Experimental investigation into turning of AZ91D magnesium

alloy under air coolant using response surface methodology

ABSTRACT

The metal technology in 21st century is shifting towards development of more light weight

structures due to increasing demands of automobile, aerospace, biomedical, electronics,

telecommunication, nuclear and computer fields. Magnesium is being considered the lightest

among structural metals having a density of 1.74 g/cm 3 which is 35% lighter than Aluminium

(2.7 g/cm3) and more than four times lighter than steel (7.86 g/cm 3). It is lightweight like

plastic materials but tough like metals. Other mechanical properties like machinabilty,

castability, weldability, recyclability, higher specific strength & stiffness and electromagnetic

shielding capacity have made it attractive for afore mentioned fields but the corrosion and

poor creep resistance are the barriers in its use.

To overcome the shortcomings of pure magnesium, and to improve its performance, many

types of magnesium alloys have been developed, AZ91D being most popular of these. Most

of the magnesium alloy parts are produced by casting methods. So, machining of the

produced castings is necessary for functional purpose. Machining is also required for

providing variation in sizes according to functional requirement of the element.

The key problems faced while dry turning of the Mg alloy are autoignition & flank built up

due to higher cutting temperatures; and difficult chip removal. Further, the water based and

oil based coolants cannot be used being hazardous. Besides safety, the manufacturing

industry requires the production methods to provide highest possible productivity with good

surface quality products. In the present study, pressurised air coolant has been used to

investigate its effect on turning magnesium alloy with PCD cutting tool. Also, the three
cutting parameters i.e. cutting speed, feed and coolant air pressure have been optimised in

order to minimise surface finish & cutting temperature and maximize material removal rate.
Introduction
Background

The development of science and technology in last century started with the
onset of the capitalism and industrial revolution which led to significant cultural
and institutional changes in human society. From atomic bomb to cell phones,
the technological developments in the century have been profound, both
endangering as well as improving human life. Civilisation progressed at a fast
pace towards modernism, making technology more invasive to everyday life of
the people. Gradually, this development shifted from macro to micro in the last
quarter of 20th century. Invention and experimentation continued throughout the
century in metallurgical field and metal technologies also, resulting in
producing high purity metals, high strength alloys, light weight low density
alloys and materials highly resistant to corrosion, abrasion, erosion etc.

Stringent legislations to protect the environment and health; and oil embargo led
to production of light weight automotive vehicles and search for light weight
low density materials started which resulted in the development of aluminium
alloys, titanium alloys and plastics to replace iron and steel where possible. But
the metal technology in 21st century is shifting towards development of more
light weight structures due to increasing demands of automobile, aerospace,
biomedical, telecommunication, nuclear and computer fields. Although plastics
are also lighter materials but strength and recyclability issues have changed the
focus to magnesium; being the lightest structural metal.

A study from the US department of Energy and other related studies show that
10% mass reduction of a conventional vehicle results in about 5.5% in fuel
economy. Figure 1 shows the relation between vehicle mass and fuel
consumption [1]. Lighter vehicles require smaller powertrains which contribute
in reducing emission gases like CO2, NOx and SOx which are considered harmful
for environment and health. Magnesium is being considered the lightest among
structural metals having a density of 1.74 g/cm 3 which is 35% lighter than
Aluminium (2.7 g/cm3) and more than four times lighter than steel (7.86 g/cm 3).
It is lightweight like plastic materials but tough like metals [2]. Other
mechanical properties like machinabilty, castability, weldability, recyclability,
higher specific strength & stiffness and electromagnetic shielding capacity have
made it attractive for afore mentioned fields.

[2] Buldum BB, Sik A and Ozkul I, “Investigation of Magnesium Alloy Machinability”,
International Journal of Electronics, Mechanical and Mechatronics Vol.2 pp. 261-268, 2008

Figure 1 – Relation between Vehicle mass and fuel consumption

[1] Eliezer, D., E. Aghion and F.H. Froes, 1998. Magnesium science and technology, Adv Mat Performance, 5:
201-212.

Magnesium

Magnesium was discovered in 1755 by Joseph Black outside a Greek city called
Magnesia and hence got its name. It was successfully isolated first by Sir
Humphrey Davy in 1808 by electrolysis of wet magnesium sulphate. Its atomic
number is 12, atomic weight 24 and is placed in second column of periodic
table alongwith other alkaline earth metals. It has hexagonal close-packed
crystal structure and freezes at 650ºC. It stands at 8 th place according to Clarke
number (represents the amount of the element by mass in the Earth’s surface
layer); at 4th place in the Earth after iron, oxygen & silicon; and its abundance as
metal is second in sea water after sodium. So, it can be considered as
inexhaustible source which is distributed throughout the world.

