Forjabilitatea Aliajelor de Magneziu Modificate AZ si ZK
Forgeability of Modified AZ and ZK Wrought Magnesium Alloys
Gerrit Kurz1, Wilhelmus W. Sillekens2, Robert J. Werkhoven2, Dietmar Letzig1,
Dr.ing. Ion Badoi3
1
GKSS Research Centre Geesthacht – Magnesium Innovation Centre; Geesthacht, GERMANY
2
TNO Science and Industry – Materials Technology; Eindhoven, NETHERLANDS
3
SC INTEC SA Bucharest ROMANIA
1. Rezumat
Comparartiv cu piesele turnate produsele din
aliajele de magneziu deformate au atribute favorabile
in ceea ce priveste proprietatile mecanice.In plus ele
asigura o clasa complementara de forme si geometrii.
Aceste aliaje sunt utilizate pentru dezvoltari in
domeniul tehnologiilor de forjare a magneziului.In
acest context proiectul European de cercetare
MagForge are ca obiectiv general elaborarea unor
tehnologii eficiente pentru industria producatoare de
componente forjate din aliaje de magneziu. Unul din
impedimentele actuale referitoare la forjarea
magneziului este lipsa aliajelor de magneziu
adecvate.Forjabilitatea aliajelor de magneziu trebuie
imbunatatita atat din punct de vedere al tehnicitatii
etapelor de procesare cat si al calitatii produsului
rezultat in sensul cresterii performantelor mecanice.
Aceasta este una din temele principale ale
proiectului.
Acest articol prezinta rezultatele obtinute in
aceast domeniu special. Strategia adoptata in acest
sens, consta in inducerea finisarii grauntilor cristalini
si stabilizarea microstructurii aliajelor comerciale de
magneziu forjate prin pamanturi rare.
In conformitate cu practica comuna
semifabricatele turnate au fost fost procesate prin pre-
extrudare. Calitatea semifabricatelor din aliaje de
aluminiu modificate a fost evaluata la nivel de
laborator pe baza probelor conice forjate. Rezultatele
au aratat o crestere semnificativa a calitatii
microstructurii comparativ cu aliajele comerciale
actuale.
2. Materialul semifabricatului
Principalul obiectiv al proiectului MagForge
este de a matrita componente din aliaje de magneziu
care indeplinesc toate proprietatile pieselor din
aluminiu cu forma similara. Datele din literatura de
specialitate re-feritoare la aliajele de magneziu
selectate AZ80 si ZK60,evidentiaza o diferenta mica
intre proprietatile componentelor forjate din
magneziu si aluminiu. In scopul obtinerii tuturor
1. Abstract
Wrought magnesium alloy products have
favourable attributes compared to castings parts with
regard to mechanical properties. In addition they
provide a complementary class of shapes and
geometries. These alloys are the current drivers for
developments within the field of magnesium forging
technology. Within this context, the European
research project MagForge is being conducted with
the overall goal to provide tailored and cost-effective
technologies for the industrial manufacturing of
forged magnesium alloy components. One of the
present impediments to magnesium forging is the
unavailability of suitable magnesium alloys:
Forgeability of magnesium alloys in terms of the
robustness of processing windows and the resulting
product quality in terms of mechanical performance
need to be improved. Hence this is one of the main
topics of the project.
This paper reports on the progress made in
this particular area. The strategy adopted for
advancement consists in inducing grain refinement
