WE43 alloy ment of Mg2Si compound in the as-cast alloys. It is well known that
mainly focuses on additions of Y, Nd, Zr and reduction of HRE el- Mg–Al–Si based alloys are a potential elevated temperature mag-
ements. At the same time, Zn element is also chosen to further nesium alloys because the Mg2Si phase in Mg–Al–Si based alloys
enhance the mechanical properties of the modified WE43 alloy. has high melting point, high hardness, low density, high elastic
Table 3 lists the RT tensile properties for some modified-WE43 modulus and low thermal expansion coefficient, and the Mg2Si phase
alloys with Zn and/or Gd additions[53–55]. It can be found from Table 3 is very stable and can impede grain boundary sliding at elevated
that for the modified-WE43 PM alloy with 0.2 wt%Zn addition, temperatures. However, under the low solidification rates Mg–Al–
after being T6-treated, its tensile strength (UTS) and yield strength Si based alloys easily form undesirable, coarse, Chinese script shaped
(YS) might reach 345 MPa and 196 MPa[53], respectively, signifi- Mg2Si phases, which would affect the mechanical properties of the
cantly higher than the typical values (250 MPa in UTS and 162 MPa alloys. Therefore, the modification and refinement of Mg2Si phase
in YS) of the commercial WE43 alloy [1] . It is further reported are thought as one of the vital factors to improve the mechanical
that the enhancement in strength and ductility for the modified- properties of Mg–Al–Si based alloys. Up to now, it has been re-
WE43 alloys with minor Zn addition is possibly associated with the ported that the Chinese script shaped Mg2Si phases in Mg–Al–Si
larger volume fraction of precipitation phases due to a reduction based alloys might be modified and/or refined by Sb[59–61], Ca and
of the solubility of rare earth elements (RE) in the α-Mg matrix, the P additions[62–65]. However, some researchers also found that Sb ad-
larger aspect ratio (length to width) of precipitates and a decrease dition is not an effective modifier of Mg2Si phase[62], that Ca addition
in stacking fault energy[55]. Obviously, due to good aging hardenability results in cast defects such as a hot-crack[66], that P addition pro-
of Mg–RE based alloys, the high mechanical properties of the duces ignition and the amount of P addition is difficult to control[59].
modified-WE43 alloys are mainly attributed to a high volume frac- Recent results indicated that Sr and Sn additions are also an effec-
tion of fine β′ (base-centered orthorhombic structure, a = 0.640 nm, tive modifier and/or refiner of Chinese script shaped Mg2Si phases
b = 2.223 nm and c = 0.521 nm) and β′′ (hexagonal, a = 0.642 nm, in Mg–Al–Si based alloys[61,67,68]. Pan’s group in CCMg[69,70] investi-
c = 0.521 nm) metastable precipitates in the matrix[56], as shown in gated the effects of Sb, Sn and Sr on the as-cast microstructure and
Fig. 4. mechanical properties of the AZ61–0.7Si magnesium alloy, and found

Fig. 2. Fatigue strength of AZ91D–xNd magnesium alloys: (a) 0.5 wt%Nd; (b) 1.0 wt%Nd; (c) 1.5 wt%Nd[8].
1214 F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221

Table 3
RT Tensile properties for some modified-WE43 alloys with Zn and/or Gd additions

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
Mg–4.0Y–2.8Nd–0.2Zn–0.4Zr PM-as-cast 205 ± 8 162 ± 7 5.0 ± 0.4 Pan’s group
PM-T6 304 ± 8 225 ± 5 6.4 ± 0.3 in CCMg

Note: T6-Solution treated + peak-aged.

