Magnesium, Magnesium Alloys, and Magnesium Composites

265 Pages·2011·20.29 MB·English

by  Manoj Gupta

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MAGNESIUM,
MAGNESIUM ALLOYS,
AND MAGNESIUM
COMPOSITES
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MAGNESIUM,
MAGNESIUM ALLOYS,
AND MAGNESIUM
COMPOSITES
Manoj Gupta
Nai Mui Ling Sharon
A JOHN WILEY & SONS, INC. PUBLICATION
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Copyright(cid:1)c 2011byJohnWiley&Sons,Inc.Allrightsreserved.
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LibraryofCongressCataloging-in-PublicationData:
Magnesium,magnesiumalloys,andmagnesiumcomposites/authoredby
ManojGupta,NaiMuiLingSharon.
p.cm.
Includesindex.
ISBN978-0-470-49417-2(hardback)
1.Magnesium. 2.Magnesiumcompounds. 3.Magnesiumalloys.
4.Metalliccomposites. I.Gupta,M.(Manoj) II.Nai,MuiLingSharon.
TA480.M3M3252011
620.1(cid:2)87–dc22
2010018479
PrintedintheUnitedStatesofAmerica
10 9 8 7 6 5 4 3 2 1
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CONTENTS
PREFACE xv
ACKNOWLEDGMENTS xvii
1
INTRODUCTION TO MAGNESIUM 1
1.1 Introduction 1
1.2 CharacteristicsofPureMagnesium 4
1.2.1 AtomicPropertiesandCrystalStructure 4
1.2.2 PhysicalProperties 4
1.2.3 ElectricalProperties 4
1.2.4 MechanicalProperties 5
1.3 Applications 5
1.3.1 AutomotiveApplications 5
1.3.2 AerospaceApplications 7
1.3.3 MedicalApplications 8
1.3.4 SportsApplications 9
1.3.5 ElectronicApplications 10
1.3.6 OtherApplications 10
1.4 Summary 11
References 11
2
SYNTHESIS TECHNIQUES FOR MAGNESIUM-BASED
MATERIALS 13
2.1 Introduction 13
2.2 LiquidPhaseProcesses 14
2.2.1 SandCasting 14
2.2.2 DieCasting 15
2.2.3 SqueezeCasting 16
2.2.4 SSMCasting 17
2.2.4.1 Thixomolding 17
2.2.4.2 Rheocasting 18
2.2.5 StirCasting 18
2.2.6 SprayForming 19
2.2.7 MeltInfiltrationMethod 20
2.2.8 InSituSynthesis 21
v
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vi CONTENTS
2.3 SolidPhaseProcess 21
2.3.1 Blending 21
2.3.2 MechanicalAlloying 23
2.3.3 PowderConsolidation(Compaction) 24
2.3.4 SinteringMethods 26
2.3.4.1 ConventionalSintering 28
2.3.4.2 MicrowaveSintering 29
2.4 DisintegratedMeltDepositionMethod 32
2.5 MechanicalDisintegrationandDepositionMethod 35
2.6 Summary 36
References 36
3
MAGNESIUM ALLOYS 39
3.1 Introduction 39
3.1.1 EffectsofAdditionofMetallicElementsonMagnesium 40
3.1.1.1 Aluminum 40
3.1.1.2 Beryllium 40
3.1.1.3 Calcium 40
3.1.1.4 Cerium 40
3.1.1.5 Copper 40
3.1.1.6 Iron 40
3.1.1.7 Lithium 40
3.1.1.8 Manganese 41
3.1.1.9 Molybdenum 41
3.1.1.10 Nickel 41
3.1.1.11 RareEarthMetals(RE) 41
3.1.1.11.1Neodymium 41
3.1.1.12 Silicon 41
3.1.1.13 Silver 41
3.1.1.14 Strontium 41
3.1.1.15 Thorium 42
3.1.1.16 Tin 42
3.1.1.17 Titanium 42
3.1.1.18 Yttrium 42
3.1.1.19 Zinc 42
3.1.1.20 Zirconium 42