and stabilisation of the microstructures by rare-earth
and complementary modifications of the commercial
AZ80 and ZK60 forging magnesium alloys.
In line with common practice, forging slugs
were prepared from cast billets by pre-extrusion. The
quality of the modified magneium alloy slugs is
assessed on the basis of laboratory-scale cone-forging
trials. The results show a significant improvement of
microstructure quality over the existing comercial
alloys.
2. Feedstock Material
The main target of the MagForge project is
to forge a magnesium component that fulfils all
requirements of the same shaped aluminium
component. Literature data on the basic alloys
selected, AZ80 and ZK60, show a very small gap
between the mechanical properties of the forged
components and the properties for aluminium
components. In order to fulfil all the properties of the
prorietatilor componentelor din aluminiu este
necesara cresterea rezistentei celor doua aliaje de
magneziu.
In acest scop aliajele deformate de magneziu
AZ80 si ZK60 au fost modificate cu pamanturi rare
ytriu si ceriu.Aliajele de magneziu AZ80 si ZK60 au
fost modificate cu o cantitate mai mica de ceriu
(AZ80 Cer1%/Zk60 Cer1%)respectiv o cantitate mai
mare de ceriu (AZ80 Cer2%/ZK60 Cer2%).In amble
cazuri cantitatea de ytriu a fost mai mica de 1%.
Compozitia aliajului AZ80 Y a fost similara
cu cea a aliajului AZ80 Cer2 dar a fost adaugata o
cantitate mai mica de ytriu (<1 % procente de masa)
O cantitate mica de calciu (<1 % procente de masa) a
fost combinta cu aliajul ZK60 Cer2 pentru a produce
Aliajul ZK60 Ca.
In scopul obtinerii unei microstructuri
omogene cu graunti fini, aliajele de magneziu
modificate in stare turnata au fost extrudate indirect a
o temperatura a semifabricatului de 280 C si un
raport de extrudare de 16,5. A fost obtinuta o textura
tipica de extrudare a materiei prime care orienteaza
planele bazale cu directia de extrudare[8}.
Materia prima a fost prelucrata in
semifabricate pentru forjare cu diametru de 25 mm si
lungime de 50 mm.
Dupa extrudare, probele au fost supuse
analizei microstructurale. Sectiunea transversala a
probelor turnate si forjate a fost slefuita, atacata si
examinata prin microscopie optica. Pentru pregatirea si
atacul probelor s-a utilizat solutie de acid picric [9].
In Fig. 1 si 2 sunt prezentate microstructurile
materiei prime reprezentand aliajele de magneziu
modificate AZ80 si ZK60. Marimea medie a grauntilor
cristalini a fost determinata utilizandu-se cateva
micrografii ale fiecarui aliaj.
Microstructurile aliajelor AZ80 Cer1 si
AZ80 Cer2 sunt aproape similare, dimensiunea
grauntilor fiind de 12 si 14 µm.
Micostrutura exrudata a aliajului AZ80 Y a
fost mai mai neomogena decat a celor doua aliaje
AZ80 Cer1 si AZ80 Cer2. La toate cele trei aliaje s-
au observat particule intermetalice de (Mg17Al12) sub
forma de placi.
AZ80 Cer 1
Average grain size: 14 µm
AZ80 Y
Average grain size: 16 µm
200 µm
Figura 1. Microstructura materiei prime extrudata aliaj modificat AZ80
Figure 1. Microstructure of the extruded modified AZ80 feedstock material.
aluminium component it is necessary to improve the
strength of the two magnesium alloys.
Therefore the wrought magnesium alloys
AZ80 and ZK60 were modified by alloying with rare
earth elements, yttrium and cerium. The AZ80 and
ZK60 alloys were modified with a small quantity of
