Focused Development of Magnesium Alloys Using The Calphad Approach
Focused Development of Magnesium Alloys Using The Calphad Approach
Abstract
In traditional alloy development, experimental investigations with many different alloy
compositions are performed. The selection criteria for multicomponent alloying elements and
their compositions become diffuse in a traditional approach. Computational thermochemistry
as used in the Calphad approach can provide a clear guideline for such selections and helps to
avoid large scale experiments with less promising alloys. Thus, it is a powerful tool to cut
down on cost and time during development of Mg-alloys. An overview of the Calphad
method is given. As an example of application, recent developments of new creep resistant
magnesium alloys that show about 100 times less creep than the best commercial alloys are
reported. Also outlined are the methods used in our long-term project of construction of the
necessary thermodynamic magnesium alloy database for several alloying elements like Al, Li,
Si, Mn, Ca, Sc, Y, Zr and Rare Earths (Ce, Gd, Nd), using the Calphad method combined
with key experiments.
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
relations can be given quantitatively. thermodynamic equilibrium calculations
• The driving forces for all phase started about a century ago with the first
transformations are available. understanding of alloying behavior,
• Local phase equilibria can be microstructure development and
calculated, providing a numerical input metallurgical reactions. These applications
to materials processing software, for are far from being "old-fashioned", though.
example in solidification simulation or Today we are able to apply quantitative
reactor modeling. phase equilibrium calculations in
• The reading of multicomponent phase multicomponent multiphase materials to
diagrams is drastically simplified by the development of technical alloys and
the fact that all the interesting two- also to the optimization of near-
dimensional sections in temperature, equilibrium processing conditions [1]. This
composition or even chemical potential goes as far as setting the electronic carrier
can be readily calculated, plotted and concentration in CdTe semiconductors by
read directly, instead of trying to annealing at appropriate partial pressures
envisage or construct them from an of Cd [15]. Many successful applications
only graphically available set of phase rely on the fact that the actual process
diagrams and their complex conditions are close to equilibrium and a
projections. Moreover, for any selected large number of examples covering metals,
individual alloy, the amounts of the alloys, intermetallics, ceramics,
phases present and their compositions semiconductors, geological materials,
can be calculated as function of nuclear core materials or even waste and a
temperature. It may be rather variety of processes were given [1]. The
cumbersome to extract that information calculations of solidification paths under
if only a printed set of ternary phase equilibrium conditions or even with the
diagrams is given, and it is virtually popular Scheil model are also considered
impossible for quaternary or higher as very useful direct applications, since no
order systems. kinetic data are needed when completely
blocking the solid state diffusion in the
This powerful tool in materials research Scheil model [2]. An application to the
goes beyond a mere “calculation of phase magnesium alloys AZ91 and AZ62 was
diagrams”. This is why the term given together with different experimental
“computational thermochemistry” is methods [16].
frequently used to describe the current However, even materials
state of the Calphad approach. It is processing far from equilibrium (such as
depicted in Fig. 1 and will be detailed splat cooling, mechanical alloying,
below. annealing of reactive thin film multilayers)
requires a sound knowledge of
2.2 Applications and software thermodynamic data of equilibrium and
metastable phases [17,18,19]. Using the
Applications of the Calphad Calphad approach the driving forces for
approach can be classified in four metastable phase formation or even
categories: direct applications, coupling complete metastable phase diagrams can
with steady state reactor modeling, be calculated to provide "road maps" for
coupling with micro-kinetics, and coupling the engineering of these advanced
with macro-kinetics. Only the latter two materials.
require the knowledge of kinetic data of A coupling with steady state reactor
the materials system. modeling is done as follows. A reactor like
The direct applications of an electric arc furnace can be modeled by
information read from phase diagrams or splitting it up to a certain number of
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
reactor stages. Within each stage a (local) numerical methods [1, 2].
equilibrium calculation can be performed Thermodynamic software and data
using the thermodynamic data set of the sets are called as a "subroutine" to provide
materials system. In addition to the number local equilibrium calculations and the
of stages one has to specify the feed phases driving forces for diffusion. These
(amounts, compositions, temperatures, calculations yield quantitative data at
input stages), the enthalpy locally prevailing temperature, pressure,
supplied/evolved or the temperature composition or chemical potentials. It is
imposed on each stage, pressure of each advisable to use the "subroutine" approach
stage and optionally distribution and not to fully integrate the
coefficients of phases which may simulate thermodynamic and diffusion software.
kinetic inhibitions. Steady-state The thermochemical and phase equilibrium
equilibrium is attained by equilibrium calculations in real systems may become
calculations where the output of one stage rather complex and should be thoroughly
is used as input of the next stage in co- and tested separately for internal consistency
counter-current flow reactors. and accuracy. A prominent example of this
Convergence is usually achieved with approach is the DICTRA software [22],
reasonably estimated initial values for each just a few applications are mentioned here
stage obtained by separate equilibrium for the multicomponent diffusion in steel
calculations. A nice example is the [22,23].
