Optimisation of alloy composition for highly-formable magnesium sheet

The effectiveness of Ca or Gd addition on ductility and formability of Mg-Zn-Zr based dilute alloys in deep drawing has not been systematically compared previously.In this study,formable Mg-Zn-Gd-Zr and Mg-Zn-Ca-Zr sheet alloys are produced by hot rolling.These sheets have similarly weakened basal texture,but the sheet of the Mg-Zn-Gd-Zr alloys has higher ductility and formability than that of Mg-Zn-Ca-Zr alloys.The combined addition of 0.2wt%Ca and 0.4wt%Gd to the Mg-1Zn-0.5Zr(wt%)alloy leads to a Mg-1Zn-0.4Gd-0.2Ca-0.5Zr alloy that has even better ductility,and its formability during deep drawing is comparable to the benchmark Al6016 sheet.An increase in Ca content from 0.2wt%to 0.5wt%leads to decreased sheet ductility and formability,predominantly due to grain boundary embrittlement.

Textural Evolution of AZ31B Magnesium Alloy Sheets Undergoing Repeated Unidirectional Bending at Room Temperature

In this paper, repeated unidirectional bending （RUB）, was applied to improve the texture of AZ31B magnesium alloy sheets so as to enhance their stamping properties. The samples undergoing RUB were annealed at different temperatures. The mechanical properties, formability, textural components and microstructure of the samples before and after RUB were characterized and compared. It was found that the basal textural component was reduced dramatically by RUB, and that （1212） and （1211） textural components appeared. Annealing has a great effect on the mechanical properties of samples undergoing RUB. The plasticity and stamping formability of samples were greatly improved by RUB and annealing at 260℃ for 1 h, and elongation to fracture and Erichsen value were increased to 38% and 67%, respectively.

Incremental forming of free surface with magnesium alloy AZ31 sheet at warm temperatures

The formabilityof AZ31 sheet begins to increase drastically at 150℃.The incremental forming technique was thus applied to AZ31 sheet at 150℃to utilize the formability to its fullest capacity at the lowest possible temperature for forming applications.A surface scanning technique was used followed by the tool path generation to incrementally form an egg surface.After thorough examination of various tool paths,the surface was most successfully produced by forming an intermediate shape followed by a series of tool paths.Flexible scale stickers were devised to improve the accuracy in the measurement of grid deformation.

Structure and properties of AZ31B magnesium alloy sheets processed by repeatedly unidirectional bending at different temperatures

Repeatedly unidirectional bending(RUB) was applied to the magnesium alloy sheet to improve the basal texture.The effect of RUB temperature on resulting structure and room temperature properties was investigated.The texture components of the sheet undergoing RUB at recovery temperature were similar to those of the sheet undergoing RUB at room temperature(RT).As the RUB temperature increased to above recrystallization temperature,the texture components became more disperse and the pyramidal components increased.With the increase of RUB temperature,the grain size near the surface of the sheets undergoing RUB tended to grow up.When the sheets were processed by RUB at medium-high temperature followed by annealing at 533 K,the yield strength and fracture elongation were lower than those of the cold rolled sheet;however,the Erichsen value was slightly higher than that of the cold rolled sheet.The sheet undergoing RUB at RT followed by annealing at 533 K represented the best mechanical properties.

The Stamping Formability of AZ31 Magnesium Alloy Sheet Improved by Equal-channel Angular Pressing

Equal channel angular pressing （ECAP） processing and annealing were applied to the AZ31 magnesium alloy sheets to evaluate the potential improvement in the mechanical properties and formability. The ECAP experiment was conducted at 300 ℃ in a die having an included angle of 90o between two channels by the BCZ route with the sheets rotated by 90°about the normal axis of plate plane. The tensile tests and conical cup tests were conducted at various temperatures from 20 to 250 ℃. The experimental results indicated that improving the working temperatures could lead to the soft in the material and the enhancement of ductility. Comparatively, the ECAPed AZ31 alloy sheets showed the lower yield strength and smaller conical cup value （CCV） than the unECAPed counterpart in the room temperature. The difference in yield strength between them became small in the elevated temperature, but the ECAPed samples still had the smaller CCV value, implying the improved formability. The texture of the AZ31 alloy sheets could be modified by ECAP and the decrease in the yield strength and more uniform deformation realized in the material, so the formability of AZ31 alloy sheets was improved.

