High-performance ultra-lean biodegradable Mg–Ca alloys and guidelines for their processing

High-performance ultra-lean binary Mg–Ca alloys are engineered by intelligent alloying and thermo-mechanical processing using hot-extrusion. With Ca-alloying contents as low as 0.2-0.6 wt.%, remarkable room-temperature tensile properties are obtained with tensile strength values as high as 380–420 MPa, or ductility values reaching a maximum of 36 %. By means of multiscale structural and chemical analysis using electron microscopy and energy dispersive X-ray spectroscopy, we show that multimodal strengthening mechanisms can be activated by modifying the spatial distribution of Ca as secondary phase. Our results indicate that strong precipitation strengthening is achieved when Mg2Ca phase particles are dispersed within the grains. On the other hand, preferential distribution of the Mg2Ca precipitates along grain boundaries imparts substantial grain-boundary strengthening by the Hall-Petch effect. Apart from secondary-phase precipitation, the role of Ca as solute atoms is paramount in promoting homogeneous deformation. The presence of Ca directly alters the intrinsic stacking fault energies and modifies the cross-slip energy barriers such that the slip-transition probability from pyramidal-to-basal and vice-versa becomes comparable. Both effects ensure competitive activation of basal and non-basal slip, thereby reducing the mechanical anisotropy. The mechanical performance in the current work, when compared to earlier reported studies of Mg alloys with similar or higher alloying content, shows a 2 to 10-fold increase in tensile strength without compromising ductility.