Applications of Magnesium and Its Alloys: A Review

Optimization of wear parameters for ECAP-processed ZK30 alloy using response surface and machine learning approaches: a comparative study

The present research applies different statistical analysis and machine learning (ML) approaches to predict and optimize the processing parameters on the wear behavior of ZK30 alloy processed through equal channel angular pressing (ECAP) technique. Firstly, The ECAPed ZK30 billets have been examined at as-annealed (AA), 1-pass, and 4-passes of route Bc (4Bc). Then, the wear output responses in terms of volume loss (VL) and coefficient of friction (COF) have been experimentally investigated by varying load pressure (P) and speed (V) using design of experiments (DOE). In the second step, statistical analysis of variance (ANOVA), 3D response surface plots, and ML have been employed to predict the output responses. Subsequently, genetic algorithm (GA), hybrid DOE-GA, and multi-objective genetic algorithm techniques have been used to optimize the input variables. The experimental results of ECAP process reveal a significant reduction in the average grain size by 92.7% as it processed through 4Bc compared to AA counterpart. Furthermore, 4Bc exhibited a significant improvement in the VL by 99.8% compared to AA counterpart. Both regression and ML prediction models establish a significant correlation between the projected and the actual data, indicating that the experimental and predicted values agreed exceptionally well. The minimal VL at different ECAP passes was obtained at the highest condition of the wear test. Also, the minimal COF for all ECAP passes was obtained at maximum wear load. However, the optimal speed in the wear process decreased with the number of billets passes for minimum COF. The validation of predicted ML models and VL regression under different wear conditions have an accuracy range of 70-99.7%, respectively.

Functionalized magnesium alloys obtained by superplastic forming process retain osteoinductive and antibacterial properties: An in-vitro study

OBJECTIVES

This study aimed to investigate the biocompatibility, osteogenic and antibacterial activity of biomedical devices based on Magnesium (Mg) Alloys manufactured by Superplastic Forming process (SPF) and subjected to Hydrothermal (HT) and Sol-Gel Treatment (Sol-Gel).

METHODS

Mg-SPF devices subjected to Hydrothermal (Mg-SPF+HT) and Sol-Gel Treatment (Mg-SPF+Sol-Gel) were investigated. The biocompatibility of Mg-SPF+Sol-Gel and Mg-SPF+HT devices was observed by indirect and direct cytotoxicity assays, whereas the colonization of sample surfaces was assessed by confocal microscopy. qRT-PCR analysis and microbial growth curve analyses were employed to evaluate the osteogenic and antibacterial activity of both SPF-Mg treated devices, respectively.

RESULTS

Mg-SPF+HT and Mg-SPF+Sol-Gel showed a high degree of biocompatibility. Analysis of mRNA expression of osteogenic genes in cells cultured on Mg-treated devices revealed a significant upregulation of the expression levels of BMP2 and Runx-2. Furthermore, the bacterial growth in strains developed in contact with both the Mg-SPF+HT and Mg-SPF+Sol-Gel devices was lower than that observed in the control.

SIGNIFICANCE

Hydrothermal and Sol-Gel Treatments of Mg alloys obtained through the SPF process demonstrated bioactive, osteogenic and antibacterial activity, offering a promising alternative to conventional Mg-based devices. The obtained Mg-based materials may have the potential to enhance the tunability of temporary devices in maxillary reconstruction, eliminating the need for second surgeries, and ensuring a good bone reconstruction and a reduced implant failure rate due to bacterial infections.

Synthesis Technology of Magnesium-Doped Nanometer Hydroxyapatite: A Review

Ion substitution techniques for nanoparticles have become an important neighborhood of biomedical engineering and have led to the development of innovative bioactive materials for health systems. Magnesium-doped nanohydroxyapatite (Mg-nHA) has good bone conductivity, biological activity, flexural strength, and fracture toughness due to particle doping technology, making it an ideal candidate material for biomedical applications. In this Review, we have systematically presented the synthesis methods of Mg-nHA and their application in the field of biomedical science and highlighted the pros and cons of each method. Finally, some future prospects for this important neighborhood are proposed. The purpose of this Review is to provide readers with an understanding of this new field of research on bioactive materials with innovative functions and systematically introduce the latest technologies for obtaining uniform, continuous, and morphologically diverse Mg-nHA.

