2019 EDITED BY Vineet V. Joshi J. Brian Jordon Dmytro Orlov Neale R. Neelameggham The Minerals, Metals & Materials Series Vineet V. Joshi (cid:129) J. Brian Jordon (cid:129) Dmytro Orlov (cid:129) Neale R. Neelameggham Editors Magnesium Technology 2019 123 Editors VineetV.Joshi J.BrianJordon PacificNorthwest National Laboratory TheUniversity of Alabama Richland, WA,USA Tuscaloosa,AL, USA DmytroOrlov Neale R.Neelameggham LundUniversity IND LLC Lund,Sweden SouthJordan, UT,USA ISSN 2367-1181 ISSN 2367-1696 (electronic) TheMinerals, Metals& Materials Series ISBN978-3-030-05788-6 ISBN978-3-030-05789-3 (eBook) https://doi.org/10.1007/978-3-030-05789-3 LibraryofCongressControlNumber:2018964033 ©TheMinerals,Metals&MaterialsSociety2019 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartofthematerialis concerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation,broadcasting,reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation,computersoftware,orbysimilarordissimilarmethodologynowknownorhereafterdeveloped. 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ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Magnesium and its alloys are being investigated widely for applications that require extraordinarily high strength-to-weight ratio, vibration damping, electromagnetic shielding, reductionincarbonfootprint,sustainabilityimprovements,andlowtoxicity.Inthepastdecade or so, this drive has led to increased adoption of magnesium and its alloys in everyday products and it is no longer regarded as an esoteric material. The overarching goal of its widespread adoption and replacement of conventional materials such as steel and aluminum alloys has been restricted because of the cost of the material, limited sources of primary material, alloying constraints, high chemical reactivity, and challenges associated with its plasticity. Researchers/scientists, engineers, and economists from industry, government agencies/laboratories, and academic institutions alike are actively developing roadmaps for next-generation products and addressing these challenges as quickly as possible through uniqueandinnovativemethods.TheTMSMagnesiumCommitteehasbeenactivelyinvolved in providing a platform to these entities for disseminating the latest information, develop- ments,andcutting-edgeresearchanddevelopment,andshowcasingthelatesttrendsrelatedto magnesiumanditsalloysthroughtheMagnesiumTechnologySymposium,whichtakesplace every year at the TMS Annual Meeting. This proceedings volume retains the essence of this longstanding tradition. The 20th volume in the series, Magnesium Technology 2019, is the proceedings of the Magnesium Technology Symposium held during the 148th TMS Annual Meeting & Exhibition in San Antonio, Texas, March 10–14, 2019. The volume captures commentaries and papers from 16 different countries. The papers have been categorized systematically based on topics pertaining to casting and solidification, thermomechanical processing, deformation mechanisms, modeling, corrosion, recycling, and applications. The symposium began with keynote sessions that featured several distinguished invited speakers from government organization, industry, and academia, who provided their per- spectives on the state of the art, goals, and opportunities in magnesium alloy research and development. Dr. Sarah Kleinbaum from the US Department of Energy described the status and challenges associated with vehicle lightweighting and incorporation of magnesium components in various vehicle subsystems from 2012 through today and identified the tech- nicalchallengesthatcurrentlylimittheirfulladoption.Dr.SeanAgnewfromtheUniversityof Virginia discussed the role of thermally activated slip in rare earth-containing alloys and compared it with the popular traditional alloys. This was followed by a talk on Magnesium Alloy Sheet for Transportation Applications by Dr. Chris Romanowski from Danieli FATA Hunter, who reviewed the strategies that need to be implemented for widespread adoption of magnesium alloy sheet for automotive applications. The final talk in this session was