Accelerated design of high-performance Mg-Mn-based magnesium alloys based on novel bayesian optimization

Magnesium(Mg),being the lightest structural metal,holds immense potential for widespread applications in various fields.The development of high-performance and cost-effective Mg alloys is crucial to further advancing their commercial utilization.With the rapid advancement of machine learning(ML)technology in recent years,the“data-driven''approach for alloy design has provided new perspectives and opportunities for enhancing the performance of Mg alloys.This paper introduces a novel regression-based Bayesian optimization active learning model(RBOALM)for the development of high-performance Mg-Mn-based wrought alloys.RBOALM employs active learning to automatically explore optimal alloy compositions and process parameters within predefined ranges,facilitating the discovery of superior alloy combinations.This model further integrates pre-established regression models as surrogate functions in Bayesian optimization,significantly enhancing the precision of the design process.Leveraging RBOALM,several new high-performance alloys have been successfully designed and prepared.Notably,after mechanical property testing of the designed alloys,the Mg-2.1Zn-2.0Mn-0.5Sn-0.1Ca alloy demonstrates exceptional mechanical properties,including an ultimate tensile strength of 406 MPa,a yield strength of 287 MPa,and a 23%fracture elongation.Furthermore,the Mg-2.7Mn-0.5Al-0.1Ca alloy exhibits an ultimate tensile strength of 211 MPa,coupled with a remarkable 41%fracture elongation.

Interplay of laser power and pore characteristics in selective laser melting of ZK60 magnesium alloys:A study based on in-situ monitoring and image analysis

This study offers significant insights into the multi-physics phenomena of the SLM process and the subsequent porosity characteristics of ZK60 Magnesium(Mg)alloys.High-speed in-situ monitoring was employed to visualise process signals in real-time,elucidating the dynamics of melt pools and vapour plumes under varying laser power conditions specifically between 40 W and 60 W.Detailed morphological analysis was performed using Scanning-Electron Microscopy(SEM),demonstrating a critical correlation between laser power and pore formation.Lower laser power led to increased pore coverage,whereas a denser structure was observed at higher laser power.This laser power influence on porosity was further confirmed via Optical Microscopy(OM)conducted on both top and cross-sectional surfaces of the samples.An increase in laser power resulted in a decrease in pore coverage and pore size,potentially leading to a denser printed part of Mg alloy.X-ray Computed Tomography(XCT)augmented these findings by providing a 3D volumetric representation of the sample internal structure,revealing an inverse relationship between laser power and overall pore volume.Lower laser power appeared to favour the formation of interconnected pores,while a reduction in interconnected pores and an increase in isolated pores were observed at higher power.The interplay between melt pool size,vapour plume effects,and laser power was found to significantly influence the resulting porosity,indicating a need for effective management of these factors to optimise the SLM process of Mg alloys.

Magnesium alloys as alternative anode materials for rechargeable magnesium-ion batteries:Review on the alloying phase and reaction mechanisms

Magnesium-ion batteries(MIBs)are promising candidates for lithium-ion batteries because of their abundance,non-toxicity,and favorable electrochemical properties.This review explores the reaction mechanisms and electrochemical characteristics of Mg-alloy anode materials.While Mg metal anodes provide high volumetric capacity and dendrite-free electrodeposition,their practical application is hindered by challenges such as sluggish Mg^(2+)ion diffusion and electrolyte compatibility.Alloy-type anodes that incorporate groups XIII,XIV,and XV elements have the potential to overcome these limitations.We review various Mg alloys,emphasizing their alloying/dealloying reaction mechanisms,their theoretical capacities,and the practical aspects of MIBs.Furthermore,we discuss the influence of the electrolyte composition on the reversibility and efficiency of these alloy anodes.Emphasis is placed on overcoming current limitations through innovative materials and structural engineering.This review concludes with perspectives on future research directions aimed at enhancing the performance and commercial viability of Mg alloy anodes and contributing to the development of high-capacity,safe,and cost-effective energy storage systems.

