Development and Applications of New Lightweighting Metal Technologies: High Strength Al and Mg Alloys

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (28 February 2022) | Viewed by 24815

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Guest Editor
School of Materials Science & Engineering, and Advanced Research Institute for Multidisciplinary Science (ARIMS), Beijing Institute of Technology, Beijing 100081, China
Interests: aerospace materials; integrated computational materials engineering (ICME); aluminum; magnesium; alloy design; solidification; heat treatment; thermodynamics; kinetics; grain refinement; precipitation
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Special Issue Information

Dear Colleagues,

As the concerns on global warming as a result of CO2 emission are increasing, vehicle lightweighting through new structural materials has become more and more important. Traditionally, metallic materials are the key components in supporting all transports. Recently, new materials such as carbon fiber-reinforced composites (CFRC) have provided better opportunities for cutting the weight of cars and buses. However, the difficulties in CFRC product certification, maintenance standardization, and connecting reliability calls for old metallic materials to cut the weight while increasing strength in order to meet the ever increasing demand. As a result, this Special Issue is focused on the development and applications of new lightweighting metal technologies with special attention given to high strength Al and Mg alloys.

Articles concerning high strength aluminum alloys, magnesium alloys, and their processing and characterizations are welcome. This is an excellent opportunity for metallic materials scientists and engineers all over the world to get their latest work published on all aspects of the physical and mechanical metallurgy of lightweight alloys as well as processing technologies. Any new non-constructive testing such as computed tomography and process optimization such as multiscale modeling for evaluating the properties and aluminum and magnesium alloys for end applications, in automotive, aerospace, and marine fields are welcome. Therefore, this Special Issue will cover—but is not limited to—the following fundamental and applied research topics:

  • Light-weight design;
  • High Strength Al and Mg alloys;
  • Alloy development;
  • Nano-precipitates;
  • Grain refinement;
  • Plasticity mechanisms;
  • In situ observation/nano- micro-CT analysis;
  • Processing innovation;
  • Process control;
  • Phase quantification and measurements;
  • Thermodynamic calculation;
  • Kinetic modeling;
  • Density functional theory;
  • Molecular dynamics;
  • Microstructure evolution;
  • Non-destructive characterization;
  • Defect quantification and prediction;
  • Mechanical design and testing;
  • Material and process modeling;
  • Integrated computational materials engineering;
  • Forming, joining, machining;
  • Corrosion ;
  • Fatigue and fracture;
  • Structural applications (automotive, aerospace, ...);
  • Additive manufacturing.

In keeping with the long-standing tradition of publishing the most recent and highest quality work on Special Issues of our Metals Journal, this Special Issue features a collection of manuscripts entitled “Development and Applications of New Lightweighting Metal Technologies: High Strength Al and Mg Alloys”. This issue features the finest and latest breaking articles in aluminum and magnesium alloy development from 2021 and is listed with the main indexing services, making the articles readily searchable and available on the web and citable.

Please ensure your paper is submitted on time, and thank you for your interest in the “Development and Applications of New Lightweighting Metal Technologies: High Strength Al and Mg Alloys” on Metals.

Prof. Dr. Junsheng Wang
Guest Editor

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Keywords

  • light-weight design
  • high strength Al and Mg alloys
  • alloy development
  • nano-precipitates
  • grain refinement
  • plasticity mechanisms
  • in situ observation/ nano- micro-CT analysis
  • processing innovation
  • process control
  • phase quantification and measurements
  • thermodynamic calculation
  • kinetic modeling
  • density functional theory
  • molecular dynamics
  • microstructure evolution
  • non-destructive characterization
  • defect quantification and prediction
  • mechanical design and testing
  • material and process modeling
  • integrated computational materials engineering
  • forming, joining, machining
  • corrosion
  • fatigue and fracture
  • structural applications (automotive, aerospace, ...)
  • additive manufacturing

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Published Papers (10 papers)

