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<p>In this study, the influences of Ca and Zn contents on microstructures, mechanical properties and corrosion resistances of Mg-3Al-<i>X</i><sub>1</sub>Ca-X<sub>2</sub>Zn-0.4Mn alloys (wt.%) (<i>X</i><sub>1</sub> = 0.5, 0.8 and <i>X</i><sub><i>2</i></sub> = 0.8, 1.2) were systematically investigated. Three alloys were produced through gravity die casting which was followed by homogenization and hot rolling. Chemical composition of the alloys was determined by using XRF. Microstructural analyses using XRD and SEM-EDX revealed that alloys have multiphase structure, including α-Mg, Mg<sub>17</sub>Al<sub>12</sub>, Al<sub>2</sub>Ca and Al<sub>8</sub>Mn<sub>5</sub> phases. Tensile tests in rolling (RD) and transverse (TD) directions showed that the Mg-3Al-1.2Zn-0.5Ca–0.4Mn alloy exhibited superior in-plane isotropy. Therefore, the yield strength, tensile strength and fracture strain of Mg-3Al-1.2Zn-0.5Ca-0.4Mn alloys were measured at 155 MPa, 240 MPa and 7% in the RD, 155 MPa, 245 MPa and 8% in the TD, respectively, while its hardness value reached 64 HV. On the other hand, immersion corrosion tests indicated that the Mg-3Al-0.8Zn-0.8Ca-0.4Mn alloy had the lowest corrosion rates (11.5-24.6 mm/year) over 24-120 h. These results demonstrate clear correlations between alloy composition, microstructural evolution and the resulting mechanical and corrosion performance, providing guidance for designing Mg-Al-Ca-Zn-Mn alloys with optimized properties.</p>

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Development of Mg-Al-Zn-Ca-Mn Alloys with High Strength, Stretch Formability and Corrosion Resistance for Applications in Automotive and Aerospace Industries

  • 期刊论文

  • 发表日期：

    2025年12月29日

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  • Yousef Fhail Boom,
  • Ali Gungor,
  • Alper Incesu

摘要

In this study, the influences of Ca and Zn contents on microstructures, mechanical properties and corrosion resistances of Mg-3Al-X1Ca-X2Zn-0.4Mn alloys (wt.%) (X1 = 0.5, 0.8 and X2 = 0.8, 1.2) were systematically investigated. Three alloys were produced through gravity die casting which was followed by homogenization and hot rolling. Chemical composition of the alloys was determined by using XRF. Microstructural analyses using XRD and SEM-EDX revealed that alloys have multiphase structure, including α-Mg, Mg17Al12, Al2Ca and Al8Mn5 phases. Tensile tests in rolling (RD) and transverse (TD) directions showed that the Mg-3Al-1.2Zn-0.5Ca–0.4Mn alloy exhibited superior in-plane isotropy. Therefore, the yield strength, tensile strength and fracture strain of Mg-3Al-1.2Zn-0.5Ca-0.4Mn alloys were measured at 155 MPa, 240 MPa and 7% in the RD, 155 MPa, 245 MPa and 8% in the TD, respectively, while its hardness value reached 64 HV. On the other hand, immersion corrosion tests indicated that the Mg-3Al-0.8Zn-0.8Ca-0.4Mn alloy had the lowest corrosion rates (11.5-24.6 mm/year) over 24-120 h. These results demonstrate clear correlations between alloy composition, microstructural evolution and the resulting mechanical and corrosion performance, providing guidance for designing Mg-Al-Ca-Zn-Mn alloys with optimized properties.