3.1.2 ClassificationsofMagnesiumAlloys 42
3.1.2.1 AlloyDesignations 42
3.1.2.2 TemperDesignations 43
3.2 CastingAlloys 44
3.2.1 CharacteristicsofCastingAlloys 44
3.2.2 PhysicalPropertiesofCastingAlloys 44
3.2.3 MechanicalPropertiesofCastingAlloys 47
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3.3 WroughtAlloys 47
3.3.1 CharacteristicsofWroughtAlloys 47
3.3.2 MechanicalPropertiesofWroughtAlloys 47
3.4 MagnesiumElektronSeriesAlloys 55
3.4.1 MagnesiumElektronCastingAlloys 55
3.4.2 WroughtMagnesiumElektronAlloys 56
3.5 MagnesiumAlloysforElevatedTemperatureApplications 62
3.5.1 Mg–Al–REAlloys 63
3.5.2 Mg–Al–CaAlloys 65
3.5.3 Mg–Al–Ca–REAlloys 66
3.5.4 Mg–Zn–Al–CaAlloys 72
3.5.5 Mg–Al–SrAlloys 72
3.5.6 Mg–Al–SiAlloys 76
3.5.7 Mg–RE–ZnAlloys 76
3.5.8 Summary—CreepStrength 76
3.6 Magnesium-BasedBulkMetallicGlasses 76
References 81
4
FUNDAMENTALS OF METAL MATRIX COMPOSITES 87
4.1 Introduction 87
4.1.1 FactorsAffectingPropertiesofMMCs 88
4.2 Materials 89
4.2.1 Matrix 90
4.2.2 Reinforcements 90
4.3 InterfaceBetweenMatrixandReinforcement 94
4.3.1 TailoringtheInterfaceforEnhancedPerformance 95
4.3.2 MethodsofInterfaceEngineering 96
4.3.3 TailoringtheInterfaceThroughChoiceofProcessingTechnique 96
4.3.4 InterfacialFailure 96
4.4 TheoreticalPredictionofProperties 97
4.4.1 Density 97
4.4.2 ElectricalConductivity 97
4.4.2.1 Rayleigh–MaxwellEquation 97
4.4.2.2 Kerner’sModel 98
4.4.2.3 ROMsModel 98
4.4.3 CoefficientofThermalExpansion 99
4.4.3.1 ROMs(UpperBound) 99
4.4.3.2 Turner’sModel(LowerBound) 99
4.4.3.3 Kerner’sModel 100
4.4.4 ElasticModulus 100
4.4.4.1 RuleofMixtures 100
4.4.4.2 Halpin–TsaiModel 101
4.4.4.3 EffectofPorosityonElasticModulus 101
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4.4.5 YieldStrength 102
4.4.5.1 ShearLagTheories 102
4.4.5.2 StrengtheningFactors 103
4.4.5.2.1 ThermalandElasticModulus
Mismatch 103
4.4.5.2.2 Load-bearingEffect 104
4.4.5.2.3 OrowanStrengthening 105
4.4.5.2.4 Hall–PetchEffect 105
4.4.6 Ductility 105
4.5 Summary 107
References 107
5
MAGNESIUM COMPOSITES 113
5.1 Introduction 113
5.2 Materials 114
5.2.1 Matrix 114
5.2.2 Reinforcements 114
5.2.2.1 TypeofReinforcements 114
5.2.2.2 ShapeofReinforcements 116
5.2.2.3 AmountofReinforcements 116
5.2.2.4 LengthScaleofReinforcements 116
5.2.2.5 DuctilityEffectsofReinforcements 118
5.3 Magnesium-BasedCompositeswithAl O 121
2 3
5.3.1 AdditionofSub-Micrometer-SizeAl O 122
2 3
5.3.1.1 MgReinforcedwith0.3µmAl O (byDisintegrated
2 3
MeltDeposition) 122
5.3.1.2 MgReinforcedwith0.3µmAl O (byPowder
2 3
Metallurgy—MicrowaveSintering) 123
5.3.2 AdditionofNanosizeAl O 124
2 3
5.3.2.1 MgReinforcedwith50nmAl O (byDisintegrated
2 3
MeltDeposition) 124
5.3.2.2 MgReinforcedwith50nmAl O (byPowder
2 3
Metallurgy—ConventionalSintering) 125
