Magnesium-aluminum-based alloys are among the earliest binary alloys used for casting, encompassing both cast and wrought alloys. They remain the most widely used group of magnesium alloys today. Most of these alloys contain additional elements to enhance their properties. Several ternary alloys have been developed based on Mg-Al systems, including Mg-Al-Zn, Mg-Al-Mn, Mg-Al-Si, and Mg-Al-RE, forming four distinct series. Among these, Mg-Al-Zn and Mg-Al-Mn alloys are the most commonly used in industry, with ZM5 being a representative example. These alloys are known for their high strength, good ductility, and favorable casting characteristics.
The AZ series, such as Mg-Al-Zn alloy AZ91, exhibits high yield strength and is widely used in the production of thin-walled die castings with complex geometries, like engine and powertrain housings, electronic enclosures, and hand tools. In contrast, the AM series—AM60, AM50, and AM20—contains less aluminum than the AZ series, offering better fracture toughness but lower yield strength. These alloys are typically used in applications subjected to impact loads, such as car door panels, dashboards, chair frames, wheels, and sporting equipment.
However, AZ and AM-based magnesium alloys suffer from poor high-temperature creep resistance, which is more than an order of magnitude lower than that of conventional alloys. At temperatures above 150°C, their tensile strength drops significantly. To address this issue, researchers have focused on improving the properties of precipitated phases by adding alloying elements, as well as enhancing the microstructure, morphology, and thermal stability of the base material. Additionally, 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 generally improves casting performance, 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. As illustrated, the equilibrium structure of ZM5 consists of α + γ phases. It is a solid solution where both aluminum and zinc are dissolved in magnesium. The γ phase, MgAl12Zn, gives ZM5 its exceptional mechanical properties, making it suitable for use in aircraft, missiles, and high-load automotive components such as shells, gearboxes, and aircraft wheels.
ZM5 and ZM10 exhibit good fluidity, but they tend to form micropores during solidification, resulting in poor sealing properties. Therefore, they are ideal for sand casting, metal casting, and pressure casting. To improve the hermeticity of the final product, impregnation treatment may be applied.
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