Research Progress of Additively Manufactured Magnesium Alloys: A Review

doi:10.11900/0412.1961.2022.00063

Acta Metall Sin

2023, Vol. 59

Issue (2): 205-225 DOI: 10.11900/0412.1961.2022.00063

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Research Progress of Additively Manufactured Magnesium Alloys: A Review

TANG Weineng¹, MO Ning¹, HOU Juan²(

)

1.Mg & Mg Alloy Research Institute, Technology Center, Baosteel Metal Co., Ltd., China Baowu Steel Group Corporation, Shanghai 200940, China
2.School of Materials and Chemistry, University of Shanghai for Science and Technology, Shanghai 200093, China

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TANG Weineng, MO Ning, HOU Juan. Research Progress of Additively Manufactured Magnesium Alloys: A Review. Acta Metall Sin, 2023, 59(2): 205-225.

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Abstract

Mg alloys are attractive in the fields of aerospace, automotive, and biomedical engineering, owing to the advantages of light weight, high specific strength, excellent damping property, good biocompatibility, and in vivo degradable property. However, conventional methods for manufacturing Mg alloys, such as casting and deformation processing, yield low-quality large-scale monolithic and complex structures, which hinder the applications of Mg parts. Additive manufacturing (AM) is a burgeoning alternative to manufacture monolithic parts through layer-by-layer deposition of metallic materials using 3D model data. In this paper, the latest research progress in AM of Mg alloys, which focuses on technological processes and influencing factors, macro and microstructures, mechanical properties, and corrosion properties of parts manufactured primarily by selective laser melting (SLM) and wire and arc AM (WAAM), are comprehensively reviewed. Currently, additively manufactured Mg parts with a relative density > 99% have been achievable through both SLM and WAAM after process optimization, and their mechanical properties and corrosion resistance have been comparable to those of casting and wrought parts, indicating a great potential for engineering applications. Finally, the future development trend and research direction of AM of Mg alloys are proposed from the perspectives of materials design, process improvement, and performance evaluation.

Key words: magnesium alloy additive manufacturing selective laser melting wire and arc additive manufacturing microstructure mechanical property

Received: 17 February 2020

ZTFLH:

TG146

Fund: National Key Research and Development Program of China(2021YFB3701102);National Natural Science Foundation of China(52073176);Natural Science Foundation of Shanghai(22-ZR1443000)

About author: HOU Juan, associate professor, Tel: 18217727686, E-mail: houjuanlife@yahoo.com

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00063 OR https://www.ams.org.cn/EN/Y2023/V59/I2/205

Fig.1 Illustration of the selective laser melting (SLM) process (a) and general scanning strategy used for SLMed magnesium alloys (b)

Fig.2 SEM images from WE43 samples produced with various laser powers (P) and scan rates (v) of SLM^[23]

Fig.3 Process map for Mg-9%Al, results as function of the range of laser power and scan rate^[35]

Fig.4 Evaporative fumes during the SLM process of Mg vapor (a) and macro cracks observed on the as built samples (b)^[24]

Table 1 Optimized processing parameters of SLM examined for Mg and Mg alloys in literatures^{[21-25,35-42]}

Fig.5 Schematic of wire and arc additive manufacturing (WAAM)^[44]

Table 2 Comparison between SLM and WAAM^[47]

Fig.6 Cross-section view and microstructures of the TIG-based WAAM AZ80M wall^[53] (TIG—tungsten inert gas welding)
(a) overall microstructure (b) top arc zone
(c) interlayer transition region (d) intermediate zone (e) bottom zone

Fig.7 Effect of CMT characteristics on energy input process (a) and subsequent weld appearances (left) and weld geometries (right) (b-d) of the deposited weld beads (CMT—cold metal transfer, α—wetting angle)^[54]

Table 3 Optimized WAAM process parameters of Mg alloys in literatures^[44,50-57]

Fig.8 Schematics showing the principle of capillary-mediated binderless 3D printing (a-e) and macrograph of printed pure Mg parts (f)^[67]

Fig.9 Electron backscatter diffraction images showing grain sizes of SLMed WE43 sample (a-c), powder extruded sample (d, e), and as-cast WE43 sample (f) (AM—additive manufacturing, PE—powder extruded)^[70]

Fig.10 SEM images showing the cross section (a) and the vertical section (b) microstructures of the AZ91D sample built at 166.7 J/m^3[22] (OLR—overlapping region, CST—center of scanning track)

Fig.11 SEM images showing microstructures of SLMed WE43 sample (a-c) in compared with as-cast WE43 sample (d-f)^[70]

Fig.12 BSE (a-c) and TEM (d-f) images of microstructures of SLMed WE43 sample^[42] (ppts—precipitates)

Fig.13 Cross-section microstructure of WAAM fabricated AZ31B sample (a), trends in as-measured grain size of fabricated object corresponding to torch feed speed (b), and OM images showing the top layer (c), central part (d), and boundary (e) of fabricated object with processing parameter of 100 A, 10 V, and F = 400 mm/min (HAZ—heat affected zone)^[44]

Fig.14 OM images showing the interlayer microstructures of WAAM AZ31 component (a, b), and EBSD image corresponded to the area in Fig.14b (c)^[54]

Fig.15 OM image showing the microstructure of AZ61 alloy fabricated by WAAM^[51]

Fig.16 Summary chart showing the yield strength (a) and ultimate tensile strength (b) vs elongation to failure for Mg alloys manufactured by different methods (Data extracted from Refs.[21-25,51,52,54-57,76,77], LD—longitudinal direction, TD—transverse direction)

Fig.17 Electrochemical response of SLM WE43 alloys in compared with as-cast WE43 alloy^[41]
(a) open circuit potential (E) of WE43 in the cast, as-SLMed, and SLM + HIP + HT conditions in 0.1 mol/L NaCl for up to 10 min (HIP—hot isostatic pressing, HT—heat treatment)
(b) potentiodynamic polarisation curves of the same specimens tested in Fig.17a following exposure to 0.1 mol/L NaCl for a conditioning period
(c) the quantitative data on corrosion potential (E_corr) and corrosion current density (i_corr) acquired from the potentiodynamic polarisation analysis (Fig.17b)

Fig.18 Schematic of hybrid deposition and micro rolling^[102,103]

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