Journal of Materials Processing Technology 145 (2004) 134141

Process optimisation for a squeeze cast magnesium alloy

M.S. Yong
a,
, A.J. Clegg
b
a
Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore
b
Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University,
Loughborough, Leicestershire LE11 3TU, UK
Accepted 28 July 2003
Abstract
The paper reports the inuence of key process variables on zirconium-free (RZ5DF) and zirconium-containing (RZ5) magnesiumzinc
rare earths alloys by examination of the microstructure and mechanical properties of specimens produced by squeeze casting. Applied
pressures from0.1 to 120 MPa were considered and it was established that an applied pressure greater than 40 MPa was required to suppress
the formation of microporosity. Increasing the applied pressure from 0.1 to 60 MPa, produced a reduction in cell size from 127 to 21 m.
The metal pouring and die temperatures considered in the investigation were within the range of 720780 and 225275

C, respectively. It
was established that the intermediate die temperature of 250

C produced the highest tensile properties and that the presence of zirconium
did not improve the as-cast properties of the squeeze cast alloy. The highest UTS value obtained for the zirconium-free RZ5DF alloy was
198 MPa compared to 195 MPa for the ZR5 alloy. These UTS value were approximately 50% higher than those for material cast under
atmospheric pressure.
2003 Elsevier B.V. All rights reserved.
Keywords: Magnesium alloys; Squeeze casting; Mechanical properties; Grain renement
1. Introduction
Magnesium alloys have properties that make them attrac-
tive for certain applications. However, even complex alloys
have limitations in respect of strength, stiffness and abra-
sion resistance. It is possible that these limitations can be
overcome by using metal matrix composites (MMC) with
a magnesium-based alloy. Although several manufacturing
processes can be used to produce such composites, the cast-
ing route is especially attractive given its ability to produce
complex shapes. However, in order to obtain the benets
of reinforcement, the casting process must deliver castings
that are free of defects such as gas or shrinkage porosity.
Squeeze casting is capable of delivering such castings and
consequently has been used to produce cast MMC. Before
advocating squeeze casting for MMC production, however
it is necessary to understand the inuence of process vari-
ables on the base alloy and that was the purpose of the work
described in this paper.

Corresponding author. Present address: Singapore Institute of Manu-

facturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore.
E-mail address: msyong@simtech.a-star.edu.sg (M.S. Yong).
The majority of investigations to evaluate the effect of
squeeze casting parameters have considered aluminium al-
loys and their composites. The most important parameters
in squeeze casting have been identied as melt temperature,
melt quality (i.e. the absence of oxide lms and inclusions)
and quantity, die temperature, applied pressure, and duration
of applied pressure [1,2]. In the case of composites, inltra-
tion velocity and preform temperature can be added to the
list [35]. These variables are equally relevant to magne-
sium alloys and their composites was conrmed by several
researchers [613]. A signicant difference between magne-
sium and aluminium is the formers lower volumetric heat
of fusion, which means that solidication should occur at a
faster rate [14].
An understanding of the effects of process variables is es-
sential because the structure and properties of alloys can be
optimised without recourse to expensive alloying elements
or nucleating agents [6]. This paper reports an investigation
of the inuence of zirconium grain renement, applied pres-
sure, and pouring and die temperatures on the as-cast prop-
erties of specied magnesium-based alloys. This work was
a prerequisite to that on composites that will be reported in
a future paper.
0924-0136/$ see front matter 2003 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2003.07.006
M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141 135
2. Experimental methodology
Two magnesium alloys were used: commercially avail-
able RZ5, which contains zirconium, and a zirconium-free
version (hereafter referred to as RZ5DF). Their composi-
tions are presented in Table 1.
The effect of applied pressure on the RZ5DF alloy was
rst evaluated whilst maintaining metal pouring temperature
at 750

C, die temperature at 250

C, duration of applied
pressure at 25 s, and delay before application of pressure at
4 s. Following establishment of the optimum applied pres-
sure (at 60 MPa), the inuence of metal pouring and die
temperatures was investigated whilst the applied pressure,
delay and duration were kept constant. The pouring tem-
peratures investigated were 720, 750 and 780

C and the
die temperatures were 225, 250 and 275

C. The selection
of the experimental ranges for pouring and die tempera-
tures was guided by the literature. Pure magnesium melts
at 640

