Tensile failure mode transitions from subzero to elevated deformation temperature in Mg–6Al–1Zn alloy

Abstract

Understanding the temperature dependent deformation behavior of Mg alloys is crucial for their expanding use in the aerospace sector. This study investigates the deformation mechanisms of hot-rolled AZ61 Mg alloy under uniaxial tension along rolling direction (RD) and transverse direction (TD) at −50, 25, 50, and 150°C. Results reveal a transition from high strength with limited elongation at −50°C to significant softening and maximum ductility at 150°C. TD samples consistently showed 2%–6% higher strength than RD; however, this yield anisotropy diminished at 150°C due to the shift from twinning to thermally activated slip and recovery. Fractography indicated a change from semi-brittle to fully ductile fracture with increasing temperature. Electron backscattered diffraction (EBSD) analysis confirmed twinning-driven grain refinement at low temperatures, while deformation at high temperatures involved grain elongation along shear zones, enabling greater strain accommodation before material failure.

Keywords

Mg alloy / deformation temperature / twinning dynamics / grain refinement / dynamic recovery / fracture mechanics

References

[1] H. Fu, F. Zhang, X. Liu, et al., Achieving synergistic strength-ductility optimization in ultralight Mg–11Li alloy by ultrahigh pressure treatment, Mater. Charact., 225(2025), art. No. 115162.

[2] S.F. Chu, Y.X. Li, Z.H. Xiong, P. Liu, D. Qiu, and X.Q. Zeng, Achieving stable coherent pure Y nanoprecipitates in a Mg–Y alloy, Mater. Charact., 214(2024), art. No. 114081.

[3] J.F. Xiao, Y.Y. Gao, J.F. Song, et al., Insights into the effects of Sm on microstructure evolution mechanism and mechanical properties of Mg–8Gd–2Y–1Zn–0.5Zr cast alloy at high temperature, Mater. Sci. Eng. A, 899(2024), art. No. 146475.

[4] H.M.R. Tariq, H.H. Kang, U.M. Chaudry, M.K. Khan, and T.S. Jun, Impact of surface roughness on the yield drop of hot-rolled AZX311 Mg alloy, Adv. Eng. Mater., 27(2025), No. 9, art. No. 2401689.

[5] A. Malik, S. Abrar, F. Nazeer, and U.M. Chaudry, Retaining high strength and high elongation to fracture under dynamic compressive loading in a homogenized AZ31–Ca–Mn–Zr alloy at a temperature of 250°C, Arch. Civ. Mech. Eng., 25(2025), No. 4, art. No. 187.

[6] H. Wang, J.L. Dong, P.H. Fu, et al., Exploring the mechanisms of texture evolution in a low-alloyed Mg–Zn–Ca alloy during extrusion, Mater. Charact., 225(2025), art. No. 115168.

[7] U.M. Chaudry, H.M.R. Tariq, N. Ansari, et al., Effect of CaO content and annealing treatment on the room-temperature mechanical properties of AZ61 and AZ61–CaO alloys, Metals, 13(2023), No. 12, art. No. 1962.

[8] L.Q. Guan, Y.L. Deng, A. Luo, X.B. Guo, and C.P. Tang, Activation of slip and enhanced ductility in as-extruded Mg–Gd–Y–Nd alloys through Si addition, Mater. Sci. Eng. A, 804(2021), art. No. 140736.

[9] Chaudry UM, Rehan Tariq HM, Hamad K, Khan MK, Jun TS. Twinning-induced texture weakening in Mg alloy and its consequent influence on ductility and formability. Mater. Sci. Technol., 2025, 41(2): 101.

[10] J.W. Zhou, Y. Yang, D.Q. Fang, et al., Ductile heat-resistant Mg–Gd–Y alloys of high strength via lamellated heterostructure, Mater. Sci. Eng. A, 937(2025), art. No. 148466.

[11] M.A. Khan, M.A. Afifi, M.A. Hafeez, et al., Evolution of microstructure, texture, and mechanical performance of Mg–13Gd–2Er–0.3Zr alloy by double extrusion at different temperatures, Arch. Civ. Mech. Eng., 25(2025), No. 1, art. No. 26.

[12] H.M.R. Tariq, M. Ishtiaq, H.H. Kang, U.M. Chaudry, and T.S. Jun, A critical review on the comparative assessment of rare-earth and non-rare-earth alloying in magnesium alloys, Metals, 15(2025), No. 2, art. No. 128.