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Research

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19 pages, 5486 KiB  
Article
Quantifying the Effects of Grain Refiners Al-Ti-B and La on the Microstructure and Mechanical Properties of W319 Alloy
by Xinxiu Liu, Bing Wang, Quan Li, Junsheng Wang, Chi Zhang, Chengpeng Xue, Xinghai Yang, Guangyuan Tian, Xiaoguang Liu and Hongqun Tang
Metals 2022, 12(4), 627; https://doi.org/10.3390/met12040627 - 5 Apr 2022
Cited by 15 | Viewed by 2399
Abstract
It is well known that the microstructure distribution in recycled Al-Si alloys has a large impact on the final mechanical properties. In this study, the microstructure, including Fe-rich intermetallics and microporosity, was quantitatively adjusted using multi-scale characterization with microalloying rare earth elements and [...] Read more.
It is well known that the microstructure distribution in recycled Al-Si alloys has a large impact on the final mechanical properties. In this study, the microstructure, including Fe-rich intermetallics and microporosity, was quantitatively adjusted using multi-scale characterization with microalloying rare earth elements and traditional grain refiners as the objects of study. It was found that the addition of Al-Ti-B to W319 recycled aluminum alloy reduces the microstructure size and Fe-rich intermetallics, while the addition of La facilitates the transformation of harmful β-Fe into less harmful particles and the densification of coarse eutectic Si, promoting the refining effects on the microstructure additionally. Therefore, the RE and Al-Ti-B master alloy could be a potential new grain refining agent, especially for Al-cast alloys when the ductility is critical for designing. The improvement in elongation far exceeds the original level, up to 69.6%, while maintaining the same level of strength or even better. At the same time, the excessive addition of La may lead to the depletion of Cu and Ti elements during heat treatment, degrading ductility and strength. Full article
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12 pages, 3509 KiB  
Article
In Vitro Corrosion Performance of As-Extruded Mg–Gd–Dy–Zr Alloys for Potential Orthopedic Applications
by Chen Liu, Junsheng Wang, Yongdong Xu, Yu Fu, Jungang Han, Zhaoxun Cao, Xiaohu Chen, Shuming Zhao and Xiurong Zhu
Metals 2022, 12(4), 604; https://doi.org/10.3390/met12040604 - 31 Mar 2022
Cited by 1 | Viewed by 2161
Abstract
In this study, different contents of rare earth elements with high solid solubility (Gd and Dy) were added into Mg and fabricated through homogenization and hot extrusion processes that enable few second phase formation to efficaciously inhibit the galvanic corrosion. The microstructure and [...] Read more.
In this study, different contents of rare earth elements with high solid solubility (Gd and Dy) were added into Mg and fabricated through homogenization and hot extrusion processes that enable few second phase formation to efficaciously inhibit the galvanic corrosion. The microstructure and phase characterization of the as-extruded Mg–Gd–Dy–Zr alloys were analyzed by scanning electron microscopy, electron backscattered diffraction, and X-ray diffraction. The in vitro biodegradation behavior of the as-extruded Mg–Gd–Dy–Zr alloys was investigated via the electrochemical measurement and immersion test. The results revealed that all the as-extruded alloys with different RE additions exerted fully recrystallized microstructures. The average grain size was appropriately 20 μm to 30 μm for all alloys and gradually increased by adding more RE. Only a few tiny second-phase particles less than 5 μm dispersed for all the samples and the volume fraction of particles increased slightly with the increase in RE content. The as-extruded Mg–Gd–Dy–Zr alloys with low RE content (GD0.6) allowed for a satisfactory corrosion resistance in Hank’s solution with a controlled corrosion rate less than 0.5 mm/year, which is considered as the tolerance limit for the corrosion rate of orthopedic implants. This study provides a cost-effective choice for promoting biodegradable magnesium alloys for potential orthopedic applications with low rare earth content in Mg alloys. Full article