Research advances of magnesium and magnesium alloys globally in 2023

Magnesium materials have attracted the attention of many researchers,and the related research is expanding.This article summarizes the advance in the research and development of magnesium materials globally in 2023 from bibliometric and scientific perspectives.More than 4680 articles on Mg and its alloys were published and indexed in the Web of Science(WoS)Core Collection database last year.The bibliometric analyses show that the traditional structural Mg alloys,functional Mg materials,and corrosion and protection of Mg alloys are still the main research focus.Therefore,this review paper mainly focuses on the research progress of Mg cast alloys,Mg wrought alloys,bio-magnesium alloys,Mg-based energy storage materials,corrosion and protection of Mg alloys in 2023.In addition,future research directions are proposed based on the challenges and obstacles identified throughout this review.

Comprehensive insights into recent innovations:Magnesium-inclusive high-entropy alloys

This review focuses on thermodynamic and physical parameters,synthesis methods,and reported phases of Magnesium(Mg)containing high-entropy alloys(HEAs).Statistical data of publications concerning Mg-containing HEAs were collected and analyzed.Data on the chemical elements included in Mg-containing HEAs,their theoretical end experimental densities,thermodynamic parameters,physical parameters,fabricated techniques and reported phases were also collected and discussed.On the basis of this information,a new classification for HEAs was proposed.It is also shown that the existing thermodynamic parameters cannot accurately predict the formation of a single phase solid solution for Mg-containing HEAs.The physical parameters of Mg-containing HEAs are within a wide range,and most of the synthesized Mg-containing HEAs have a complex multiphase structure.

Degradation and biocompatibility of one-step electrodeposited magnesium thioctic acid/magnesium hydroxide hybrid coatings on ZE21B alloys for cardiovascular stents

Constructing a functional hybrid coating appears to be a promising strategy for addressing the poor corrosion resistance and insufficient endothelialization of Mg-based stents.Nevertheless,the steps for preparing composite coatings are usually complicated and time-consuming.Herein,a novel composite coating,composed of bioactive magnesium thioctic acid(MTA)layer formed by deposition and corrosion-resistant magnesium hydroxide(Mg(OH)_(2))layer grown in situ,is simply fabricated on ZE21B alloys via one-step electrodeposition.Scanning electron microscopy(SEM)shows that the electrodeposited coating has a compact and uniform structure.And the high adhesion of the MTA/Mg(OH)_(2)hybrid coating is also confirmed by the micro-scratch test.Electrochemical test,scanning kelvin probe(SKP),and hydrogen evolution measurement indicate that the hybrid coating effectively reduces the degradation rate of Mg substrates.Haemocompatibility experiment and cell culture trial detect that the composite coating is of fine biocompatibility.Finally,the preparation mechanism of MTA/Mg(OH)_(2)hybrid coatings is discussed and proposed.This coating shows a great potential application for cardiovascular stents.

The influence of yttrium and manganese additions on the degradation and biocompatibility of magnesium-zinc-based alloys:In vitro and in vivo studies

The repair and regeneration of bone defects are highly challenging orthopedic problems.Recently,Mg-based implants have gained popularity due to their unique biodegradation and elastic modulus similar to that of human bone.The aim of our study is to develop a magnesium alloy with a controllable degradation that can closely match bone tissue to help injuries heal in vivo and avoid cytotoxicity caused by a sudden increase in ion concentration.In this study,we prepared and modified Mg-3Zn,Mg-3Zn-1Y,and Mg-2Zn-1Mn by hot extrusion,and used Mg-2.5Y-2.5Nd was as a control.We then investigated the effect of additions of Y and Mn on alloys'properties.Our results show that Mn and Y can improve not only compression strength but also corrosion resistance.The alloy Mg-2Zn-1Mn demonstrated good cytocompatibility in vitro,and for this reason we selected it for implantation in vivo.The degraded Mg-2Zn-1Mn implanted a bone defect area did not cause obvious rejection and inflammatory reaction,and the degradation products left no signs of damage to the heart,liver,kidney,or brain.Furthermore,we find that Mg-2Zn-1Mn can promote an osteoinductive response in vivo and the formation of bone regeneration.

