Skip to main content

Advertisement

SpringerLink
Log in

Microstructure, Tensile Properties and Fracture Behavior of Squeeze-Cast Mg Alloy AZ91 with Thick Cross Section

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

As the most popular magnesium alloy, AZ91 is desired in the automotive-related manufacturing industry because of its high specific strength and good corrosion resistance. AZ91-based automotive components are made by conventional high-pressure die casting (C-HPDC) and are unable to provide adequate mechanical properties to components with heavy cross sections because of the high level of gas and shrinkage porosity in C-HPDC parts. To expand the usage of AZ91, a replacement for the C-HPDC to minimize the porosity content is needed. In this research, Mg alloy AZ91 with a cross-sectional thickness of 10 mm was squeeze cast (SC) under an applied pressure of 90 MPa. A counterpart was made by C-HPDC for comparison with SC AZ91. The porosity of the SC and C-HPDC AZ91 specimens was evaluated by optical microscopy and density measurements. The SC AZ91 was almost pore free, whereas the counterpart had a porosity of 3.57%. Microstructural analyses by scanning electron microscopy showed that the SC and C-HPDC AZ91 contained phases of primary α-Mg, β-Mg17Al12 eutectic and Al-Mn intermetallic. Tensile testing indicated that the ultimate tensile strength and elongation (ef) of the SC alloy were 171.7 MPa and 3.0%, which resulted in improvements of 33 and 77% compared with those of the C-HPDC counterpart. The strain-hardening rate and tensile toughness of the SC AZ91 during deformation were higher than those of the HPDC specimen. SEM fractography revealed characteristics of plastic deformation on the flat fractured surface of the SC AZ91, whereas brittle fracture prevailed on the HPDC counterpart.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Automotive applications, Retrieved from https://www.intlmag.org/page/app_automotive_ima, May 2020

  2. J.P. Weiler, A Review of Magnesium Die-Castings for Closure Applications, J. Magn. Alloys, 2019, 7, p 297–304

    Article  CAS  Google Scholar 

  3. A.A. Luo, Magnesium Casting Technology for Structural Applications, J. Magn. Alloys, 2013, 1, p 2–22

    Article  CAS  Google Scholar 

  4. J.P. Weiler, J.T. Wood, R. Klassen, E. Maire, R. Berkmortel, and G. Wang, Relationship Between Internal Porosity and Fracture Strength of Die-Cast Magnesium AM60B Alloy, Mater. Sci. Eng. A, 2005, 395, p 315–322

    Article  Google Scholar 

  5. X. Sun, K.S. Choi, and D.S. Li, Predicting the Influence of Pore Characteristics on Ductility of Thin-Walled High Pressure Die Casting Magnesium, Mater. Sci. Eng., A, 2013, 572, p 45–55

    Article  CAS  Google Scholar 

  6. X. Li, S.M. Xiong, and Z. Guo, Failure Behavior of High Pressure Die Casting AZ91D Magnesium Alloy, Mater. Sci. Eng., A, 2016, 672, p 216–225

    Article  CAS  Google Scholar 

  7. X. Li, S.M. Xiong, and Z. Guo, Correlation Between Porosity and Fracture Mechanism in High Pressure Die Casting of AM60B Alloy, J. Mater. Sci. Technol., 2016, 32, p 54–61

    Article  CAS  Google Scholar 

  8. Z. Sun, L. Ren, X. Geng, L. Fang, X. Wei, and H. Hu, Influence of Wall Stocks on Mechanical Properties of HPDC AZ91, Key Eng. Mater., 2019, 793, p 41–45

    Article  Google Scholar 

  9. M. Zhou, N. Li, and H. Hu, Effect of Cross-Sectional Thicknesses on Tensile Behavior and Microstructure of High Pressure Die Cast Magnesium Alloy AM50, Mater. Sci. Forum, 2005, 475, p 463–468

    Article  Google Scholar 

  10. P. Sharifi, Y. Fan, H.B. Anaraki, A. Banerjee, K. Sadayappan, and J.T. Wood, Evaluation of Cooling Rate Effects on the Mechanical Properties of Die Cast Magnesium Alloy AM60, Metall. Mater. Trans. A, 2016, 47A, p 5159–5168

