Data analysis of the influence of microstructure, composition, and loading conditions on stress corrosion cracking behavior of Mg alloys

Stress corrosion cracking (SCC) can be a crucial problem in applying rare earth (RE) Magnesium alloys in environments where mechanical loads and electrochemical driven degradation processes interact. It has been proven already that the SCC behavior is associated with microstructural features, compositions, loading conditions, and corrosive media, especially in-vivo. However, it is still unclear when and how mechanisms acting on multiple scales and respective system descriptors predictable contribute to SCC for the wide set of existing Mg alloys. In the present work, suitable literature data along SCC of Mg alloys has been analyzed to enable the development of a reliable SCC model for MgGd binary alloys. Pearson correlation coefficient and linear fitting are utilized to describe the contribution of selected parameters to corrosion and mechanical properties. Based on our data analysis, a parameter ranking is obtained, providing information on the SCC impact with regard to ultimate tensile strength (UTS) and fracture elongation of respective materials. According to the analyzed data, SCC susceptibility can be grouped and mapped onto Ashby type diagrams for UTS and elongation of respective base materials tested in air and in corrosive media. The analysis reveals the effect of secondary phase content as a crucial materials descriptor for our analyzed materials and enables better understanding towards SCC model development for Mg-5Gd alloy based implant.

Comparison of 2D and 3D Plasma Electrolytic Oxidation (PEO)-Based Coating Porosity Data Obtained by X-ray Tomography Rendering and a Classical Metallographic Approach

In this work, the porosity of plasma electrolytic oxidation (PEO)-based coatings on Al- and Mg-based substrates was studied by two imaging techniques-namely, SEM and computer microtomography. Two approaches for porosity determination were chosen; relatively simple and fast SEM surface and cross-sectional imaging was compared with X-ray micro computed tomography (microCT) rendering. Differences between 2D and 3D porosity were demonstrated and explained. A more compact PEO coating was found on the Al substrate, with a lower porosity compared to Mg substrates under the same processing parameters. Furthermore, huge pore clusters were detected with microCT. Overall, 2D surface porosity calculations did not show sufficient accuracy for them to become the recommended method for the exact evaluation of the porosity of PEO coatings; microCT is a more appropriate method for porosity evaluation compared to SEM imaging. Moreover, the advantage of 3D microCT images clearly lies in the detection of closed and open porosity, which are important for coating properties.

Effect of solution heat treatment on the internal architecture and compressive strength of an AlMg4.7Si8 alloy

The evolution of the microstructure of an AlMg4.7Si8 alloy is investigated by scanning electron microscopy and ex situ synchrotron tomography in as-cast condition and subsequent solution treatments for 1 h and 25 h at 540 °C, respectively. The eutectic Mg₂Si phase, which presents a highly interconnected structure in the as-cast condition, undergoes significant morphological changes during the solution heat treatment. Statistical analyses of the particle distribution, the sphericity, the mean curvatures and Gaussian curvatures describe the disintegration of the interconnected seaweed-like structure followed by the rounding of the disintegrated fractions of the eutectic branches quantitatively. The ternary eutectic Si resulting from the Si-surplus to the stoichiometric Mg₂Si ratio of the alloy undergoes similar changes. The morphological evolution during solution heat treatment is correlated with results of elevated temperature compression tests at 300 °C. The elevated temperature compressive strength is more sensitive to the degree of interconnectivity of the three dimensional Mg₂Si network than to the shape of the individual particles.

Sub-micrometre holotomographic characterisation of the effects of solution heat treatment on an AlMg7.3Si3.5 alloy

A strip cast AlMg7.3Si3.5 alloy is investigated by sub-micrometre holotomographic analysis achieving a voxel size of (60 nm)³ by cone beam magnification of the focused synchrotron beam using Kirkpatrick-Baez mirrors. The three-dimensional microstructure of the same specimen volume in the as-cast state is compared with that after exposure to 540 °C for 30 min resolving microstructural features down to 180 nm. The three-dimensional analysis of the architecture of the eutectic Mg₂Si and the Fe-aluminides reveals how the as-cast microstructure changes during the solution treatment. The alloy in the as-cast condition contains a highly interconnected seaweed-like Mg₂Si eutectic. The level of three-dimensional interconnectivity of the Mg₂Si eutectic phase decreases by only partial disintegration during the heat treatment correcting the two-dimensional metallographic impression of isolated round particles. Statistical analyses of the particle distribution, sphericity, mean curvatures and Gaussian curvatures describe quantitatively the architectural changes of the Mg₂Si phase. This explains the decrease of the high temperature strength of the alloy by the solution treatment tested in hot compression.

In situ synchrotron tomographic investigation of the solidification of an AlMg4.7Si8 alloy

The solidification sequence of an AlMg4.7Si8 alloy is imaged in situ by synchrotron microtomography. Tomograms with (1.4 μm)³/voxel have been recorded every minute while cooling the melt from 600 °C at a cooling rate of 5 K min^-1 to 540 °C in the solid state. The solidification process starts with the three-dimensional evolution of the α-Al dendritic structure at 590 °C. The growth of the α-Al dendrites is described by curvature parameters that represent the coarsening quantitatively, and ends in droplet-like shapes of the secondary dendrite arms at 577 °C. There, the eutectic valley of α-Al/Mg₂Si is reached, forming initially octahedral Mg₂Si particles preferentially at the bases of the secondary dendrite arms. The eutectic grows with seaweed-like Mg₂Si structures, with increasing connectivity. During this solidification stage Fe-aluminides form and expand as thin objects within the interdendritic liquid. Finally, the remaining liquid freezes as ternary α-Al/Mg₂Si/Si eutectic at 558 °C, increasing further the connectivity of the intermetallic phases. The frozen alloy consists of four phases exhibiting morphologies characteristic of their mode of solidification: α-Al dendrites, eutectic α-Al/Mg₂Si "Chinese script" with Fe-aluminides, and interpenetrating α-Al/Mg₂Si/Si ternary eutectic.