Nb2CTx MXene reinforcement stimulated microstructure and mechanical properties of magnesium

In this study, Nb2CTx MXene reinforced commercially pure magnesium composite was processed using traditional blend-press-sinter technique. The added one volume percentage of Nb2CTx MXene was fairly dispersed around the magnesium particles despite having sporadic clustering. Nb2CTx MXene reinforcement was stable and developed defect free strong interfacial bonding with the magnesium matrix. The small amount of chemically compatible and thermally stable Nb2CTx MXene reinforcement was successful in enhancing the bulk hardness and compressive yield strength, compressive strength, ductility and fracture toughness of the commercially pure magnesium.

Corrosion inhibition of magnesium alloy AZ31 in chloride-containing solutions by aqueous permanganate

In this work, corrosion of the AZ31 magnesium alloy was examined in 0.05 M NaCl solutions containing 0.01–0.150 mol/dm3 of potassium permanganate as a corrosion inhibitor. A set of electrochemical impedance spectroscopy, linear sweep voltammetry, and hydrogen evolution measurements revealed high inhibitor effectiveness at relatively high (0.150 mol/dm3) KMnO4 concentrations. Based on data of energy-dispersive X-ray analysis, scanning electron microscopy, and Raman spectroscopy, a mechanism of the corrosion inhibition of AZ31 alloy by potassium permanganate in chloride-containing media was proposed.

Effect of Al Concentration on Basal Texture Formation Behavior of AZ-Series Magnesium Alloys during High-Temperature Deformation

Magnesium and its alloys have been restricted in their industrial applications due to problems related to their formability. To overcome this issue, controlling the crystallographic texture is important, and the texture formation mechanism should be investigated in relation to factors including deformation conditions and solute atoms. In particular, the effects of solute atoms on the texture formation behavior should be further analyzed because they can considerably affect the deformation behavior. Thus, in this study, to clarify the effect of aluminum concentration on the texture formation behavior and microstructure, high-temperature uniaxial compression tests were conducted on three types of AZ-series magnesium alloys (AZ31, AZ61, and AZ91). Compression was conducted at 673 K and 723 K, with strain rates of 0.05 s^-1 and 0.005 s^-1, up to a true strain of -1.0. Cylindrical specimens were prepared from a rolled plate that had a (0001) basal texture and was compressed parallel to the c-axis of the grains. Consequently, work softening and fiber texture formation were observed in all the specimens. During the deformation, the development of grain boundaries, which is a typical characteristic of continuous dynamic recrystallization (CDRX), was observed, and the (0001) texture was highly developed with increasing Al content. Although each alloy was associated with the same deformation conditions and mechanisms, the AZ31 alloy exhibited a non-basal texture component. The stacking fault energy contributed to the generation of slip systems and gliding, and it was seen as the main reason for texture variation.

Effect of Recrystallization Behavior of AZ31 Magnesium Alloy on Damping Capacity

For a wide industrial application of magnesium alloys, a method for imparting high damping properties while maintaining mechanical properties is required. Controlling the crystallographic texture seems to be useful, because dislocations are known to have a significant influence on the damping characteristics of magnesium alloys. In addition, textures are affected by the microstructure and texture variation when the deformation or annealing is applied. However, there were less reports about their effect on damping capacity. Therefore, the effect of twinning and annealing, which can affect the recrystallization, were investigated in this study. An AZ31 alloy was hot rolled at 673 K with a reduction ratio of 10% and 50%, and then annealed at 673 K and 723 K for 0.5, 1, 2, and 3 h, respectively. SEM-EBSD was used to examine the microstructure and texture. In addition, each specimen's hardness and internal friction were contemporarily measured. As a result, hot rolling produced tensile twins and their fraction increased with internal friction when the reduction ratio increased. Due to annealing, a discontinuous type of static recrystallization occurred within the twinning grains, and was highly activated along with the increasing annealing temperature and the fraction of twinning. In the samples annealed at 723 K, the internal friction continuously increased over the annealing time, whereas in the samples annealed at 673 K, the decrease in dislocation density was delayed while the internal friction showed a relatively low value.