5.3.2.3 MgReinforcedwith50nmAl O (byPowder
2 3
Metallurgy—MicrowaveSintering) 126
5.3.2.4 AZ31BReinforcedwith50nmAl O (by
2 3
DisintegratedMeltDeposition) 127
5.3.2.5 AZ31BReinforcedwith50nmAl O andwithCa
2 3
addition(byDisintegratedMeltDeposition) 128
5.3.2.6 AZ31Reinforcedwith50nmAl O (byDisintegrated
2 3
MeltDeposition) 129
5.3.3 AdditionofHybridReinforcements(withAl O ) 130
2 3
5.3.3.1 MgReinforcedwithAl O ofDifferentSizes(by
2 3
PowderMetallurgy—ConventionalSintering) 130
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5.3.3.2 MgReinforcedwithAl O ofDifferentSize(by
2 3
PowderMetallurgy—MicrowaveSintering) 131
5.3.3.3 MgReinforcedwithMg-NanoAl O Concentric
2 3
AlternatingMacroRing(byPowder
Metallurgy—MicrowaveSintering) 132
5.3.3.4 MgReinforcedwithAl O andMWCNT(byPowder
2 3
Metallurgy—MicrowaveSintering) 133
5.4 Magnesium-BasedCompositeswithMgO 134
5.4.1 AdditionofNanosizeMgO 135
5.4.1.1 MgReinforcedwith36nmMgO(byDisintegrated
MeltDeposition) 135
5.5 Magnesium-BasedCompositeswithSiC 136
5.5.1 AdditionofMicrometer-SizeSiC 136
5.5.1.1 MgandAZ91DReinforcedwith150µmSiC(byStir
Casting) 136
5.5.1.2 MgandAZ91Reinforcedwith100µmSiC(byLiquid
Infiltration) 137
5.5.1.3 MgReinforcedwith40µmSiC(byMeltStir
Technique) 138
(a)TestedatRoomTemperature 138
(b)TestedatElevatedTemperatures 139
5.5.1.4 MgReinforcedwith38µmSiC(byDisintegratedMelt
Deposition) 139
(a)EffectofExtrusionTemperature 140
(b)EffectofHeatTreatment 141
(c)EffectofRecycling 142
5.5.1.5 MgReinforcedwith35µmSiC(byConventional
Casting) 143
5.5.1.6 MgReinforcedwith25µmSiC(byDisintegratedMelt
Deposition) 144
5.5.1.7 MgReinforcedwith25µmSiC(byConventional
Casting) 145
5.5.1.8 Mg–AlReinforcedwith20µmSiC(byPowder
Metallurgy) 146
(a)Liquid-PhaseSintering 146
(b)Solid-PhaseSintering 147
5.5.1.9 AZ91CReinforcedwith12.8µmSiC(byVacuumStir
Casting) 148
5.5.2 AdditionofSub-Micrometer-SizeSiC 149
5.5.2.1 MgReinforcedwith0.6µmSiC(byDisintegrated
MeltDeposition) 149
(a)EffectofHeatTreatment 150
5.5.3 AdditionofNanosizeSiC 151
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5.5.3.1 MgReinforcedwith50nmSiC(byMelt
Casting—UltrasonicCavitation) 151
5.5.3.2 Mg4ZnReinforcedwith50nmSiC(byMelt
Casting—UltrasonicCavitation) 152
5.5.3.3 Mg6ZnReinforcedwith50nmSiC(byMelt
Casting—UltrasonicCavitation) 153
(a)As-CastCondition 153
(b)Heat-TreatedCondition(T5) 154
5.5.3.4 MgReinforcedwith45–55nmSiC(byPowder
Metallurgy) 155
(a)WithoutSinteringProcess 155
(b)HybridMicrowave-AssistedSintering 156
5.5.4 AdditionofHybridReinforcement(withSiC) 157
5.5.4.1 MgReinforcedwithSiCofDifferentSizes(byPowder
Metallurgy—MicrowaveSintering) 157
5.5.4.2 MgReinforcedwith50nmAl O and50nmSiC(by
2 3
PowderMetallurgy—MicrowaveSintering) 158
5.5.4.3 MgReinforcedwith50nmSiCandMWCNT(by