production of metallurgical grade silicon in Coupling computational
an electric arc furnace, where the thermochemistry with macro-kinetics is at
ChemSage software was used [20]. It the front end of integration in materials
should be noted that actual kinetic data processing software. Comprehensive
(diffusion, fluid flow, ...) of the materials simulation of dynamic, macro-scale
system are not necessary in this approach. processes involving fluid flow constitute
The optionally imposed phase distribution the highest level of complexity and
coefficients are not considered as detailed requirement of additional system data. An
kinetic data, for example the imposed example is the simulation of technical
fraction of NH3 in MOCVD growth of alloy casting, where in up to three-
nitride semiconductors in a simple one- dimensional simulation of the moving
stage reactor [21]. mushy solidification front, void formation
A coupling of the Calphad at hot spots and macro-segregation may be
approach with micro-kinetics concerns covered. The other aspect of
mostly solid state transformations, growth microsegregation, dendrite shape
or dissolution of precipitates, reactions at formation and ultimately the development
solid/solid interfaces and so on. Fluid flow of microstructure is still mostly treated
and heat transfer problems do not occur or separately. Both aspects require
are irrelevant. Thermal equilibrium is often thermodynamic equilibrium calculations at
assumed since thermal diffusion is much the core of appropriate process simulation
faster compared to species diffusion in software that tries to solve the
solids. The framework of multicomponent simultaneous mass- heat- and momentum-
(multiphase) diffusion is used, which transfer with moving phase boundaries [2].
requires the full data set of diffusion Such process simulation software is
coefficients of all species in all phases. working in the framework of
Possibly even the nucleation may be computational fluid dynamics (CFD) or
included with an appropriate model. The flow-sheeting. Depending on the
phase growth is usually assumed to be complexity, the full set of data for the
diffusion controlled. Appropriate software macro-kinetic description of the system
is designed with analytical and/or may be needed, possibly including the
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
micro-kinetic data. The current challenge aiming at an automatic calculation of
is to incorporate exact thermodynamic multicomponent phase diagrams without
phase equilibrium calculation into the need to provide user knowledge of the
commercial software packages like system.
Phoenics, Fluent, Aspen, Process and so
on. To this aim a general software interface
TQ (ChemApp) has been developed that 2.3 Thermodynamic modeling of
allows to call the most widely used Gibbs multicomponent multiphase equilibria
energy minimizers as a subroutine [1, 24].
An example for the casting process, where The basic principle to find the equilibrium
the link to thermodynamic software was state of a multicomponent alloy (or
programmed with another software system) is to minimize its total Gibbs
interface, is given by [25]. If the simulation energy, G, at constant temperature T,
of mushy zone is also included in an pressure P, and overall composition:
attempt to couple macro- and micro-
kinetics, the computation time becomes a G = ∑ nφ Gφ = min
φ
major issue [26]. Another problem is that
the thermodynamic software subroutine (1)
φ
has to be 100% reliable and convergent for where G is the molar Gibbs energy of any
each individual complex equilibrium possible phase φ in the system and nφ is its
calculation even if starting from unrealistic amount. Minimization is done by
initial values set by the process software. distributing the given amount of alloy
Envisaging about 105 calls of the components onto the various available
thermodynamic subroutine, a single failure phases, subject to the overall material
return would obstruct the process balance. The stable equilibrium is
simulation. described by a phase assembly of all
The early versions of software to phases with nφ > 0, whereas the metastable
calculate multicomponent phase equilibria, phases (nφ = 0) do not materialize. Each
Solgasmix by Eriksson [27], and to phase has its own composition which is
calculate (mainly binary) phase diagrams, generally different from the fixed overall
the Lukas-programs [28], were given away alloy composition.