Effect of Temperature on the Complex Modulus of Mg-Based Unidirectionally Aligned Carbon Fiber Composites

Composite materials based on magnesium-lithium (MgLi) and magnesium-yttrium (MgY) matrices reinforced with unidirectional carbon fibers were prepared using the gas pressure infiltration method. Two types of carbon fibers were used, high-strength PAN-based T300 fibers and high-modulus pitch-based Granoc fibers. The PAN-based carbon fibers have an internal turbostratic structure composed of crystallites. The pitch-based carbon fibers have a longitudinally aligned graphite crystal structure. The internal carbon fiber structure is crucial in the context of the interfacial reaction with the alloying element. There are various mechanisms of bonding to carbon fibers in the case of magnesium-lithium and magnesium-yttrium alloys. This paper presents the use of the DMA method for the characterization of the role of alloying elements in the quality of interfacial bonding and the influence on the complex modulus at increasingly elevated temperatures (50-250 °C). The complex modulus values of the composites with T300 fibers were in the range of 118-136 GPa. The complex modulus values of the composites with Granoc fibers were in the range of 198-236 GPa. The damping capacity of magnesium-based unidirectionally aligned carbon fiber composites is related to the quality of the interfacial bonding.

Role of Solvent Used in Development of Graphene Oxide Coating on AZ31B Magnesium Alloy: Corrosion Behavior and Biocompatibility Analysis

Clinical applications of bio-absorbable magnesium (Mg) and its alloys can be enhanced by increasing their corrosion resistance, using surface modification and functionality. In this study, we synthesized graphene oxide (GO) through improved Hummers' method and deposited it on biodegradable AZ31B Mg alloy for further characterization. Different suspensions of GO were prepared in various solvents, like deionized water, ethanol, and acetone by ultra-sonication. Electrophoretic deposition (EPD) was used to develop GO coatings on AZ31B Mg using different GO suspensions. Effect of various solvents on corrosion behavior, as well as in vitro biocompatibility, was studied. The optimized EPD parameters were 3 volts and 90 s for coating. Different characterization techniques were used to study GO and prepared coatings. Atomic force microscopy found that the average thickness of GO was ~1 nm. Electrochemical behavior of coatings was studied through electrochemical impedance spectroscopy (EIS) and Tafel analysis in Ringer's lactate solution. Tafel analysis revealed that GO coatings deposited by GO water suspension increased corrosion protection efficiency of AZ31B Mg alloy by ~94%. After 72 h incubation in MC3T3-E1 osteoblast cells extract, in vitro analysis was performed to determine the cell viability and biocompatibility of the GO- coated and bare Mg samples. GO coatings deposited by GO water suspension demonstrated ~2× cell viability, as well as nontoxicity and better biocompatibility compared to the bare and other GO-coated Mg samples.

Laser-Arc Hybrid Cladding of Al-Mg Alloy Coating on AZ80 Mg Alloy: Effect of Laser Beam Oscillations Amplitude

The effect of beam oscillating amplitude on the microstructure and performance of AZ80 Mg alloy cladded with Al-Mg alloy coating by laser-arc hybrid welding was studied. The penetration depth decreases significantly while welds are widened because of the increase in the oscillating area of a laser beam. Alloy segregation and keyhole-induced porosity can be suppressed by the laser beam oscillation. With the increase in the oscillating amplitude, the Al distribution becomes uniform in the weld seam because of the rapid and fierce stirring by the oscillating laser. However, the diluting of the cladded Al alloy restrains the formation of the brittle Mg₁₇Al₁₂ phase, and then causes the weakening of hardness and wear resistance of the cladded layer. Considered comprehensively, the optimized oscillating amplitude was 1 mm, which can produce the weld seam with good appearance, fewer segregation and porosity defects, and acceptable hardness and wear resistance.

