Abstract
Despite the increased use of magnesium (Mg) alloys in diverse engineering applications in recent years, further incorporation of complex Mg alloy castings remains challenging due to the alloy’s relatively high susceptibility to hot tearing. A significant reduction in hot tearing via grain refinement was achieved in aluminum and ferrous alloys; however, an effective, long-lasting and inexpensive grain refiner for aluminum-containing Mg alloys remains elusive. In this work, a TiB2 grain refiner was fabricated via a novel spark plasma sintering (SPS) powder metallurgy process. Then, its effectiveness in grain refining an AZ91D magnesium alloy was compared to that of a commercially available TiB2 grain refiner produced by hot extrusion. Due to the homogeneous distribution of the TiAl3 and TiB2 particles in the grain refiner, as well as their effect on the alloy’s microstructure evolution and solidification behavior, the SPS-TiB2 grain refiner was observed to achieve a significant reduction in the grain size and hot tearing of the Al-containing AZ91D magnesium alloy.
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