Iranian Journal of Materials Science and Engineering

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In the present study, the early stages of the surface oxidation and fluoridation of liquid AZ91D and AM60B alloys under ultra-high purity (UHP) argon, dry air, and air mixed with two different protective fluorine-bearing gases were studied. The chemical composition, morphology and thickness of the surface films formed inside the trapped bubbles were characterized by SEM and EDS analyses. It is found that the molten AM60B alloy is more sensitive to impurities under UHP argon gas than AZ91D alloy. Under dry air atmosphere, the entire surface of molten AZ91D alloy is covered with an oxide layer and thinner thickness than the surface film formed on AM60B alloy which has a rough surface exhibiting granular growth in later stages of oxidation. The EDS analyses show that film chemistry is mainly composed of Mg, Al, and O elements. Under fluorine-bearing gas/air mixtures with either SF₆ or HFC-R134a at 3.5%vol., a fresh surface film formed with a flat and dense morphology of a uniform thickness composed of mixed Mg, F, Al, and O elements. It is observed that there is a lower O:F intensity ratio in the surface film formed on the molten AZ91D alloy under 1,1,1,2-tetra-fluoroethane (HFC-R134a) mixed with dry air compared to the AM60B alloy under both air/ R134a and air/SF₆ mixtures which shows a higher fluorine concentration in the surface film a leading to a better oxidation resistance .

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A full factorial design of experiment was applied running 36 experiments to investigate the effects of milling parameters including cutting speed with three levels of 62.83, 94.24 and 125.66 m/min, feed rate with three levels of 0.1, 0.2 and 0.3 mm/tooth, cutting depth with two levels of 0.5 and 1 mm and machining media with two levels, on surface integration properties of magnesium AZ91C alloy such as grain size, secondary phase percent, surface microhardness and surface roughness. In all cases, a fine grained surface with higher secondary phase sediment and microhardness obtained comparing the raw material. According to analysis of variance results, the most effective parameter on grain size, secondary phase percent and microhardness was cutting depth and the most effective parameter on surface roughness was feed rate. although the grain size in all machined samples was smaller than that of the raw material but due to the dual effect of cryogenic conditions, which both cool and lubricate and reduce the temperature and strain rate at the same time, the direct effect of this parameter on grain size was not significant. Also, the all interaction effects of parameters on grain size and microhardness were significant.

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Magnesium and the alloys made from the same metal are utilized in the engineering applications such as automotive, marine, and aircraft, among others due to high strength to weight. Nevertheless, the applications of magnesium alloys are currently limited to a certain level due to their poor wear and corrosion properties. Another effective strategy for enhancing these properties involves utilizing the process of equal channel angular extrusion (ECAE), which serves to refine the grain structure, thereby resulting in improved material properties. This paper aims to establish the relationship between grain size reduction and wear and corrosion of AZ91 alloy. The wear performances of both coarse-grained and fine-grain alloy were conducted using L9 orthogonal array of experiments in order to study the effects of control parameters on wear performance. In the study, it has also been identified that through ECAP, the corrosion barrier and wear characteristics of the alloy were enhanced due to fine-grain-structure and the spheroidal precipitation of the second β-phase particles. Further, the influence of these changes on the performance of the AZ91 Mg alloy was assessed using SEM.