Fig. 4. TEM images (a and b) and SAED patterns (c) of the solution-treated Mg–4Y–2Nd–1Gd–0.4Zr alloy aged at 200 °C for 136 h along [0001]α axis zone[1,56].

that adding 0.4 wt%Sb or 0.6 wt%Sn to the AZ61–0.7Si alloy could 2.4. Modification of casting magnesium alloys by reducing impurity
refine the Chinese script shaped Mg2Si phases in the alloy, but the elements
modification of Mg2Si phases is not obvious. Oppositely, adding small
amounts of Sr can obviously modify and refine the Mg2Si phases The impurity elements, such as Fe, Si, Cu and Ni, always
in the alloy[69,70]. After adding 0.09 wt%Sr to the AZ61–0.7Si alloy, present in magnesium alloys, which are very harmful to their
the morphology of Mg2Si phases in the alloy changes from coarse performance[71–76]. The impurity Fe element, even with a small
Chinese script shape to fine granule and/or irregular polygonal amount, can remarkably impair the corrosion resistance of mag-
shapes[69], as shown in Fig. 5. Accordingly, the tensile and creep prop- nesium alloys[77]. At present, the purification technologies for
erties of the Sr-containing AZ61–0.7Si alloy are greatly improved. reducing impurity elements mainly focus on reducing Fe element.

Fig. 5. SEM images for the AZ61–0.7Si alloy (a), AZ61–0.7Si–0.4Sb alloy (b), AZ61–0.7Si–0.6Sn alloy (c) and AZ61–0.7Si–0.09Sr alloy (d)[69].
F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221 1215

Fig. 6. Corrosion rate of AZ91 and AM60 magnesium alloys by weight loss measured in 3.5% NaCl solution for 36 h (a) and polarization curves of AZ91 alloy with different
Fe content (b).

