Near-liquidus molding of Mg–Al and Mg–Al–Zn alloys

Abstract A novel application of the injection molding technique for net-shape forming of Mg–9Al–1Zn and Mg–6Al alloys, starting from a particulate precursor, was investigated. It was revealed that tight control of the alloy’s temperature within a narrow range around the liquidus level generated structures with high integrity and diminished some disadvantages inherent for conventional casting which utilizes superheated melts. The homogeneous matrix consisted of fine near-equiaxed α-Mg grains/cells surrounded by mostly discontinuous precipitates of Mg 17 Al 12 intermetallics. The primary solid phase was either completely absent or present in negligible amounts, not exceeding 5%, with a morphology ranging from globules to degenerated rosettes. The structural integrity and fine microstructure improved mechanical properties which exhibited a superior combination of strength and ductility. The role of Mg 17 Al 12 phase as a factor controlling ductility in Mg–Al and Mg–Al–Zn alloys is considered.