Texture evolution of extruded AZ31 magnesium alloy sheets

The evolution of texture during the annealing and hot rolling process of extruded AZ31 magnesium alloy sheets was studied. There are two kinds of texture components in the extruded AZ31 sheets. One is {0002}<1010> and the other is {1010}<1120>. The {0002}<1010>component predominates. After annealing at 723 K for 3 h, both {0002}<1010> and {1010}<1120> components are strengthened moderately. This indicates that grains with both two components mentioned above grow faster than those with other orientations. The {1010}<1120> component disappears and the intensity of {0002}<1010> component decreases significantly after hot rolling with a 30% reduction at 623 K. This is mainly attributed to rotational dynamic recrystallization (RDX) during the hot rolling.

Microstructures and tensile properties of AZ31 magnesium alloy thin sheet

Microstructures, tensile properties, fracture characteristics of commercial AZ31 magnesium alloy thin sheet were studied by optical microscopy, scanning electron microscopy and uniaxial tensile test. Tensile tests were carried out at room temperature and 473K, with strain rates of 8.3×10 -44.2×10 -3s -1. The results show that grain refinement effects are better at high temperature, and it increases with the decrease of strain rate at 473K. Compared with that tested at room temperature, no apparent uniform plastic deformation stage exists in the stress—strain curves tested at 473K; afterwards, the stress—strain curve presents wavelike downward under condition of the small strain rate. Yield strength and tensile strength of the alloy decrease drastically while the elongation increases greatly. With the increase of strain rate, yield strength and tensile strength of the alloy increase, but the elongation decreases. The fracture of the alloy tested at room temperature is quasi-cleavage failure and ductile failure at 473K.

Cold stamping for AZ31B magnesium alloy sheet of cell phone house

Electric product house of magnesium alloy sheet is usually obtained by warm stamping owing to its poor plasticity and formability at room temperature.The formability of AZ31B magnesium alloy sheet can be improved by repeated unidirectional bending(RUB)process through control of(0002)basal texture.Compared with as-received sheet,the Erichsen value(IE)of the sheet underwent RUB process increases to 5.90 from 3.53 at room temperature.It is also confirmed that cell phone houses could be stamped successfully in crank press with AZ31B magnesium alloy sheets underwent RUB process.It provides an alternative to the electronics industry in the application of magnesium alloys.

锌铝镁冲压后表面黑点缺陷原因分析

针对唐钢镀锌铝镁板在冲压过程中出现的表面黑点现象,使用光学显微镜(OM)、扫描电子显微镜(SEM)及能谱仪等检测仪器进行检测,分析其冲压后表面出现黑点的原因,结果表明,在锌铝镁镀层钢板冲压过程中,镀层开裂,润滑油夹杂着异物颗粒在宽裂纹处聚集,表现为黑点缺陷。

Microstructure and mechanical properties of a high ductility Mg–Zn–Mn–Ce magnesium alloy

A high-ductility ZME200(Mg–2.3Zn–0.4Mn–0.2Ce^(1))alloy was newly developed for vehicle closure and structure applications,based on an earlier ZE20(Mg–2.0Zn–0.2Ce)alloy for extrusion applications.Previous study indicates that the hot deformation behavior of as-cast ZME200 alloy varies with processing parameters,namely temperature and strain rate.In this follow-up study,a conventional rolling process was optimized to obtain magnesium sheets with a very fine grain structure and high ductility.The microstructure,mechanical properties,and corrosion resistances of ZME200 alloy were investigated,and compared with those of commercial AZ31 magnesium alloy.It was demonstrated that the ZME200 alloy sheet exhibits extraordinarily higher ductility(36%in tensile elongation),much superior stretch formability(an Erichsen value of 9.5),lower anisotropy,comparable strength and corrosion resistance to AZ31 alloy.The unique RD–TD double split texture with remarkably reduced intensity and grain refinement gives rise to the significantly improved ductility and formability at room-temperature.