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17 pages, 7185 KiB  
Article
Effect of Heat Treatment on Microstructural Evolution and Microhardness Change of Al-5Zn-0.03In-1Er Alloy
by Jin Cui, Zhichao Tang, Muzhi Yu, Jiajin Hu, Xiaoyang Chen, Zhengbing Xu and Jianmin Zeng
Metals 2022, 12(3), 370; https://doi.org/10.3390/met12030370 - 22 Feb 2022
Cited by 3 | Viewed by 1735
Abstract
Adding an appropriate amount of Er element to Al-Zn-In alloys can improve the electrochemical performance of Al alloys; it is convenient to study the electrochemical behavior of the alloy in the rest of our work. However, Er segregation in solid solutions which reduced [...] Read more.
Adding an appropriate amount of Er element to Al-Zn-In alloys can improve the electrochemical performance of Al alloys; it is convenient to study the electrochemical behavior of the alloy in the rest of our work. However, Er segregation in solid solutions which reduced the comprehensive properties of alloys was difficult to reduce and there was no report on the homogenization of Al-Zn-In alloys. We found that the ultra-high temperature treatment (UHTT) can obviously reduce Er segregation. To explore the better homogenization treatment and the microstructure evolution of Al-5Zn-0.03In-1Er alloy after UHTT, we carried out a series of heat treatments on the alloy and characterized the microstructure of the alloy by optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), energy spectrum analysis (EDS) and transmission electron microscopy (TEM). The results showed that the main element Er of the Al-Zn-In-Er was largely enriched in grain boundaries after UHTT; the distribution Zn and In was almost unchanged. The as-cast Al-Zn-In-Er alloy consisted mainly of α(Al) solid solution and Al3Er phase. As the temperature of UHTT increased and the treatment time prolonged, the precipitated phase dissolved into the matrix, and there were dispersed Al3Er particles in the crystal. The proper UHTT for reducing the interdendritic segregation of the alloy was 615 °C × 32 h, which was properly consistent with the results of the evolution of the statistical amount of interdendritic phase, the line scanning analysis and the microhardness. Moreover, the microhardness of the alloy after treatment of 615 °C × 32 h was obviously higher than that of the as-cast alloy because of the anchoring effect of Al3Er nanoparticles on the movement of dislocations. Full article
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11 pages, 3514 KiB  
Article
Erosion Layer Growth between Solid 316L Stainless Steel and Al–Li Alloy Melt
by Zhanwei He, Xiaojun Hu, Wan Han, Xudong Mao and Kuo-Chih Chou
Metals 2022, 12(2), 350; https://doi.org/10.3390/met12020350 - 17 Feb 2022
Cited by 2 | Viewed by 1511
Abstract
The erosion experiments of Al–Li melt on 316L stainless steel were carried out at different temperatures and holding times. In this study, the microstructure and composition of an Al–Li/316L liquid–solid interface was analyzed by inductively coupled plasma atomic emission spectroscope (ICP-AES), scanning electron [...] Read more.
The erosion experiments of Al–Li melt on 316L stainless steel were carried out at different temperatures and holding times. In this study, the microstructure and composition of an Al–Li/316L liquid–solid interface was analyzed by inductively coupled plasma atomic emission spectroscope (ICP-AES), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The phase transformation and structure evolution of the erosion process were studied to explain the erosion mechanism and kinetics. The results showed that Fe/Cr/Ni–Al intermetallic compounds (IMC) were formed at the Al–Li/316L interface, and the diffusion of Cr atoms lead to the accumulation of Ti in the Al–Li melt, to form TiAl3 and CrAl4. With the increase in temperature and holding time, the thickness of the Fe-containing erosion layer (EL) increased, and the morphology of Ti-containing erosion particles (EP) became larger and more regular. The apparent activation energy (Ea) of the Fe-containing erosion layer was 124.82 kJ·mol−1. Meanwhile, a kinetics equation for predicting the service life of 316L was obtained. The research results provided a theoretical guidance for the smelting and casting of an Al–Li alloy. Full article
