Karl Ulrich Kainer

Wires of magnesium alloys possess a high potential, e.g., as filler materials, for joining applications but also for biodegradable applications, such as suture materials. While the typical process of producing wires is based on a wire drawing process, direct extrusion by using adjusted dies to deal with high degrees of deformation allows a one-step manufacturing of wires to some extent. In this work, the extrusion of wires with a thickness of 1 mm and even lower is shown feasible for pure magnesium and three Al-containing magnesium alloys (AZ31, AZ80, AZ91). The surface quality and the mechanical properties are improved with increasing Al content. It is shown that, despite the large difference in the degrees of deformation, the properties and their development are similar to those of extruded round bars. Wrapping tests were carried out as an exemplary more complex forming procedure, and the behavior is correlated to the microstructure and texture of the extruded wires.

Open-porous MAX phase skeletons from Ti₃SiC₂ were manufactured by Microwave-Assisted Self-propagating High-temperature Synthesis (MASHS) and subsequently subjected to squeeze casting infiltration with an Al-Si lightweight casting alloy (EN AC-44200). This alloy was chosen due to its high flowability, corrosion resistance and good machinability. The manufactured composites, together with a reference sample of the original alloy, underwent testing of thermal properties, including thermal conductivity and diffusivity, specific heat and thermal expansion in the temperature range 50-500 °C, which corresponds to the expected working temperatures of the material. The fabricated AlSi/Ti₃SiC₂ composites have significantly increased thermal stability, with coefficients of thermal expansion (approximately 10-11 × 10⁻⁶ °C⁻¹) half that of the original alloy. As regards mechanical properties, the instrumental Young’s modulus and Vickers hardness of the composite materials are 170.8 and 8.5 GPa, respectively. Moreover, the microstructure and phase composition, structural defects and potential impacts between constituents of the manufactured composites were characterized using SEM, TEM and STEM microscopy and EDS and XRD analysis.

The influence of SiO₂ particles on the microstructure, phase composition, corrosion and wear performance of plasma electrolytic oxidation (PEO) coatings on AM50 Mg was investigated. Different treatment durations were applied to fabricate coatings in an alkaline, phosphate-based electrolyte (1 g/L KOH + 20 g/L Na₃PO₄ + 5 g/L SiO₂), aiming to control the incorporated amount of SiO₂ particles in the layer. It was found that the uptake of particles was accompanied by the coating growth at the initial stage, while the particle content remained unchanged at the final stage, which is dissimilar to the evolution of the coating thickness. The incorporation mode of the particles and phase composition of the layer was not affected by the treatment duration under the voltage-control regime. The corrosion performance of the coating mainly depends on the barrier property of the inner layer, while wear resistance primarily relies on the coating thickness.

As-cast ZK40 alloys, modified with the addition of CaO, Gd, Nd and Y were investigated. Solution heat treatments were performed based on differential thermal analysis results. The unmodified ZK40 alloy exhibited microstructure with nearly no intermetallic compound but with precipitates formed during the solution treatment. The modified ZK40 alloys exhibited a semi-dissolved network of intermetallic compounds along the grain boundaries and zones of intermetallic compounds within the grains. Interestingly, no precipitates were observed immediately next to the grain boundaries. The energy dispersive X-ray spectroscopy line scans showed an enrichment of Zn and Zr in the regions where the precipitates are found, suggesting that they are Zn-Zr precipitates. The ageing behaviour was compared between the as-cast and the solution treated materials and it was found that apart from the ZK40-Gd, ZK40-Nd and ZK40-Y aged at 200 °C after solution treatment, there is no notable ageing response for the investigated alloys.

As a generalized semi-finished product, the use of magnesium sheets requires addressing two major aspects of their processing: their microstructure and texture control, which are both essential for the forming behavior of such sheets during their forming to parts. Further, the processing of such sheets is complex, and therefore expensive, and requires simplification. In this work, magnesium alloys AZ31, ZE10, and ME21 are investigated in the form of conventionally rolled sheets, as well as in the form of extruded sheets. Their microstructural and textural development are correlated to their mechanical and forming properties. During extrusion, strong textures develop that hinder stretch-forming operations, even in rare earth-containing alloys. Chemical composition and process parameters have a significant impact on the texture development, and enable the design of sheet materials with weak textures and potentially enhanced formability.