Magnesium looks shiny grey metal having density of 1.74 g/cm 3 which is 35%
lighter than Aluminium (2.7 g/cm3) and more than four times lighter than steel
(7.86 g/cm3). Table 1 shows the comparison of physical properties of
Magnesium, Aluminium and Iron.

Table 1. Comparison of physical properties of Magnesium, Aluminium and Iron [3]

Property Magnesium Aluminium Iron

Crystal structure HCP FCC BCC

Density at 20ºC (g/cc) 1.74 2.70 7.86

Young’s modulus of elasticity (106 Mpa) 44.126 68.947 206.842

240 (for AZ91 320 (for A380
Tensile Strength (Mpa) 350
alloy) alloy)
Melting Point (ºC) 650 660 1536

Boiling Point (ºC) 1100 2519 2861

[3] M. K. Kulekci, “Magnesium and its alloys

applications in automotive industry”, Int J Adv
Manuf Technol 39:851–865, 2008.

Magnesium is highly inflammable in powder or thin strip form but its ignition
becomes difficult in bulk form. If ignited, it becomes difficult to extinguish by
water, carbon dioxide and nitrogen. Brilliant white light is produced by
magnesium while burning in air which was used as flashlight for photography in
earlier days. It is found in about 60 minerals but commercially important
minerals are magnesite, dolomite, carnalite, brucite, talc and olivine[4]. It is
extracted from minerals either by electrolysis or by reduction.

[4] Simandl GJ, Schultes J et. al, “Magnesium - Raw Materials, Metal Extraction and Economics -
Global Picture”, Proceedings of the Ninth Biennial SGA Meeting, Dublin, pp 827-830, 2007

The useful mechanical properties of magnesium include machinabilty, vibration

damping, hardness, electromagnetic wave shielding and low toxicity. Its
specific stiffness is of the order of aluminium and iron and specific tensile
strength is much higher in comparison as shown in figure 2.On the negative side
it has properties like insufficient strength, galvanic corrosion, insufficient
elongation, low creep resistance and low heat resistance [5]. To overcome these
shortcomings and to improve its performance, it becomes necessary to make its
alloys by adding suitable metals in proper ratio.
[5] Watarai Hisao, “Trend of Research and Development for Magnesium Alloys
- Reducing the Weight of Structural Materials in Motor Vehicles”, Science and technology Trends, Quarterly
review no. 18, pp 84-97, January 2006
160

140
Specific Stiffness (MN-m/kg)
120
Specific Strength (kN-m/kg)
100

80

60

40

20

0
Mg Al Iron

Figure 2. Comparison of basic structural properties of magnesium with aluminium and

iron [6]
[6] Mustafa, K.K., 2008. Magnesium and its alloys applications in automotive industry, International Journal of
Advance Manufacturing Technology, 39: pp 851-86.2005

Magnesium Alloys

Although pure magnesium has excellent mechanical properties but it becomes

necessary to alloy it by melting and adding other elements in order to improve
its practical performance and to overcome its shortcomings. Various elements
which are alloyed with magnesium include aluminium, zinc, manganese,
zirconium, cerium, thorium, silicon, calcium, rare earth, lithium, silver, yttrium
etc. Most common alloys are AZ based magnesium alloys containing
aluminium and zinc as major alloying elements for room temperature
applications. Addition of these elements in proper amount with pure magnesium
has shown in improvement of strength, workability, castability, weldability,
creep resistance and corrosion resistance. Alloying of
cerium, thorium and zirconium make the alloy to perform better at elevated
temperature range i.e. 260-370ºC[7]. Table 2 shows the commonly used
magnesium alloys and their application.

Table 2. Commonly used magnesium alloys, their basic properties and

applications[8]

Aluminium-zinc alloy (AZ91) is the main alloy used in die casting since it
possess good castability, corrosion resistance and other mechanical properties
but its drawback is lacks of creep resistance above 100ºC [9]. AE42 containing
rare earth metals shows better creep resistance besides possessing good
strength, castabilty and resistance to corrosion [10]. Magnesium-thorium alloys
present very good creep resistance at higher temperature (~ 350ºC) and good in
castability but are very costly [11]. Recently developed Mg-Al-Sr alloy exhibits
excellent heat resistant properties besides strength, castability and corrosion
resistance due to which it has been used in engine blocks by BMW [12].
Aluminium-manganese (AM) alloy has high ductility and toughness but it is
difficult to die cast. Table 3 shows the mechanical properties of various
magnesium alloys.
Table 3. Mechanical properties of various magnesium alloys [13]
Alloy Tensile Strength Yield Strength Elongation Creep (%) @ 150ºC,
(MPa) (MPa) (%) 35 MPa, 200 hr
AZ91D 240 165 3 2.54

