Enhancement of Mechanical and Dissolution Properties of a Cast Magnesium Alloy via Equal Angular Channel Processing
Two decades of the Shale Revolution has transforming transformed the global energy market, in part by the adaption of multi-stage dissolvable frac plugs. Magnesium has been favored for the bulk of plugs, requiring development of materials to suit specific field requirements. Herein, the mechanical and dissolution results from equal channel angular pressing (ECAP) of two cast dissolvable magnesium alloy are described. ECAP was selected as a route to increase the mechanical properties of two formulations of dissolvable magnesium, as solutionizing failed. In this study, 1” square cross section samples cast Mg alloys formulations containing rare earth were processed at temperatures ranging from 200 to 350 °C, at a rate of 0.005”/s, with a backpressure from 0 to 70 MPa, in a brass, or brass + graphite sheet. Generally, the yield and ultimate tensile strength (UTS) doubled for all. For formulation DM-2, the yield increased from 100 MPa to 250 MPa; UTS from 175 MPa to 325 MPa, but the strain fell from 2 to 1%. Formulation DM-3 yield increased from 75 MPa to 200 MPa, UTS from 150 MPa to 275 MPa, with strain increasing from 1 to 3%. Meanwhile, ECAP has also been found to reduce the dissolution rate significantly. A microstructural analysis showed grain refinement of the alloy and the movement of secondary phases away from the grain boundary. It is believed that reconfiguration of the grain boundary phases increased the mechanical properties and decreased the dissolution rate. ECAP processing of dissolvable high rare earth content magnesium is possible despite the brittleness of the material. ECAP is a possible processing route to increase mechanical properties for dissolvable aluminum alloys that do not extrude.
[1] M. Höök, R. Hirsch, K. Aleklett, “Giant Oil Field Decline Rates and Their Influence on World Oil Production”, In Energy Policy June 2009.
[2] J. J. Andreas, “The Shale Revolution in the U.S. and its Impact on Energy Markets, Energy Security, and the U.S. Energy Transition”, In International Report of the Konrad-Adenauer-Stiftung January 2015.
[3] L. D. Helms, “Horizontal Drilling,” North Dakota Department of Mineral Resources Newsletter, vol. 35, no. 1, pp. 1–3, 2008.
[4] U.S. Government Accountability Office, “Oil and Gas Information on Shale Resources, Development, and Environmental and Public Health Risks,” 2012.
[5] Z. Walton, M. Fripp, J. Porter, G. Vargus, “Evolution of Frac Plug Technologies – Cast Iron to Composites to Dissolvable", SPE Middle East Oil and Gas Show and Conference, March 2019.
[6] C. Gradl, “Review of Recent Unconventional Completion Innovations and their Applicability to EGS Wells”, 43rd Workshop on Geothermal Reservoir Engineering, February 2018.
[7] H. Hu, X. Nie, Y. Ma, “Corrosion and Surface Treatment of Magnesium Alloys”, Magnesium Alloys Properties in Solud and Liquid States, 2014.
[8] W.D. Callister, (2007) “Materials Science and Engineering: An Introduction. Mechanical Properties of Metals” New York: John Wiley & Sons.
[9] W.D. Callister, (2007) “Materials Science and Engineering: An Introduction. Applications and Processing of Metal Alloys” New York: John Wiley & Sons.
[10] R. Yadav, Y. Dewang, J. Raghuvanshi, “Study on Metal Extrusion Process. International Journal of LNCT 2(6)”, 124-230, July 2018.
[11] A. Azushima, R. Kopp, A. Korhonen, D.Y. Yang, F. Micari, G.D. Lahoti, P. Groche, J. Yanagimoto, N. Tsuji, A. Rosochowski, A. Yanagida, “Severe Plastic Deformation (SPD) Processes for Metals”, CIRP Annals, Volume 57, Issue 2, 2008, Pages 716-735.
[12] M. Meyers, K. Chawla, (2008) “Mechanical Behavior of Materials. Imperfections: Point and Line Defects”, Cambridge: Cambridge University Press.
[13] M. Meyers, A. Mishra, D.J. Benson, “Mechanical Properties of Nanocrystalline Materials”, Prog. Mater. Sci. 2006, 51:427–556.
[14] Schiøtz J., Di Tolla F.D., Jacobsen K.W. Softening of nanocrystalline metals at very small grain sizes. Nature. 1998;391:561–563.
[15] Y. Zhu, T. Lowe, T. Langdon, “Performance and Applications of Nanostructured Materials Produced by Severe Plastic Deformation”, Scripta Materialia, Volume 51, Issue 8, 2004, Pages 825-830.
[16] Y. Haung, T. Langdon, “Advances in Ultrafine-Grained Materials”, Materials Today, Volume 16, Issue 3, March 2013, Pages 85-93.
[17] F. Djavanroodi, M. Ebrahimi, B. Rajabifar, S. Akramizadeh, “Fatigue Design Factors for ECAPed Materials”, Materials Science and Engineering A, October 2018, Pages 745-750.