free as source code, which substantially We have thus to supply the
fostered the development of the field. More functions Gφ for all the phases. For the
general mathematical relations to calculate pure element i in the φ phase the Gibbs
phase diagrams were laid out by Hillert 0 ,φ
energy function Gi (T ) = Giφ (T ) − H iSER
[29] which were eventually programmed in
is described by the equation
Thermocalc [30]. Currently a number of
software packages, sometimes combined 0 ,φ
with databases, are commercially Gi (T ) = a + b ⋅ T + c ⋅ T ⋅ ln T + d ⋅ T 2
available. Frequently used are ChemSage + e ⋅ T 3 + f ⋅ T −1 + g ⋅ T 7 + h ⋅ T − 9
and Fact, recently merged to become (2)
FactSage, MTDATA, Thermocalc, and a
second generation of software, Pandat 1,
1
More and updated information is found at the MTDATA
corresponding websites: http://www.npl.co.uk/npl/cmmt/mtdata
ChemSage http://gttserv.lth.rwth- Pandat http://www.computherm.com/
aachen.de/gtt/ Thermocalc http://www.thermocalc.se/
Fact: http://www.crct.polymtl.ca/fact/fact.htm More Web Sites
http://www.crct.polymtl.ca/FACT/web
FactSage http://www.factsage.com/ sites.htm
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
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c − 2 c −1 c
where H iSER is the molar enthalpy of the E
G tern,φ = ∑∑∑ xi x j xk {L1ijk,φ ( xi + δ ijk )
stable element reference (SER) at 298.15 K i =1 j > i k > j
and 1 bar. The values of the parameters a, + L ( x j + δ ijk ) + L3ijk,φ ( xk + δ ijk )}
2 ,φ
ijk
b, c,... are usually taken from the SGTE
compilation by Dinsdale [6]. (7)
c − 3 c − 2 c −1 c
E
G quat ,φ = ∑∑∑∑ xi x j xk xl {L1ijkl
,φ
( xi + δ ijkl )
Stoichiometric phases like the binary i =1 j > i k > j l > k
compound AmBn can be described by the
+ L ( x j + δ ijkl ) + L3ijkl,φ ( xk + δ ijkl ) + L4ijkl,φ ( xl + δ ijkl )}
2 ,φ
relation ijkl
(8)
m n where
G1A:2m Bn = ⋅ G10,φ + ⋅ G20,φ δijk = (1-xi-xj-xk)/3
m+n m+n
(9)
+ amn + bmn ⋅ T + ...
(3) δijkl = (1-xi-xj-xk-xl)/4
(10)
where the last two terms stand for the
Gibbs energy of formation of AmBn from It is noted that in a ternary system (c=3) δijk
the pure components 1(=A) and 2(=B) in = 0 whereas in a quaternary system with xl
the specified reference state φ. ≠ 0 the same term δijk ≠ 0. Instead of Eqs.
The molar Gibbs energy, Gφ, of a (7,8) one might have used seemingly
binary disordered solution phase φ, simpler equations where the δijk and δijkl
applicable for most liquids or substitutional terms would have been omitted. The main
solid solutions, is generally described as: advantage of the given formulation is that
Eq. (7) always reduces to the regular
Gφ = x1G10,φ + x2G20,φ + RT ( x1 ln x1 + x2 ln x2 ) solution contribution if all the three L-
+ x1 x2 L12 (
0 ,φ
+ L112,φ ( x1 − x2 ) + L12
2 ,φ
( x1 − x2 ) 2 + ... ) parameters are identical:
(4)
if
Hillert [31] pointed out the advantages of L1ijk,φ = L2ijk,φ = L3ijk,φ = Lφijk
this specific formulation [32] of the power (11)
series for the excess term to the ideal then
c − 2 c −1 c
solution when this equation is used for
extrapolation to ternary systems.
E
G tern , φ = ∑∑∑ xi x j xk Lφijk
i =1 j > i k > j
For a multicomponent solution
(12)
phase with c components the following
equation is used:
c c
even in a quaternary or higher order
G = ∑ xiG
φ
i
0 ,φ
+ RT ∑ xi ln xi + G E bin ,φ
system. Without using the δijk term in Eq.
i =1 i =1 (7) a residual quantity xixjxkLijk(1-xl) would
tern ,φ quat ,φ
+ GE
+ G
+ ...
E
be left in quaternary. This occurrence of xl
(5) would be incompatible with the regular
The excess contributions originating from interaction of the three species i-j-k,
all the binary interactions (EGbin) or ternary correctly given in Eq. (12). Such a regular
interactions (EGtern) or quaternary interaction can be derived from
interactions (EGquat) are: thermodynamic principles assuming
c −1 c n different pairwise i-j bond energies and an
E
G bin ,φ = ∑∑ xi x j ∑ Lvij,φ ( xi − x j ) v ideal entropy term [33]. The same
i =1 j >i v =0
reasoning is valid for the quaternary
(6)
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
interaction2. and G(Mg) can be calculated from Eq. (5),
This has been clearly pointed out setting EGtern = EGquat = 0. This enables
by Hillert [31, 33] and in fact the Eqs. (5- equilibrium calculations in the entire
10) are just extensions of his equations. quaternary alloy system. It is a general
The formulation is slightly different, the experience that the binary interactions are
present δijk (and δijkl) variables are invariant most prominent, that is, the higher order
to a permutation of indices whereas interactions like EGtern are usually small.