Progress in twin roll casting of magnesium alloys: A review

Twin roll casting was commercialized for a strip production from ferrous and non-ferrous alloys in the 1950 s;however,its application to magnesium has proven difficult and still creates major challenges.This report describes global efforts in expanding manufacturing capabilities of magnesium sheet through twin roll casting path,offering many benefits,including a reduction in number of processing steps and energy savings.In addition to hardware design,alloy transformation during processing,product microstructure and properties,examples of successful solutions along with present technology and knowledge limitations are discussed.A particular attention is paid to developments at Canmet MATERIALS,having the only in North America pilot scale twin roll casting facility,devoted to magnesium.Efforts are described that aim at design of new magnesium alloys,which could take advantage of unique processing conditions during twin roll casting and contribute to the overall progress in magnesium sheet manufacturing.

The slip activity during the transition from elastic to plastic tensile deformation of the Mg-Al-Mn sheet

The deformation behavior of the Mg-Al-Mn sheet was investigated during tensile loading along the rolling(RD)and transversal direction(TD)with special attention to the early stage of deformation.The activity of dislocation slip systems during the transition from elastic to plastic deformation was revealed by the acoustic emission(AE)technique.The parametrization and statistical AE analysis using the adaptive sequential k-mean(ASK)clustering provided necessary information about the individual deformation mechanisms and their evolution.The AE findings were supported by microstructural analyses,including in-situ secondary electron(SE)imaging and Schmid factor estimation for the activity of particular dislocation slip systems with respect to the loading direction.It was found that basal slip is the dominating mechanism up to the stress of~80 MPa in both loading directions with an absolute dominance during the RD-loading,while during the TD-loading,the contribution of prismatic slip to the deformation at stresses above 50 MPa was determined.Below the yielding in both loading directions,the predominance of prismatic over pyramidal slip was found at the stress in the range of 80-110 MPa and the opposite tendency occurred at stresses between 110 and 140 MPa.

不同退火温度下预压缩镁板冲压成形性能研究

为探讨孪晶对镁合金静态再结晶的影响机制,首先对1 mm厚AZ31镁板沿轧向预压缩7%引入{1012}拉伸孪晶,然后对预孪晶镁板在200、250、300和350℃下进行3 h的退火处理,研究了镁板显微组织演变,探讨了温度对力学性能和冲压成形性能的影响规律。结果表明:200℃退火镁板未发生再结晶,保留了孪晶片层结构,同时去除了残余应力,降低了位错密度,导致基体软化。随着退火温度的升高,再结晶发生完全,晶粒尺寸先增大后减小,300℃的退火试样晶粒尺寸达到峰值。孪晶结构导致了晶格畸变,在基体中引入了较高的储存能,利于再结晶晶粒的形核及生长。随退火温度的升高,镁板的屈服强度(YS)和极限抗拉强度(UTS)先降低后升高,在300℃时最低;伸长率(EL)先升高后降低,在300℃最佳。随着退火温度升高到300℃,因再结晶晶粒的逐渐长大,晶粒取向变得有利,导致基体软化,从而YS和UTS降低,EL升高。而350℃退火的试样晶粒尺寸变得更加均匀细小,利于强度的改善。随着退火温度的升高,镁板的加工硬化指数n先增加后减小,屈强比ReL/Rm和塑性应变比r先减小后增加,300℃退火试样的n值最大、Re L/Rm和r值最小,使其达到了优异的杯突成形性能。

基于共轭梯度算法的镁板热轧压下量PID控制优化

为了进一步提高镁合金板热轧厚度成形控制能力,设计了一种基于共轭梯度算法的镁合金板热轧压下量PID控制方法。基于共轭梯度算法对压下量PID控制优化,引入到双辊热轧镁合金板带横向厚度分布的预测与控制中。研究结果表明:板带预测压下量分布和真实情况相吻合,说明基于共轭梯度算法的导电用镁合金板热轧压下量PID控制优化设计具有良好可靠性。该预测模型平均绝对误差为4.2μm,这验证了基于共轭梯度算法的导电用镁合金板热轧压下量PID控制优化是可行的。该研究有助于提高热轧镁合金板材的成形效率,也可托找到其它的合金轧制领域,具有很好的应用推广价值。

Microstructures and mechanical properties of hot rolled AZ31 Mg alloy sheets

The microstructures and mechanical properties of hot rolled AZ31 Mg alloy sheets were studied to understand the microstrucrure evolution during AZ31 Mg alloy hot rolling process. The roller was heated to 180℃with burning hydrogen, and the extruded plates were rolled at 400℃from 10 to 1 mm with a reduction of 30% in thickness per pass. The result shows that there is no side-cracking of these rolled sheets every pass. The extruded microstructures are greatly refined and mechanical properties are improved. The fine grains of about 4μm were obtained of the final 0.9 mm sheets.

