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.
Abstract: The principal purpose of this paper is to find the influence of maximum fatigue load on the probabilistic aspect of fatigue crack propagation life at a specified grown crack in magnesium alloys. The experiments of fatigue crack propagation are carried out in laboratory air under different conditions of the maximum fatigue loads to obtain the fatigue crack propagation data for the statistical analysis. In order to analyze the probabilistic aspect of fatigue crack propagation life, the goodness-of fit test for probability distribution of the fatigue crack propagation life at a specified grown crack is implemented through Anderson-Darling test. The good probability distribution of the fatigue crack propagation life is also verified under the conditions of the maximum fatigue loads.
Abstract: In this study, the effects of B4C and SiC particle reinforcements on wear properties of magnesium matrix metal composites produced by pressure infiltration method were investigated. AZ91 (9%Al-1%Zn) magnesium alloy was used as a matrix. AZ91 magnesium alloy was melted under an argon atmosphere. The melt was infiltrated to the particles with an appropriate pressure. Wear tests, hardness tests were performed respectively. Microstructure characterizations were examined by light optical (LOM) and scanning electron microscope (SEM). The results showed that uniform particle distributions were achieved in both B4C and SiC reinforced composites. Wear behaviors of magnesium matrix metal composites changed as a function of type of particles. SiC reinforced composite has better wear performance and higher hardness than B4C reinforced composite.
Abstract: This study aimed for improving wear resistance of AM60 magnesium alloy by Ti addition (0, 0.2, 0.5, 1wt%Ti). An electric resistance furnace was used to produce alloys. Pure Mg together with Al, Al-Ti and Al-Mn were melted at 750 0C in a stainless steel crucible under controlled Ar gas atmosphere and then poured into a metal mould preheated at 250 0C. Microstructure characterizations were performed by light optical (LOM) and scanning electron microscope (SEM) after the wear test. Wear rates and friction coefficients were measured with a pin-on-disk type UTS-10 Tribometer test device under a load of 20N. The results showed that Ti addition altered the morphology and the amount of b-Mg17Al12 phase in the microstructure of AM60 alloy. b-Mg17Al12 phases on the grain boundaries were refined with increasing amount of Ti. An improvement in wear resistance of AM60 alloy was observed due to the alteration in the microstructure by Ti addition.
Abstract: This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.
Abstract: In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.
Abstract: The use of magnesium alloys is limited due to their
susceptibility to corrosion although they have many attractive
physical and mechanical properties. To increase mechanical and
corrosion properties of these alloys, many deposition method and
coating types are used. Electroless Ni–B coatings have received
considerable interest recently due to its unique properties such as
cost-effectiveness, thickness uniformity, good wear resistance,
lubricity, good ductility and corrosion resistance, excellent
solderability and electrical properties and antibacterial property. In
this study, electroless Ni-B coating could been deposited on AZ91
magnesium alloy. The obtained coating exhibited a harder and
rougher structure than the substrate.
Abstract: It is necessary to predict a fatigue crack propagation
life for estimation of structural integrity. Because of an uncertainty
and a randomness of a structural behavior, it is also required to
analyze stochastic characteristics of the fatigue crack propagation life
at a specified fatigue crack size. The essential purpose of this study is to find the effect of load ratio
on probability distribution of the fatigue crack propagation life at a
specified grown crack size and to confirm the good probability
distribution in magnesium alloys under various fatigue load ratio
conditions. To investigate a stochastic crack growth behavior, fatigue
crack propagation experiments are performed in laboratory air under
several conditions of fatigue load ratio using AZ31. By Anderson-Darling test, a goodness-of-fit test for probability
distribution of the fatigue crack propagation life is performed. The
effect of load ratio on variability of fatigue crack propagation life is
also investigated.
Abstract: To develop AZ91D magnesium alloys with improved
properties, we have applied TiN and VN/TiN multilayer coatings
using DC magnetron sputter technique. Coating structure, surface
morphology, chemical bonding and corrosion resistance of coatings
were analyzed by x-ray diffraction (XRD), scanning electron
microscope (SEM), x-ray photoelectron spectroscopy (XPS), and
tafel extrapolation method, respectively. XPS analysis reveal that VN
overlayer reacts with oxygen at the VN/TiN interface and forms more
stable TiN layer. Morphological investigations and the corrosion
results show that VN/TiN multilayer thin film coatings are quite
effective to optimize the corrosion resistance of Mg alloys.
