Magnesium-aluminum-based alloys are among the earliest binary alloys used in casting, encompassing both cast and wrought alloys. These alloys remain the most widely utilized grade series today. Most magnesium-aluminum alloys also contain additional alloying elements. Based on these, several ternary alloys have been developed, including Mg-Al-Zn, Mg-Al-Mn, Mg-Al-Si, and Mg-Al-RE, forming four major series. Among them, Mg-Al-Zn and Mg-Al-Mn alloys are the most commonly used in industrial applications, with ZM5 being a typical example. These alloys are known for their high strength, good ductility, and favorable casting properties.
The AZ series, such as Mg-Al-Zn alloy AZ91, has a high yield strength and is widely used in the production of thin-walled die-cast components with complex geometries, including engine and powertrain housings, electronic enclosures, and hand tools. On the other hand, the AM series, like AM60, AM50, and AM20, which contain lower aluminum content than the AZ series, exhibit excellent fracture toughness but lower yield strength. They are typically used in impact-loaded areas, such as car door panels, dashboards, chair frames, wheel hubs, and sporting equipment.
However, the high-temperature creep resistance of AZ and AM-based magnesium alloys is significantly lower compared to other common alloys. When temperatures exceed 150°C, their tensile strength drops rapidly. To enhance the high-temperature performance of magnesium-aluminum alloys, researchers have focused on improving the precipitated phase, microstructure, morphology, and thermal stability. In addition to enhancing existing AZ-based alloys, new heat-resistant magnesium alloys such as AS (Mg-Al-Si), AE (Mg-Al-RE), and Mg-Al-Ca have been developed. Although increasing aluminum content improves casting properties, the Al content in AS and AE series alloys is kept low to minimize discontinuous precipitation phases.
Figure 11-1 shows an isothermal section at 25°C of the Mg-Al-Zn system. From the diagram, it can be seen that the equilibrium structure of ZM5 consists of α + γ phases. It is a solid solution where aluminum and zinc are dissolved simultaneously in a magnesium matrix. The γ phase, MgAlâ‚â‚‚Zn, gives ZM5 its high strength and makes it suitable for critical applications in aircraft, missiles, and high-load automotive engine parts, such as airframe shells, motor gearboxes, and aircraft wheels.
ZM5 and ZM10 possess good fluidity, but they tend to form micropores during solidification, resulting in poor sealing properties of the castings. They are suitable for sand casting, metal casting, and pressure casting. To improve the sealing characteristics, impregnation treatment may be applied.
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