The Effect of (Mg, Zn)12Ce Phase Content on the Microstructure and the Mechanical Properties of Mg–Zn–Ce–Zr Alloy

The quantitative study of rare earth compounds is important for the improvement of existing magnesium alloy systems and the design of new magnesium alloys. In this paper, the effective separation of matrix and compound in Mg–Zn–Ce–Zr alloy was achieved by a low-temperature chemical phase separation technique. The mass fraction of the (Mg, Zn)₁₂Ce compound was determined and the effect of the (Mg, Zn)₁₂Ce phase content on the heat deformation organization and properties was investigated. The results show that the Mg–Zn–Ce compound in both the as-cast and the homogeneous alloys is (Mg, Zn)₁₂Ce. (Mg, Zn)₁₂Ce phase formation depends on the content and the ratio of Zn and Ce elements in the initial residual melt of the eutectic reaction. The Zn/Ce mass ratios below 2.5 give the highest compound contents for different Zn contents, 5.262 wt.% and 7.040 wt.%, respectively. The increase in the amount of the (Mg, Zn)₁₂Ce phase can significantly reduce the critical conditions for dynamic recrystallization formation. Both the critical strain and the stress decrease with increasing rare earth content. The reduction of the critical conditions and the particle-promoted nucleation mechanism work together to increase the amount of dynamic recrystallization. In addition, it was found that alloys with 6 wt.% Zn elements tend to undergo a dynamic recrystallization softening mechanism, while alloys with 3 wt.% Zn elements tend to undergo a dynamic reversion softening mechanism.

Influence of Alkaline Earth Metals on Structure Formation and Magnesium Alloy Properties

The main aim of this work is to improve the structure and properties of the magnesium alloy ML5 by modifying it with alkaline earth metals (ALM). The separate and joint influence of calcium and barium on the macrostructure and microstructure of the alloy of Mg-Al-Zn system was investigated. The qualitative and quantitative estimation of the structural components was carried out. Alkali earth metals were included in complex intermetallic phases and serve as additional crystallization centers. Modification of magnesium alloys with alkaline earth metals is established in an amount of 0.05 to 0.1 wt. % increased the bulk percentage of intermetallic phases by ~1.5 times, shifting them towards smaller size groups while simultaneously forming spherical intermetallic phases located in the grain centre and serving as additional crystallization centers. In this case, grain size reduction and significant refinement of the alloy structural components were provided. The dependency of the separate and joint influence of alkali earth metals on the castings complex of properties of the magnesium alloy has been established. Thus, a separate modification of the ML5 alloy provided the maximum level of its strength and ductility with the addition of 0.1% Ca or Ba. The modification of the complex (0.1% Ca + 0.1% Ba) of the magnesium alloy decreased the dimensions of its structural components 1.5 times and increased the strength of the alloy by 20%, the ductility by 2 times and the long-term heat resistance 1.5 times due to the formation of the intermetallic phases of the complex composition. Linear dependences were obtained that describe the influence of the characteristics of the structural components of the modified magnesium alloy on its mechanical properties. The developed technology for modifying cast magnesium alloys with alkaline earth elements provides an improvement in casting quality and allows the reliability and durability of responsible casting operation.

Casting Welding from Magnesium Alloy Using Filler Materials That Contain Scandium

Based on the results achieved in systematic studies of structure formation and the formation of multicomponent phases, a scandium-containing filler metal from system alloy Mg-Zr-Nd for welding of aircraft casting was developed. The influence of scandium in magnesium filler alloy on its mechanical and special properties, such as long-term strength at elevated temperatures, was studied by the authors. It is established that modification of the magnesium alloy with scandium in an amount between 0.05 and 0.07% allows a fine-grained structure to be obtained, which increases its plasticity up to 70% and heat resistance up to 1.8 times due to the formation of complex intermetallic phases and the microalloying of the solid solution. Welding of the aircraft castings made of magnesium alloy with scandium-containing filler material allows obtaining a weld with a dense homogeneous fusion zone and the surrounding area without any defects. The developed filler material for welding surface defects (cracks, chips, etc.) formed during operation on aircraft engine bodies makes it possible to restore cast body parts and reuse them. The proposed filler material composition with an improved set of properties for the welding of body castings from Mg-Zr-Nd system alloy for aircraft engines makes it possible to increase their reliability and durability in general, extend the service life of aircraft engines, and obtain a significant economic effect.