ceriu (AZ80 Cer1% / ZK60 Cer1%) and an elevated
(AZ80 Cer2% / ZK60 Cer2%) amount of cerium.
Both amounts of yttriu were smaller than 1 wt. %.
The alloy composition of AZ80 Y was
similar to AZ80 Cer2, but a small quantity of yttrium
(<1 wt. %) was added. A small quantity of calcium
(<1 wt. %) was combined with alloy ZK60 Cer2 to
produce the ZK60 Ca.
In order to obtain homogeneous, fine-
grained microstructures all the cast modified
magnesium alloys were indirectly extruded with a
billet temperature of 280 °C and an extrusion ratio of
16.5. Was obtained a typical extrusion texture of the
feedstock which orients the basal planes parallel to
the extrusion direction [8].
The feedstock was machined to forging
slugs of 25 mm diameter and 50 mm length.
Following extrusion, samples were
subjected to microstructural analysis. Was carried out
on polished and etched central sections of the slugs
and forgings and examinated by optical microscopy.
For sample preparation an etching solution based on
picric acid was applied [9].
In Figures 1 and 2 the microstructures of the
modified magnesium alloys AZ80 and ZK60
feedstock are shown. The average grain size was
determined using several micrographs of each alloy.
The microstructures of the alloys AZ80 Cer1
and AZ80 Cer2 are quite similar as are the grain sizes
of 12 and 14 µm.
The microstructure of the AZ80 Y alloy
extrusion was more inhomogeneous than that of the
two alloys AZ80 Cer1 and AZ80 Cer2. In all three
alloys, lath-shaped (Mg17Al12) intermetallic particles
were also observed.
AZ80 Cer 2
Average grain size: 12 µm
200 µm
200 µm
 În contrast cu aliajele AZ80, aliaje de
modificare ZK60 au fost mai neomogene.
Micrografiile aliajelor ZK60 Cer1 şi ZK60 Cer2 au
relevat neomogenitatea microstructurilor care
conţinde graunti cristalini cu o variaţie larga de
dimensiuni. Graunti cristalini cu dimensiuni foarte
mici, în intervalul 2-4 μm coexistand cu graunti mari
nerecristalizati.
Dimensiunile medii ale grauntilor au fost de
13 µm pentru aliajul ZK60 Cer1si 18 µm pentru
aliajul ZK60 Cer2 . Microstructura aliajului ZK60 Ca
este mult mai omogena si dimensiunea grauntilor de
9 µm este mai mica decat in cazul altor alije ZK60
modificate.
ZK60 Cer 1
Average grain size: 13 µm
ZK60 Ca
Average grain size: 9 µm
200 µm
Figura 2. Microstructura materiei prime extrudata aliaj modificat ZK60
Figure 2. Microstructures of the extruded modified ZK60 feedstock materials.
3.Probe de forjare
Experimentarile de forjare au fost realizate
pe o presa hidraulica cu forta nominala de 1000kN si
o viteza a travrsei superioare de 10 mm/sec.
Componenta alesa a fost un butuc de roata
stilizat.Aceasta este o piesa forjata de dimensiuni
Mici cu forma simetrica .Matrita superioara a avut un
orificiu pentru evacuarea aerului.Imprimarea acestui
orificiu pe piesa forjata a fost un bun indiciu pentru
umplerea matritei.Toate piesele au fost forjate cu
preincalzirea matritelor.
Experimentarile (dimensiunile semifabri-
catelor: Ø 25 mm, lungime 50 mm), au fost efectuate
la temperaturi de 175, 200, 250, 300, 350, 400 şi 450
° C. Toate piesele au fost forjate într-o singura faza.
La începutul procesului de forjare
semifabricatul a fost plasat vertical în matrita şi apoi
comprimat. In scopul evitarii ruperii materialului
matrita inferioara si superioara au fost preincalzite la
