MAGNESIUM ALLOYS: TYPES, PROPERTIES AND APPLICATIONS

Magnesium alloys are well-known for being the lightest structural alloys [1]. They are made
of magnesium, the lightest structural metal, mixed with other metal elements to improve the
physical properties. These elements include manganese, aluminium, zinc, silicon, copper,
zirconium, and rare-earth metals [2].

Some of magnesium’s favourable properties include low specific gravity and a high strength-
to-weight ratio. As a result, the material lends itself to a range of automotive, aerospace,
industrial, electronic, biomedical, and commercial applications.

Here, you can learn about the various types of magnesium alloys and their designations, the
physical properties of magnesium alloys, and the applications in which magnesium alloys are
used.

Types and designation

Magnesium alloys can be categorized into two groups: cast alloys and wrought alloys.

Cast alloys are basically made by pouring the molten liquid metal into a mould, within which
it solidifies into the required shape. Common cast alloys of magnesium consist of different
amounts – but not exceeding 10% – of aluminium, manganese and zinc as principal alloying
elements. Other alloying elements have been recently used, as well, mostly to enhance creep
resistance, such as zirconium and rare-earth metals. Besides, mechanical properties of cast
alloys are augmented by heat treatments.

Wrought alloys, on the other hand, are alloys subjected to mechanical working, such as
forging, extrusion, and rolling operations, to reach the desired shape. Aluminium, manganese
and zinc are also the main alloying elements. Wrought alloys of magnesium are sorted into heat
treatable and non-heat treatable alloys.

In order to understand the compositions of the alloys, designation systems have been created
showing the alloying elements and their relative information. One of the most widely used
designation systems is the ASTM Standard Alloy Designation System. It is made of four parts,
described in the following example [3]:

Magnesium Alloy: AZ91E-T6

• First part (AZ): designates the two main alloying elements (aluminium, zinc)
• Second part (91): designates the percentage amount of the main alloying elements (9%
and 1%, respectively)
• Third part (E): differentiates alloys having the same amounts of the main alloying
elements (fifth standardised alloy with the above percentages)
• Fourth part (T6): designates the condition of the alloy (temper)
So, in the ASTM designation system, magnesium alloys are named and grouped by means of
their main alloying elements. Table 1 shows the principal alloying elements and their relative
designations.
Principal Alloying Element ASTM Designation

Manganese M

Aluminium-Manganese AM

Aluminium-Zinc-Manganese AZ

Zirconium K

Zinc-Zirconium ZK

Zinc-Zirconium-Rare Earth Metal ZE

Rare Earth Metal-Zirconium EZ

Zinc-Copper-Manganese ZC

Aluminium-Silicon-Manganese AS

Magnesium alloys are materials of interest mostly due to their high strength-to-weight ratios,
exceptional machinability and low cost. They have a low specific gravity of 1.74 g/cm3 and a
relatively low Young’s modulus (42 GPa) compared to other common alloys such as
aluminium or steel alloys [4]. They suffer, however, from brittleness and poor formability at
room temperature [4]. Their formability increases with increasing temperature, but that requires
high energy. Furthermore, studies have shown that formability can be enhanced at the expense
of strength, by weakening the basal texture of the Mg alloys [1].

Magnesium alloys are the third most popular non-ferrous casting material. The physical
properties of the alloys change based on their chemical compositions. Adding different alloying
elements would result in different properties at different conditions.

• Aluminium improves strength, hardness and ductility, facilitating the alloy’s casting
process.
• Zinc increases room-temperature strength, fluidity in casting, and corrosion resistance.
• Manganese increases the resistance of AM and AZ alloys to saltwater corrosion by
forming intermetallic compounds with iron-like metals, to be removed during melting.
• Rare earth metals help increase strength and resistance to high-temperature creep and
corrosion, and decrease porosity and weld cracking.
 • Zirconium is a strong grain refiner when added to alloys containing zinc and rare earth
metals.
• Beryllium helps decrease surface oxidation during casting and welding.
• Calcium increases grain refinement, which helps in controlling the metallurgy of the
alloy [4].

Applications

Magnesium alloys cover a wide array of applications, from automotive and aerospace
applications to electronic and biomedical uses.

Structural applications

Automotive, aerospace, industrial, and commercial applications are examples of structural

applications. The advantage of magnesium alloys to be used in such applications is their light
weight, high strength-to-weight ratio, high stiffness-to-weight ratio, castability, machinability,
and great damping [4].

• Automotive: support brackets for brakes and clutch, housing for transmission

• Aerospace: landing wheels, helicopter rotor fittings, gearbox housings

• Industrial: high-speed operating machinery, such as textile machines

• Commercial: luggage, hand tools, computer housings, ladders

Electronic applications

Electronic applications include electronic packaging, hard drive arms, cell phone and portable
media device housings. Magnesium alloys are being used instead of plastics due to their light
weight, strength and durability. They also are relatively better for heat dissipation and
protection against electromagnetic and radio frequency interference [5].

Medical applications

Portable medical equipment and wheelchairs that require light material make good use of
magnesium alloys. Also, cardiovascular stents and orthopaedic devices are potential
applications of some magnesium alloys due to magnesium’s biocompatibility and
bioabsorbability [4].