Abstract: Tensile specimens of nonflammable AZ91D Mg alloy were fabricated in this study via cold chamber die-casting process. Dimensions of tensile specimens were 25mm in length, 4mm in width, and 0.8 or 3.0mm in thickness. Microstructure observation was conducted before and after tensile tests at room temperature. In the die casting process, various injection distances from 150 to 260mm were employed to obtain optimum process conditions. Distribution of Al12Mg17 phase was the key factor to determine the mechanical properties of die-cast Mg alloy. Specimens with 3mm of thickness showed superior mechanical properties to those with 0.8mm of thickness. Closed networking of Al12Mg17 phase along grain boundary was found to be detrimental to mechanical properties of die-cast Mg alloy.
Abstract: The fatigue crack growth is stochastic because of the fatigue behavior having an uncertainty and a randomness. Therefore, it is necessary to determine the probability distribution of a grown crack size at a specific fatigue crack propagation life for maintenance of structure as well as reliability estimation. The essential purpose of this study is to present the good probability distribution fit for the grown crack size at a specified fatigue life in a rolled magnesium alloy under different specimen thickness conditions. Fatigue crack propagation experiments are carried out in laboratory air under three conditions of specimen thickness using AZ31 to investigate a stochastic crack growth behavior. The goodness-of-fit test for probability distribution of a grown crack size under different specimen thickness conditions is performed by Anderson-Darling test. The effect of a specimen thickness on variability of a grown crack size is also investigated.
Abstract: Single crystals of Magnesium alloys such as pure Mg,
Mg-1Zn-0.5Y, Mg-0.1Y, and Mg-0.1Ce alloys were successfully
fabricated in this study by employing the modified Bridgman method.
To determine the exact orientation of crystals, pole figure
measurement using X-ray diffraction were carried out on each single
crystal. Hardness and compression tests were conducted followed by
subsequent recrysatllization annealing. Recrystallization kinetics of
Mg alloy single crystals has been investigated. Fabricated single
crystals were cut into rectangular shaped specimen and solution
treated at 400oC for 24 hrs, and then deformed in compression mode
by 30% reduction. Annealing treatment for recrystallization has been
conducted on these cold-rolled plates at temperatures of 300oC for
various times from 1 to 20 mins. The microstructure observation and
hardness measurement conducted on the recrystallized specimens
revealed that static recrystallization of ternary alloy single crystal was
very slow, while recrystallization behavior of binary alloy single
crystals appeared to be very fast.
Abstract: Single crystals of Magnesium alloys such as Mg-1Al,
Mg-1Zn-0.5Y, Mg-3Li, and AZ31 alloys were successfully fabricated in this study by employing the modified Bridgman method. Single
crystals of pure Mg were also made in this study. To determine the exact orientation of crystals, Laue back-reflection method and pole figure measurement were carried out on each single crystal. Dimensions of single crystals were 10 mm in diameter and 120 mm in
length. Hardness and compression tests were conducted and the results
revealed that hardness and the strength strongly depended on the
orientation. The closer to basal one the orientation was, the higher hardness and compressive strength were. The effect of alloying was
not higher than that of orientation. After compressive deformation of single crystals, the orientation of the crystals was found to rotate and to be parallel to the basal orientation.
Abstract: As the material used for fuselage structure must
possess low density, high strength to weight ratio, the selection of
appropriate materials for fuselage structure is one of the most
important tasks. Aluminum metal itself is soft and low in strength. It
can be made stronger by giving proper combination of suitable alloy
addition, mechanical treatment and thermal treatment. The usual
thermal treatment given to aluminum alloys is called age-hardening
or precipitation hardening. In this paper, the studies are carried out on
7075 aluminum alloy which is how to improve strength level for
fuselage structure. The marked effect of the strength on the ternary
alloy is clearly demonstrated at several ageing times and
temperatures. It is concluded that aluminum-zinc-magnesium alloy
can get the highest strength level in natural ageing.
Abstract: This study was aimed for investigating of
manufacturing high aluminum content Mg alloys using a horizontal
twin roll caster. Recently, weight saving has been key issues for lighter
transport equipments as well as electronic component parts. As
alternative materials to aluminum alloys, developing magnesium alloy
with higher strength has been expected. Normally high Aluminum
content Mg alloy has poor ductility and is difficult to be rolled because
of its high strength. However, twin roll casting process is suitable for
manufacturing wrought Mg alloys because materials can be cast
directly from molten metal. In this study, manufacturing of high
aluminum content magnesium alloy sheet using the roll casting
process has been carried out. Effects of manufacturing parameter, such
as roll velocity, pouring temperature and roll gap, on casting was
investigated. A microscopic observation of the crystals of cross section
of as cast strip as well as rolled strip was conducted.