[18] K. Alaneme, E. Okotete, “Enhancing Plastic Deformability of Mg and Its Alloys—A Review of Traditional and Nascent Developments”, Journal of Magnesium and Alloys, Volume 5, Issue 4, 2017, Pages 460-475.
[19] S. Fu, Q. Li, X. Jinh, Q. Zhang, Z. Chen, W. Liu, “Review on Research and Development of Heat Resistant Magnesium Alloy”, (2012) International Conference on Mechanical Engineering and Materials Science.
[20] A. Bahmani, S. Arthanari, K. Shin, “Formulation of Corrosion Rate of Magnesium Alloys using Microstructural Parameters”, Journal of Magnesium and Alloys, Volume 8, Issue 1, 2020, Pages 134-149.
[21] M.W. Vaughan, A.I. Karayan, A. Srivastava, B. Mansoor, J.M. Seitz, R. Eifler, I. Karaman, H. Castaneda, H.J. Maier, “The Effects of Severe Plastic Deformation on the Mechanical and Corrosion Characteristics of a Bioresorbable Mg-ZKQX6000 Alloy”, Materials Science and Engineering C, May 2020.
[22] Y. Lapovok, “The Role of Back-Pressure in Equal Channel Angular Extrusion”, (Jan 2005), Journal of Materials Science; New York Vol. 40, Iss. 2.
[23] A. Yamashita, Z. Horita, T. Langdon, “Improving the Mechanical Properties of Magnesium and a Magnesium Alloy Through Severe Plastic Deformation”, Materials Science and Engineering: A, Volume 300, Issues 1–2, 2001, Pages 142-147.
[24] P. Zhou, H. Wang, H. Nie, W. Cheng, X. Niu, Z. Wang, W. Liang, “Effect of ECAP Temperature on Precipitation and Strengthening Mechanisms of Mg–9Al–1Si Alloys”, Journal of Materials Research 33, 1822–1829 (2018).
[25] E. Dogan, M.W. Vaughan, S.J. Wang, I. Karaman, G. Proust, “Role of Starting Texture and Deformation Modes on Low-Temperature Shear Formability and Shear Localization of Mg–3Al–1Zn Alloy”, Acta Materialia, Volume 89, 2015, Pages 408-422.
[1] M. Höök, R. Hirsch, K. Aleklett, “Giant Oil Field Decline Rates and Their Influence on World Oil Production”, In Energy Policy June 2009.
[2] J. J. Andreas, “The Shale Revolution in the U.S. and its Impact on Energy Markets, Energy Security, and the U.S. Energy Transition”, In International Report of the Konrad-Adenauer-Stiftung January 2015.
[3] L. D. Helms, “Horizontal Drilling,” North Dakota Department of Mineral Resources Newsletter, vol. 35, no. 1, pp. 1–3, 2008.
[4] U.S. Government Accountability Office, “Oil and Gas Information on Shale Resources, Development, and Environmental and Public Health Risks,” 2012.
[5] Z. Walton, M. Fripp, J. Porter, G. Vargus, “Evolution of Frac Plug Technologies – Cast Iron to Composites to Dissolvable", SPE Middle East Oil and Gas Show and Conference, March 2019.
[6] C. Gradl, “Review of Recent Unconventional Completion Innovations and their Applicability to EGS Wells”, 43rd Workshop on Geothermal Reservoir Engineering, February 2018.
[7] H. Hu, X. Nie, Y. Ma, “Corrosion and Surface Treatment of Magnesium Alloys”, Magnesium Alloys Properties in Solud and Liquid States, 2014.
[8] W.D. Callister, (2007) “Materials Science and Engineering: An Introduction. Mechanical Properties of Metals” New York: John Wiley & Sons.
[9] W.D. Callister, (2007) “Materials Science and Engineering: An Introduction. Applications and Processing of Metal Alloys” New York: John Wiley & Sons.
[10] R. Yadav, Y. Dewang, J. Raghuvanshi, “Study on Metal Extrusion Process. International Journal of LNCT 2(6)”, 124-230, July 2018.
[11] A. Azushima, R. Kopp, A. Korhonen, D.Y. Yang, F. Micari, G.D. Lahoti, P. Groche, J. Yanagimoto, N. Tsuji, A. Rosochowski, A. Yanagida, “Severe Plastic Deformation (SPD) Processes for Metals”, CIRP Annals, Volume 57, Issue 2, 2008, Pages 716-735.
[12] M. Meyers, K. Chawla, (2008) “Mechanical Behavior of Materials. Imperfections: Point and Line Defects”, Cambridge: Cambridge University Press.
[13] M. Meyers, A. Mishra, D.J. Benson, “Mechanical Properties of Nanocrystalline Materials”, Prog. Mater. Sci. 2006, 51:427–556.
[14] Schiøtz J., Di Tolla F.D., Jacobsen K.W. Softening of nanocrystalline metals at very small grain sizes. Nature. 1998;391:561–563.