[13] J.M. Lin, P.H. Fu, Y.W. Ding, et al., Simultaneously improving strength and ductility of cast Mg–Gd–Zn alloy through Er addition, Mater. Charact., 224(2025), art. No. 115020.

[14] S. Zeon Han, B. Ryu, I.S. Jeong, S.H. Lim, and E.A. Choi, Simultaneous enhancement of strength and ductility in Al–Zn–Cu casting alloy with trace Mg addition designed by first principle calculation, Mater. Des., 244(2024), art. No. 113140.

[15] Ali Siddique J, Kim BH, Rafiei S, et al. . Role of dislocation density on the onset and intensity of stretcher strain marks in novel Al–Mg alloys with high Mg content. J. Mater. Res. Technol., 2025, 35: 5552.

[16] P. Kurt and S.C. Kurnaz, Investigation of microstructure, mechanical properties and corrosion behaviour of as-cast Mg–4Sn–2Al–X (X = 0.5 Ca and 0.25 Mn) alloys, Int. J. Met., (2025), art. No. 1576.

[17] Nam ND. Corrosion behavior of Mg–5Al based magnesium alloy with 1 wt.% Sn, Mn and Zn additions in 3.5 wt.% NaCl solution. J. Magnesium Alloys, 2014, 2(2): 190.

[18] Chaudry UM, Jun TS, Tariq HMR, Minhas BZ, Ur Rehman MAKumar D, Ansari N. Corrosion behavior of Mg alloys in simulated body fluids. Magnesium Alloys for Biomedical Applications, 2024, Boca Raton. CRC Press177.

[19] Hou CH, Ye ZS, Qi FG, et al. . Effect of Al addition on microstructure and mechanical properties of Mg–Zn–Sn–Mn alloy. Trans. Nonferrous Met. Soc. China, 2021, 31(7): 1951.

[20] J.R. Lee, M.-S. Lee, Y. Noh, and T.S. Jun, Thermal activation and dislocation dynamics in Ti–6Al–4V alloy, Int. J. Mech. Sci., 277(2024), art. No. 109426.

[21] Tariq HMR, Chaudry UM, Kim CS, Jun TS. Effect of calcium on the rate of grain boundary migration in pure magnesium during annealing. Met. Mater. Int., 2024, 30(7): 2038.

[22] Zhang Q, Li QA, Chen XY, Zhao JX, Bao J, Chen ZY. Dynamic precipitation and recrystallization mechanism during hot compression of Mg–Gd–Y–Zr alloy. J. Mater. Res. Technol., 2021, 15: 37.

[23] Shah SSA, Liu MP, Khan A, et al. . Recrystallization aspects and factors affecting their roles in Mg alloys: A comprehensive review. J. Magnesium Alloys, 2025, 13(5): 1879.

[24] Roodposhti PS, Sarkar A, Murty KL, Brody H, Scattergood R. Grain boundary sliding mechanism during high temperature deformation of AZ31 Magnesium alloy. Mater. Sci. Eng. A, 2016, 669: 171.

[25] Tariq HMR, Chaudry UM, Ishtiaq M, Kim M, Ali M, Jun TS. Effect of Al addition on the room and cryogenic temperature deformation of Mg–xAl–1Zn–1Ca alloy (x = 2, 3 wt.%). J. Magnesium Alloys, 2024, 12(11): 4694.

[26] C.S. Patil, S. Chakraborty, and S.R. Niezgoda, Cross slip based dynamic recovery during plane strain compression of aluminium and its role in preferential nucleation of the cube-oriented recrystallized grains, Acta Mater., 272(2024), art. No. 119913.

[27] J.R. Xing, G. Lei, Z.Y. Wang, H.J. Cui, C. Kong, and H.L. Yu, Fracture toughness and fracture mechanism of Al–Mg–Si alloy sheet subjected to pre-cryorolling and subsequent bake hardening, J. Alloy. Compd., 1008(2024), art. No. 176665.

[28] U.M. Chaudry, H.M.R. Tariq, N. Ansari, C.S. Kim, S.Y. Lee, and T.S. Jun, Exceptional improvement in the yield strength of AZ61 magnesium alloy via cryo-stretching and its implications on the grain growth during annealing, J. Alloy. Compd., 970(2024), art. No. 172630.