The research about purification technologies of casting magne- 3. Development of New Types of Casting Magnesium Alloys
sium alloys has been carried out and some flux purification
technologies have been developed[75–102]. However, some investi- In the past decade, the research and development of new types
gations also reveal that the effects of these flux additions to achieve of casting magnesium alloys mainly focus on low cost casting mag-
lower Fe content are not very satisfactory[75]. Furthermore, these flux nesium alloys and high strength casting magnesium alloys. The
additions into the alloys would result in secondary pollution. former mainly includes Mg–Al, Mg–Zn, and Mg–Sn based alloys
Recently, a new flux-less purification technology for effectively without or with minor RE additions[4,69,70,106–118], and the latter mainly
reducing impurity elements in casting magnesium alloys, melt self- includes Mg–Gd and Mg–Nd based alloys[119–135].
purifying technology (MSPT), has been successfully developed by
Pan’s group in CCMg[98–103]. MSPT is a novel and low cost method, 3.1. Low cost casting magnesium alloys
which can be used to effectively reduce the content of impurity el-
ements especially Fe. Its mechanism is mainly related to the change Table 5 lists the tensile and/or creep properties of some low cost
of the solubility of Fe in magnesium melt at the different tempera- casting magnesium alloys developed by Pan’s group in CCMg and
tures. The iron particles and compounds containing Fe can precipitate other researchers in China. As shown in Table 5, these developed
from magnesium melt and settle down to the bottom of the melting alloys mainly focus on the HPDC and PM alloys including Mg–Al–
crucible at the relatively low temperatures (650–680 °C). The method Zn based HPDC alloys with minor Ce and Y additions, Mg–Zn–Al/
has been successfully applied for reducing impurity Fe, Si, Ni and Ca based PM alloys with minor Sn, Sr, Cu, Mn and Ce additions, Mg–
Cu elements especially Fe in AZ and AM series alloys, and the results Zn–Sn–Al based PM alloys with minor Sr addition and Mg–Sn–Ca/
indicate that the Fe content for the treated-AM60 alloys can be lower Sr/Mn based PM alloys with minor Ce, Y and Gd additions. For the
than 20 ppm[98,99]. Additionally, if this purification technology is com- developed low cost HPDC alloys, it is found that the ultimate tensile
bined with adding Zr, Mn or controlling temperature gradient strength, yield strength and elongation at RT for the AZ81–1.5Ce–
method, the Fe content in magnesium melt will be reduced to lower 0.1Sr and AZ81–1.0Y–0.1Sr alloys respectively reach 275 MPa,
than 5 ppm[100–102]. In some cases, the magnesium alloy with 2 ppm 163 MPa and 10.4% for the former; and 258 ± 8 MPa, 144 ± 5 MPa
Fe has also been fabricated by Pan’s group in CCMg. and 7.7% ± 0.3% for the latter. Fig. 7 shows the SEM images of the
After the flux-less purification treatment, the magnesium alloys two HPDC alloys. As shown in Fig. 7, the grains of the two HPDC
exhibit obviously improved corrosion resistance at RT. For example, alloys are very fine and the Mg17Al12 phases in the two alloys mainly
Pan’s group in CCMg recently investigated the corrosion behavior exhibit relatively fine quasi-continuous and/or disconnected shapes,
of as-cast AZ91 and AM60 alloys, and found that the corrosion rate which obviously are beneficial to the mechanical properties. At the
decreases rapidly with decreasing Fe content, as shown in Fig. 6 and same time, the two HPDC alloys do not fail after 105 cycles for a given
Table 4. The corrosion rate of the AM60 alloy with 15 ppm Fe, load of 90 MPa and their corrosion-resistance is also higher than
1.82 mm/y, is quite low. At the same time, Gao et al.[104] and Atrens that of the commercial AZ91 alloy (Table 6). For the developed low
et al.[105] also reported the similar results on the corrosion behav- cost PM alloys, it is found that the ZA84 (Mg–8Zn–4Al–0.25Mn) alloys
ior of casting magnesium alloys after impurity Fe reduction. The with small amount of Sn or Sr additions exhibit the relatively high
decrease of impurity elements is also very helpful to improve the tensile and creep properties, and its strengthening mechanism is
mechanical properties. The modified AZ81 alloys with reducing im- possibly related to the effects of Sn and Sr additions on the mod-
purity, developed by Pan’s group in CCMg, exhibits the tensile ification and refinement of the Mg32(Al,Zn)49 and Al2Mg5Zn2 phases,
strength of 280 ± 6 MPa and elongation of (16 ± 0.7)%. as shown in Fig. 8.
A low cost corrosion resistant modified-AZ91 alloy has been de-
veloped recently by Pan’s group in CCMg (Table 7), which is potential
Table 4
for application of automobile wheels. The new developed AZ91–
Corrosion properties in 3.5% NaCl solution for the AZ91 alloy with different Fe contents
0.5X low pressure shell mold casting (LPSMC) alloy obtain the
Experimental alloys Ecorr (VSCE) icorr (μA cm−2) Pi (mm/y) relatively high ultimate tensile strength and yield strength at RT,
AZ91-35 ppm Fe −1.34 5.26 0.12 255 MPa and 155 MPa. Fig. 9 shows the optical and SEM images for
AZ91-65 ppm Fe −1.44 46.95 1.07 the above mentioned AZ91–0.5X LPSMC as-cast alloy. As shown in
AZ91-150 ppm Fe −1.33 108.38 2.47
Fig. 9, although the grain size of the LPSMC alloy is relatively large,
1216 F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221

Table 5
Tensile and/or creep properties for some low cost casting magnesium alloys

Compositions Test Tensile properties Creep References


(wt%) conditions properties
Room temperature 150 °C
(×10−8 s−1)
UTS YS δ UTS YS δ
(MPa) (MPa) (%) (MPa) (MPa) (%)