[15] Y. Zhu, T. Lowe, T. Langdon, “Performance and Applications of Nanostructured Materials Produced by Severe Plastic Deformation”, Scripta Materialia, Volume 51, Issue 8, 2004, Pages 825-830.
[16] Y. Haung, T. Langdon, “Advances in Ultrafine-Grained Materials”, Materials Today, Volume 16, Issue 3, March 2013, Pages 85-93.
[17] F. Djavanroodi, M. Ebrahimi, B. Rajabifar, S. Akramizadeh, “Fatigue Design Factors for ECAPed Materials”, Materials Science and Engineering A, October 2018, Pages 745-750.
[18] K. Alaneme, E. Okotete, “Enhancing Plastic Deformability of Mg and Its Alloys—A Review of Traditional and Nascent Developments”, Journal of Magnesium and Alloys, Volume 5, Issue 4, 2017, Pages 460-475.
[19] S. Fu, Q. Li, X. Jinh, Q. Zhang, Z. Chen, W. Liu, “Review on Research and Development of Heat Resistant Magnesium Alloy”, (2012) International Conference on Mechanical Engineering and Materials Science.
[20] A. Bahmani, S. Arthanari, K. Shin, “Formulation of Corrosion Rate of Magnesium Alloys using Microstructural Parameters”, Journal of Magnesium and Alloys, Volume 8, Issue 1, 2020, Pages 134-149.
[21] M.W. Vaughan, A.I. Karayan, A. Srivastava, B. Mansoor, J.M. Seitz, R. Eifler, I. Karaman, H. Castaneda, H.J. Maier, “The Effects of Severe Plastic Deformation on the Mechanical and Corrosion Characteristics of a Bioresorbable Mg-ZKQX6000 Alloy”, Materials Science and Engineering C, May 2020.
[22] Y. Lapovok, “The Role of Back-Pressure in Equal Channel Angular Extrusion”, (Jan 2005), Journal of Materials Science; New York Vol. 40, Iss. 2.
[23] A. Yamashita, Z. Horita, T. Langdon, “Improving the Mechanical Properties of Magnesium and a Magnesium Alloy Through Severe Plastic Deformation”, Materials Science and Engineering: A, Volume 300, Issues 1–2, 2001, Pages 142-147.
[24] P. Zhou, H. Wang, H. Nie, W. Cheng, X. Niu, Z. Wang, W. Liang, “Effect of ECAP Temperature on Precipitation and Strengthening Mechanisms of Mg–9Al–1Si Alloys”, Journal of Materials Research 33, 1822–1829 (2018).
[25] E. Dogan, M.W. Vaughan, S.J. Wang, I. Karaman, G. Proust, “Role of Starting Texture and Deformation Modes on Low-Temperature Shear Formability and Shear Localization of Mg–3Al–1Zn Alloy”, Acta Materialia, Volume 89, 2015, Pages 408-422.
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:80268", author = "Tim Dunne and Jiaxiang Ren and Lei Zhao and Peng Cheng and Yi Song and Yu Liu and Wenhan Yue and Xiongwen Yang", title = "Enhancement of Mechanical and Dissolution Properties of a Cast Magnesium Alloy via Equal Angular Channel Processing", abstract = "Two decades of the Shale Revolution has transforming transformed the global energy market, in part by the adaption of multi-stage dissolvable frac plugs. Magnesium has been favored for the bulk of plugs, requiring development of materials to suit specific field requirements. Herein, the mechanical and dissolution results from equal channel angular pressing (ECAP) of two cast dissolvable magnesium alloy are described. ECAP was selected as a route to increase the mechanical properties of two formulations of dissolvable magnesium, as solutionizing failed. In this study, 1” square cross section samples cast Mg alloys formulations containing rare earth were processed at temperatures ranging from 200 to 350 °C, at a rate of 0.005”/s, with a backpressure from 0 to 70 MPa, in a brass, or brass + graphite sheet. Generally, the yield and ultimate tensile strength (UTS) doubled for all. For formulation DM-2, the yield increased from 100 MPa to 250 MPa; UTS from 175 MPa to 325 MPa, but the strain fell from 2 to 1%. Formulation DM-3 yield increased from 75 MPa to 200 MPa, UTS from 150 MPa to 275 MPa, with strain increasing from 1 to 3%. Meanwhile, ECAP has also been found to reduce the dissolution rate significantly. A microstructural analysis showed grain refinement of the alloy and the movement of secondary phases away from the grain boundary. It is believed that reconfiguration of the grain boundary phases increased the mechanical properties and decreased the dissolution rate. ECAP processing of dissolvable high rare earth content magnesium is possible despite the brittleness of the material. ECAP is a possible processing route to increase mechanical properties for dissolvable aluminum alloys that do not extrude.", keywords = "Equal channel angular processing, dissolvable magnesium, frac plug, mechanical properties.", volume = "15", number = "4", pages = "41-6", }
