Magnesium-based alloys are highly sought after in the industry due to their lightweight and reliable strength. However, the hexagonal crystal structure of magnesium results in the mechanical properties’ anisotropy. This anisotropy is effectively addressed by alloying magnesium with elements like zirconium, zinc, and rare earth metals (REM). The addition of these elements promotes rapid seed formation, yielding small grains with a uniform orientation distribution, thereby reducing anisotropy. Despite these benefits, the formation of intermetallic phases (IP) containing Zn, Zr, and REM within the microstructure can be a concern. Some of these IP phases can be exceedingly hard and brittle, thus weakening the material by providing easy pathways for crack propagation along grain boundaries (GBs). This issue becomes particularly significant if intermetallic phases form continuous layers along the entire GB between two neighboring GB triple junctions, a phenomenon known as complete GB wetting. To mitigate the risks associated with complete GB wetting and prevent the weakening of the alloy’s structure, understanding the potential occurrence of a GB wetting phase transition and how to control continuous GB layers of IP phases becomes crucial. In the investigation of a commercial magnesium alloy, ZEK100, the GB wetting phase transition (i.e., between complete and partial GB wetting) was successfully studied and confirmed. Notably, complete GB wetting was observed at temperatures near the liquidus point of the alloy. However, at lower temperatures, a coexistence of a nano-scaled precipitate film and bulk particles with nonzero contact angles within the same GB was observed. This insight into the wetting transition characteristics holds potential to expand the range of applications for the present alloy in the industry. By understanding and controlling GB wetting phenomena, the alloy’s mechanical properties and structural integrity can be enhanced, paving the way for its wider utilization in various industrial applications.
The grain boundary wetting phase transition in an industrial EZ33A cast alloy is studied. 12% of the grain boundaries are completely wetted at the temperature slightly higher than the eutectic transformation temperature (530°C). The fraction of wetted grain boundaries increases with temperature, reaches a maximum of 85% at 570°C, and does not change further until the alloy melts. In the as-cast state, the alloy has low ductile properties at the ambient temperature. The microstructure in the as-cast state corresponds to the wetting state at about 560°C, which indicates that the cooling rate in casting is almost equal to that in quenching. The volume and the surface fraction of the second phase and the hardness measured at the least wetted state of samples point to its good machinability. The wetting data are used to suggest a sequence of heat treatment and machining for processing EZ33A alloy parts.
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