tempertura semifabriacatului.
Dupa forjare, piesele au fost racita in aer.
Aceste experimente au fost realizate pentru
determinarea celor mai bune aliaje de magneziu
modificate pentru forjarea in matrita.
In scopul identificarii celui mai bun aliaj
pentru forjare au fost selectate urmatoarele criterii:
In contrast to the AZ80 alloys, the modified
ZK60 alloys were more inhomogeneous.
Micrographs of ZK60 Cer1 and ZK60 Cer2 alloys
revealed inhomogeneous microstructures containing
grains with a wide variation of sizes. Very small
grains with sizes in the range 2–4 µm coexist with
large unrecrystallised grains.
Average grain sizes of about 13 µm in ZK60
Cer1 and 18 µm in ZK60 Cer2 were found. The
microstructure of ZK60 Ca is more homogeneous and
the grain size of 9 µm is smaller than in the case of
other modified ZK60 alloys.
ZK60 Cer 2
Average grain size: 18 µm
200 µm
200 µm
3.Forging Trials
The forging experiments were carried out on
a hydraulic press with a nominal force of 1000 kN
and a ram speed of 10 mm/s.
The component of choice was a stylised
wheel hub. It is a small-size forging of symmetrical
shape The upper die had got a de-aeration borehole.
The print of this borehole on the forged part was a
good indicator of die filling. All forgings were
produced with pre-heated tools
The experiments (slug dimensions: Ø 25
mm, length 50 mm), were carried out at temperatures
of 175, 200, 250, 300, 350, 400 and 450 °C. All parts
were forged in one step.
At the beginning of the forging process the
slug was placed vertically in the die and then
compressed. In order to avoid material failure during
the process, both the upper and lower dies were pre-
heated to the slug temperature. An oil-based,
graphite-pigmented compound was used as lubricant.
After forging, the parts were cooled down
with ambient air. These experiments were performed
to determine the best magnesium alloys modification
for die forging.
In order to find the best forging alloy the
following selection criteria were chosen:
 - Formabilitate buna la temperatura joasa
- Proces permis
De asemenea in scopul comparatiei, probe
identice de forjare au fost realizate cu aliajele
comerciale AZ80 si ZK60. In Figurile 3 si 4 sunt
prezentate rezultatele forjarii. Numai aliajul ZK60 si
varinta sa modificata au asigurat umplerea matritei la
temperatura joasa de 175 C. Piesele forjate din
aliajele ZK60 si ZK60 Cer2 nu au prezentat fisuri la
rece in flanse. Fisuri la rece au aparut in flanse si la
forjarea aliajelor ZK60 Cer1 si ZK60 Ca. In
comparatie cu aliajele ZK60 la temperaturi mai mari
de 200 C aliajele AZ80 Cer2 si AZ80 Y au asigurat o
umplere acceptabila matritei.
- Good formability at low temperatures
- Broad process window
Oslo, roar comparison purposes, identical
forging trials were performed on the commercial
alloys AZ80 and ZK60. Figures 3 and 4 display the
forging results. Only the alloy ZK60 and its
modifications showed sufficient filling of the die at
the lowest forging temperature of 175 C. Only the
forgings of the alloys ZK60 and ZK60 Cer2 showed
no evidence of cold cracking in the flange. Cold
cracks appeared in the flange of the forgings of ZK60
Cer1 and ZK60 Ca. In comparison to the ZK60
alloys, acceptable die filling of the AZ80 Cer2 and
AZ80 Y alloys was obtained at the higher
temperature of 200°C.