AM60 220 130 6 2.15

AM50 200 125 6-10 2.15

AM20 135 105 10 -

AS41 225 135 4.5 -

AS21 170 110 4 -

AE42 225 140 8-10 0.33

Designation of Magnesium Alloys

American Society of Testing and Materials (ASTM) International prescribed

designation of magnesium alloy is mostly used although different countries
have their own numbering system also. The designation system according to
ASTM is shown in figure 3. First letter shows the principal alloying element
and second letter shows the second major alloying element. Then there are two
numerals which indicate the weight percentage of these two alloying elements
respectively. The last digit indicates the development stage of the composition
as registered with ASTM. It is used to distinguish the alloys containing the same
percentages of the two principal alloying elements. The various letters denote
the following stages:-
 A-First composition,
 B-Second composition,
 C-Third composition registered with ASTM,
 D-High purity, and
 E-High corrosion resistance
 Figure 3. Designation of magnesium alloys

In the given example, AZ91D alloy contains 9% aluminium by weight, 1% zinc

by weight and this is the fourth generation of alloy composition registered with
ASTM. Accordingly, the most common cast magnesium alloys of AM60 series
are AM60A and AM60B and that of AZ91 series AZ91A, AZ91B, AZ91C,
AZ91D AND AZ91E. Table 4 shows the symbols of various elements added for
making alloys of magnesium.

Table 4. Symbols of various alloying elements [2]

Letter Alloying Elements

A Aluminium
C Copper
E Rare Earth Metal
H Thorium
K Zirconium
L Lithium
M Manganese
Q Silver
S Silicon
Y Yttrium
Z Zinc

AZ91D magnesium alloy

From the beginning of this century, extensive studies have been carried out on
AZ series magnesium alloys, particularly on AZ91 composition alloys, as these
have found extensive use in automotive, aerospace, computer and
communication industry due to high strength to weight ratio and good
castability [2]. Composition of this alloy is shown in Table 5. This alloy is also
designated as UNS M11916 according to Unified Number System

Table 5. Composition of AZ91D Mg alloy (in %age by weight) [ASM International]

Al Zn Ni Cu Mn Ni Si Fe Othe Mg
r
8.3 - 0.35 <0.002 <0.03 0.15 <0.002 <0.1 <0.005 <0.02 Bal
9.7 -1.0 - 0.5

Physical and chemical Properties of AZ91D Mg Alloy

The crystal structure of this alloy is HCP. Density of AZ91D magnesium alloy
is 1.81 g/cm3 which is slightly greater than the density of pure magnesium, due
to alloying elements. But still it is very less as compared to Aluminium (2.7
g/cm3) and Iron (7.86 g/cm3). There is probability of ignition in the alloy
resulted by oxidation when it reaches a particular temperature which depends
upon the size of material specimen as well as stability of heating source. As the
alloy has good thermal conductivity, the larger specimen are difficult to auto
ignite but dust of the alloy is much prone to ignition. Mg vapour produced
during melting enhances the combustion rate and ignition starts [14].

All magnesium alloys are reactive to oxygen; hence the oxides are always
present on outer layer. Corrosion resistance of the magnesium alloys is high to
alkalis and hydrofluoric acids but the resistance is less to other acids and salty
surroundings [15]. But there is high affinity of the alloy to galvanic corrosion
due to Mg being most anodic structural metal. So its direct contact with other
metals must be avoided. Paintings and coatings are generally used on finished
products to protect them from environment. Magnesium alloy is also suitable in
the environment of elevated temperatures thanks to its high thermal
conductivity i.e. 72.6 W/m-K. Table 6 shows the physical properties of AZ91D
magnesium alloy.

Table 6 Physical properties of AZ91D magnesium alloy [16]

 Physical Property Value

Crystal Structure HCP

Density (g/cm3) 1.81

Liquidus temperature (ºC) 599

Solidus temperature (ºC) 470

Incipient Melting Temperature 420-435

Coefficient of Thermal Expansion (20-100ºC, µm/mm/ºC) 26.0

Specific Heat of Fusion (kJ/kg) 373

Specific Heat (kJ/kg-ºC) 1.04

Thermal Conductivity (20ºC, W/m-K) 72.7

Electrical Conductivity (MS/m) 6.6

Mechanical properties of AZ91D magnesium alloy

Magnesium alloys of various types are available comprising a wide range of

mechanical properties. These properties depend upon the composition,
manufacturing method, heat treatment and other such factors. Important
mechanical properties of consideration for engineering applications and design
are tensile strength, yield strength, ultimate strength, elongation, compressive
strength, shear strength, hardness, fatigue strength, toughness, fluidity, creep
resistance etc. Table 7 shows the values of various mechanical properties of
AZ91D alloy [17].