Machine learning-guided accelerated discovery of structure-property correlations in lean magnesium alloys for biomedical applications

Magnesium alloys are emerging as promising alternatives to traditional orthopedic implant materials thanks to their biodegradability,biocompatibility,and impressive mechanical characteristics.However,their rapid in-vivo degradation presents challenges,notably in upholding mechanical integrity over time.This study investigates the impact of high-temperature thermal processing on the mechanical and degradation attributes of a lean Mg-Zn-Ca-Mn alloy,ZX10.Utilizing rapid,cost-efficient characterization methods like X-ray diffraction and optical microscopy,we swiftly examine microstructural changes post-thermal treatment.Employing Pearson correlation coefficient analysis,we unveil the relationship between microstructural properties and critical targets(properties):hardness and corrosion resistance.Additionally,leveraging the least absolute shrinkage and selection operator(LASSO),we pinpoint the dominant microstructural factors among closely correlated variables.Our findings underscore the significant role of grain size refinement in strengthening and the predominance of the ternary Ca_(2)Mg_(6)Zn_(3)phase in corrosion behavior.This suggests that achieving an optimal blend of strength and corrosion resistance is attainable through fine grains and reduced concentration of ternary phases.This thorough investigation furnishes valuable insights into the intricate interplay of processing,structure,and properties in magnesium alloys,thereby advancing the development of superior biodegradable implant materials.

Influence of laser parameters on the microstructures and surface properties in laser surface modification of biomedical magnesium alloys

Biodegradable implants from magnesium(Mg)alloys have emerged in the biomedical field especially in the orthopedic and cardiovascular stent applications owing to their low density,high specific strength,excellent machinability,good biocompatibility,and biodegradability.The primary shortcoming of Mg-based implants is their low corrosion resistance in the physiological environment,which results in premature mechanical integrity loss before adequate healing and the production of excessive hydrogen gas,which is harmful to the body tissues and negatively affects the biocompatibility of the implant.Laser surface modification has recently received attention because it can improve the surface properties such as surface chemistry,roughness,topography,corrosion resistance,wear resistance,hydrophilicity,and thus cell response to the surface of the material.The composition and microstructures including textures and phases of laser-treated surfaces depend largely on the laser processing parameters(input laser power,laser scan velocity,frequency,pulse duration,pressure,gas circulation,working time,spot size,beam focal position,and laser track overlap)and the thermophysical properties of the substrate(solubility,melting point,and boiling point).This review investigates the impacts of various laser surface modification techniques including laser surface melting,laser surface alloying,laser cladding,laser surface texturing,and laser shock peening,and highlights their significance in improving the surface properties of biodegradable Mg alloys for implant applications.Additionally,we explore how different laser process parameters affect its composition,microstructure,and surface properties in each laser surface modification technique.

Research progress on semi-continuous casting of magnesium alloys under external field

High-performance magnesium alloys are moving towards a trend of being produced on a large scale and in an integrated manner.The foundational key to their successful production is the high-quality cast ingots.Magnesium alloys produced through the conventional semi-continuous casting process inevitably contain casting defects,which makes it challenging to manufacture high-quality ingots.The integration of external field assisted controlled solidification technology,which combines physical fields such as electromagnetic and ultrasonic fields with traditional semi-continuous casting processes,enables the production of high-quality magnesium alloy ingots characterized by a homogeneous microstructure and absence of cracks.This article mainly summarizes the technical principles of those external field assisted casting process.The focus is on elaborating the refinement mechanism of different types of electromagnetic fields,ultrasonic fields,and combined physical fields during the solidification of magnesium alloys.Finally,the development prospects of producing highquality magnesium alloy ingots through semi-continuous casting under the external field were discussed.