Influences of Mg17Al12 Phase Morphology on the Mechanical Properties of AZ80 Magnesium Alloy Subjected to Aging

The influence of Mg17Al12 phase morphology on the mechanical properties of AZ80 magnesium alloy subjected to aging was studied. Scanning electron microscopy, X-ray diffraction analysis and hardness indentation were used to reveal the microstructural evolution and mechanical properties of alloys during aging. The results show that Mg17Al12 phase mostly formed at grain boundaries with discontinuous lamellas morphology during aging at 150 °C. In contrast, continuous short rod and spherical Mg17Al12 particles formed transgranularly as aged at 320 °C. Both the strength of the alloy and elongation under room temperature were slightly improved via 150 °C aging.

Bone Union Quality after Fracture Fixation of Mandibular Head with Compression Magnesium Screws

For some years now, fixation devices created with resorbable magnesium alloys for the mandibular head have been clinically available and are beginning to be used. It is thus valuable to evaluate the quality of unions in these cases. The aim of this study was radiological comparison of magnesium versus titanium open reduction and rigid fixations in the mandible condylar head. Thirty-one patients were treated for fractures of the mandibular head with magnesium WE43 alloy headless compression screws (diameter 2.3 mm) and, as a reference group, 29 patients were included with similar construction titanium screws (diameter 1.8 mm). The 12-month results of the treatment were evaluated by the texture analysis of CT. Near similar treatment results were found with magnesium screws in traditional titanium fixation. Magnesium screws result in a higher density of the bone structure in the mandibular head. Conclusions: The quantitative evaluation of bone union after surgical treatment of mandibular head fracture with magnesium compression headless screws indicates that stable consolidation was achieved. Undoubtedly, the resorption process of the screws was found to be incomplete after 12 months, evidenced by a marked densification of the bone structure at the fracture site.

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.

Biodegradable Magnesium Biomaterials—Road to the Clinic

In recent decades, we have witnessed radical changes in the use of permanent biomaterials. The intrinsic ability of magnesium (Mg) and its alloys to degrade without releasing toxic degradation products has led to a vast range of applications in the biomedical field, including cardiovascular stents, musculoskeletal, and orthopedic applications. With the use of biodegradable Mg biomaterials, patients would not suffer second surgery and surgical pain anymore. Be that as it may, the main drawbacks of these biomaterials are the high corrosion rate and unexpected degradation in physiological environments. Since biodegradable Mg-based implants are expected to show controllable degradation and match the requirements of specific applications, various techniques, such as designing a magnesium alloy and modifying the surface characteristics, are employed to tailor the degradation rate. In this paper, some fundamentals and particular aspects of magnesium degradation in physiological environments are summarized, and approaches to control the degradation behavior of Mg-based biomaterials are presented.

Clinical Evaluation of Magnesium Alloy Osteosynthesis in the Mandibular Head

Titanium alloys are used in skeletal surgery. However, once bone union is complete, such fixation material becomes unnecessary or even harmful. Resorbable magnesium materials have been available for several years (WE43 alloy). The aim of this study was to clinically compare magnesium versus titanium open reduction and rigid fixations in mandible condylar heads. Ten patients were treated for fractures of the mandibular head with magnesium headless compression screws (2.3 mm in diameter), and 11 patients were included as a reference group with titanium screws (1.8 mm in diameter) with similar construction. The fixation characteristics (delay, time, and number of screws), distant anatomical results (mandibular ramus height loss, monthly loss rate, and relative loss of reconstructed ramus height), basic functional data (mandibular movements, facial nerve function, and cutaneous perception) and the influence of the effects of the injury (fracture type, fragmentation, occlusion, additional fractures, and associated diseases) on the outcome were evaluated. The long-term results of treatment were evaluated after 18 months. Treatment results similar to those of traditional titanium fixation were found with magnesium screws. Conclusions: Resorbable metal screws can be a favored option for osteosynthesis because surgical reentry can be avoided. These materials provide proper and stable treatment results.

