Microstructure and mechanical properties of Mg-Nd-Zn-Zr alloy fabricated by TIG-based wire – Arc directed energy deposition with pulsed current

Abstract

In this study, the Mg-Nd-Zn-Zr alloy thin-wall specimens were prepared by tungsten inert gas (TIG) based wire-arc directed energy deposition (WA-DED) with different pulsed currents. The arc characteristics of different pulsed current frequents were observed. The microstructures, and mechanical properties of as-deposited (AD), 5 Hz, 10 Hz, 15 Hz, and 20 Hz specimens were systematically analyzed and evaluated. The uniformly equiaxed crystals with random grain orientations and intergranular network Mg-Nd-Zn eutectics were found in the WA-DED fabricated Mg-Nd-Zn-Zr alloy thin-wall specimens. No significant voids were found. The microstructures were regulated, and the mechanical properties were improved by adjusting the pulsed current frequency. The 10 Hz specimen had the optimal microstructure with an average grain size of 10.35 μm. Concurrently, the 10 Hz specimen exhibits excellent strength-ductility synergy and isotropic, benefiting from the finely equiaxed crystals. The average microhardness of the 10 Hz specimen was 68.51 HV0.2, and the ultimate tensile strengths in the building and traveling directions were 223 MPa and 229.7 MPa, respectively, and the yield strengths in the building and traveling directions were 138.3 MPa and 145.3 MPa, respectively. Notably, the elongations in the building and traveling directions of the 10 Hz specimen were 16.8 % and 17.4 %, respectively. The local strain evolution and fracture surfaces of AD and 10 Hz specimens in the building and traveling directions were observed. The mechanisms of grain refinement and mechanical properties improvement were revealed.