AZ81–1.5Ce–0.1Sr HPDC-as-cast 275 ± 9 163 ± 8 10.4 ± 0.3 – – – – Pan’s


AZ81–1.0Y–0.1Sr HPDC-as-cast 258 ± 8 144 ± 5 7.7 ± 0.3 – – – – group in
AE81M PM-as-as-cast 280 ± 6 100 ± 4 16 ± 0.7 – – – – CCMg
AZ61–0.7Si–0.1Sr PM-as-cast 184 115 5.9 173 108 18.1 1.18a Yang et al.[69]
AZ61–0.7Si–0.4Sb PM-as-cast 175 99 5.0 160 91 16.0 1.27a
ZA84–1.0Sn PM-as-cast 194 149 4.3 175 134 14.6 1.14a Yang and Pan[106]
ZA84–0.1Sr PM-as-cast 190 152 4.9 174 136 15.8 2.86a Yang et al.[107]
Mg–3.8Zn–2.2Ca–1.0Ce PM-as-cast 146 119 3.5 133 109 9.9 0.90a Yang et al.[108]
Mg–3Sn–2Ca–1.5Ce PM-as-cast 157 140 3.4 142 131 14.9 2.97b Yang et al.[109]
Mg–3Sn–2Ca–1.5Y PM-as-cast 150 137 3.2 139 129 14.1 3.11b Yang and Pan[110]
Mg–3Sn–2Ca–0.5Gd PM-as-cast 145 131 3.0 132 125 13.6 4.47b Yang et al.[111]
Mg–3Sn–2Sr–1.0Ce PM-as-cast 153 117 4.6 137 104 20.0 3.89b Yang et al.[112]
Mg–3Sn–1Mn–1.0Ce PM-as-cast 165 134 3.9 148 122 15.4 3.34a Pan and Yang[113]
Mg–4.5Zn–4.5Sn–2Al–0.2Sr PM-as-cast 238 – 12.1 133 – 24.3 – He et al.[115]
Mg–6Al–4Zn–0.6Sn PM-as-cast 240 116 10.7 – – – – Dong et al.[116]
Mg–8.0Zn–1.0Al– PM-as-cast 250 97 17.1 – – – – Wang et al.[117]
0.5Cu–0.5Mn
a
150 °C and 50 MPa for 100 h.
b 150 °C and 70 MPa for 100 h.

Fig. 7. Optical and SEM images for the AZ81–1.5Ce–0.1Sr HPDC alloy (a and b) and AZ81–1.0Y–0.1Sr HPDC alloy (c and d) developed in CCMg.

the size and distribution of the secondary phases in the alloy are 3.2. High strength casting magnesium alloys
fine and uniform. In addition, the LPSMC alloy does not fail after
105 cycles for a given load of 90 MPa. In addition, the corrosion- The new high strength casting magnesium alloys mainly in-
resistance of the LPSMC alloys is also higher than that of the cludes Mg–Gd and Mg–Nd based alloys[1,119–135]. For the Mg–Gd based
commercial AZ91 alloy (Table 8). alloys, they can further be divided into Mg–Gd–Y, Mg–Gd–Sm,

Table 6
Corrosion properties for the HPDC Mg–Al based alloys developed in CCMg

Compositions (wt%) Ecorr (V) Icorr (A) Rp (Ω) Corrosion rate in 3.5% NaCl
solution (g m−2 h−1)

AZ81–1.5Ce–0.1Sr −1.527 2.018 × 10−6 8924.5 10.168


AZ81–1.0Y–0.1Sr −1.492 4.491 × 10−7 25039.05 9.236
Commercial AZ91 −1.433 3.921 × 10−4 69.9 17.245
F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221 1217

Fig. 8. SEM images for the ZA84–1.0Sn PM alloy (a) and ZA84–0.1Sr PM alloy developed in CCMg[106,107].

Table 7
As-cast RT mechanical properties for modified-AZ91 LPSMC alloys developed in CCMg

Compositions (wt%) Test conditions UTS (MPa) YS (MPa) δ (%) Fatigue properties (MPa)

AZ91–0.5X LPSMC-as-cast 197 103 7.8 –


LPSMC-T6 255 155 4.2 90 (>105 cycles)

Fig. 9. Optical (a) and SEM image (b) for the AZ91–0.5X LPSMC alloy developed in CCMg.