    Article  Google Scholar 

  11. K.V. Yang, C.H. Caceres, and M.A. Easton, Strengthening Micromechanisms in Cold-Chamber High-Pressure Die-Cast Mg-Al Alloys, Metall. Mater. Trans. A, 2014, 45A, p 4117–4128

    Article  Google Scholar 

  12. X. Li, S.M. Xiong, and Z. Guo, Improved Mechanical Properties in Vacuum-Assist High-Pressure Die Casting of AZ91D Alloy, J. Mater. Process. Technol., 2016, 231, p 1–7

    Article  CAS  Google Scholar 

  13. J. Jiang, Y. Wang, G. Chen, J. Liu, Y. Li, and S. Luo, Comparison of Mechanical Properties and Microstructure of AZ91d Alloy Motorcycle Wheels Formed by Die Casting and Double Control Forming, Mater. Des., 2012, 40, p 541–549

    Article  CAS  Google Scholar 

  14. Souissi, S., Souissi, N., Barhoumi, H, M ben Amar, C Bradai, F. Elhalouani (2019) Characterization of the role of squeeze casting on the microstructure and mechanical properties of the T6 heat treated 2017A aluminum alloy, Advances in Materials Science and Engineering, 2019, Article ID 4089537, pp 1-9

  15. S. Bin, S. Xing, L. Tian, N. Zhao, and L. Li, Influence of Technical Parameters on Strength and Ductility of AlSi9Cu3 Alloys in Squeeze Casting, Trans. Nonferrous Met. Soc. China, 2013, 23, p 977–982

    Article  CAS  Google Scholar 

  16. L. Fang, X. Zhang, B. Xiong, H. Hu, X. Nie, and J. Tjong, Squeeze Casting of Aluminum Alloy A380: Microstructure and Tensile Behavior, China Foundry, 2015, 12(5), p 367–374

    Google Scholar 

  17. L. Fang, X. Zhang, H. Hu, X. Nie, and J. Tjong, Microstructure and Tensile Properties of Squeeze Cast Aluminum Alloy A380 Containing Ni and Sr Addition, Adv Mater. Process. Technol., 2017, 3(1), p 90–100

    Google Scholar 

  18. L. Fang, X. Zhang, L. Ren, H. Hu, X. Nie, and J. Tjong, Effect of Ni Addition on Tensile Properties of Squeeze cast Al Alloy A380, Adv. Mater. Process. Technol., 2018, 4(2), p 200–209

    Google Scholar 

  19. Q. Zhang, M. Masoumi, and H. Hu, Influence of Applied Pressure on Tensile Behaviour and Microstructure of Squeeze cast Mg alloy AM50 with Ca Addition, J. Mater. Eng. Perform., 2012, 14(4), p 539–545

    Google Scholar 

  20. X. Zhang, M. Wang, Z. Sun, and H. Hu, Cross-sectional Thickness-Dependent Tensile Properties of Squeeze Cast Magnesium Alloy AM60, China Foundry, 2012, 9(2), p 178–183

    CAS  Google Scholar 

  21. Z. Han, H. Pan, Y. Li, A.A. Luo, and A.K. Sachdev, Study on Pressurized Solidification Behavior and Microstructure Characteristics of Squeeze Casting Magnesium Alloy AZ91D, Metall. Mater. Trans. A, 2015, 46B, p 328–336

    Article  Google Scholar 

  22. X. Chen, Y. Zhang, Y. Lu, and X. Li, Microstructure and Mechanical Properties of AZ91-Ca Magnesium Alloy Cast by Different Processes, China Foundry, 2018, 15(4), p 263–269

    Article  Google Scholar 

  23. X. Zhang, L. Fang, X. Geng, Z. Sun, H. Hu, and X. Nie, Pouring Temperature-Dependent Tensile Properties of Squeeze Cast Magnesium Alloy Aj62, Adv. Mater. Process. Technol., 2018, 4(2), p 262–271

    Google Scholar 

  24. Standard Test Method for Density of High-Modulus Fibers, D3800-99, ASTM Standards, ASTM, 15.03, 2002, p 186–187

  25. Standard Test Method for Dry and Wet Bulk Density, Water Absorption, and Apparent Porosity of Thin Sections of Glass-Fiber Reinforced Concrete, C948-81, ASTM Standards, ASTM, 04.05, 2002, pp 588-589

  26. M.M. Avedesian and H. Baker, Magnesium and Magnesium Alloys-ASM Specialty Handbook, ASM International, Materials Park, 1999, p 232