presentedbyDr.DavidKlaumuenzerfromVolkswagenAG,whopresentedhisperspectiveon Magnesium Process and Alloy Development for Applications in the Automotive Industry. TheMagnesiumCommitteealsoco-sponsoredtheTMS-DGMSymposiumonLightweight Metals: A Joint US-European Symposium on Challenges in Light Weighting the Trans- portation Industry. This symposium, jointly organized by TMS and DGM (the German MaterialsSociety),coveredsustainableuseoflightweightmetalsinthedesignandtailoringof monolithic and composite cast, wrought, and additive materials, as well as in the v vi Preface manufacturing of semi-finished and finished products, and included contributions to possible scientific and technological relevance across the different material classes. The organizers of thissymposium,Eric A.Nyberg,WilhelmusH.Sillekens (EuropeanSpaceAgency),Juergen Hirsch (Hydro Aluminium Rolled Products GmbH), and Norbert Hort (Helmholtz-Zentrum Geesthacht) compiled six papers pertaining to magnesium technology, which have been included in this publication. Finally, the 2018–2019 Magnesium Committee is grateful to and expresses deep appre- ciation for all authors for contributing to the success of the symposium; our panel of distin- guished keynote speakers for sharing their valuable thoughts on the future of magnesium technology; the reviewers for their best efforts in reviewing the manuscripts; and the session chairs, judges, TMS staff members, and other volunteers for their excellent support, which allowed us to develop a successful, high-quality symposium and proceedings volume. Vineet V. Joshi Chair J. Brian Jordon Vice Chair Dmytro Orlov Past Chair Neale R. Neelameggham Advisor Contents Part I Magnesium Technology 2019: Keynote Session Magnesium Alloy Sheet for Transportation Applications . . . . . . . . . . . . . . . . . . . 3 Chris Romanowski Magnesium for Automotive Lightweighting: Status and Challenges . . . . . . . . . . . 13 Sarah Kleinbaum Magnesium Process and Alloy Development for Applications in the Automotive Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 David Klaumünzer, Jose Victoria Hernandez, Sangbong Yi, Dietmar Letzig, Sang-hyun Kim, Jae Joong Kim, Min Hong Seo, and Kanghwan Ahn Thermally Activated Slip in Rare Earth Containing Mg–Mn–Ce Alloy, ME10, Compared with Traditional Mg–Al–Zn Alloy, AZ31. . . . . . . . . . . . . . . . . . . . . . . 21 Vikaas Bajikar, Jishnu J. Bhattacharyya, Nathan Peterson, and Sean R. Agnew Part II Magnesium Technology 2019: Alloy Design and Casting Bimodal Casting Process of Eco-Mg Series Alloys by Vertical High-Speed Press Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fabrizio D’Errico Investigation of the Evolution of the Microstructure in the Directionally Solidified Long-Period Stacking-Ordered (LPSO) Magnesium Alloy as a Function of the Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Daria Drozdenko, Kristián Máthis, Stefanus Harjo, Wu Gong, Kazuya Aizawa, and Michiaki Yamasaki TEM Studies of In Situ Formation of MgO and Al C During Thixomolding 4 3 of AZ91 Magnesium Alloy Conducted in CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2 Ł. Rogal, L. Litynska-Dobrzynska, and Bogusław Baran FFF of Mg-Alloys for Biomedical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 M. Wolff, T. Mesterknecht, A. Bals, T. Ebel, and R. Willumeit-Römer Effects of Gd/Y Ratio on the Microstructures and Mechanical Properties of Cast Mg–Gd–Y–Zr Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 J. L. Li, D. Wu, R. S. Chen, and En-Hou Han Part III Magnesium Technology 2019: Thermomechanical Processing Evolution of Heterogeneous Microstructure of Equal-Channel Angular Pressed Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Qizhen Li vii viii Contents NovelMagnesiumAlloyProcessingviaShear-AssistedProcessingandExtrusion (ShAPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 S.Mathaudhu,N.Overman,S.Whalen,M.Olszta,D.Catalini,K.Kruska,J.Darsell, V. Joshi, X. Jiang, A. Devaraj, and G. Grant Effects of the Extrusion Temperature on Microstructure, Texture Evolution and Mechanical Properties of Extruded Mg–2.49Nd–1.82Gd–0.19Zn–0.4Zr Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Lei Xiao, Guangyu Yang, Shifeng Luo, and Wanqi Jie Influence of Thermomechanical Treatment on Tension-Compression Yield Asymmetry of Extruded Mg–Zn–Ca Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 P. Dobroň, M. Hegedüs, J. Olejňák, D. Drozdenko, K. Horváth, and J. Bohlen Homogeneous Grain Refinement and Ductility Enhancement in AZ31B Magnesium Alloy Using Friction Stir Processing. . . . . . . . . . . . . . . . . . . . . . . . . . 