Hillert’s original variables (vijk) are not. In the next level of refinement these
It should be also noted that the calculations can be used to identify key
ternary and quaternary interaction terms in experiments at decisive conditions in the
Eqs. (7,8) provide a subregular behavior four ternary edge systems, either to verify
with a linear composition dependence that EGtern ≅ 0 or to determine quantitative
inside the {}-bracket. No higher terms values. In addition, solid solutions of
have yet been used in practice. In a binary compounds into the ternary systems
predictive approach from the known binary and true ternary compounds have to be
systems to a c-component system one modeled.
would not use any ternary or quaternary Using both EGbin and EGtern in Eq.
interaction terms. If those are used at all it (5) results not only in experimentally
certainly does not make sense to envisage a supported calculations in the ternary edge
higher than the subregular order given in systems, it also improves the reliability of
Eqs. (7,8). calculations in the quaternary alloy system.
Reviewing Eqs. (5-10) it becomes In the next level key experiments in the
evident what is really meant by the quaternary system can be identified.
predictive capability of this approach. Let Experience shows that generally EGquat ≅ 0
us, for simplicity, assume that we deal with if EGbin and EGtern are described properly.
a c=4 component magnesium alloy system This interactive approach
which comprises, in addition to “extrapolative calculations” – “key
stoichiometric compounds, just two experiments” – “supported modeling” is
solution phases, the liquid phase L and the also useful during assessment of the EGbin
(Mg) solid solution. Once EGbin of the six of individual binaries. In ternary or higher
binary edge system have been assessed, GL order systems, however, it is indispensable
considering the huge number of possible
2
It should be noted that the binary interaction of
experimental conditions that cannot be
Eq.(6) could equivalently be written in the same handled by a plain trial and error approach,
style as Eqs. (7,8): limited resources given.
c −1 c More complex solution phases
E
G bin ,φ = ∑∑ xi x j require models that take the specific
i =1 j > i
(13) physical nature of the interactions between
n
the components and/or the crystalline
∑A
v =0
v +1,φ
ij ( xi + δ ij ) n−v
( x j + δ ij ) v
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
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Substantial progress had been made on the thermodynamic data sets are marked with
thermodynamic modeling of solutions [35], grey background in Fig. 2. Two main paths
specifically for liquids [36], selected for the current Mg-alloy development are
intermetallic compounds [37], order- indicated by arrows. The first group of
disorder phase transitions [38], oxides [39], alloys are Li-containing, aiming at a
electronic materials [40], and more further density reduction and improved
advanced models for the composition ductility. The second group with Sc and
dependence of intermediate phases [41]. RE-additions aims at increased creep
resistance. In this paper the second group
is discussed as an example of focused alloy
3. Magnesium Database development.
Development To create the thermodynamic phase
descriptions the Calphad method is used as
3.1 Thermodynamic Modeling given above and depicted in Fig. 1. After
critically reviewing the experimental data
In order to use the Calphad and selecting the appropriate models for all
approach as a tool in magnesium alloy phases, the actual determination of the
design, a high quality thermodynamic thermodynamic parameters (like the amn,
database for Mg-alloys is needed. bmn, or Lvij,φ ) is done by multidimensional
Development of a reliable thermodynamic least square optimization. This
database for multicomponent alloys optimization is, depending on the
requires a combination of experiments and complexity of the system, done stepwise
computational thermochemistry with a until finally all parameters of that system
feedback of data from alloy application. are optimized simultaneously taking all the
Since numerous binary and ternary experimental information (phase equilibria
subsystems have to be treated and and thermodynamic quantities) into
validated with key experiments before account.
multicomponent alloys can be calculated
reliably, this development becomes a long- 3.2 Key Experiments coupled with
term project. In our group a modeling and applications
thermodynamic database for several
alloying elements like Al, Li, Si, Mn, Ca, In Mg-systems the experimental
Sc, Y, Zr and Rare Earth elements has literature data were very sparse in both,
been under construction for more than six phase diagram data and thermodynamic
years and is still ongoing. The base of this properties. Only a few ternary system were
13-component system are the binary investigated in more detail and calculated
systems. Figure 2 gives an overview of the thermodynamically [42,43,44]. An attempt
necessary systems and the current state of to apply these calculations for alloy
assessment. Highlighted in the first column development was published [45].
are the included elements. Also shown are Several experimental methods are
the current quaternary aim systems Al-Mg- being applied in our group to produce a
Li-Si and Mg-Mn-Sc-RE (with RE = Ce, sufficient experimental basis for a
Gd, Sc and Y).78 independent binary multicomponent Mg-database. For
systems are necessary as basis for a 13- preparation of highly reactive and
component system. 26 of them could be evaporating alloys containing Mg, Li and
taken from literature and included in our Ca the levitation melting technique was
database after checking the consistency. adapted. The main advantages are crucible
For 23 binary systems the thermodynamic free melting, suppressing of evaporation
descriptions were created by our group. with protective gas overpressure and visual
These system with existing consistent control of energy supply to avoid
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
overheating. Other preparation methods Investigations started with binary
include arc and electron beam melting for Mg-Sc alloys. Scandium was chosen for
extremely high melting intermetallic precipitation hardening because of its large
phases, see Table 1. solubility in (Mg) and the retrograde
During thermal analysis (DTA) the solubility at lower temperatures. The
alloys were protected in a sealed tantalum binary phase diagram had to be re-
crucible, Fig. 3. The development of investigated [61], it is shown in Fig. 4.
