Accelerated Corrosion Rate of Wire Arc Additive Manufacturing of AZ91D Magnesium Alloy: The Formation of Nano-scaled AlMn Phase

IF 3.9 2区材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING

Acta Metallurgica Sinica-English Letters Pub Date : 2025-04-16 DOI:10.1007/s40195-025-01858-6

Dongchao Li, Fen Zhang, Lanyue Cui, Yueling Guo, Rongchang Zeng

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Abstract

Additive manufacturing (AM) technologies, with their high degree of flexibility, enhance material utilization in the fabrication of large magnesium alloy parts, effectively meeting the demands of complex geometries. However, research on the corrosion resistance of magnesium alloy components produced via AM is currently limited. This study investigates the microstructural and corrosion characteristics of AZ91D magnesium alloy fabricated by wire arc additive manufacturing (WAAM) compared to its cast counterpart. A large-sized AZ91D bulk part was deposited on an AZ31 base plate using a layer-by-layer stacking approach. The results showed that the WAAM AZ91D was featured by obviously refined grains from 228.92 μm of the cast one to 52.92 μm on the travel direction-through thickness (TD-TT) and 50.07 μm on the normal direction-through thickness (ND-TT). The rapid solidification process of WAAM inhibited the formation of β-Mg₁₇Al₁₂ phase while promoting the formation of uniformly distributed network of dislocations, the dispersive precipitation of nano Al₈Mn₅ phase, as well as Zn segregation. WAAM AZ91D demonstrated the occurrence of pitting corrosion and inferior corrosion resistance compared to cast AZ91D, attributed to the micro-galvanic corrosion between the α-Mg matrix and Al₈Mn₅ particles and the increased number of grain boundaries.

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AZ91D镁合金电弧增材制造加速腐蚀：纳米AlMn相的形成

增材制造（AM）技术以其高度的灵活性，提高了大型镁合金零件制造的材料利用率，有效地满足了复杂几何形状的需求。然而，目前对增材制造镁合金部件的耐腐蚀性能研究有限。研究了电弧增材制造（WAAM）工艺制备的AZ91D镁合金与铸造AZ91D镁合金的显微组织和腐蚀特性。采用逐层叠加的方法在AZ31基板上沉积了大尺寸AZ91D体件。结果表明：WAAM AZ91D合金的行向透厚度（TD-TT）为228.92 μm，法向透厚度（ND-TT）为50.07 μm，晶粒细化明显；WAAM的快速凝固过程抑制了β-Mg17Al12相的形成，促进了位错均匀分布网络的形成、纳米Al8Mn5相的弥散析出以及Zn的偏析。由于α-Mg基体与Al8Mn5颗粒之间发生微电蚀，晶界增加，WAAM AZ91D与铸态AZ91D相比出现点蚀，耐蚀性能较差。

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来源期刊

Acta Metallurgica Sinica-English Letters METALLURGY & METALLURGICAL ENGINEERING-

CiteScore

6.60

自引率

14.30%

发文量

122

审稿时长

2 months

期刊介绍： This international journal presents compact reports of significant, original and timely research reflecting progress in metallurgy, materials science and engineering, including materials physics, physical metallurgy, and process metallurgy.