Deformation mechanisms and microstructural characteristics of AZ61 magnesium alloys processed by a continuous expansion extrusion approach

The unique continuous extrusion-based severe plastic deformation approaches were proposed recently to process high-performance magnesium(Mg)alloys,while the in-depth deformation mechanisms under such complicated thermomechanical conditions were not well understood.In the present work,the fundamental deformation behaviors of AZ61 Mg alloy from 25 to 400°C were firstly examined under uniaxial compression deformation.Then the deformation mechanisms and microstructural characteristics of AZ61 Mg alloy during continuous expansion extrusion forming(CEEF)were systematically investigated by microstructural observations,finite element and cellular automata simulations.The results showed that the continuous evolutions of temperature,larger strain level and complex stress state with strain rate range of 0∼5.98 s−1 during CEEF brought the distinctive dynamic recrystallization behaviors and texture development in AZ61 Mg alloy,which were different to that of uniaxial compression deformation.In details,a remarkable grain refinement was achieved via CEEF processing due to the simultaneous actions of continuous dynamic recrystallization(CDRX)and discontinuous dynamic recrystallization(DDRX).Gradually enhanced CDRX were observed from center to edge region,which had significant effects on the texture distribution and texture strength.The c-axis of most grains rotated under distinctive shear strain following parabolic metal flow,resulting in stable fiber texture.In addition,the evolution of the internal texture of the alloy led to an obvious increase in the Schmid factor for the activation of basalc+aslip system.©2022 Chongqing University.Publishing services provided by Elsevier B.V.on behalf of KeAi Communications Co.Ltd.

Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21^(st )century

Rising concerns about climate change drive the demand for lightweight components.Magnesium(Mg)alloys are highly valued for their low weight,making them increasingly important in various industries.Researchers focusing on enhancing the characteristics of Mg alloys and developing their Metal Matrix Composites(MMCs)have gained significant attention worldwide over the past decade,driven by the global shift towards lightweight materials.Friction Stir Processing(FSP)has emerged as a promising technique to enhance the properties of Mg alloys and produce Mg-MMCs.Initially,FSP adapted to refine grain size from the micro to the nano level and accelerated the development of MMCs due to its solid-state nature and the synergistic effects of microstructure refinement and reinforcement,improving strength,hardness,ductility,wear resistance,corrosion resistance,and fatigue strength.However,producing defect-free and sound FSPed Mg and Mg-MMCs requires addressing several variables and their interdependencies,which opens up a broad range of practical applications.Despite existing reviews on individual FSP of Mg,its alloys,and MMCs,an attempt has been made to analyze the latest research on these three aspects collectively to enhance the understanding,application,and effectiveness of FSP for Mg and its derivatives.This review article discusses the literature,classifies the importance of Mg alloys,provides a historical background,and explores developments and potential applications of FSPed Mg alloys.It focuses on novel fabrication methods,reinforcement strategies,machine and tool design parameters,material characterization,and integration with other methods for enhanced properties.The influence of process parameters and the emergence of defects are examined,along with specific applications in mono and hybrid composites and their microstructure evolution.The study identifies promising reinforcement materials and highlights research gaps in FSP for Mg alloys and MMCs production.It concludes with significant recommendations for further exploration,reflecting ongoing advancements in this field.

Towards designing high mechanical performance low-alloyed wrought magnesium alloys via grain boundary segregation strategy:A review

Low-alloyed magnesium(Mg)alloys have emerged as one of the most promising candidates for lightweight materials.However,their further application potential has been hampered by limitations such as low strength,poor plasticity at room temperature,and unsatisfactory formability.To address these challenges,grain refinement and grain structure control have been identified as crucial factors to achieving high performance in low-alloyed Mg alloys.An effective way for regulating grain structure is through grain boundary(GB)segregation.This review presents a comprehensive summary of the distribution criteria of segregated atoms and the effects of solute segregation on grain size and growth in Mg alloys.The analysis encompasses both single element segregation and multi-element co-segregation behavior,considering coherent interfaces and incoherent interfaces.Furthermore,we introduce the high mechanical performance low-alloyed wrought Mg alloys that utilize GB segregation and analyze the potential impact mechanisms through which GB segregation influences materials properties.Drawing upon these studies,we propose strategies for the design of high mechanical performance Mg alloys with desirable properties,including high strength,excellent ductility,and good formability,achieved through the implementation of GB segregation.The findings of this review contribute to advancing the understanding of grain boundary engineering in Mg alloys and provide valuable insights for future alloy design and optimization.

