journal article·2021-10

Effect of Surface Roughness Induced by Milling Operation on the Corrosion Behavior of Magnesium Alloys

Uttam Reddy, Dhananjay Dubey, Subha Sanket Panda, Nikhila Ireddy, Jayant Jain, Kallol Mondal, Sudhanshu S. Singh

Publisher page

Abstract

In this work, the effect of surface roughness, induced by milling operation, on the corrosion properties of the as-cast AZ31 and the as-cast AZ80 magnesium alloys has been studied. The surface roughness was measured with varying feed rate (21, 200 and 320 mm/min) and cutting speed (100, 640 and 1330 rpm) at a constant depth of cut for both the alloys. The variation in the surface roughness has been correlated with the hardness, ductility and volume fraction of the Mg17Al12 precipitates in both the alloys. The corrosion behavior has been evaluated by conducting immersion test in a freely aerated 3.5 wt.% NaCl solution. The corrosion rates have been observed to be directly related to the surface roughness. The higher corrosion resistance of the machined AZ80 alloy as compared to the AZ31 alloy has been ascribed to the combined effect of the lower surface roughness and the partial dissolution of Mg17Al12 eutectic precipitates in the AZ80 alloy due to the increase in the temperature during milling, which was calculated analytically.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Magnesium Alloys: Properties and Applications · Aluminum Alloys Composites Properties · Aluminum Alloy Microstructure Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (47)