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14 pages, 3298 KiB  
Article
Insights into Poisoning Mechanism of Zr by First Principle Calculation on Adhesion Work and Adsorption Energy between TiB2, Al3Ti, and Al3Zr
by Jianqiang Wu, Qilin Ruan, Simin Chen, Chuanchao Meng, Zhengbing Xu, Chunhua Wei, Hongqun Tang and Junsheng Wang
Metals 2022, 12(2), 286; https://doi.org/10.3390/met12020286 - 6 Feb 2022
Cited by 8 | Viewed by 2817
Abstract
Al-Ti-B intermediate alloys are widely used as grain refiners in aluminum alloys owing to the presence of Al3Ti and TiB2 phases. However, the existence of Zr in aluminum alloy melts often results in coarse grain size, leading to Al-Ti-B failure [...] Read more.
Al-Ti-B intermediate alloys are widely used as grain refiners in aluminum alloys owing to the presence of Al3Ti and TiB2 phases. However, the existence of Zr in aluminum alloy melts often results in coarse grain size, leading to Al-Ti-B failure called Zr poisoning. There are three kinds of poisoning mechanisms related to TiB2, Al3Ti, and a combination of TiB2 and Al3Ti for Zr. First, Zr forms ZrB2 or Ti2Zr with TiB2 in Al-Ti-B to reduce the nucleation ability. Second, Zr existing in the aluminum melt with a high melting point Al3Zr then attracts Ti to reduce the dispersion of Ti as a growth inhibitor. Third, Zr reacts with Al3Ti on TiB2 surface to form Al3Zr, thereby increasing the degree of mismatch with Al and diminishing the refiner’s ability as a nucleation substrate. To gain a better understanding of the mechanism of Zr poisoning, the first principle was used in this study to calculate the adhesion works (ZrB2//Al3Ti), (Ti2Zr//Al3Ti), (Al3Zr//Al3Ti), (Al3Ti//Al), (TiB2//Al3Zr), and (Al3Zr//Al), as well as the surface energy of Al3Zr and adsorption energies of Al to Al3Ti or Al3Zr. The results demonstrated that Zr poisoning originated from the second guess. Zr element exiting in aluminum melt led to the formation of an Al3Zr (001) surface. The interfacial adhesion work of Al3Zr (001)//Al3Ti (001) was not weaker than that of TiB2//Al3Ti. As a result, Al3Zr first combined with Al3Ti to significantly decline the adsorption of Al3Ti (001) on Al, losing its role as a nucleating agent and grain coarsening. Overall, to prevent failure of the grain refiner in Zr containing aluminum melt, the adhesion work interface between the generated phase of the grain refiner and Al3Zr must remain lower to avoid the combination of the generated phase of grain refiner with Al3Zr. In sum, these findings look promising for evaluating future effects of grain refinement in Zr containing aluminum melt. Full article
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15 pages, 10463 KiB  
Article
An Investigation into Microstructures and Mechanical Properties of 1060 Pure Aluminum during Submerged Friction Stir Processing at a High Rotating Speed
by Yuchen Peng, Qi Zhang, Lingyou Wen, Zonghua Xie, Biao Huang, Shanshan Hu, Hongqun Tang and Chunhua Wei
Metals 2022, 12(2), 201; https://doi.org/10.3390/met12020201 - 21 Jan 2022
Cited by 5 | Viewed by 2690
Abstract
In this work, 1060 pure aluminum was subjected to high rotating speed submerged friction stir processing (HRS-SFSP). The heat cycle curve of the processing area was measured by K-type thermocouple and temperature recorder. The microstructure, grain size, texture, and tensile fracture of the [...] Read more.
In this work, 1060 pure aluminum was subjected to high rotating speed submerged friction stir processing (HRS-SFSP). The heat cycle curve of the processing area was measured by K-type thermocouple and temperature recorder. The microstructure, grain size, texture, and tensile fracture of the processing area were analyzed by electron backscattered diffraction and scanning electron microscopy. The results show that the HRS-SFSP caused severe plastic deformation of 1060 aluminum and produced fine recrystallized grains. The minimum average grain size was 0.686 μm at the 2-pass. In addition, the dislocation density in the stirred region was greatly reduced and the high angle grain boundaries (HAGBs) were dominant. The texture strength of pure aluminum increased with the increase in processing passes. The maximum hardness of 66.3 HV and ultimate tensile strength of 95.2 MPa were obtained at 1-pass, which were 86% and 33.9% higher than those of the base material, respectively. The hardness and strength of the stirring zone (SZ) decreased with the increase in the number of processing passes. Therefore, HRS-SFSP pure aluminum can obtain high strength and hardness while maintaining good plasticity. Full article