Consideration of Castability and Formability for New Magnesium Alloys

A comprehensive consideration based on castability or plastic formability, as well as mechanical properties for development of either cast magnesium alloys or wrought magnesium alloys is a very important issue. To develop new magnesium alloy sheets with high formability at room temperature, the microstructure, texture, ductility and anisotropy of rolled Mg-Zn-Gd alloy sheets were investigated. The sheets exhibit an excellent ultimate elongation of nearly 50% and an uniform elongation greater than 30% with a very low planar anisotropy. The new sheet has a random basal texture and the basal pole is tilted by maximum 40° from the normal direction towards the transverse direction. The majority of grains in the tilted texture have an orientation favorable for both basal slip and tensile twining because of their high Schmid factor. The low planar anisotropy, the large uniform elongations and the high strain hardening rate observed in the Mg-Zn-Gd sheets result in excellent room temperature formability, the Erichsen values reach ~8, well comparable with the conventional aluminum alloys sheets at room temperature. The solidification pathways and phase equilibria of Mg-Al-Ca alloys have been profoundly investigated by using thermal analysis and thermodynamic calculations. The relationship between hot tearing tendency and alloy compositions were discussed in terms of strength of the mushy zone, solidification pathways and feeding mechanisms, et al. Thixoforming refers to as that metal components are formed in their semi-solid state. Criteria for thixoforming are summarized and then the thixoformability of Mg-Al-Ca based alloys (AC alloys) are evaluated using the thermodynamic calculations based on the consideration of metallurgical parameters.

热浸镀锌铝镁镀层钢板硅烷涂装性能评价

以热浸镀纯Zn镀层板为对比,对具有不同表面状态(涂油或钝化)的热浸镀锌铝镁(ZM)镀层平板及双拉变形板在汽车主机厂进行了硅烷电泳处理,随后对其硅烷膜和电泳漆膜的品质进行了评价。结果表明:ZM镀层板的硅烷涂装性能优于纯Zn镀层板;变形对纯Zn镀层和ZM镀层的涂装性能无明显影响,但表面钝化会明显降低电泳漆膜的附着力和耐蚀性。

Study on the formation of intermetallic phases in the new type of Zn-Mg coatings on steel sheets

Zn-Mg alloy coatings were obtained by physical vapor deposition （PVD） on electroplated steel sheets. Study on the formation of intermetallic phases in the coatings was conducted through the use of X-ray diffraction （XRD） ,scanning electron microscope （SEM） and glow discharge optical emission spectrometry （GDOES）. It is found that MgZn2 is the main Zn-Mg alloy phase formed after heat treatment. The formation of Mg-Zn intermetallic phases is controlled not only by thermodynamics, but also by kinetics. MgZn2 has different morphologies, such as laminar structure,porous structure and floc-like structure,which are mainly determined by the annealing temperature. Obvious diffusion of Mg starts at 350 ℃, and the diffusion of iron increases significantly when the temperature is elevated to 380℃.

两步升温热轧工艺对AZ31镁合金薄板各向异性及成形性能影响

采用两步梯度升温轧制工艺对AZ31镁合金板材进行轧制,探究轧制过程对镁合金板材显微组织织演化、各向异性及成形性能的影响。第I步轧制在300℃开展,其每道次压下量为15%;第II步轧制在550℃进行,其每道次压下量为40%。经过共4道次轧制后,最终获得厚度为1 mm的镁合金薄板。结果显示,第I步低温轧制过程不更换轧制方向时,试样中生成大量剪切带;而更换轧制方向时,组织内部主要为孪晶和再结晶晶粒。随着II步轧制温度的升高,由于动态再结晶急剧激发,剪切带数量及尺寸逐渐减小,晶粒明显细化。根据IGMA分析得出,非基面滑移,特别是棱柱面滑移活动增强。轧制退火后的AZ31镁合金薄板的力学性能得到提高,各向异性减小,冲压成形性能得到明显改善。