Effect of Ca/Al ratio on microstructure and mechanical properties of Mg-Al-Ca-Mn alloys

The effect of Ca/Al ratio on microstructure and mechanical properties of the as-cast and as-extruded Mg-Al-Ca-Mn alloys were investigated. The as-cast Mg-Al-Ca-Mn alloys with Ca/Al mass ratios less than 0.50 contain divorced and lamellar eutectic (Mg,Al)₂Ca. When Ca/Al ratio is greater than 0.90, fine lamellar Mg₂Ca phase is formed in the as-cast Mg-Al-Ca-Mn alloys. After extrusion, the second phases are broken and dispersed along the extrusion direction. The area fraction of DRXed regions decrease with increasing Ca/Al ratio, the microstructure changes from an almost fully recrystallized structure to a bimodal structure consisting of fine dynamically recrystallized (DRXed) grains and coarse deformed regions. With increasing Ca/Al ratio, the DRXed grains and dispersed second phases are refined. The as-extruded alloys exhibit a strong basal fiber texture, the intensity of which is increased with increasing Ca/Al ratio. With increasing Ca/Al ratio, the {0002}<11-20> texture component in the DRXed regions is suppressed, and shifted to a {0002}<10-10> texture component. The strength of the as-extruded Mg-Al-Ca-Mn alloys increases significantly with increasing Ca/Al ratio. The as-extruded Mg-2.7Al-3.5Ca-0.4Mn (wt%) alloy exhibits a tensile proof strength of 438 MPa and an ultimate tensile strength of 457 MPa. The extraordinary high strengths are attributed to the ultrafine DRXed grains pinned by fragmented secondary phases, strong basal texture and dense nano-scale precipitates. The present research indicates that the Mg-Al-Ca-Mn alloys have a great potential as next generation low-cost ultrahigh-strength wrought Mg alloys.