techniques for producing these crucibles However, binary MgSc precipitates form
and sealing the lids free of micro-cracks very slowly during ageing and improve the
were found to be essential for reproducible mechanical properties only slightly
DTA measurements of these highly because of their incoherent interface.
reactive and easily vaporizing alloys. For Therefore, Mn was added as second
phase and crystal structure analysis X-ray alloying element. The precipitation of
diffractometry at room and high Mn2Sc was predicted by thermodynamic
temperature, electron microscopy and calculations. Mn2Sc precipitations form
metallography are also used in a combined coherently and were found very efficient
approach. for improving creep resistance and
These techniques have been applied hardness. New MgSc15Mn1 or
in our work on ternary and quaternary MgSc6Mn1 alloys show about 100 times
alloy systems for improvement of creep better creep resistance than the best
resistance [46], thermal stability, spray commercial WE43 alloy at 350°C and 30
forming (Mg-Mn-Sc-RE, Mg-Al-Ca-RE) MPa [46].
and density reduction (Mg-Li-Al-Si, Mg- In spite of the good properties of
Al-Ca-Si) [47,48]. Thermodynamic this first generation of Mg-Mn-Sc alloys,
descriptions supported by experimental the high cost of Sc addition (6 wt.% Sc or
work of several subsystems were published more) initiated a search for a second
for Mg-Sc [49], Mn-Sc [50], Al-Sc [51], generation by investigating quaternary
Al-Gd-Mg [52], Gd-Li-Mg [53] , Ca-Li- systems.
Mg [54], Al-Li-Si [55,56] and Al-Ca [57]. Additional alloying elements Ce,
The thermodynamic and technical Gd, Y and Zr were considered for this
application of the ternary Al-Mg-Sc system purpose to achieve a sufficient quantity of
was also discussed [58,59]. suitable precipitates to improve mechanical
In the following the new cerium properties using a minimum of expensive
containing quaternary system Mg-Mn-Sc- alloy element addition. These element
Ce together with Mg-Mn-Sc-Gd, Mg-Mn- combinations Mg-Mn-(Sc, Ce, Gd, Y, Zr)
Sc-Y and Mg-Mn-Sc-Zr are shown as form a variety of quaternary systems and
example for the selection of new creep within those there is a huge amount of
resistant alloys using computational possibilities to select alloy compositions.
thermochemistry. More details of alloy Therefore phase diagram and other
selection in the quaternary systems Mg- calculations were performed to identify
Mn-(Sc, Gd, Y, Zr) will be published soon promising candidates.
[60].
4.2 Alloy selection in the Mg-Mn-Ce-Sc
system
4. First generation of creep
resistant ternary Mg-Mn-Sc-(Ce) For a first alloy selection several
vertical sections of phase diagrams in
alloys
various ranges of Mn and Ce were
calculated. For practical reasons the Mn
4.1 Ternary Mg-Mn-Sc alloys
content was limited at 1.5 wt.%. First
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
alloys were cast with 3 to 5 wt.% Ce and disregarded because of the very slow
up to 15 wt.% Sc. The reason of these high kinetics and the incoherence of this
alloying elements addition was the lack of precipitate. In other words the higher Sc-
knowledge about the amount and the content does not substantially improve the
mechanical effect of the precipitations that calculated amount of mechanically
are possibly formed during heat treatment. efficient precipitates. In fact, the
The calculated quaternary phase equilibria mechanical properties of this alloy with 9
are presented in two-dimensional sections wt.% Sc show no remarkable difference to
with constant Mn and Ce content. Fig. 5 that with 6.3 wt.% Sc [62].
shows a T-x section with constant 1.5 wt.% The amount of the favored Mn2Sc
Mn, 4.2 wt.% Ce from 0- 15 wt.% Sc. particles is mainly controlled by the Mn-
Primary crystallization of Mn2Sc phase can content. Therefore the Sc-content could be
be observed for a wide range of higher Sc decreased to economically and technically
contents. The L + Mn2Sc phase field and suitable amounts and possibly be supported
several different solid phases stable at by precipitates stemming from cheaper
lower temperatures can be seen. Rare Earth additions. In a second
A large variety of phase diagram generation of creep resistant alloys,
sections can be calculated using the promising quaternary candidates were
thermodynamic database. At this point the selected primarily by computational
question how to identify promising alloy thermochemistry.
candidates from all these calculated
diagrams becomes important. What phase
diagram features are related to what alloy 5. Second generation of creep
processing steps? What is needed is a list
of beneficial phase diagram features, resistant, low-scandium alloys
derived from the relevant alloy processing
steps. The most important of these points 5.1 Alloy selection in the Mg-Mn-Sc-Gd
are given in Table 2, they are applied in the system
following discussion.