[29] S. Sudharsan and A. Raja Annamalai, Fatigue behavior of ascast and heat-treated Mg–Gd–Y–Er alloy at room temperature, Eng. Fail. Anal., 176(2025), art. No. 109652.

[30] Chaudry UM, Hamad K, Kim JG. On the ductility of magnesium based materials: A mini review. J. Alloy. Compd., 2019, 792: 652.

[31] Shah SSA, Liu MP, Khan A, et al. . Twinning aspects and their efficient roles in wrought Mg alloys: A comprehensive review. J. Magnesium Alloys, 2024, 12(6): 2201.

[32] Tariq HMR, Chaudry UM, Kim CS, Jun TS. Synergetic improvement in strength and ductility of AZX211 Mg alloy facilitated by {10–12}-{01–12} twin-twin interactions during pre-stretching at cryogenic temperature. J. Mater. Res. Technol., 2024, 29: 3249.

[33] U.M. Chaudry, M.S. Lee, and T.S. Jun, Dynamic recrystallization of commercially pure titanium during cryogenic compression, Mater. Charact., 206(2023), art. No. 113423.

[34] Zhang K, Shao ZT, Robson J, Huang Y, Zheng JH, Jiang J. Achieving high ductility and strength in magnesium alloy through cryogenic-hot forming. J. Magnesium Alloys, 2023, 11(9): 3130.

[35] M. Arul Kumar, B. Clausen, L. Capolungo, et al., Deformation twinning and grain partitioning in a hexagonal close-packed magnesium alloy, Nat. Commun., 9(2018), No. 1, art. No. 4761.

[36] Sadiq S, Tariq HMR, Han SC, Muhammad Nadzri NI, Jun TS. Impact of cyclic cryogenic treatment on the hardening behavior of pre-strained CoCrFeMnNi alloy. J. Mater. Res. Technol., 2025, 36: 9549.

[37] Tariq HMR, Masood Chaudry U, Suh JS, Kim YM, Jun TS. Effect of cryogenic temperature on the strengthening mechanisms of AZ61 Mg alloy extruded at different temperatures. J. Mater. Res. Technol., 2024, 33: 335.

[38] Chaudry UM, Tariq HMR, Zubair M, Ansari N, Jun TS. Implications of twinning on the microstructure development, crystallographic texture and mechanical performance of Mg alloys- a critical review. J. Magnesium Alloys, 2023, 11(11): 4146.

[39] Yang YM, Li YF, Yi DW, et al. . Revealing the microstructure evolution mechanism and mechanical responses of a novel Al–Zn–Mg–Cu alloy by hot deformation process. J. Mater. Res. Technol., 2024, 29: 3699.

[40] Simkin BA, Ng BC, Crimp MA, Bieler TR. Crack opening due to deformation twin shear at grain boundaries in near-γ TiAl. Intermetallics, 2007, 15(1): 55.

[41] Chaudry UM, Tariq HMR, Ansari N, Lee SY, Jun TS. Room and cryogenic deformation behavior of AZ61 and AZ61–xCaO (x = 0.5, 1 wt.%) alloy. J. Magnesium Alloys, 2024, 12(5): 1996.

[42] Trimby PW, Cao Y, Chen ZB, et al. . Characterizing deformed ultrafine-grained and nanocrystalline materials using transmission Kikuchi diffraction in a scanning electron microscope. Acta Mater., 2014, 62: 69.

[43] Teng X, Wierzbicki T, Couque H. On the transition from adiabatic shear banding to fracture. Mech. Mater., 2007, 39(2): 107.

[44] Harris MB, Watts LS, Homer ER. Competition between shear band nucleation and propagation across rate-dependent flow transitions in a model metallic glass. Acta Mater., 2016, 111: 273.

[45] Wright TW, Walter JW. On stress collapse in adiabatic shear bands. J. Mech. Phys. Solids, 1987, 35(6): 701.

[46] Masood Chaudry U, Tekumalla S, Gupta M, Jun TS, Hamad K. Designing highly ductile magnesium alloys: Current status and future challenges. Crit. Rev. Solid State Mater. Sci., 2022, 47(2): 194.

RIGHTS & PERMISSIONS

University of Science and Technology Beijing