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14 pages, 10452 KiB  
Article
Effect of Heat Treatment on the Cyclic Deforming Behavior of As-Extruded ZA81M Magnesium Alloy
by Tianjiao Luo, Jianguang Feng, Chenye Liu, Cong Wang, Yingju Li, Xiaohui Feng, Ce Zheng, Qiuyan Huang, Weirong Li and Yuansheng Yang
Metals 2022, 12(1), 146; https://doi.org/10.3390/met12010146 - 13 Jan 2022
Viewed by 1665
Abstract
In the present work, the effect of heat treatment on the cyclic deformation behavior of as-extruded ZA81M magnesium alloy was investigated. Two heat treatment conditions were applied to the as-extruded ZA81M alloy: a solution treatment (T4, 653 K for 40 h and quenched [...] Read more.
In the present work, the effect of heat treatment on the cyclic deformation behavior of as-extruded ZA81M magnesium alloy was investigated. Two heat treatment conditions were applied to the as-extruded ZA81M alloy: a solution treatment (T4, 653 K for 40 h and quenched with 298 K water) and a solution treatment plus artificial aging (T6, 348 K for 32 h (pre-aging at low temperature) and 453 K for 8 h (the second aging) and quenched with 353 K water). The results showed that the fine second phase precipitated after the aging treatment, the tensile yield strength of the T6-treated specimens increased, and the stress amplitude of T6-treated specimens was always higher than that of T4-treated specimens. The T6-treated specimens had a higher total strain energy density and a shorter fatigue life at a strain amplitude of 0.4%, and a lower total strain energy density and a longer fatigue life at a strain amplitude of 0.8%, compared to the T4-treated specimens. All fatigue cracks of the T4 and T6 ZA81M alloy were initiated at the second phase or along the grain boundary and propagated perpendicular to the loading direction. Full article
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21 pages, 43443 KiB  
Article
Effect of Er-Rich Precipitates on Microstructure and Electrochemical Behavior of the Al–5Zn–0.03In Alloy
by Muzhi Yu, Jin Cui, Zhichao Tang, Zinan Shen, Xiaoyang Chen, Zhengbing Xu and Jianmin Zeng
Metals 2022, 12(1), 131; https://doi.org/10.3390/met12010131 - 10 Jan 2022
Cited by 7 | Viewed by 1758
Abstract
The effect of Er-rich precipitates on microstructure and electrochemical behavior of the Al–Zn–In anode alloy is investigated. The results showed that with the increase in Er content, the microstructure was refined, the amount of interdendritic precipitates gradually increased, and the morphology changed from [...] Read more.
The effect of Er-rich precipitates on microstructure and electrochemical behavior of the Al–Zn–In anode alloy is investigated. The results showed that with the increase in Er content, the microstructure was refined, the amount of interdendritic precipitates gradually increased, and the morphology changed from discontinuous to continuous network gradually. With the addition of Er element, the self-corrosion potential of the Al–5Zn–0.03In–xEr alloy moved positively, the self-corrosion current density decreased, and the corrosion resistance increased. When the Er content was less than 1 wt.%, the addition of Er improved the dissolution state of the Al–5Zn–0.03In–xEr alloy, and increased the current efficiency of the Al–5Zn–0.03In–xEr alloy. When the Er content was more than 1 wt.%, the current efficiency was reduced. The major precipitate of the alloy was Al3Er. According to the element composition of Al3Er in the Al–Zn–In–Er alloy, the simulated-segregated-phase alloy was melted to explain the effect of Al3Er segregation on the electrochemical behavior of alloys, and the polarization curve and AC impedance spectrum of the simulated-segregated-phase alloy and the Al–Zn–In alloy were measured. The results showed that Al3Er was an anodic segregation phase in the Al–Zn–In–Er alloy, and the preferential dissolution of the segregation phase would occur in the alloy, but the Al3Er phase itself was passivated in the dissolution process, which inhibited the further activation of the dissolution reaction of the Al–Zn–In–Er alloy to a certain extent. Full article