Fig. 6 shows phase amounts during Several vertical sections in the
equilibrium solidification for an alloy with quaternary Mg-Mn-Sc-Gd system were
1.5 wt.% Mn, 4.2 wt.% Ce and 6.3 wt.% studied in the ranges of 0-1.5 wt.% Mn, 0-
Sc, indicated by dotted line in Fig. 5. Small 10 wt.% Sc and 0-10 wt.% Gd. The
amounts of primary Mn2Sc and calculated quaternary phase equilibria are
significantly larger amounts of CeMg12 are presented in two-dimensional sections with
expected in that alloy. In fact, in the constant Mn and Gd content. Figure 9
micrograph of this alloy after T5 heat shows a T-x section with constant 1 wt.%
treatment (aged after casting) fine grained Mn, 5 wt.% Gd from 0- 1 wt.% Sc. A
Mn2Sc associated with larger crystal of preferable primary solidification of (Mg), a
CeMg12 can be seen in Fig. 7 [62]. It will large one-phase field of (Mg) and several
be shown later that the finely distributed different solid phases stable at lower
Mn2Sc particles have a very positive effect. temperatures can be seen.
One alloy with higher Sc content was For an alloy with 1 wt.% Mn, 5
studied to promote the favored Mn2Sc wt.% Gd and 0.8 wt.% Sc (indicated by the
precipitations. The calculated phase right dotted line in Fig. 9) equilibrium
amounts in Fig. 8 for an alloy with 1.5 phase amounts during solidification and
wt.% Mn, 3.2 wt.% Ce and 9.0 wt.% Sc heat treatment are given in Fig. 10. At the
show no remarkable differences to the liquidus temperature of 650°C, primary
alloy with 6.3 wt.% Sc in Fig. 6. The low- (Mg) is formed and consumes the melt
temperature formation of MgSc should be totally down to the solidus point at 619°C.
At 590°C the first precipitate Mn2Sc starts
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
forming, which can be seen in the enlarged is formed and consumes the melt totally
insert in Fig. 10. Large amounts of the down to the solidus point at 613°C. The
second precipitate GdMg5 start forming at Mn12Y phase is only stable in the solid
425°C. Similar positive features are state in a high temperature range from 605
observed for an alloy with only 0.3 wt.% to 322°C and may not form at all during
Sc. The equilibrium phase amounts during fast cooling. The established Mn2Sc and
solidification and heat treatment for that the new Mg24Y5, even in very large
alloy with 1 wt.% Mn, 5 wt.% Gd and 0.3 amount, could form by ageing in a
wt.% Sc (indicated by the left dotted line in favorable temperature range. This makes
Fig. 9) are given in Fig. 11. The Mn23Sc6 MgMn1Y5Sc0.8 also a promising alloy.
phase is formed as first precipitate in the In order to check if the amount of
solid state. Both alloys fulfill all features Mn2Sc could be raised by increasing the
illustrated in Table 2 and were classified as manganese content to 1.5 wt.%, we can
very promising for further large scale creep examine Fig. 14 for the alloy
experiments. MgMn1.5Y5Sc0.8. This alloy is
In fact, first results of these alloys disqualified since Mn2Sc forms as the
show a creep resistance similar to the primary phase from the liquid, clearly seen
previous ternary high-scandium Mg-Mn-Sc in the inset of Fig. 14. (Mg) forms only
alloys, about 100 times better than best secondary, and even Mn12Y forms as a
commercial WE43 alloy at 350°C and 30 tertiary phase during solidification. Such a
MPa, as detailed later. microstructure cannot be “repaired” by
heat treatment. It would be difficult to
envisage such a drastic change caused by
5.2 Alloy selection in the Mg-Mn-Sc-Y raising the Mn-content from 1.0 to 1.5
system wt.% without the thermodynamic
calculations.
