Mechanical properties and applications of Magnesium alloy – Review

Mechanical and Computational Fluid Dynamic Models for Magnesium-Based Implants

Today, mechanical properties and fluid flow dynamic analysis are considered to be two of the most important steps in implant design for bone tissue engineering. The mechanical behavior is characterized by Young's modulus, which must have a value close to that of the human bone, while from the fluid dynamics point of view, the implant permeability and wall shear stress are two parameters directly linked to cell growth, adhesion, and proliferation. In this study, we proposed two simple geometries with a three-dimensional pore network dedicated to a manufacturing route based on a titanium wire waving procedure used as an intermediary step for Mg-based implant fabrication. Implant deformation under different static loads, von Mises stresses, and safety factors were investigated using finite element analysis. The implant permeability was computed based on Darcy's law following computational fluid dynamic simulations and, based on the pressure drop, was numerically estimated. It was concluded that both models exhibited a permeability close to the human trabecular bone and reduced wall shear stresses within the biological range. As a general finding, the proposed geometries could be useful in orthopedics for bone defect treatment based on numerical analyses because they mimic the trabecular bone properties.

Influence of Alloying Materials Al, Cu, and Ca on Microstructures, Mechanical Properties, And Corrosion Resistance of Mg Alloys for Industrial Applications: A Review

Magnesium is renowned for its favorable low-density attributes, rendering it a viable choice for commercial engineering applications in which weight has substantial design implications. Magnesium (Mg) stands as a readily obtainable metallic element, exhibiting robustness, efficient heat dissipation, and excellent damping properties. The utilization of pure magnesium remains infrequent due to its susceptibility to instability under high temperatures and pronounced vulnerability to corrosion within humid environments. Hence, the incorporation of magnesium alloys into the design process of aircraft, automotive, and biomedical applications assumes paramount importance. This Review presents a comprehensive review of research endeavors and their resultant achievements concerning the advancement of magnesium alloys. Specifically focusing on aerospace, automotive, and biomedical applications, the Review underscores the pivotal role played by alloying constituents, namely aluminum (Al), copper (Cu), calcium (Ca), and PEO coatings, in influencing the microstructural attributes, mechanical potency, and resistance to corrosion.

Effect of Traverse Speed Variation on Microstructural Properties and Corrosion Behavior of Friction Stir Welded WE43 Mg Alloy Joints

The growing demand for Magnesium in the automotive and aviation industries has enticed the need to improve its corrosive properties. In this study, the WE43 magnesium alloys were friction stir welded (FSW) by varying the traverse speed. FSW eliminates defects such as liquefication cracking, expulsion, and voids in joints encountered frequently in fusion welding of magnesium alloys. The microstructural properties were scrutinized using light microscopy (LM) and scanning electron microscopy (SEM). Additionally, the elemental makeup of precipitates was studied using electron dispersive X-ray spectroscopy (EDS). The electrochemical behavior of specimens was evaluated by employing potentiodynamic polarization tests and was correlated with the microstructural properties. A defect-free weldment was obtained at a traverse and rotational speed of 100 mm/min and 710 rpm, respectively. All weldments significantly improved corrosion resistance compared to the base alloy. Moreover, a highly refined microstructure with redistribution/dissolution of precipitates was obtained. The grain size was reduced from 256 µm to around 13 µm. The corrosion resistance of the welded sample was enhanced by 22 times as compared to the base alloy. Hence, the reduction in grain size and the dissolution/distribution of secondary-phase particles within the Mg matrix are the primary factors for the enhancement of anti-corrosion properties.

Investigation of a New Screw Press Forming Process for Manufacturing Connectors from ZK60 Magnesium Alloy Preforms

This article discusses a new technology of forming connector forgings from ZK60 magnesium alloy preforms by die forging on a screw press. The purpose of the study was to evaluate the feasibility of using preforms cast from the ZK60 magnesium alloy to forge a connector forging with improved mechanical properties compared to those obtained by casting. It also aimed to establish whether this new forging method has the potential for replacing the multi-stage forging process conducted on hydraulic presses used for high-strength Mg alloys. A numerical analysis of the proposed approach was performed by the finite element method, applying the popular DEFORM computer software for simulating forming processes. The numerical results confirmed that the developed method produces parts with the desired shape. The numerical results also provided information regarding the behavior of the workpiece's material and the screw press forging process, including the distributions of strains and temperatures, the Cockcroft-Latham damage criterion, and energy required to form connector forgings. The proposed screw press forging process for producing ZK60 alloy connectors from cast preforms was verified by experimental tests. The connector forgings produced from the ZK60 magnesium alloy were then subjected to qualitative tests.

Natural Coatings and Surface Modifications on Magnesium Alloys for Biomedical Applications

Magnesium (Mg) alloys have great potential in biomedical applications due to their incomparable properties regarding other metals, such as stainless steels, Co-Cr alloys, and titanium (Ti) alloys. However, when Mg engages with body fluids, its degradation rate increases, inhibiting the complete healing of bone tissue. For this reason, it has been necessary to implement protective coatings to control the rate of degradation. This review focuses on natural biopolymer coatings used on Mg alloys for resorbable biomedical applications, as well as some modification techniques implemented before applying natural polymer coatings to improve their performance. Issues such as improving the corrosion resistance, cell adhesion, proliferation, and biodegradability of natural biopolymers are discussed through their basic comparison with inorganic-type coatings. Emphasis is placed on the expected biological behavior of each natural polymer described, to provide basic information as a reference on this topic.

