High cycle fatigue characterization of two die-cast magnesium alloys

High cycle fatigue characterization of two die-cast magnesium alloys

M A TE RI A L S CH A RACT ER IZ A TI O N 59 ( 20 0 8 ) 5 6 7 –5 7 0 High cycle fatigue characterization of two die-cast magnesium alloys Y. Yang a,⁎,...

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M A TE RI A L S CH A RACT ER IZ A TI O N 59 ( 20 0 8 ) 5 6 7 –5 7 0

High cycle fatigue characterization of two die-cast magnesium alloys Y. Yang a,⁎, Y.B. Liu b a

School of Materials Science and Engineering, Changchun University of Technology, 17 Yan'an Road, Changchun City, Jilin Province, Changchun 130012, PR China b Key Laboratory of Automobile Materials Ministry of Education, Jilin University, Changchun 130025, PR China

AR TIC LE D ATA

ABSTR ACT

Article history:

High cycle fatigue characteristics of two magnesium alloys including die-cast AZ91D and

Received 14 June 2006

AZ91D with 1%Ce(wt.%) addition were investigated. High cycle fatigue tests were carried out

Received in revised form

at a stress ratio(R) of 0.1 and a frequency of 90 Hz using cylindrical specimens at different

10 April 2007

maximum applied stress levels. Fatigue crack growth tests were conducted at R = 0.1 and a

Accepted 20 April 2007

frequency of 20 Hz using single edge V-notched plate specimens. The results showed that some new rod-like Al11Ce3 phases were observed, and the elongation, yield and tensile

Keywords:

strength of the materials are significantly improved in AZ91D alloy with 1%Ce(wt.%)

Die cast magnesium alloy

addition. Die-cast AZ91D magnesium alloy with 1%Ce(wt.%) addition exhibits higher fatigue

Cerium

performance. The superior fatigue behavior of the alloy containing 1%Ce(wt.%) is mostly due

High cycle fatigue

to the grain refinement, Al11Ce3 and fined β phases at the grain boundary diffusely and cast

Fatigue crack growth

characteristics improvement. The fractographs of two die-cast magnesium alloys shows basically quasi-cleavage fracture. © 2007 Elsevier Inc. All rights reserved.

1.

Introduction

Recently, magnesium alloys are very attractive materials due to their low density, high specific strength and easily recycled compared with other metals and alloys. As low-weight structural materials, there have been significant increase in usage of magnesium alloy for automobile, aerospace components, computer, mobile phones and household equipments. AZ91D alloy with about 9 wt.% Al and 1 wt.% Zn is the most common die-cast alloy in automotive applications due to excellent cast ability and good room-temperature mechanical properties [1–3]. However, low fatigue strength under service conditions have been an important factor in limiting the use of magnesium alloys in lowly stressed designs [4,5]. Cerium is an important alloying element in magnesium alloys, which can

improve their casting characteristics, high temperature properties, corrosion and wear resistance properties [6–8]. However, few researches on the effect of cerium on high cycle fatigue behavior of die-cast AZ91D magnesium alloy have been reported [9]. In the present study, the high cycle fatigue and fatigue crack growth behavior of two magnesium alloys including die-cast AZ91D and AZ91D containing 1%Ce(wt.%) were discussed.

2.

Experimental Procedures

Die-cast AZ91D alloy and the alloy with 1%Ce(wt.%) addition were used for tensile and fatigue studies. The chemical compositions of two test alloys are shown in Table 1. Uniaxial

⁎ Corresponding author. Tel.: +86 431 866 447 72; fax: +86 431 857 164 26. E-mail addresses: [email protected] (Y. Yang)., [email protected] (Y.B. Liu). 1044-5803/$ – see front matter © 2007 Elsevier Inc. All rights reserved. doi:10.1016/j.matchar.2007.04.016

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Table 1 – The chemical compositions of two test alloys (wt.%) Materials

Al

Zn Mn

Ce

Fe

Ni

Si

Mg

AZ91D 8.76 0.68 0.21 0 ≤ 0.006 ≤ 0.001 ≤ 0.05 Balance AZ91D-1% 8.82 0.64 0.22 0.95 ≤ 0.006 ≤ 0.001 ≤ 0.05 Balance Ce

tensile test was carried out at an initial strain rate 1 × 10− 4/s using cylindrical specimens with 6 mm gauge diameter and 20 mm gauge length on a MTS 810 machine. High cycle fatigue test with a stress-controlled constant amplitude was conducted on a PLG-20C high frequency fatigue testing machine in laboratory air at room temperature using a sine-wave form with a stress ratio of 0.1 and a frequency of 90 Hz. In the constant stress amplitude tests, the specimens were loaded until specimen failure or to a maximum number of cycles of 107. The fracture surfaces of the tested specimens were observed using a JSM-5600LV scanning electron microscope (SEM). The fatigue crack growth rates were studied using a single edge-notched specimen with a thickness, width, and length of 3 mm, 13 mm and 75 mm. All specimens were polished using fine aluminum oxide powder before testing. Fatigue crack growth tests were conducted in laboratory air, at a stress ratio of 0.1 with different maximum stress and a frequency of 20 Hz using a sevo-hydraulic material test system (Instron 8511). The tests were terminated at the stress intensity factor range value where no physical crack growth for 107 cycles of loading. The stress intensity factor range was calculated using the following equations [10]: pffiffiffiffiffiffiffiffiffi DK ¼ Kmax  Kmin ¼ f ða=WÞDr ðpaÞ f ða=WÞ ¼ 1:12  0:23ða=WÞ þ 10:55ða=WÞ2  21:7ða=WÞ3 þ 30:38ða=WÞ4

ð1Þ

ð2Þ

where ΔK, Kmax, Kmin, Δσ, W, a are the stress intensity factor range, maximum stress intensity factor, minimum stress intensity factor, stress range, width of specimen and crack length, respectively.