    Google Scholar 

  27. T.J. Collins, ImageJ for Microscopy, Biotechniques, 2007, 43(1), p S25–S30

    Article  Google Scholar 

  28. Standard Test Methods for Tension Testing Wrought and Cast Aluminum-and Magnesium-Alloy Products, B557M, ASTM Standards, ASTM, 02 02, 2002, p 424-439

  29. D.R. Poirier, G.H. Geiger, Transport Phenomena in Materials Processing, TMS, 1994

  30. MAGMASOFT 5.3: Manual (2017). Retrieved from http://www.magmasoft.com, May 2020

  31. D. Borello, A. Salvagni, and K. Hanjalic, Effects of Rotation on Flow in an Asymmetric Rib-Roughened Duct: LES Study, Int. J. Heat Fluid Flow, 2015, 55, p 104–119

    Article  Google Scholar 

  32. H. Zambrano, L. Di, G. Sigalotti, F. Peña-Polo, and L. Trujillo, Turbulent Models of Oil flow in a Circular Pipe with Sudden Enlargement, Appl. Math. Model., 2015, 39, p 6711–6724

    Article  Google Scholar 

  33. S. Schneiderbauer, S. Pirker, C. Chimani, R. Kretz, Studies on flow characteristics at high-pressure die-casting, IOP Conf. Ser.: Mater. Sci. Eng., 2012, 27, p 1–6

  34. X. Li, Z. Guo, and S. Xiong, Influence of Melt Flow on the Formation of Defect Band in High Pressure Die Casting of AZ91D Magnesium Alloy, Mater. Charact., 2017, 129, p 344–352

    Article  CAS  Google Scholar 

  35. Z. Sun, X. Geng, L. Ren, H. Hu, Microstructure, Tensile Properties and Fracture Behavior of HPDC Magnesium Alloy AZ91, International Journal of Materials, Mechanics and Manufacturing, 2020, in press

  36. J. Song, S.-M. Xiong, M. Li, and J. Allison, The Correlation Between Microstructure and Mechanical Properties of High-Pressure Die-Cast AM50 Alloy, J. Alloy. Compd., 2009, 477, p 863–869

    Article  CAS  Google Scholar 

  37. J.P. Weiler and J.T. Wood, Modeling the Tensile Failure of Cast Magnesium Alloys, J. Alloy. Compd., 2012, 537, p 133–140

    Article  CAS  Google Scholar 

  38. Z. Guo, S. Xiong, B. Liu, L. Mei, and J. Allison, Determination of The Heat Transfer Coefficient at Metal–Die Interface of High Pressure Die Casting Process of AM50 Alloy, Int. J. Heat Mass Transf., 2008, 51, p 6032–6038

    Article  CAS  Google Scholar 

  39. Z. Sun, M. Zhou, N. Li, and H. Hu, Strain-Hardening and Fracture Behavior of Die Cast Magnesium Alloy AM50, Adv Mater Sci Eng, 2007, 2007, p 64195–64200

    Google Scholar 

  40. F.C. Campbell, Ed., Elements of Metallurgy and Engineering Alloys, ASM International, Cleveland, 2008

    Google Scholar 

  41. Toughness, NDT Education Resource Center, B. Larson, Editor, 2001–2011, The Collaboration for NDT Education, Iowa State University

Download references

Acknowledgments

The authors would like to thank the Natural Sciences and Engineering Research Council of Canada and the University of Windsor for supporting this work. We thank Laura Kuhar, PhD, from Edanz Group (www.edanzediting.com/ac) for editing a draft of this manuscript.

Author information

Authors and Affiliations

  1. Department of Mechanical, Automotive and Materials Engineering, University of Windsor, 401 Sunset Ave, Windsor, ON, N9B 3P4, Canada

    Yintian Fu, Yuxian Li, Anita Hu, Henry Hu & Xueyuan Nie

Authors
  1. Yintian Fu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuxian Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Anita Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Henry Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xueyuan Nie
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Henry Hu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Fu, Y., Li, Y., Hu, A. et al. Microstructure, Tensile Properties and Fracture Behavior of Squeeze-Cast Mg Alloy AZ91 with Thick Cross Section. J. of Materi Eng and Perform 29, 4130–4141 (2020). https://doi.org/10.1007/s11665-020-04910-x

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-020-04910-x

Keywords

Search

Navigation