PowderMetallurgy—MicrowaveSintering) 159
5.6 Magnesium-BasedCompositeswithY O 160
2 3
5.6.1 AdditionofNanosizeY O 160
2 3
5.6.1.1 MgReinforcedwith29nmY O (byDisintegrated
2 3
MeltDeposition) 160
5.6.1.2 MgReinforcedwith29nmY O (byPowder
2 3
Metallurgy—ConventionalSintering) 162
5.6.1.3 MgReinforcedwith32–36nmY O (byDisintegrated
2 3
MeltDeposition) 163
5.6.1.4 MgReinforcedwith30–50nmY O (byPowder
2 3
Metallurgy—MicrowaveSintering) 164
(a)EffectofAmountofY O Addition 164
2 3
(b)EffectofHeatingRate 165
(c)EffectofExtrusionRatio 165
5.6.2 AdditionofHybridReinforcements(withY O ) 166
2 3
5.6.2.1 MgReinforcedwithY O andNanosizeCu(by
2 3
PowderMetallurgy—MicrowaveSintering) 166
5.6.2.2 MgReinforcedwithY O andNanosizeNi(by
2 3
PowderMetallurgy—MicrowaveSintering) 167
5.7 Magnesium-BasedCompositeswithZrO 168
2
5.7.1 AdditionofNanosizeZrO 168
2
5.7.1.1 MgReinforcedwith29–68nmZrO (byDisintegrated
2
MeltDeposition) 168
5.7.1.2 MgReinforcedwith29–68nmZrO (byPowder
2
Metallurgy—ConventionalSintering) 169
5.8 Magnesium-BasedCompositeswithCNT 170
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5.8.1 AdditionofMWCNTs 171
5.8.1.1 MgReinforcedwithMWCNTs(byDisintegratedMelt
Deposition) 171
5.8.1.2 MgReinforcedwithMWCNTs(byPowder
Metallurgy—ConventionalSintering) 172
5.8.1.3 AZ91DReinforcedwithMWCNTs(byPowder
Metallurgy—MechanicalMilling) 173
5.8.1.4 AZ91DReinforcedwithMWCNTs(byMeltStirring
Method) 174
5.8.1.5 AZ31ReinforcedwithCNTs(byDisintegratedMelt
Deposition) 175
(a)TensileTest 175
(b)CompressionTest 176
5.9 Magnesium-BasedCompositeswithMetallicAdditions 176
5.9.1 AdditionofMicrometer-SizeCopper 177
5.9.1.1 MgReinforcedwith8–11µmCu(byDisintegrated
MeltDeposition) 177
5.9.1.2 AZ91AReinforcedwith8–11µmCu(by
DisintegratedMeltDeposition) 178
5.9.1.3 AZ91AandMgReinforcedwith8–11µmCu(by
DisintegratedMeltDeposition) 179
5.9.2 AdditionofNanosizeCopper 180
5.9.2.1 MgReinforcedwith50nmCu(byPowder
Metallurgy—MicrowaveSintering) 180
5.9.3 AdditionofNickel 181
5.9.3.1 MgReinforcedwithMicrometer-SizeNi(by
DisintegratedMeltDeposition) 181
5.9.4 AdditionofTitanium 183
5.9.4.1 MgReinforcedwithMicrometer-SizeTi(by
DisintegratedMeltDeposition) 183
5.9.4.2 MB15AlloyReinforcedwithMicrometer-SizeTiAlloy
(byPowderMetallurgyRoute) 184
5.9.5 AdditionofMolybdenum 185
5.9.5.1 MgReinforcedwithMicrometer-SizeMo(by
DisintegratedMeltDeposition) 185
5.9.6 AdditionofAluminum 186
5.9.6.1 MgReinforcedwithMicrometer-SizeAl(byPowder
Metallurgy—MicrowaveSintering) 186
5.9.6.2 MgReinforcedwith18nmAl(byPowder
Metallurgy—ConventionalSintering) 187
5.9.7 AdditionofIronWireMesh 188
5.9.7.1 MgReinforcedwithInterconnectedFeWireMesh(by
DisintegratedMeltDeposition) 188
5.9.7.2 MgReinforcedwithFeWireMeshandCarbonFibers
(byDisintegratedMeltDeposition) 189