Effect of corrosion behavior of cast and extruded ZK60 magnesium alloys processed via friction extrusion

The increasing demand for high-strength,corrosion-resistant magnesium alloys in transportation has led to the development of new processing techniques.In this work,cast and extruded ZK60 magnesium alloys were processed using the innovative solid-phase process,Friction Extrusion(FE).The microstructure was analyzed using Scanning Electron Microscopy(SEM),and Energy Dispersive Spectroscopy(EDS),showing a marked reduction in grain size,uniform solute distribution(Zn and Zr),and second phases after FE processing.Moreover,optical micrographs and Electron Backscatter Diffraction(EBSD)were employed to further evaluate the alloy microstructure.The corro-sion resistance and electrochemical behavior were analyzed using potentiodynamic polarization,Scanning Electrochemical Cell Impedance Microscopy(SECCIM),and atomic emission spectroelectrochemistry analysis(AESEC).Time evolution surface imaging and post-corrosion microstructures were also analyzed to support the understanding of underlying corrosion mechanisms.Corrosion initiation and propagation in FE-processed samples followed grain boundary patterns,differing from cast and extruded ZK60 behaviors.Electrochemical measurements and in-situ time-dependent optical imaging demonstrated that FE processing enhanced corrosion potential,reduced corrosion current,and increased cathodic activity.Additionally,FE processing reduced the disparity in pitting potential between cast and extruded samples,resulting in intermediate pitting potentials.Higher Mg and lower Zn dissolution was observed in the lower anodic currents for FE-processed samples.During aggravated anodic current cycles,Mg dissolution equalized,but the Zn/Mg dissolution ratio increased for FE-processed extruded samples,suggesting less cathodic activation and better resistance to further pitting.

A review on developing high-performance ZE41 magnesium alloy by using bulk deformation and surface modification methods

Magnesium(Mg)alloys are generally used in light-weight structural applications due to their higher specific strength.However,the usage of these Mg alloys is limited due to their poor formability at room temperature,which is attributed to lower count of slip systems associated with the hcp crystal structure.To address these limitations,several new magnesium alloys and also many processing strategies have been developed and reported in the literature.ZE41 Mg is an alloy with significant quantities of zinc(Zn)and rare earth(RE)elements and has emerged as a promising material for aerospace,automotive,electronics,biomedical and many other industries.To make this alloy more competitive and viable,it should possess better mechanical and corrosion properties.Hence,the current paper reviews the effect of bulk mechanical processing on grain refinement,microstructural modification,and corresponding changes in the mechanical behaviour of ZE41Mg alloy.Further,the effect of various surface modification techniques on altering the surface microstructure and surface properties such as wear and corrosion are also briefly summarized and presented.This review also discusses the challenges and the future perspectives in developing high-performing ZE41 Mg alloys.

Degradation Rate Assessment of Biodegradable Magnesium Alloys

Biodegradable magnesium alloys have been widely used in medical implants. But safety concerns were put forward for the high degradation rate of biodegradable magnesium alloy. The optimal biodegradable magnesium alloys that give rise to the desired degradation rate hasn’t yet to be defined. Assessing the degradation rate of biodegradable magnesium alloys involves in vitro testing, in vivo testing, numerical modeling, understanding the factors influencing their degradation in physiological environments, biocompatibility testing, and clinical studies. It is important to standardize analytical tools aimed at assessing the degradation rate of biodegradable magnesium alloys. It is advisable to identify the threshold for safe degradation rate of biodegradable magnesium alloys in biomedical applications.