Tailoring of Biodegradable Magnesium Alloy Surface with Schiff Base Coating via Electrostatic Spraying for Better Corrosion Resistance

In this study, three new Schiff bases were synthesized from paeonol and amino acids to prepare a compound Schiff base coating on the Mg-Zn-Y-Nd alloy (ZE21B alloy) surface by electrostatic spraying, and these three single Schiff base coatings were prepared on the ZE21B alloy as control. The results of SEM and XPS confirmed the successful preparation of the coating. Immersion tests and electrochemical tests showed that both the single coating and the compound coating significantly improved the corrosion resistance of ZE21B alloy, and the compound coating could play a synergistic corrosion inhibition effect, thus showing the best corrosion resistance.

Microalloying Design of Biodegradable Mg-2Zn-0.05Ca Promises Improved Bone-Implant Applications

Mg and its alloys have been comprehensively studied and show huge potential for clinical orthopedic applications. However, balancing the mechanical strength and corrosion resistance of alloys is still a challenge. In light of this, micro-level contents of Zn and Ca were added to pure Mg to fabricate a Mg-2Zn-0.05Ca microalloy to expectedly enhance the mechanical strength and concurrently improve the corrosion resistance. The characteristics of the rolled Mg-2Zn-0.05Ca microalloy were explored using optical microscopy, X-ray diffraction, and tensile tests. The corrosion behavior and mechanical strength loss were explored using electrochemical and immersion tests. The effects of the microalloy extract on the proliferation, adhesion, and osteogenic differentiation of MC3T3-E1 cells were systematically studied. Moreover, implantations were done in femoral condyles of rabbits to study the degradation properties, osteogenic effect, mechanical strength loss, and biosafety of the microalloy. The ultimate tensile strength and yield strength of the rolled microalloy were found to be significantly elevated to 257 ± 2.74 and 237.6 ± 8.29 MPa, respectively. The microalloy showed a stable and gradual strength loss during degradation, both in vivo and in vitro. Concurrently, the microalloy exhibited improved corrosion resistance ability and especially, in vivo, the rolled microalloy exhibited a comparable degradation rate to that of rolled pure Mg within the initial 12 weeks of implantation. Additionally, the microalloy promoted osteogenesis, both in vitro and in vivo, and no short- and long-term toxicities of the microalloy were observed in rabbits. This study suggested that the rolled Mg-2Zn-0.05Ca microalloy effectively balanced the mechanical strength and corrosion resistance and showed potential application as bone implants.

The Analysis of Deformability, Structure and Properties of AZ61 Cast Magnesium Alloy in a New Hammer Forging Process for Aircraft Mounts

This article presents the analysis of the deformability, structure and properties of the AZ61 cast magnesium alloy on the example of a new forging process of aircraft mount forgings. It was assumed that their production process would be based on drop forging on a die hammer. Two geometries of preforms, differing in forging degree, were used as the billet for the forging process. It was assumed that using a cast, unformed preform positively affects the deformability of hard-deformable magnesium alloys and flow kinematics during their forging and reduces the number of operations necessary to obtain the correct product. Numerical analysis of the proposed new technology was carried out using DEFORM 3D v.11, a commercial program dedicated to analyzing metal forming processes. The simulations were performed in the conditions of spatial strain, considering the full thermomechanical analysis. The obtained results of numerical tests confirmed the possibility of forming the forgings of aviation mounts from the AZ61 cast magnesium alloy with the proposed technology. They also allowed us to obtain information about the kinematics of the material flow during forming and process parameters, such as strain intensity distribution, temperatures, Cockcroft-Latham criterion and forming energy. The proposed forging process on a die hammer was verified in industrial conditions. The manufactured forgings of aircraft mounts made of AZ61 magnesium alloy were subjected to qualitative tests in terms of their structure, conductivity and mechanical properties.

Toughness and Durability of Interfaces in Dissimilar Adhesive Joints of Aluminum and Carbon-Fiber-Reinforced Thermoplastics

The toughness and the durability under a high humidity condition of the interfaces in dissimilar adhesive joints of carbon-fiber-reinforced thermoplastic with a polyamide-6 matrix and Al alloy were evaluated by two test methods, in which a tensile opening load was applied to the specimens to cleave the interfaces apart in two different ways. In the double cantilever beam (DCB) test, the specimens were continuously pulled apart at a constant velocity, while in the wedge test, the specimens are pulled apart at a constant displacement. The crack growth along the interface in the DCB test was dynamically monitored with the assistance of mechanoluminescence for the accurate detection of the phenomena at the crack tip. The wedge test was employed for the evaluation of the durability of the interfaces under high humidity conditions. It was found that the adhesive joints were failed by various failure modes depending on the surface pretreatment and environmental conditions. Throughout the work, discussion was made concerned with the interfacial structures and the adhesion mechanism of dissimilar adhesive joints.

Microstructure Characteristics and Its Effect on the Fracture in the Triple Junction Region of Friction Stir Welded Mg Alloys Subjected to Tension

Because of the tensile strength decreasing of the friction stir welded wrought magnesium (Mg) alloy compared to the base material, the reasons for the failure of weld has been focused on. After the fracture in transverse tension, the crack went through the welded joint from the center of the weld to the transition zone between the thermal-mechanical affected zone and weld zone. In the present study, the microstructure characteristics and its effect on the facture in the triple junction region is investigated. Based on the metallography and the electron back-scattered diffraction (EBSD) technology, it was observed that a twin band extended from the triple junction region to the middle of weld. The profuse twinning in the twin band was considered to play an important role on the crack propagation from the stir zone edge to the crown zone.