83 Vivek Patel, Wenya Li, Quan Wen, Yu Su, and Na Li Microstructure and Texture Evolution During Hot Compression of Cast and Extruded AZ80 Magnesium Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Paresh Prakash, Amir Hadadzadeh, Sugrib Kumar Shaha, Mark A. Whitney, Mary A. Wells, Hamid Jahed, and Bruce W. Williams Experimental Investigation of Friction Coefficient of Magnesium Alloy Developed Through Friction Stir Processing with PKS Ash Powder Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 R. S. Fono-Tamo, Esther Titilayo Akinlabi, and Jen Tien-Chien A Review and Case Study on Mechanical Properties and Microstructure Evolution in Magnesium–Steel Friction Stir Welding . . . . . . . . . . . . . . . . . . . . . . 101 Suryakanta Sahu, Omkar Thorat, Raju Prasad Mahto, Surjya Kanta Pal, and Prakash Srirangam Effects of Sn on Microstructures and Mechanical Properties of As-Extruded Mg−6Al−1Ca−0.5Mn Magnesium Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Huajie Wu, Ruizhi Wu, Daqing Fang, Yuesheng Chai, and Chao Liang Part IV Magnesium Technology 2019: Corrosion and Surface Protection Effect of Alloying with Rare-Earth Metals on the Degradation of Magnesium Alloys Studied Using a Combination of Isothermal Calorimetry and Pressure Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Lars Wadsö, Norbert Hort, and Dmytro Orlov Effects of Li on Microstructures and Corrosion Behaviors of Mg–Li–Al Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Yang Li, Tingchao Li, Qilong Wang, and Yun Zou GalvanicallyGradedInterface:AComputationalModelforMitigatingGalvanic Corrosion Between Magnesium and Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Kurt A. Spies, Vilayanur V. Viswanathan, Ayoub Soulami, Yuri Hovanski, and Vineet V. Joshi Iron Content in Relationship with Alloying Elements and Corrosion Behaviour of Mg3Al Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Ha Ngoc Nguyen, Jong Il Kim, Young Min Kim, and Bong Sun You Microstructures, Corrosion and Mechanical Properties of Mg–Si Alloys as Biodegradable Implant Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Weidan Wang, Ming Gao, Yuanding Huang, Lili Tan, Ke Yang, and Norbert Hort Contents ix The Influence of Temperature and Medium on Corrosion Response of ZE41 and EZ33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 M. AbdelGawad, A. U. Chaudhry, and B. Mansoor Alloy Design Strategies of the Native Anti-corrosion Magnesium Alloy. . . . . . . . . 169 Tao Chen, Yuan Yuan, Jiajia Wu, Tingting Liu, Xianhua Chen, Aitao Tang, and Fusheng Pan Corrosion Bending Fatigue of RESOLOY® and WE43 Magnesium Alloy Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Petra Maier, Adam Griebel, Matthias Jahn, Maximilian Bechly, Roman Menze, Benjamin Bittner, and Jeremy Schaffer Sacrificial Cathodic Protection of Mg Alloy AZ31B by an Mg–5Sn Surface Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 C. F. Glover, T. W. Cain, and J. R. Scully Part V Magnesium Technology 2019: Fundamentals, Mechanical Behavior, Twinning, Plasticity, Texture and Fatigue I Evolution of the Intermetallic Particle Distribution in Thixomolded Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 B. T. Anthony, B. G. Dowdell, and V. M. Miller Revealing the Role of Combined Loading on the Tension–Compression Asymmetry in a Textured AZ31 Magnesium Alloy . . . . . . . . . . . . . . . . . . . . . . . . 199 C. Kale, S. Srinivasan, P. Haluai, and K. N. Solanki An Investigation of Detwinning Behavior of In-plane Compressed E-form Mg Alloy During the In Situ Tensile Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 JaiveerSingh,Min-SeongKim,Seong-EumLee,Joo-HeeKang,andShi-HoonChoi Characterization of Staggered Twin Formation in HCP Magnesium. . . . . . . . . . . 