Recent developments and applications on high-performance cast magnesium rare-earth alloys

During the past decades,with the increasing demands in lightweight structural materials,Mg alloys with low density and high performance have been extensively investigated and partly applied in some industries.Especially when rare earth(RE)elements are added as major alloying elements to Mg alloys,the alloy strength and creep resistance are greatly improved,which have promoted several series of Mg-RE alloys.This paper reviews the progress and developments of high-performance Mg-RE alloys in recent years with emphasis on cast alloys.The main contents include the alloy design,melt purification,grain refinement,castability,novel liquid casting and semisolid forming approaches,and the industrial applications or trials made of Mg-RE alloys.The review will provide insights for future developments of new alloys,techniques and applications of Mg alloys.

Research advances of magnesium and magnesium alloys worldwide in 2022

More than 4600 papers in the field of Mg and Mg alloys were published and indexed in the Web of Science(WoS)Core Collection database in 2022.The bibliometric analyses indicate that the microstructure,mechanical properties,and corrosion of Mg alloys are still the main research focus.Bio-Mg materials,Mg ion batteries and hydrogen storage Mg materials have attracted much attention.Notable contributions to the research and development of magnesium alloys were made by Chongqing University(>200 papers),Chinese Academy of Sciences,Shanghai Jiao Tong University,and Northeastern University(>100 papers)in China,Helmholtz Zentrum Hereon in Germany,Ohio State University in the USA,the University of Queensland in Australia,Kumanto University in Japan,and Seoul National University in Korea,University of Tehran in Iran,and National University of Singapore in Singapore,etc.This review is aimed to summarize the progress in the development of structural and functional Mg and Mg alloys in 2022.Based on the issues and challenges identified here,some future research directions are suggested.

Corrosion resistance and anti-soiling performance of micro-arc oxidation/graphene oxide/stearic acid superhydrophobic composite coating on magnesium alloys

Magnesium(Mg)alloys,the lightest metal construction material used in industry,play a vital role in future development.However,the poor corrosion resistance of Mg alloys in corrosion environments largely limits their potential wide applications.Therefore,a micro-arc oxidation/graphene oxide/stearic acid(MAO/GO/SA)superhydrophobic composite coating with superior corrosion resistance was fabricated on a Mg alloy AZ91D through micro-arc oxidation(MAO)technology,electrodeposition technique,and self-assembly technology.The composition and microstructure of the coating were characterized by scanning electron microscopy,X-ray diffraction,energy dispersive spectroscopy,and Raman spectroscopy.The effective protection of the MAO/GO/SA composite coating applied to a substrate was evaluated using potentiodynamic polarization,electrochemical impedance spectroscopy tests,and salt spray tests.The results showed that the MAO/GO/SA composite coating with a petal spherical structure had the best superhydrophobicity,and it attained a contact angle of 159.53°±2°.The MAO/GO/SA composite coating exhibited high resistance to corrosion,according to electrochemical and salt spray tests.

Additive manufacturing of magnesium and its alloys: process-formabilitymicrostructure-performance relationship and underlying mechanism

Magnesium and its alloys,as a promising class of materials,is popular in lightweight application and biomedical implants due to their low density and good biocompatibility.Additive manufacturing(AM)of Mg and its alloys is of growing interest in academia and industry.The domain-by-domain localized forming characteristics of AM leads to unique microstructures and performances of AM-process Mg and its alloys,which are different from those of traditionally manufactured counterparts.However,the intrinsic mechanisms still remain unclear and need to be in-depth explored.Therefore,this work aims to discuss and analyze the possible underlying mechanisms regarding defect appearance and elimination,microstructure formation and evolution,and performance improvement,based on presenting a comprehensive and systematic review on the relationship between process parameters,forming quality,microstructure characteristics and resultant performances.Lastly,some key perspectives requiring focus for further progression are highlighted to promote development of AM-processed Mg and its alloys and accelerate their industrialization.