Specific stiffness of AZ91D alloy is 24.75 MN-m/kg and specific strength is

132.6 kN-m/kg. Its specific strength is almost equivalent to its competitive
metals i.e. aluminium and iron [Table 2]. Higher specific strength of this alloy
makes it more demanding for light weight structural components. The
magnesium alloy can be rolled into plates, shapes, and strips. It can be cast,
forged, welded and machined. The important mechanical properties according
to processing capabilities are discussed below:-

Castability: Castability of AZ91D magnesium alloy is very good due to high

fluidity (the ability of a molten metal to flow through mould before
solidification). It is suitable for high pressure die casting due to its lower
melting point. Aided by its dimensional stability and consistent shrinkage rates,
it is possible to produce net shape castings of even small and geometrically
complex components which eliminate post-cast machining also [19]. Also the
components are released with minimum force from dies resulting in minimum
distortion and residual stresses.

Table 7. Mechanical properties of AZ91D Magnesium alloy

Mechanical Property Value

Tensile Ultimate Strength, MPa 240
Tensile Yield Strength, MPa 165
Elongation at Break 3%
Compressive Yield Strength, MPa 165
Young’s Modulus of Elasticity, GPa 44.8
Poisson’s Ratio 0.35
Fatigue Strength, MPa 97.0
Shear Modulus, GPa 17
Shear Strength, MPa 140
Charpy Impact, J 2.70
Hardness – Brinnel 63.0
Hardness – Rockwell E 75.0

Weldability: The magnesium alloy is easy to be fabricated and joined at

elevated temperatures (200 - 315ºC). Almost all welding techniques are suitable
for AZ series alloys in which aluminium content helps to refine grain structure.
However, the welding defects such as formation of cracks, oxide films and
cavities have been reported [20].
Formability: It is so easy to form, so that the forming can be done only in
single step which require many steps for steel [18]. Almost every forming
method like deep drawing, spinning, bending, stretch forming etc. can be
employed in the temperature range of 150 - 300ºC [15].

Forgeability: AZ series magnesium alloys have moderate forgeability using

conventional forging methods due to low plastic deformation characteristics
although AM series alloy shows gives better results [21].

Damping Capacity: As the magnesium alloys are used in automobiles and

other structural members, it should be able to absorb vibrations and shocks for
quieter and comfortable operation. The damping capacity is associated with
dislocations and impurity atoms. Although pure magnesium exhibits unique
damping characteristics but alloying affects it negatively. However the
damping capacity can be increased by solution treatment and precipitation heat
treatment of magnesium alloy [22].

Impact & Dent Resistance: The magnesium alloy has very good resistance to
impact and dent due to its elastic energy absorption characteristics which
makes it favourite for automobile safety devices, portable tools and mobile
electronics components [23].

Anti-Galling: This alloys exhibits low galling tendency which makes it useful
as bearing surface, even for a shaft having Brinnel Hardness above 400 [23].

Recyclability: Magnesium alloys are highly recyclable. The energy required to

recycle the alloys is only 5% of the energy required for extraction of new alloy
from magnesium minerals. Also, the recycled magnesium alloy consists of
almost same physical and mechanical properties as parent alloy. So, the
recycling of magnesium alloys becomes of utmost importance towards cost
reduction, natural resources preservation and environment protection. [24] Its
recyclability and low density gives it upper hand in competition with plastics.

Creep Resistance: As discussed earlier, the AZ and AM series alloys posses

reasonable room temperature strength, ductility and very good creep resistance
but show poor mechanical properties at elevated temperatures (>100ºC). This
poor creep resistance in the AZ91D alloy is caused by the essential amount of
β-Mg17Al12 phase in this alloy. This phase makes the grain boundary to slide
and migrate [25].

Machinability:
 Machining—Magnesium is recognized as the easiest of structural metals to machine and is the
“standard” of the cutting tool industry when comparing machinability of metals. The low power
requirements for machining magnesium alloys permit the use of deeper cuts and higher feed
rates, thus permitting fast and efficient machining when compared to other metals. Magnesium
alloys also normally produce well-broken chips, which are easy to handle.
.
[22] Zhang J, Tao Y et. al., “Influence of Heat Treatment on Damping Capacity of Magnesium
Alloy AZ91D”, Material Science Forum, vol. 488-489, pp 733-736, 2005.