200 °C 450 °C

AZ80 Cer1

AZ80 Cer2
Print of the borehole

AZ80 Y
Print of the borehole

Figura 3. Rezultatele forjarii aliajului modificat AZ80

Figure 3. Forging results of the modified AZ80 alloys

175 °C 450 °C

ZK60 Cer1
Print of the borehole

Print of the borehole

ZK60 Cer2

Print of the borehole

ZK60 Ca 400 °C

Figura 4. Rezultatele forjarii aliajului modificat ZK60

Figure 4. Forging results of the modified ZK60 alloys.

In cazul tuturor aliajelor modificate AZ80 In all the modified AZ80 alloys cold cracks
s-au observat fisuri la temperatura de 200°C . Cu in the flange were observed at a forging temperature
toate acestea, piesele forjate in intervalul 250°C si at 200°C. However, the components of all alloys
350°C nu au prezentat fisuri si au umplut forged in the temperature range between 250°C and
corespunzator matrita. La temperaturide fojare de
400°C in cazul aliajului ZK60 Ca au aparut fisuri
care au distrus piesa (Figura 4).
Forjarea tuturor celorlalte aliaje la
tempera-tura de 450°C a prezentat o umplere
suficienta a matritei.Nu au fost vizibile fisuri la
forjarea aliajelor ZK60 Cer1 si Cer2 la acesta
temperatura de procesare.Componentele forjate din
aliajele ZK60 si AZ80Y nu prezentat fisuri discrete
la cald. O fisurare mai accentuata a aparut la
piesele forjate din celelalte aliaje AZ80.
350 °C showed no cracks and sufficient filling of the
die. At the forging temperature of 400 °C hot cracks
appeared in the ZK60 Ca forging and destroyed the
part (Figure 4).
The forgings of all the other alloys showed
sufficient die filling up to a forging temperature of
450°C. No hot cracks were visible in the forgings of
the alloys ZK60 Cer1 and Cer2 at this process
temperature. The forged components of ZK60 and
AZ80Y displayed mild hot cracking. Stronger hot
cracking appeared in the forgings of the other AZ80
alloys.

4. Concluzii
A fost investigat comportamentul la
matritare al aliajelor de magneziu conventionle si
modificate. A fost demonstrat faptul ca procesul de
forjre ofera posibilitatea de a produce piese cu o
geometrie complexa.
In special testele de forjare la temperaturile
de 175°C pentru ZK60 Cer2 si 200°C pentru AZ80
Y au aratat bune rezultate.Ambele aliaje modificate
au aratat o buna formabilitate la temperaturi scazute.
Rezultatele probelor de forjare pentru
aliajele AZ80 Y si ZK60 Cer2 au aratat ca au o buna
formabilitate la temperatura scazuta precum si cea
mai larga posibilitate de procesare.
Datorită faptului că de magneziu este de
aproximativ de 35% mai uşor decât de aluminiu,
acesta oferă potenţial pentru inlocuirea aliajelor de
aluminiu din componenta automobilelor.
4. Conclusions
The behaviour of conventional and modified
magnesium alloys during closed-die forging was
investigated. It has been demonstrated that the
forging process of these alloys offers the possibility
to produce parts with a complex geometry.
Especially the forging tests at temperatures
of 175 °C for ZK60 Cer2 and 200 °C for AZ80 Y
showed good results. Both modified alloys showed
good formability at low temperatures.
The results of the forging trials show that the
alloys AZ80 Y and ZK60 Cer2 have the best
formability at low temperatures as well as the
broadest processing window.
Due to the fact that magnesium is about 35%
lighter than aluminium, it offers potential for the
substitution of aluminium alloys in automotive
components.

5. Multumiri
Proiectul MagForge este realizat in cadrul
programului Comisiei Europene “Actvitati de
cercetare orizontala de implicare a IMM-urilor” sub
numarul de contract COLL-CT-2006-03022008.
Multumiri deosebite pentru sprijinul
financiar.
5. Acknowledgments
The MagForge project is being conducted
for the European Commission within the framework
of the programme “Horizontal Research Activities
involving SMEs” under the contract number COLL-
CT-2006-03022008.
The financial support is gratefully
acknowledged.

6. References
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[2] J. Becker, G. Fischer, Manufacture and properties of extruded and forged components in magnesium wrought
alloys, Proceedings of the 11th Magnesium Automotive and End User Seminar, 2003.
[3] G. Kurz, B. Clauw, W.H.Sillekens, D. Letzig, Die-Forging of the Alloys AZ80 and ZK60, TMS, Magnesium
Technology 2009, 197–202.
[4] J. Swiostek, G. Kurz, P. A. Beaven, D. Letzig, “Die-Forging of Commercial and Modified ZK60 Magnesium
Alloys”, International Conference “Magnesium – Broad Horizons”, Saint Petersburg, 6-8 June 2007.
[5] G. Kurz, J. Swiostek, P.A. Beaven, J. Bober, D. Letzig, Die-Forging of Magnesium Materials, SAE World
Congress 2008, Magnesium Technologies, Detroit, 14-17 April 2008, 2008-01-0213.
[6] www.leiber.com.
[7] J. Swiostek, J. Bohlen, D. Letzig, K.U. Kainer, Comparison of microstructure and mechanical properties of
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