Mg–Gd–Nd, Mg–Gd–Y/Dy–Zn and Mg–Gd–Ag series alloys accord- tensile properties of the Mg–Gd based alloys might be further im-
ing to the types of the third alloying element. Table 9 lists the RT proved. For example, the Mg–3.2Gd–0.5Zn–0.2Zr (at.%) alloy in PM-
tensile properties for parts of high strength casting magnesium alloys T6 condition exhibits relatively higher strength (UTS: 405 MPa; YS:
developed in recent years. It is found that the tensile properties of 278 MPa) than Mg–Gd–Y based alloys[123]. In addition, it is further
Mg–Gd based alloys are relatively higher than those of Mg–Nd based found from Table 9 that among the Mg–Gd based alloys, the Mg–
alloys. Similar to the above stated Mg–Y based alloy[52–56], the β′ and/ Gd–Ag based alloys exhibit the highest strength. For example, the
or β ′′ metastable phases has also been reported to be a key tensile properties of the Mg–3.4Gd–0.5Ag–0.11Zr (at.%) and the Mg–
strengthening precipitate in Mg–Gd and Mg–Nd based alloys[1]. Fig. 10 8.5Gd–2.3Y–1.8Ag–0.4Zr casting alloys in PM-T6 condition are very
shows the typical images of the β′ and/or β′′ precipitates in the Mg– high, the UTS, YS and elongation are 414 MPa, 293 MPa and 2.2%
Gd and Mg–Nd based alloys. As listed in Table 9, the Mg–10Gd– respectively for the former and 403 MPa, 268 MPa and 4.9% for
3Y/2Y–Zr alloys in Mg–Gd–Y based casting alloys, which the latter[129,130]. It is observed that among Mg–Gd–Ag based alloys,
are developed at Shanghai Jiao Tong University in China, exhibit the Mg–16Gd–2Ag–0.3Zr casting alloy, which was developed at
high comprehensive tensile properties in PM-T6 condition Shanghai Jiao Tong University in China, exhibits the highest tensile
(UTS: ~ 360 MPa; YS: ~ 240 MPa and elongation > 4%)[1,135]. At the same and yield strengths (UTS: 423 MPa and YS: 328 MPa)[131]. As for
time, the β′ strengthening precipitates in the aged Mg–10Gd–2Y– the strengthening mechanism of the Mg–16Gd–2Ag–0.3Zr alloy, it
Zr alloy are found to coarsen with an increase in the aged temperature is thought to be possibly related to the prismatic β′ plates and basal
(Fig. 11), indicating that an optimal heat treatment process is re- γ′′ in the aged-alloy because the prismatic β′ and basal γ′′ plates form
quired to obtain high strength for the Mg–Gd–Y based alloys. simultaneously and are perpendicular to each other resulting in an
Furthermore, when Zn element is added to Mg–Gd based alloys, the enhanced precipitation hardening response[131] (Fig. 12).

Table 8
Corrosion properties in 3.5% NaCl solution for the modified-AZ91 developed in CCMg

Compositions (wt%) Test conditions Ecorr (V) Icorr (A) Rp (Ω) Corrosion rate (mL cm−2 h−1)

AZ91–0.5X LPSMC-as-cast −1.410 10.00 6001.5 0.036


LPSMC-T6 −1.394 7.38 7472.7 0.019
Commercial AZ91 alloy LPSMC-as-cast −1.417 81.79 890.3 0.056
LPSMC-T6 −1.443 31.36 2196.3 0.030
1218 F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221

Table 9
RT tensile properties for parts of high strength casting Mg alloys

Series Compositions (wt%) Test conditions UTS (MPa) YS (MPa) δ (%) References

Mg–Gd–Y Mg–8Gd–3Y–0.4Zr PM-T6 362 222 7.6 Fu et al.[1]