[23] Di YB, “Study Of Preparation And Corrosion Resistance Of Ceramic

Coating Deposited On Magnesium Alloy By Microplasma Oxidation Process”,
Globe Thesis, 2006.
[24] Liu G, Wang Y and Fan Z, “A physical approach to the direct recycling of Mg-alloy scrap by
the rheo-diecasting process”, Materials Science and Engineering A 472, pp 251–257, 2008.

[25] M. S. Dargusch, G. L. Dunlop, Elevated temperature creep and microstructure of die cast
Mg-Al alloys, Proceeding of the 4th international conference on magnesium alloys and their
applications, eds. B.L. Mordike, K.U. Kainer, Wiley-VCH Verlag GmbH, Wolfsburg, Germany,
1998, p. 277-282.

5 baris, mg-props-application-potential-limitation by mordike

Precipitation hardening

Mg alloy properties

Trends of r n d

First alloying element

Second alloying element

Percentage of first alloying element by weight

Percentage of second alloying element by weight
AZ91D Development stage of composition
as registered with ASTM

[7]Elaheh, G., 2011. Materials in Automotive Application, State of the Art and Prospects, New Trends and
Developments in Automotive Industry, UK: InTech., pp: 365-394.

[8] Musfirah AH and Jaharah AG, “Magnesium and Aluminum Alloys in Automotive Industry”
Journal of Applied Sciences Research, 8(9):pp 4865-4875, 2012
[9] Yusuke, N., W. Akira and O. Koichi, 2006. Effects of Ca,Sr Additions on Properties of Mg-Al Based Alloys,
Journal of Materials Transactions, 47(4):pp 1031-1039.
[10] Baril, E., P. Labelle, and M.O. Pekguleryuz, 2003. Elevated temperature Mg-Al-Sr: Creep resistance, mechanical
properties, and microstructure, JOM-Journal of the Minerals Metals & Materials Society, 55(11), A34–A39.
[11] Pekguleryuz, M.O. and A.A. Kaya, 2003. Creep resistant magnesium alloys for powertrain applications,
Journal of Advance Material., 5(12): 866-878.
[12] Medraj, M. and A. Parvez, 2007. Examining Technical Know-How: Magnesium-Aluminum-Strontium Alloys for
More Fuel Efficient Automobiles, The Machinist - magazine, pp: 45-47.
[13]
[14] M. Liu, D.S. Shih, C. Parish, A. Atrens, The ignition temperature of Mg alloys WE43, AZ31
and AZ91, Corrosion Science 54C (2012) 139–142.

[15] Robert S. Busk, MAGNESIUM AND ITS ALLOYS, Mechanical Engineers' Handbook, 2nd ed., Edited by
Myer Kutz.
ISBN 0-471-13007-9 © 1998, pp 109-113, John Wiley & Sons, Inc.

[16] ASM Specialty Handbook - Magnesium and Magnesium

Alloys, edited by Michael M. Avedesian, and Hugh Baker, ASM
International, Metals Park, OH, (1999).
[17].Matweb, Material Property Data, www.matweb.com ].

[18] Gaines

[19] Mark Bruce, Remarkable magnesium:the 21st century structural alloy

for small components, WHITE PAPER FisherCast Global Corporation

[20] Frank Czerwinski (2011). Welding and Joining of Magnesium Alloys, Magnesium
Alloys - Design, Processing and Properties, Frank Czerwinski (Ed.), ISBN: 978-953-
307-520-4, InTech, Available from: http://www.intechopen.com/books/magnesium-
alloys-design-processing-and-properties/welding-and-joining-ofmagnesium-alloys
[21] Jiang J, Cheng Y et. al., “ Effect of Pressure on Microstructure and Mechanical
Properties of AM60B Alloy Used for Motorcycle Wheels Formed by Double Control Forming" ,
Journal of material science Technology, 2013, 29(5), 439-445,2013

Mg n aluminium alloys in auto industry-

Mechanical and physical properties

Trends of r&d
Magnesium and aluminium allos in automotive industry

Lit survey grain refinement

Trends of r&d

Machinabilty of mg n alloys – birol

Investigation of mb alloy machinabiliy – 5 baris

Mg the 21st century

First alloying element

Second alloying element

Percentage of first alloying element by weight

Percentage of second alloying element by weight

AZ91D Development stage of composition

registered with ASTM