Microstructure and Mechanical Properties of Mg/Mg Bimetals Fabricated by Wire Arc Additive Manufacturing

doi:10.11900/0412.1961.2023.00493

Acta Metall Sin

2025, Vol. 61

Issue (2): 211-225 DOI: 10.11900/0412.1961.2023.00493

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Microstructure and Mechanical Properties of Mg/Mg Bimetals Fabricated by Wire Arc Additive Manufacturing

HAN Qifei, DI Xinglong, GUO Yueling(

), YE Shuijun, ZHENG Yuanxuan, LIU Changmeng

School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China

Cite this article:

HAN Qifei, DI Xinglong, GUO Yueling, YE Shuijun, ZHENG Yuanxuan, LIU Changmeng. Microstructure and Mechanical Properties of Mg/Mg Bimetals Fabricated by Wire Arc Additive Manufacturing. Acta Metall Sin, 2025, 61(2): 211-225.

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Abstract

Mg/Mg bimetallic components, especially Mg-Al-Si/Mg-Gd-Y-Zn bimetals, hold promise for applications in the aerospace and automotive industries as structural materials because of their potential advantages of low cost, lightweight, high strength, and high plasticity. At present, Mg/Mg bimetallic components are primarily fabricated via extrusion and compound casting. However, these conventional processes are complex and have low forming efficiency. Recently, rapid advancements in additive manufacturing have enabled the real-time manufacturing of bimetallic structural components. In particular, wire arc additive manufacturing (WAAM) offers technical advantages for improving the forming efficiency of large-sized bimetallic components. Herein, to enhance the forming efficiency and interfacial performance of large-sized Mg/Mg bimetallic components, a thin-walled Mg-Al-Si/Mg-Gd-Y-Zn bimetallic component was fabricated using WAAM technology. Specifically, a Mg-Al-Si alloy thin wall was first deposited and then cooled to room temperature over a period of time. Subsequently, the top layer of the Mg-Al-Si alloy thin wall was remelted, followed by the deposition of the Mg-Gd-Y-Zn alloy. Further, the macroscopic morphology, microstructure, microhardness, and mechanical properties of the bimetallic component were examined. Based on the macroscopic morphology, bimetallic components exhibited good interface bonding through WAAM. OM images demonstrated a transition zone near the bimetallic interface with a thickness of approximately 1.4 mm. The line scanning results and EPMA mappings revealed the formation of a composition gradient in the transition zone due to element diffusion. From the Mg-Al-Si alloy side to the Mg-Gd-Y-Zn alloy side, the Al and Si contents gradually decreased, while the Gd, Y, and Zn contents gradually increased. Based on the nonequilibrium solidification phase diagram and microstructure analysis, the bimetallic component comprised three regions: the Mg-Al-Si region with the Chinese-script Mg₂Si phase; transition region comprising granular Mg₂Si, the Mg₃(Gd, Y) phase, and the Mg₅(Gd, Y) phase; and Mg-Gd-Y-Zn alloy region with the Mg₁₂Zn(Gd, Y) phase as the primary component. After microhardness testing, the hardness of the bimetallic component continuously increased from 57 HV_0.5 (Mg-Al-Si alloy side) to 90 HV_0.5 (Mg-Gd-Y-Zn alloy side) due to the composition gradient and small second phases in the transition zone. The results of tensile testing at room temperature (20 ^oC) showed that the strength of the bimetallic component was close to that of the Mg-Al-Si alloy, with an ultimate tensile strength of 236.8 MPa and a yield strength of 102.2 MPa. Meanwhile, the elongation and hardening index of the bimetallic component were close to those of the Mg-Gd-Y-Zn alloy, reaching 11.0% and 0.323, respectively. The fracture position of the WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal was located in the transition zone. The fracture mechanism of the Mg-Al-Si alloy was primarily ductile, while those of the bimetal and Mg-Gd-Y-Zn alloy were quasi-cleavage.

Key words: wire arc additive manufacturing bimetallic component microstructure strengthening mechanism

Received: 21 December 2023

ZTFLH:

TG444

Fund: National Defense Basic Scientific Research Progrom of China(JCKY2023602B012)

Corresponding Authors: GUO Yueling, professor, Tel: (010)68915097, E-mail: y.guo@bit.edu.cn

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	HAN Qifei
	DI Xinglong
	GUO Yueling
	YE Shuijun
	ZHENG Yuanxuan
	LIU Changmeng

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00493 OR https://www.ams.org.cn/EN/Y2025/V61/I2/211

Table 1 Chemical compositions of Mg-Al-Si and Mg-Gd-Y-Zn alloy wires

Fig.1 Schematics of wire arc additive manufacturing (WAAM) process of Mg-Al-Si/Mg-Gd-Y-Zn bimetallic thin-wall
(a) deposition of Mg-Al-Si alloy (b) cooling for 20 min
(c) remelting along the top of Mg-Al-Si alloy (d) deposition of Mg-Gd-Y-Zn alloy

Fig.2 Schematics of model of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetallic thin-wall (a), sampling positions for material characterization and mechanical property testing (b), and sample size for mechanical performance testing (c) (unit: mm)

Alloy

$I p$

$t p$

$I p$ / $I b$

$V s$

mm·min^-1

$V w$

cm·min^-1

$V a$

L·min^-1

$U a$

Mg-Al-Si

122

1.5

150

1.3

Remelting Mg-Al-Si

150

1.5

150

090

1.3

Mg-Gd-Y-Zn

122

1.5

150

090

1.3

Table 2 Process parameters of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal

Fig.3 Macro morphology of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal (a), low (b) and locally high (c) magnified OM images near bimetallic interface, and microhardnesses near bimetallic interface along line in Fig.3b (d)

Fig.4 Back-scattered electron (BSE) image of the transition zone (a), electron probe micro-analysis (EPMA) mapping (b-f) and line scanning (g) results of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal (w_M —mass fraction of element M, x-axis of Fig.4g is consistent with the line scan direction indicated in Fig.4a)

Fig.5 Non-equilibrium phase diagrams of Mg-Al-Si (a) and Mg-Gd-Y-Zn (b) alloys (LPSO—long period stacking ordered)

Fig.6 BSE (a, b) and secondary electron (SE) (c-f) images of the interface region of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal
(a, b) Mg-Al-Si alloy and the transition zone (a) and high-magnified image of area b in Fig.6a (b) (c, d) Mg-Al-Si alloy and the transition zone (c) and high-magnified image of area d in Fig.6c (d) (e, f) transition zone and Mg-Gd-Y-Zn alloy (e) and high-magnified image of area f in Fig.6e (f)

Table 3 Chemical compositions of each point in Fig.6

Fig.7 Room temperature (20 ^oC) tensile true stress-true strain (σ-ε) curves (a), mechanical property histogram (b), and lnσ-lnε double logarithmic fitting curves (c) of three tensile specimens (n—harding index, YS—yield strength, UTS—ultmate tensile strength, EL—elongation)

Fig.8 Macro morphologies (a, d, g), fracture morphologies (b, e, h) and microstructures of fracture longitudinal sections (c, f, i) of Mg-Al-Si (a-c), bimetal (d-f), and Mg-Gd-Y-Zn (g-i) tensile specimens after fracture

Fig.9 Schematic of the formation mechanism of precipitated phase in the transition zone of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal

Fig.10 Schematic of the formation mechanism of transition zone of WAAM Mg-Al-Si/Mg-Gd-Y-Zn bimetal

Fig.11 Curves of solute fraction in α-Mg vs solid phase fraction in Mg-Al-Si (a) and Mg-Gd-Y-Zn (b) alloys

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