In the Mg-Mn-Sc-Y system several
vertical sections in the ranges of 0-1.5
wt.% Mn, 0-10 wt.% Sc and 0-10 wt.% Y 5.3 Alloy selection in the Mg-Mn-Y-Zr
were studied. Figure 12 shows a T-x system
section of a calculated quaternary phase
diagram with constant 1 wt.% Mn, 5 wt.% For complete substitution of
Y from 0- 1 wt.% Sc. A large one-phase expensive scandium, zirconium was
field of (Mg) and several different solid checked as a possible alloying element.
phases stable at lower temperatures can be The impact of such a substitution can be
seen, like in the corresponding diagram for studied in Fig. 15 for scandium-free alloys
Gd. Differences compared to the Gd with 1 wt.% Mn, 4.5 wt.% Y and 0-1 wt.%
system can be observed concerning the Zr. This phase diagram section shows a
stable solid phases and the formation very steeply rising liquidus line, 1000°C
temperatures. In the whole range of are reached for less than 0.1 wt.% Zr.
primary crystallization of (Mg) the Moreover, and actually the reason for the
secondary phase is Mn12Y. The desired steep liquidus line, a huge primary
Mn2Sc precipitate forms only at crystallization field, L + Mn2Zr, stretches
temperatures below 500°C or even lower over the entire composition range in Fig.
with decreasing Sc content. 14. Only for extremely small Zr-additions,
For an alloy with 1 wt.% Mn, 5 wt.% Y and not discernible in Fig. 15, is a primary
0.8 wt.% Sc, indicated by dotted line in (Mg) solidification expected. The reason
Fig. 12, phase amounts during equilibrium for this destructive phase diagram feature
solidification are given in Fig. 13. At the is the extremely high thermodynamic
liquidus temperature 644°C, primary (Mg) stability of Mn2Zr in comparison to the
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
other phases. Since yttrium does not play a thermochemical calculations were prepared
significant role in that part, the only way to by squeeze casting by our project partners
diminish the L+Mn2Zr primary field would within the Thrust Research Project SFB
be a drastic reduction of the manganese 390, “Magnesium Technology”, at the TU
content. But this would also drastically Clausthal. Yield strength and creep rates of
reduce the amount of beneficial Mn- these alloys were measured in the as cast
containing precipitates. As a result, the condition and also after heat treatment
entire quaternary Mg-Mn-Y-Zr alloy [62]. It is clearly seen from Fig.17 that the
system is disqualified. secondary creep rate at 350°C of our first
generation (high-scandium) alloys is better
by a factor of 100 compared to the WE43
5.4 Defining the commercial creep benchmark alloy.
resistant benchmark alloy The first generation of alloys
showed a strong annealing response due to
In order to assess the results on the the formation of the Mn2Sc precipitates.
creep resistance measurements of the The existence of the Mn2Sc precipitates
selected new alloys a commercial alloy has was confirmed by X-ray diffraction, SEM
to be chosen as a benchmark. The history and TEM investigations and energy
of commercially developed creep resistant dispersive X-ray microanalysis. A
alloys is briefly summarized in Tab. 3. micrograph showing finely dispersed
These alloys usually contain about 0.7 Mn2Sc precipitates in a MgSc6Mn1 alloy
wt.% Zr as a grain refiner. The influence of after T5 treatment is given in Fig. 18 [62].
the Rare Earths (RE) on the creep resistance At 400°C an increase of the
generally decreases in the series Nd (Pr) > secondary creep rate can be observed for
Ce> La [63]. the Ce-containing alloys, Fig. 19. This
The current end point of disadvantage is partly compensated by
commercial alloys is given by the WE higher creep ductility caused by significant
series containing Y and Rare Earths. In grain boundary gliding in the Ce-
fact, the maximum stress that can be containing alloys [62]. Comparing Ce-
tolerated at 200°C for 100 h and 0.2% containing alloys with different Sc-content,
elongation is highest for the WE series as no significant change in the creep rate can
seen in Fig. 16. The alloy WE43 with T6 be observed, Fig. 20. The result is in line
heat treatment was chosen as the with the calculations in section 4.2 and the
benchmark alloy. Die casting alloys like minimized Sc-contents of the second
AE42 or AS21, known to be more creep generation alloys.
resistant as standard AZ or AM alloys, are
not included in the comparison since they
rank even below the ZE alloys in Fig. 16. 6.2 Second generation of creep resistant,
low-scandium alloys
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
alloy WE43. The best alloy be recognized before starting large-style
MgGd5Mn1Sc0.3 with the smallest experiments, thus reducing the
elongation after 15⋅104 s contains only 0.3 experimental effort to a reasonable
wt.% of expensive Sc. It is exactly one of volume. The next step, the experimental
the few most promising alloys indicated by study of mechanical properties of
the thermodynamic calculations. The identified promising alloys, has shown
calculated equilibrium phase amounts excellent results both in the first generation
during solidification and heat treatment for (ternary and high-scandium) and second
this alloy was shown in Fig. 11. This is generation (quaternary, low-scandium) of
considered to be a substantial progress new creep resistant alloys. Obviously,
compared to the first generation of alloys these experiments cannot be replaced by
with much higher scandium contents of 6 thermodynamic calculations. However,
or 15 wt.% Sc. considering the huge number of less
promising alloy combinations that could
have been selected by trial and error from
7. Conclusions multicomponent systems, the focused alloy
development following this approach
Focused magnesium alloy avoids a waste of time and effort.