3.

Fig. 1 – SEM micrographs of two die cast magnesium alloys (a) AZ91D (b) AZ91D with 1%Ce(wt.%) addition.

Results and Discussion

The SEM micrographs of two die cast magnesium alloys microstructures are shown in Fig. 1. In the die-cast AZ91D alloy, the β phase (Mg17Al12) can be seen at the grain boundary and primary α, eutectic α phase exist at the adjacent to β phase as shown in Fig. 1a. After adding 1%Ce(wt.%) in alloy, Fig. 1b showed that some fined β phase still remains at the grain boundaries, but some new rod-like Al11Ce3 phases are observed. The grain size of the alloy is slightly decreased from 25 μm (0%Ce) to 15 μm (1%Ce). The gas pore size of AZ91D alloy is also decreased and distributed evenly with the 1%Ce(wt.%) addition due to the excellent affinity of Ce with impurity elements O, S etc. The casting quality of alloys was improved greatly, the tendency of fatigue crack initiation reduced considering the influence of porosity on the crack formation [11].

Tensile properties of two magnesium alloys are shown in Table 2. It can be seen from the table that the elongation, tensile and yield strength of the material are significantly improved after 1%Ce(wt.%) addition. The mechanical properties improvement of Ce addition is attributed to the grain refinement and the change in the shape and distribution of β phase. The mechanical properties can be improved by grain refinement according to Hall–Petch relation. The grain growth can also be restricted by small particles (β phase) at the grain boundaries. The S–N data obtained from the high cycle fatigue test (Fig. 2) shows that the alloy with 1%Ce(wt.%) addition have improved fatigue strength at any given stress level compared to die-cast AZ91D alloy without Ce addition. The high fatigue performance of the AZ91D alloy with 1%Ce(wt.%) addition is mostly due to the amount of grain boundary increasing with the grain size decreasing, and grain boundary play a barriers role in dislocation movement plastic deformation. Furthermore, stress concentration in each grain could be reduced since the tensile stresses are undertaken by more grains and

Table 2 – Tensile properties of two test alloys Materials AZ91D AZ91D-1%Ce

0.2%Y.S (MPa)

UTS (MPa)

Elongation (%)

136 158

210 248

5.4 6.8

M A TE RI A L S CH A RACT ER IZ A TI O N 59 ( 20 0 8 ) 5 6 7 –5 7 0

569

Fig. 2 – The S–N curves of two die-cast magnesium alloys.

improved cast quality after adding 1%Ce(wt.%) in the alloy [12]. The sameness and differences in the fatigue fracture behaviors between two alloys can be seen from the SEM micrographs in Figs. 3 and 4. Fracture surface of two alloys illustrates three representative regions, which are fatigue crack initiation, growth and collapse fracture regions, respectively. Fatigue cracks initiate at porosity and inclusions locations of alloy interior for two alloys, propagate along with grain boundary, and the direction of the crack propaga-

Fig. 4 – SEM micrographs of fatigue crack growth region of two magnesium alloys (a) AZ91D (b) AZ91D with 1%Ce(wt.%) addition, the direction of the crack propagation was represented by the arrows.

tion represented by the arrows. The fractographs, Fig. 3a and b, of die-cast AZ91D and AZ91D with 1%Ce(wt.%) addition alloys show predominantly quasi-cleavage fracture. It can be seen from Fig. 4 that the fatigue crack path changes to reveal a more faceted and serrated fracture surface. The facets are basically flat and smooth, facets sizes be nearly the same as (Fig. 4a), or smaller than (Fig. 4b) the average grain size.

Fig. 3 – SEM micrographs of fatigue fracture surface of two magnesium alloys indicating different fatigue regions (a) AZ91D (b) AZ91D with 1%Ce(wt.%) addition.

Fig. 5 – Variation of fatigue crack growth rate (da/dN) with stress intensity factor range (ΔK) for two die-cast magnesium alloys.

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The typical relationship between fatigue crack growth rate, da/dN and stress intensity factor range ΔK for two alloys is shown in Fig. 5. The fatigue crack propagation (FCP) resistance of the alloy with 1%Ce(wt.%) addition is superior to that of diecast AZ91D alloy at any ΔK regions. The higher FCP resistance of with 1%Ce(wt.%) material is mostly due to rod-like Al11Ce3 and fined β phases at the grain boundary, which restrict fatigue crack propagation, and hence lower crack growth rate.

4.

Conclusions

The experimental studies on die-cast AZ91D and with 1%Ce (wt.%) addition alloys lead to the following conclusions: (a) The sizes of grain and β phase of die-cast AZ91D alloy with 1%Ce(wt.%) addition are decreased, and cast quality improved. (b) The elongation, yield and tensile strength are improved after adding 1%Ce(wt.%) in the AZ91D alloy. (c) Die-cast AZ91D magnesium alloy with 1%Ce(wt %) addition exhibits higher fatigue performance and lower fatigue crack growth rate.

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