Mg–10Gd–2Y–0.4Zr PM-T6 362 239 4.7
Mg–10Gd–3Y–0.4Zr PM-T6 370 241 4.1
Mg–12Gd–3Y–0.4Zr PM-T6 328 246 1.1
Mg–10.4Gd–3.3Y–0.46Zr PM-T6 348 237 3.0 Liu et al.[119]
Mg–10Gd–3.74Y–0.25Zr PM-T6 325 268 5.1 Li et al.[120]
Mg–9Gd–4Y–Zr PM-T6 327 279 3.3 Xiao et al.[121]
Mg–Gd–Sm Mg–8Gd–2Sm–Zr PM-T6 329 195 7.7 Fu et al.[1]
Mg–10Gd–2Sm–Zr PM-T6 347 237 3.2
Mg–Gd–Nd Mg–6Gd–2Nd–Zr PM-T6 342 182 7.9
Mg–8Gd–2Nd–Zr PM-T6 342 200 5.0
Mg–11Gd–2Nd–Zr PM-T6 353 224 3.7
Mg–Gd–Y/Dy–Zn Mg–10Gd–3Y–1.0Zn–0.4Z PM-T6 364 253 2.0 Liu et al.[119]
Mg–10Gd–3Y–1.2Zn–0.4Zr PM-T6 330 230 3.0 Li et al.[122]
Mg–3.2Gd–0.5Zn–0.2Zr (at.%) PM-T6 405 278 2.5 Ozaki et al.[123]
Mg–14Gd–3Y–1.8Zn–0.5Zr PM-T6 366 230 2.8 Zhang et al.[124]
Mg–6.5Gd–2.5Dy–1.8Zn PM-T6 392 295 6.1 Zhang et al.[125]
Mg–2.5Gd–1.0Zn–0.16Zr (at.%) SM-T6 366 260 3.3 He et al.[126]
Mg–14Gd–2Zn–0.5Zr SCC-T6 404 292 5.3 Wu et al.[133]
Mg–Gd–Ag Mg–3.4Gd–0.5Ag–0.11Zr (at.%) PM-T6 414 293 2.2 Yamada et al.[129]
Mg–8.5Gd–2.3Y–1.8Ag–0.4Zr PM-T6 403 268 4.9 Wang et al.[130]
Mg–16Gd–2Ag–0.3Zr PM-T6 423 328 2.6 Zhang et al.[131]
Mg–Nd–Zn Mg–2.75Nd–0.4Zr–0.2Zn PM-T6 305 155 11.3 Fu et al.[132]
Mg–2.75Nd–0.4Zr–0.5Zn PM-T6 313 162 10.9
Mg–1.75Nd–0.4Zr–0.2Zn PM-T6 278 126 14.0
Mg–2.25Nd–0.4Zr–0.2Zn PM-T6 298 139 13.6
Mg–3.00Nd–0.4Zr–0.2Zn PM-T6 318 165 11.0

Note: SCC, semi-continuously cast.

Fig. 10. HAADF-STEM images showing β’ precipitates for the Mg-2.66 at.% Gd alloy (a) and β’ (seeing arrows) /β’’ (seeing rectangle) precipitates for the Mg-0.5 at.%Nd alloys
aged at 200 °C for 10 h (b) and 170 °C for 100 h (c). The electron beam is parallel to [0001]α [1].

Although the above-mentioned Mg-Gd and Mg-Nd based high sand casting (LPSC), low pressure shell mold casting (LPSMC) and
strength casting magnesium alloys have been developed, the prep- low pressure die casting (LPDC), is well established for aluminum
aration technologies of these alloys are mainly related to PM. It is alloys. However, the case has not been achieved for casting mag-
well known that low pressure casting (LPC), including low pressure nesium alloys. Previous results suggest that LPC castings exhibit the

[135]
Fig. 11. Bright field TEM images taken along [0001]α for the Mg–10Gd–2Y–Zr alloys aged at 225 °C (a) and 250 °C (b) for 16 h .
F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221 1219

Fig. 12. Bright field TEM micrograph (a) and its corresponding SAED pattern (b) for the Mg–16Gd–2Ag–0.3Zr alloy aged at 200 °C for 32 h along [0001] α axis
zone [131].