Abstract: Magnesium alloy has been widely investigated as
biodegradable cardiovascular stent and bone implant. Its application
for biodegradable esophageal stenting remains unexplored. This
paper reports the biodegradation behaviors of AZ31 magnesium alloy
in artificial saliva and various types of beverage in vitro. Results
show that the magnesium ion release rate of AZ31 in artificial saliva
for a stent (2cm diameter, 10cm length at 50% stent surface
coverage) is 43 times lower than the daily allowance of human body
magnesium intakes. The degradation rates of AZ31 in different
beverages could also be significantly different. These results suggest
that the esophagus in nature is a less aggressive chemical
environment for degradation of magnesium alloys. The significant
difference in degradation rates of AZ31 in different beverages opens
new opportunities for development of degradation controllable
esophageal stent through customizing ingested beverages.
Abstract: Magnesium is used implant material potentially for
non-toxicity to the human body. Due to the excellent
bio-compatibility, Mg alloys is applied to implants avoiding removal
second surgery. However, it is found commercial magnesium alloys
including aluminum has low corrosion resistance, resulting
subcutaneous gas bubbles and consequently the approach as
permanent bio-materials. Generally, Aluminum is known to pollution
substance, and it raises toxicity to nervous system. Therefore
especially Mg-35Zn-3Ca alloy is prepared for new biodegradable
materials in this study. And the pulsed power is used in
constant-current mode of DC power kinds of anodization. Based on
the aforementioned study, it examines corrosion resistance and
biocompatibility by effect of current and frequency variation. The
surface properties and thickness were compared using scanning
electronic microscopy. Corrosion resistance was assessed via
potentiodynamic polarization and the effect of oxide layer on the body
was assessed cell viability. Anodized Mg-35Zn-3Ca alloy has good
biocompatibility in vitro by current and frequency variation.
Abstract: Scatter behavior of fatigue life in die-cast AM60B
alloy was investigated. For comparison, those in rolled AM60B alloy
and die-cast A365-T5 aluminum alloy were also studied. Scatter
behavior of pore size was also investigated to discuss dominant
factors for fatigue life scatter in die-cast materials. Three-parameter
Weibull function was suitable to explain the scatter behavior of both
fatigue life and pore size. The scatter of fatigue life in die-cast
AM60B alloy was almost comparable to that in die-cast A365-T5
alloy, while it was significantly large compared to that in the rolled
AM60B alloy. Scatter behavior of pore size observed at fracture
nucleation site on the fracture surface was comparable to that
observed on the specimen cross-section and also to that of fatigue
life. Therefore, the dominant factor for large scatter of fatigue life in
die-cast alloys would be the large scatter of pore size. This
speculation was confirmed by the fracture mechanics fatigue life
prediction, where the pore observed at fatigue crack nucleation site
was assumed as the pre-existing crack.
Abstract: This paper presents a portable robot that is to use for
welding process in shipbuilding yard. It has six degree of freedom and
3kg payload capability. Its weight is 21.5kg so that human workers can
carry it to the work place. Its body mainly made of magnesium alloy
and aluminum alloy for few parts that require high strength. Since the
distance between robot and controller should be 50m at most, the robot
controller controls the robot through EtherCAT. RTX and KPA are
used for real time EtherCAT control on Windows XP. The
performance of the developed robot was satisfactory, in welding of U
type cell in shipbuilding yard.
Abstract: Magnesium alloys have gained increased attention in recent years in automotive, electronics, and medical industry. This because of magnesium alloys have better properties than aluminum alloys and steels in respects of their low density and high strength to weight ratio. However, the main problems of magnesium alloy welding are the crack formation and the appearance of porosity during the solidification. This paper proposes a unique technique to weld two thin sheets of AZ31B magnesium alloy using a paste containing Ag nanoparticles. The paste containing Ag nanoparticles of 5 nm in average diameter and an organic solvent was used to coat the surface of AZ31B thin sheet. The coated sheet was heated at 100 °C for 60 s to evaporate the solvent. The dried sheet was set as a lower AZ31B sheet on the jig, and then lap fillet welding was carried out by using a pulsed Nd:YAG laser in a closed box filled with argon gas. The characteristics of the microstructure and the corrosion behavior of the joints were analyzed by opticalmicroscopy (OM), energy dispersive spectrometry (EDS), electron probe micro-analyzer (EPMA), scanning electron microscopy (SEM), and immersion corrosion test. The experimental results show that the wrought AZ31B magnesium alloy can be joined successfully using Ag nanoparticles. Ag nanoparticles insert promote grain refinement, narrower the HAZ width and wider bond width compared to weld without and insert. Corrosion rate of welded AZ31B with Ag nanoparticles reduced up to 44 % compared to base metal. The improvement of corrosion resistance of welded AZ31B with Ag nanoparticles due to finer grains and large grain boundaries area which consist of high Al content. β-phase Mg17Al12 could serve as effective barrier and suppressed further propagation of corrosion. Furthermore, Ag distribution in fusion zone provide much more finer grains and may stabilize the magnesium solid solution making it less soluble or less anodic in aqueous