development is possible using the powerful
tool of thermodynamic calculations. Alloy
compositions with promising possibilities Acknowledgement
of alloy microstructure design can be
selected by means of thermodynamically Part of this work is supported in the
calculated phase diagrams, phase amount »Thrust Research Project SFB 390:
charts and solidification curves. Most Magnesium Technology« by the German
importantly, element combinations and Research Concil (DFG).
compositions with unwanted properties can
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Tab. 1: Methods for key experiments in Mg-database development
Sample Preparation Levitation Melting
Arc Melting
Electron beam Melting
Reaction Sintering
Sample Analysis Thermal Analysis (DTA, STA)
X-ray Diffractometry (XRD, 25-1500°C)
Electron Microscopy (SEM/EDX/WDX)
Metallography, Optical Microscopy
Table 2: Beneficial phase equilibrium features and their relevance for (Mg)-alloy
processing
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
900
842°C [3, 4]
800
700
Temperature in °C
600
(βCa)
Liquid
500
400 369°C
300
233°C 242°C
200 181°C
145°C
(αCa)
CaLi2
100 (Li)
0
0 20 40 60 80 100
Ca at.% Li Li
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Mg
100
(Mg) + (Mg)
Ca(Li,Mg)2 Three-phase
150°C
80 Two-phase
One-phase
CaMg2
Mg
60
%
at.
40 (Li)
(αCa) + (Li) +
Ca(Li,Mg)2 Ca(Li,Mg)2
20
0
0 20 40 60 CaLi2 80 100
Ca (αCa) Liquid Li
Liquid +
at.% Li Ca(Li,Mg)2
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Mg
250°C 100
(Mg)
(Mg) +
Ca(Li,Mg)2
80
CaMg2
Mg
60
(Li)
%
at.
(Li) +
Ca(Li,Mg)2
40
(αCa) +
Ca(Li,Mg)2
20
Liquid
0
0 20 40 60 80 100
Ca Liquid + (αCa) Liquid + Li
at.% Li
(αCa) + Ca(Li,Mg)2 Ca(Li,Mg)2
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Mg
500°C 100
(Mg)
(Mg) + Ca(Li,Mg)2
Liquid + (Mg)
80
Mg
CaMg2 (Li)
%
at.
60
Liquid + Ca(Li,Mg)2
40
Liquid + (βCa)
20
Liquid
0
0 20 40 60 80 100
Ca (βCa) Li
at.% Li
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Mg
100
60
0 (Mg)
80 YY
E
YY
CaMg2 YY (Li)
Mg
60
%
at.
40 600
Ca(Li,Mg)2
500
YY
20
50
400
0
60
U
70
300
YY
YY
0
0
0 CaLi2
(βCa) 20 40 (αCa) 60 80 100
Ca Li
at.% Li
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
800
[DTA, this work]
710°C
700
Liquid
Temperature in °C
600
500 Liquid +
Ca(Li,Mg)2
400
Ca(Li,Mg)2
300
242°C
200
0 10 20 30 40 50 60
at.% Li
CaMg2 CaLi2
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
500 Ca(Li,Mg)2
+ (β Ca)
(Mg)+
400 Ca(Li,Mg)2
(Li)+
Ca(Li,Mg)2 (Mg)+(Li)+
300 Ca(Li,Mg)2
100
0 10 20 30 40 50 60 70 80
Ca 87 Ca 0
at.% Mg
Li 13 Li 13
Mg 0 Mg 87
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Liquid + (Mg)
Liquid
+ (Mg) + (Li) Liquid
Temperature in °C
(Mg)
(Li) Liquid
+ (Li)
(Mg) +
Ca(Li,Mg)2
(Li) +
Ca(Li,Mg)2
20 40 60 80 Ca 0.1
Ca 0.1
Li 0 at.% Li Li 99.9
Mg 99.9 Mg 0
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Rainer Schmid-Fetzer, Joachim Gröbner: Focused Development of Magnesium Alloys using
the Calphad Approach. Adv. Eng. Mater. 3, 947-961 (2001)
Liquid + (Mg)
Liquid Liquid
+ (Mg) + (Li)
Temperature in °C
Liquid +
(Mg) + Liquid
Ca(Li,Mg)2 + (Li)
Liquid +
(Li) +
Ca(Li,Mg)2
(Mg) +
Ca(Li,Mg)2
(Li) +
Ca(Li,Mg)2
20 40 60 80
Ca 0.5 Ca 0.5
Li 0 at.% Li Li 99.5
Mg 99.5 Mg 0
26 of 26