improved properties as compared to similar thickness castings that alloys, and then determine the optimal chemical composi-
can be made with PM process, mostly due to controlled casting filling tions. The effects of heat treatment on the microstructure,
with the application of pressure and lower porosity due to the pres- mechanical properties and corrosion resistance of the new
sure application during the entire solidification process[136]. At the alloys are also needed to be further investigated.
same time, LPC is also thought as a preferred process to produce (2) For a broader application in automobile parts for casting mag-
thick-wall magnesium castings (~10 mm thickness) that cannot be nesium alloys, a good knowledge of fatigue properties, such
produced by HPDC process. In addition, similar to PM castings, LPC as fatigue curves for constant and variable amplitude loading,
parts are also heat treatable. Therefore, in order to meet different their scatters, influence of mean stresses and notches on
application in industries for casting magnesium alloys, it is very es- fatigue strength as well as the influence of thickness and
sential to prepare high strength casting magnesium alloys by other surface (casting skin), is very necessary.
casting technologies such as LPC. Due to the above-mentioned reasons, (3) The casting process of casting magnesium alloys for the actual
in recent years a lot of works about high strength casting magne- automobile parts, such as selection of casting methods (in-
sium alloys in LPSMC conditions have been carried out at CCMg in cluding PM, HPDC, LPDC, LPSC, LPSMC, squeeze casting, sand
China, and two high strength casting magnesium alloys in LPSMC casting and so on), mold design, optimization of technolog-
conditions, Mg–Gd–Y–Ag and Mg–Gd–Y–Zn based alloys, were de- ical parameters (pouring temperature, pouring rate and so on),
veloped (Table 10). As shown in Table 10, these alloys developed in sectional sensitivity and casting defects, needs to be system-
CCMg exhibit high comprehensive tensile properties in LPSMC-T6 atically investigated.
conditions. For example, in LPSMC-T6 condition, the UTS, YS and (4) For stably reducing impurity elements in casting magne-
elongation of the developed Mg–9Gd–2Y–1Ag–0.5Zr alloy reach sium alloys, the composite purification technologies partly
~400 ± 7 MPa, 187 ± 7 MPa and 7.3% ± 0.5%, respectively. combined with the advantages of the flux purification and
flux-less purification methods are needed to be developed.
4. Conclusions (5) For wider application of casting magnesium alloys, more sys-
tematical investigation on mechanical properties at elevated
In recent years, although a lot of positive results about the temperatures and development of heat-resistant magne-
modified-AZ91, AM60 and WE43 casting magnesium alloys with sium alloys is very crucial.
various additions, Mg–Al/Zn/Sn based low cost casting magne-
sium alloys, Mg–Gd/Nd based high strength casting magnesium Acknowledgments
alloys and purification technologies for reducing impurity ele-
ments in casting magnesium alloys, have been obtained, the This work was supported by the National Natural Science Foun-
following studies still need to be further carried out. dation of China (Grant Nos. 51531002, 51474043 and 51571043),
the Ministry of Education of China (SRFDR 20130191110018),
(1) Further investigations need to be considered in order to better Chongqing Municipal Government (CSTC2013JCYJC60001, CEC
understand the effect of various alloying and micro-alloying project, Two River Scholar Project and The Chief Scientist Studio
elements on the microstructure, mechanical properties, cor- Project) and Fundamental Research Funds for the Central Univer-
rosion resistance and/or castability of casting magnesium sities (No. 106112015CDJZR135515).

Table 10
RT tensile properties for parts of high strength casting Mg alloys developed in CCMg

Compositions (wt%) Test conditions UTS (MPa) YS (MPa) δ (%)

Mg–7.5Gd–2Y–1Ag –0.5Zr LPSMC-as-cast 255 ± 8 164 ± 5 5.0 ± 0.5


LPSMC-T6 352 ± 11 193 ± 5 4.2 ± 0.3
Mg–9Gd–2Y–1Ag –0.5Zr LPSMC-as-cast 220 ± 8 116 ± 6 5.8 ± 0.2
LPSMC-T6 399 ± 7 187 ± 7 7.3 ± 0.5
Mg–4Gd–3Y–2Zn–0.6Zr LPSMC-as-cast 218 ± 7 125 ± 4 15.8 ± 0.7
Mg–6Gd–3Y–2Zn–0.6Zr LPSMC-as-cast 223 ± 9 144 ± 4 14.0 ± 0.7
Mg–8Gd–3Y–2Zn–0.6Zr LPSMC-as-cast 231 ± 6 151 ± 3 11.1 ± 0.4
1220 F. Pan et al. / Journal of Materials Science & Technology 32 (2016) 1211–1221

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