207 M. Arul Kumar, B. Leu, P. Rottmann, and I. J. Beyerlein Dislocation Behavior and Grain Boundary Segregation of Mg–Zn Alloys. . . . . . . 215 Hyo-Sun Jang and Byeong-Joo Lee Effect of Hot Working on the High Cycle Fatigue Behavior of WE43 Rare Earth Magnesium Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Saeede Ghorbanpour, Brandon A. McWilliams, and Marko Knezevic Effect of Solute Atoms on the Twinning Deformation in Magnesium Alloys . . . . . 227 Jing Tang, Wentao Jiang, Xiaobao Tian, and Haidong Fan First-Principles Investigation of the Effect of Solutes on the Ideal Shear Resistance and Electronic Properties of Magnesium . . . . . . . . . . . . . . . . . . . . . . . 231 P. Garg, I. Adlakha, and K. N. Solanki Inverse Optimization to Design Processing Paths to Tailor Formability of Mg Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Wahaz Nasim, Joshua S. Herrington, Amine A. Benzerga, Jyhwen Wang, and Ibrahim Karaman Part VI Magnesium Technology 2019: Fundamentals, Mechanical Behavior, Twinning, Plasticity, Texture and Fatigue II RecentProgressinDevelopmentandApplicationsofMgAlloyThermodynamic Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Rainer Schmid-Fetzer x Contents Hardening Effects of Precipitates with Different Shapes on the Twinning in Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Haidong Fan and Jaafar A. El-Awady Isometric Tilt Grain Boundaries and Solute Segregation in a Deformed Mg–Zn–Ca Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Y. M. Zhu and J. F. Nie Metallography of Mg Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Norbert Hort, Victor Floss, Sarkis Gavras, Gert Wiese, and Domonkos Tolnai Microstructure and Mechanical Properties of High Shear Material Deposition of Rare Earth Magnesium Alloys WE43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Z.McClelland,D.Z.Avery,M.B.Williams,C.J.T.Mason,O.G.Rivera,C.Leah, P. G. Allison, J. B. Jordon, R. L. Martens, and N. Hardwick Modeling the 3D Plastic Anisotropy of a Magnesium Alloy Processed Using Severe Plastic Deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 J. S. Herrington, Y. Madi, J. Besson, and A. A. Benzerga Multiaxial Cyclic Response of Low Temperature Closed-Die Forged AZ31B Mg Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 D. Toscano, S. K. Shaha, B. Behravesh, H. Jahed, and B. Williams Thermo-mechanical Processing of EZK Alloys in a Synchrotron Radiation Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 D.Tolnai, M.-A.Dupont,S. Gavras, K.Mathis, K.Horvath, A.Stark, andN.Schell The Effect of the Orientation of Second-Order Pyramidal <c + a> Dislocations on Plastic Flow in Magnesium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Kinshuk Srivastava and Jaafar A. El-Awady Part VII Magnesium Technology 2019: Poster Session Forging of Mg–3Sn–2Ca–0.4Al Alloy Assisted by Its Processing Map and Validation Through Analytical Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 K. P. Rao, K. Suresh, Y. V. R. K. Prasad, C. Dharmendra, and N. Hort Development of Manufacturing Processes for Magnesium Sheet . . . . . . . . . . . . . . 319 A. Javaid and F. Czerwinski Part VIII TMS-DGM Symposium on Lightweight Metals: Magnesium Incorporating an ICME Approach into Die-Cast Magnesium Alloy Component Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 J. P. Weiler Influences of SiC Particle Additions on the Grain Refinement of Mg–Zn Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Yuanding Huang, Jiang Gu, Sihang You, Karl Ulrich Kainer, and Norbert Hort Development, Characterization, Mechanical and Corrosion Behaviour Investigation of Multi-direction Forged Mg–Zn Alloy . . . . . . . . . . . . . . . . . . . . . . 339 Gajanan Anne, S. Ramesh, Goutham Kumar, Sandeep Sahu, M. R. Ramesh, H. Shivananda Nayaka, and Shashibhushan Arya Electrochemical Behaviour of ECAP-Processed AM Series Magnesium Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 K. R. Gopi and H. Shivananda Nayaka