Magnesium Nanoparticle Synthesis from Powders via Pulsed Laser Ablation in Liquid for Nanocolloid Production

Magnesium nanoparticles of various mean diameters (53–239 nm) were synthesised in this study via pulsed laser ablation in liquid (PLAL) from millimetre sized magnesium powders within isopropyl alcohol. It was observed via a 3 × 3 full factorial design of experiments that the processing parameters can control the nanoparticle distribution to produce three size-distribution types (bimodal, skewed and normal). Ablation times of 2, 5, and 25 min where investigated. An ablation time of 2 min produced a bimodal distribution with the other types seen at higher periods of processing. Mg nanoparticle Ultraviolet–Visible spectroscopy (UV–Vis) absorbance at 204 nm increased linearly with increasing ablation time, indicating an increase in nanoparticle count. The colloidal density (mg/mL) generally increased with increasing nanoparticle mean diameter as noted via increasing UV–Vis absorbance. High laser scan speeds (within the studied range of 3000–3500 mm/s) tend to increase the nanoparticle count/yield. For the first time, the effect of scan speed on colloidal density, UV–Vis absorbance and nanoparticle diameter from metallic powder ablation was investigated and is reported herein. The nanoparticles formed dendritic structures after being drop cast on aluminium foil as observed via field emission scanning electron microscope analysis. Dynamic light scattering was used to measure the size of the nanoparticles. Magnesium nanoparticle inks show promise for use in the fabrication conductive tracks or thermal insulation in electronics.

The Influence of Hydroxyapatite and Alumina Particles on the Mechanical Properties and Corrosion Behavior of Mg-Zn Hybrid Composites for Implants

Considering the necessity for a biodegradable implant alloy with good biocompatibility and mechanical strength, dual ceramic particles of HAP and Al₂O₃ were added to Mg-Zn alloy to produce a new hybrid composite using powder metallurgy. The paper reports the mechanical and corrosion behaviour of Mg-Zn/HAP/Al₂O₃ hybrid composites containing variable wt.% HAP and Al₂O₃ with 15 wt.% total ceramic content. The powders of Mg, Zn, Al₂O₃ and HAP were milled in a high-energy ball mill, and then compacted under 400 MPa and sintered at 300 °C. Density and compression strength increased with increasing Al₂O₃ content. HAP facilitated weight gain in Hanks balanced salt solution due to deposition of an apatite layer which promoted anodic behaviour with higher corrosion resistance. A hybrid composite of Mg alloy with 5 wt.% Al₂O₃ and 10 wt.% HAP displayed 153 MPa compressive strength, 1.37 mm/year corrosion resistance and bioactivity with a CA:P ratio of 1:1.55 and appears to be the most promising biodegradable implant material tested.

The Comparative Analysis of the Coatings Deposited on the Automotive Parts by the Cataphoresis Method

The paper presents preliminary research focused on the determination of the influence of surface preparation on the quality of the paint coating obtained by the cataphoresis method (KTL). The tests were carried out on steel parts used in the construction of trailers and truck bodies. The first research group consisted of cold-rolled and chemically cleaned parts, the second group were mechanically cleaned with abrasive blasting. In order to determine the influence of surface treatment on the corrosion resistance of the tested coatings, besides a corrosion test, roughness measurements were also carried out. Tests were performed on the crude surface and after coating deposition. Moreover, tests were supplemented by measuring the thickness of the coating using the magnetic induction method and the hardness with the use micro and nano hardness testers. Measurements of the tribological parameters under dry friction conditions were performed using a T11 tester. The corrosion resistance of the applied coatings was determined in a salt spray test. The obtained results were compared to those that were determined for different zinc coatings. It has been shown that the method of base steel surface preparation affects every measured parameter and property of tested paint coatings. The quality of the coating deposited on the steel base after chemical cleaning is much better than the one applied to the sandblasted surface. The measured corrosion resistance of the tested paint coatings is only greater than the corrosion resistance of the lamellar zinc coating. The other zinc coatings (galvanic, hot-dip, sherardized) show corrosion resistance by an order of magnitude higher.