Divorced eutectic in a HPDC magnesium-aluminum alloy

The morphology of the eutectic in a thin-wall high pressure die cast (HPDC) U-shape AM60 magnesium box was investigated by light microscope, SEM, TEM and EPMA. The extremely fast cooling rate taking place in the solidification process produces a highly segregated zone near the boundaries of small grains and a fine distribution of beta particles, which is typical of a completely divorced eutectic. It was shown that the segregated zone is coherent with the primary alpha-Mg grain core even if the increased aluminium content produces a deformation of the hexagonal crystal lattice, which was estimated through diffraction patterns (SADP). The variation of the alloying elements content through the grain boundaries was shown by means of EPMA line scanning. The beta particle composition was quantitatively investigated and the results show that, in comparison with the equilibrium phase diagram, the non-equilibrium phase boundary of the Mg17Al12 region is moved some percent towards the lower aluminium content, at the high cooling rate that occurs in high pressure die castings. The cubic structure of the beta phase was revealed by diffraction pattern. The presence of small Al-Mn particles both inside the grain and in the boundary region was also put in evidence by TEM. (C) 2004 Elsevier B.V. All rights reserved.