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17 pages, 4038 KiB  
Article
Effect of the Initial Texture, Recrystallization and Re-Dissolution Process on the Evolution of Texture during Solution Treatment of the 7A65 Hot Rolled Plate
by Hao Wang, Lina Jia, Wenbo Wang, Chengtong Ye, Chen Li, Xinquan Zhang and Hu Zhang
Metals 2022, 12(1), 8; https://doi.org/10.3390/met12010008 - 21 Dec 2021
Cited by 5 | Viewed by 2366
Abstract
The evolution of textures, the degree of recrystallization and the mechanical properties of 7A65 hot rolled plates during re-dissolution were studied with different thicknesses (25 mm, 65 mm, 120 mm) and different degrees of deformation. It was found that different plates exhibited different [...] Read more.
The evolution of textures, the degree of recrystallization and the mechanical properties of 7A65 hot rolled plates during re-dissolution were studied with different thicknesses (25 mm, 65 mm, 120 mm) and different degrees of deformation. It was found that different plates exhibited different trends of re-dissolution because the degrees of deformation increased and the degrees of recrystallization were different during the solution treatment. With the increase of deformation and static recrystallization degrees, texture types changed from Cube, R-Cube to Brass, R, Cube and Copper during the re-dissolution process. The value of the Schmid factor (µ¯) was calculated and the value along the rolling direction was significantly larger than along the transverse direction, which led to a lower yield strength along the rolling direction. In terms of the average contribution of the yield strength, the strengthening of the grain boundary including LAGBs (low-angle grain boundaries) was found to play a more significant role than the effect of solid atoms and dislocation densities. Therefore, the 25 mm plate exhibits the best mechanical properties, with a yield strength of 565.7 MPa along the rolling direction. Full article
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10 pages, 11230 KiB  
Perspective
A Prospective Way to Achieve Ballistic Impact Resistance of Lightweight Magnesium Alloys
by Abdul Malik, Faisal Nazeer and Yangwei Wang
Metals 2022, 12(2), 241; https://doi.org/10.3390/met12020241 - 27 Jan 2022
Cited by 10 | Viewed by 3841
Abstract
The ballistic impact resistance of lightweight magnesium alloys is an eye-catching material for the military and aerospace industries, which can decrease the cost of a project and the fuel consumption. The shockwave mitigation ability of a magnesium alloy is 100 times stronger than [...] Read more.
The ballistic impact resistance of lightweight magnesium alloys is an eye-catching material for the military and aerospace industries, which can decrease the cost of a project and the fuel consumption. The shockwave mitigation ability of a magnesium alloy is 100 times stronger than an aluminum alloy; nonetheless, ballistic impact resistance has still not been achieved against blunt and API projectiles. The major obstacles are the low hardness, low mechanical strength, basal texture and strain hardening ability under loading along the normal direction of the sheet. The high yield strength and ultimate strength can be achieved for a specific loading condition (tensile or compression) by adjusting the texture in magnesium alloys. The projectile impact along the normal direction in a strong basal-textured magnesium alloy can only produce a slip-induced deformation or minor twinning activity. Here, we propose a practical technique that can be valuable for altering the texture from c-axes//ND to c-axes//ED or TD, and can produce high strain hardening and high strength through a twinning and de-twinning activity. Subsequently, it can improve the ballistic impact resistance of magnesium alloys. The effect of the technique on the evolution of the microstructure and possible anticipated deformation mechanisms after ballistic impact is proposed and discussed. Full article
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