Show source-provided references
1. G. Song and A. Atrens, Understanding Magnesium Corrosion: A Framework for Improved Alloy Performance, Adv. Eng. Mater., 2003, 5, p 837–858.10.1002/adem.200310405 ↗
2. L.G. Song, Corrosion of Magnesium Alloys, Woodhead Publishing in Materials, Cambridge, 2011.10.1533/9780857091413 ↗
3. A. Samaniego, I. Llorente and S. Feliu Jr., Combined Effect of Composition and Surface Condition on Corrosion Behaviour of Magnesium Alloys AZ31 and AZ61, Corros. Sci., 2013, 68, p 66–71.10.1016/j.corsci.2012.10.034 ↗
4. G.-L. Song and Z. Xu, Effect of Microstructure Evolution on Corrosion of Different Crystal Surfaces of AZ31 Mg Alloy in a Chloride Containing Solution, Corros. Sci, 2012, 54, p 97–105.10.1016/j.corsci.2011.09.005 ↗
5. O. Lunder, J. Lein, T. Aune and K. Nisancioglu, The Role of Mg17Al12 Phase in the Corrosion of Mg Alloy AZ91, Corros., 1989, 45(9), p 741–748.10.5006/1.3585029 ↗
6. E. Ghali, W. Dietzel and K.-U. Kainer, General and Localized Corrosion of Magnesium Alloys: A Critical Review, J. Mater. Eng. Perform, 2004, 13, p 7–23.10.1361/10599490417533 ↗
7. R.S. Raman, The Role of Microstructure in Localized Corrosion of Magnesium Alloys, Metall. Mater. Trans. A, 2004, 35, p 2525–2531.10.1007/s11661-006-0233-5 ↗
8. F. Andreatta, I. Apachitei, A. Kodentsov, J. Dzwonczyk and J. Duszczyk, Volta Potential of Second Phase Particles in Extruded AZ80 Magnesium Alloy, Electrochim. Acta, 2006, 51, p 3551–3557.10.1016/j.electacta.2005.10.010 ↗
9. K. Kadali, D. Dubey, R. Sarvesha, H. Kancharla, J. Jain, K. Mondal and S.S. Singh, Dissolution Kinetics of Mg17Al12 Eutectic Phase and Its Effect on Corrosion Behavior of As-Cast AZ80 Magnesium Alloy, JOM, 2019, 71, p 2209–2218.10.1007/s11837-019-03470-3 ↗
10. A.A. Luo, Magnesium Casting Technology for Structural Applications, J. Magnesium Alloys, 2013, 1, p 2–22.10.1016/j.jma.2013.02.002 ↗
11. I. Zagórski and J. Korpysa, Surface Quality in Milling of AZ91D Magnesium Alloy, Adv. Sci. Technol. Res. J., 2019, 13(2), p 119–129.10.12913/22998624/108547 ↗
12. M. Uddin, H. Rosman, C. Hall and P. Murphy, Enhancing the Corrosion Resistance of Biodegradable Mg-Based Alloy by Machining-Induced Surface Integrity, Int. J. Adv. Manuf. Technol., 2017, 90, p 2095–2108.10.1007/s00170-016-9536-x ↗
13. A. Almansour, M. Azizi, A.M. Jesri and S. Entakly, Effect of Surface Roughness on Corrosion Behavior of Aluminum Alloy 6061 in Salt Solution (3.5% NaCl), Int. J. Acad. Sci. Res., 2015, 3(4), p 37–45.
14. M. Prakash, S. Shekhar, A. Moon and K. Mondal, Effect of Machining Configuration on the Corrosion of Mild Steel, J. Mater. Process. Technol., 2015, 219, p 70–83.10.1016/j.jmatprotec.2014.11.044 ↗
15. E. Aghion and B. Bronfin, Magnesium Alloys Deveopment Towards 21st Century, Mater. Sci. Forum, 2000, 350–351, p 19–30.10.4028/www.scientific.net/MSF.350-351.19 ↗
16. B. Ratna Sunil, K. Ganesh, P. Pavan, G. Vadapalli, C. Swarnalatha, P. Swapna, P. Bindukumar and P. Pradeep Kumar Reddy, Effect of Aluminum Content on Machining Characteristics of AZ31 and AZ91 Magnesium Alloys During Drilling, J. Magnesium Alloys, 2016, 4, p 15–21.10.1016/j.jma.2015.10.003 ↗
17. K. Takahashi, S. Fujii and M. Sagara, Vertical Milling and Turning Machines, U.S. Patent 4,480,366, 6 Nov 1984.
18. ASTM G1-90, Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens, ASTM International, West Conshohocken, PA, 1999
19. R. Sarvesha, W. Alam, A. Gokhale, T. Guruprasad, S. Bhagavath, S. Karagadde, J. Jain and S. Singh, Quantitative Assessment of Second Phase Particles Characteristics and Its Role on the Deformation Response of a Mg-8Al-0.5Zn Alloy, Mater. Sci. Eng. A, 2019, 759, p 368–379.10.1016/j.msea.2019.05.052 ↗
20. M.K. Yeoh, X. He Tan, P.H.N. Cheang, T.-C. Lim and R.W.O. Kwok, Effect of Solutionizing Time on Improving the Microstructure and Mechanical Properties of Aged AZ80 Mg Alloy, J. Mater. Eng. Perform, 2019, 28, p 6836–6852.10.1007/s11665-019-04382-8 ↗
21. P. Cao, D.H. StJohn and M. Qian, The Effect of Manganese on the Grain Size of Commercial AZ31 Alloy, Mater. Sci. Forum, 2005, 488–489, p 139–142.10.4028/www.scientific.net/MSF.488-489.139 ↗
22. A. Nayeb-Hashemi and J. Clark, Phase diagram of binary magnesium alloys, ASM International, Materials Park, Ohio, USA, 1988.
23. J.-D. Kim and K.-B. Lee, Surface Roughness Evaluation in Dry-Cutting of Magnesium Alloy by Air Pressure Coolant, Engineering, 2010, 2, p 788–792.10.4236/eng.2010.210101 ↗
24. Z. Sadaf, N.A. Mufti, M.Q. Saleem, M.P. Mughal and M.A.M. Qureshi, Effect of Machine Tool’s Spindle Forced Vibrations on Surface Roughness, Dimensional Accuracy, and Tool Wear in Vertical Milling of AISI P20, Int. J. Adv. Manuf. Technol, 2017, 89, p 3671–3679.10.1007/s00170-016-9346-1 ↗
25. M.M. Abootorabi-Zarchi, R.M. Razfar and A. Abdullah, Investigation of the Effect of Cutting Speed and Vibration Amplitude on Cutting Forces in Ultrasonic-Assisted Milling, J. Eng. Manuf., 2012, 226(7), p 1185–1191.10.1177/0954405412439666 ↗
26. G. Bolar, A. Das and S.N. Joshi, Measurement and Analysis of Cutting Force and Product Surface Quality During End-Milling of Thin-Wall Components, Measurement, 2018, 121, p 190–204.10.1016/j.measurement.2018.02.015 ↗
27. B. Akyuz, A Study on Wear and Machinability of AZ Series (AZ01-AZ91) Cast Magnesium Alloys, Kovove Mater, 2014, 52, p 255–262.10.4149/km_2014_5_255 ↗
28. D. Dubey, K. Kadali, S. S. Panda, A. Kumar, J. Jain, K. Mondal, S. S. Singh, Comparative Study on the Stress Corrosion Cracking Susceptibility of AZ80 and AZ31 Magnesium Alloys, Mater. Sci. Eng., A 792, 139 (2020)10.1016/j.msea.2020.139793 ↗
29. R. Sarvesha, U. -u.-. R. Ghori, Y. L. Chiu, I. P. Jones, S. Singh and J. Jain, Mechanical Property Evaluation of Second Phase Particles in a Mg-8Al-0.5Zn Alloy Using Micropillar Compression, Mater. Sci. Eng., A, vol. 775, 2020, p 138973.10.1016/j.msea.2020.138973 ↗
30. N. Tomac and K. Tonnessen, Formation of Flank Build-up in Cutting Magnesium Alloys, Annals of the CIRP, 1991, 40(1), p 79–82.10.1016/S0007-8506(07)61938-6 ↗
31. G. Song and A. Atrens, Recent Insights into the Mechanism of Magnesium Corrosion and Research Suggestions, Adv. Eng. Mater, 2008, 9, p 177–183.10.1002/adem.200600221 ↗
32. G. Song, A. Atrens, D. StJohn, J. Nairn and Y. Li, The Electrochemical Corrosion of Pure Magnesium in 1 N NaCl, Corros. Sci., 1997, 39(5), p 855–875.10.1016/S0010-938X(96)00172-2 ↗
33. M. Jamesh, T. Sankara Narayanan, P.K. Chu, I.S. Park and M.H. Lee, Effect of Surface Mechanical Attrition Treatment of Titanium Using Alumina Balls: Surface Roughness, Contact Angle and Apatite Forming Ability, Front. Mat. Sci., 2013, 7, p 285–294.10.1007/s11706-013-0208-6 ↗
34. S. Ciceka, A. Karaca, I. Torun, M. Onses and B. Uzer, The Relationship of Surface Roughness and Wettability of 316L Stainless Steel Implants with Plastic Deformation Mechanisms, Mater. Today: Proc., 2019, 7, p 389–393.
35. R. Bertolini, S. Bruschi, A. Ghiotti, L. Pezzatto and M. Dabala, The Effect of Cooling Strategies and Machining Feed Rate on the Corrosion Behavior and Wettability of AZ31 Alloy for Biomedical Applications, Procedia CIRP, 2017, 65, p 7–12.10.1016/j.procir.2017.03.168 ↗
36. E. Ghali, Magnesium and Magnesium alloys, John Wiley, New York, R.W. Revie, 793, 2000
37. R.-C. Zheng, J. Zhang, W.-J. Huang, W. Dietzel, K. Kainer, C. Blawart and K. Wei, Review of Studies on Corrosion of Magnesium Alloys, Trans. Nonferrous Met. Soc. China, 2006, 16, p 763–771.10.1016/S1003-6326(06)60297-5 ↗
38. O. Lunder, J. Lein and S. Hesjevik, Corrosion Morphologies on Magnesium Alloy AZ91, Werkst. Korros., 1994, 45, p 331–340.10.1002/maco.19940450603 ↗
39. D. Dubey, K. Kadali, S.S. Panda, A. Kumar, J. Jain, K. Mondal and S.S. Singh, Effect of Precipitate Characteristics on the Corrosion Behavior of a AZ80 Magnesium Alloy, Met. Mater. Int., 2020 https://doi.org/10.1007/s12540-020-00764-z10.1007/s12540-020-00764-z ↗
40. U. Karaguzel, M. Bakkal and E. Budak, Modeling and Measurement of Cutting Temperatures in Milling, Procedia CIRP, 2016, 46, p 173–176.10.1016/j.procir.2016.03.182 ↗
41. M. Mezbahul-Islam, A.O. Mostafa and M. Medraj, Essential Magnesium Alloys Binary Phase Diagrams and their Thermochemical Data, J. Mater., 2014, 2014, p 1–33.10.1155/2014/704283 ↗
42. S. Akcan, S. Shah, S. Moylan, P. Chhabra, S. Chandrasekar and H. Yang, Formation of White Layers in Steels by Machining and their Characteristics, Metall. Mater. Trans. A, 2002, 33, p 1245–1254.10.1007/s11661-002-0225-z ↗
43. P. Palanisamy, I. Rajendran, S. Shanmugasundaram and R. Saravanan, Prediction of Cutting Force and Temperature Rise in the End-Milling Operation, J. Eng. Manuf., 2006, 220, p 1577–1587.10.1243/09544054JEM542 ↗
44. I. Lazoglu and Y. Altintas, Prediction of Tool and Chip Temperature in Continuous and Interrupted Machining, Int. J. Mach. Tool. Manu, 2002, 42, p 1011–1022.10.1016/S0890-6955(02)00039-1 ↗
45. P. Oxley, Mechanics of Machining, Wiley, New York, 1989.
46. P. Joshi, Cutting tools, A.H. Wheeler & Co. Ltd, New Delhi, 1996
47. S. Bender, J. Göllner, A. Heyn, C. Blawert and P.B. Srinivasan, Corrosion and Surface Finishing of Magnesium and Its Alloys, in Fundamentals of Magnesium Alloy Metallurgy, Woodhead publishing limited, Cambridge, 2013, p 232–25810.1533/9780857097293.232 ↗