C and the recommended pouring temperatures for

the alloys is 720800

C [15]. A die temperature range

of 200300

C is advocated for commercial die-casting

[1,16].
Test casting: The test casting was a rectangular plate with
a length of 126 mm, a width of 75 mm and a depth of 16 mm.
Melt processing: The alloys were melted in an electric
resistance furnace using a steel crucible, the uxless method
and an argon gas cover. The die was coated with boron ni-
tride suspended in water to protect it from excessive wear.
The alloys were cast using the direct squeeze casting pro-
cess. The squeeze casting process was described in previous
papers [17,18].
Tensile testing: Tensile tests were conducted on a 50 kN
Mayes testing machine using position control and the modu-
lus was determined using a strain gauge attached to the gauge
section parallel to the direction of tensile loading. Modied
test specimens were machined according to BS18 (1987) and
Magnesium Elektron Ltd. RB4 specications [19]. The ten-
sile properties were determined from as-cast material tested
at ambient temperature.
Hardness testing: Hardness measurements were con-
ducted using the Rockwell B scale in preference to Vickers
hardness testing as the former provided improved consis-
tency. The locations of hardness measurements conducted
on the castings are shown in Fig. 1.
Metallography: Metallographic samples were prepared
using standard techniques. Specimens were nally ground
using 1000 grit silicon carbide paper, prior to polishing
with six micron and nally 1 m diamond paste. A 5%
Table 1
Specication of magnesium alloys used in the investigation
Zinc
(%)
Rare
earths (%)
Zirconium
(%)
Magnesium
RZ5 alloy 4.2 1 0.7 Balance
RZ5DF alloy 4.2 1 Balance
Fig. 1. Locations of hardness measurements (each dot represents the posi-
tion of a hardness measurement) taken in both longitudinal and transverse
directions.
nital etchant was used for the RZ5 alloy but an aceticg-
lycol etchant was found to be necessary for the RZ5DF
alloy.
Cell size: The cell size was established using the inter-
section method. Five areas were selected at random and
twenty-one measurements of cell size were taken for each
area. The average value for the 105 readings was determined.
The results and observations from this experimental pro-
gramme are presented in the following section, which also
includes a comparison of tensile strength, material hardness
and metallographic structures.
3. Results and observations
The results are reported in the sequence that the ex-
periments were conducted. As the rst objective of the
investigation was to establish an optimum applied pressure
level, these experiments were the rst to be conducted us-
ing the zirconium-free RZ5DF alloy. Once this level had
been established, a second series of experiments was con-
ducted using the RZ5DF alloy to evaluate the inuences
of metal pouring and die temperature. A third series of
experiments was conducted using the zirconium-containing
RZ5 alloy. By comparing the results of the second and third
series of experiments, the inuence of zirconium could be
established.
3.1. Series 1 experiments: the inuence of applied
pressure
3.1.1. Tensile properties
The effects of applied pressure on the tensile proper-
ties of squeeze cast RZ5DF alloy are presented in Fig. 2.
It can be seen that the highest tensile properties were ob-
tained with an applied pressure of 100 MPa and that the
lowest were produced at atmospheric pressure (0.1 MPa),
i.e. by gravity die-casting. The graph shows that there is
a signicant increase in tensile properties as the applied
pressure is increased to 60 MPa but that after this point, a
further increase in applied pressure produces little further
improvement.
136 M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141
Fig. 2. Effects of applied pressure on the tensile properties of squeeze
cast RZ5DF alloy.
3.1.2. Hardness
The hardness values along the longitudinal and trans-
verse directions of the RZ5DF alloy castings produced
with different applied pressures are shown graphically in
Fig. 3. The results show that applied pressure appears to
have little effect on hardness, since the majority of values
fall within the range 1420 HRB. However, close inspec-
tion of the detailed hardness values of castings produced
using low applied pressures (0.1, 20 and 40 MPa) revealed
that these had the lowest hardness values. Low hardness
was expected in these castings because of the presence of
porosity.
3.1.3. Metallography
Metallography was conducted to examine the inuence of
applied pressure on the cast structure. Examination of the
RZ5DF alloy specimens produced at different applied pres-
sures revealed that a critical pressure greater than 40 MPa
was required to suppress microporosity. Selected microstruc-
tures that show the effect of applied pressure on struc-
ture are shown in Fig. 4. These are complemented by the
graphical representation of the relationship between applied
pressure and cell size presented in Fig. 5. These gures
show a pronounced reduction in cell size for squeeze cast
material.
-
-
-
-
-
-------
25
20
15
10
5
0
0.1 20 40 60 80 100 120
Applied Pressure (MPa)
R
o
c
k
w
e
l
l

H
a
r
d
n
e
s
s

(
H
R
B
)
Fig. 3. The average material hardness along the longitudinal and transverse
directions of the squeeze cast RZ5DF alloy, cast with constant pouring
temperature of 750

C and die temperature of 250

C.
3.2. Series 2 experiments: the evaluation of squeeze cast
RZ5DF alloy
3.2.1. Tensile properties
The relationships between pouring temperature, die tem-
perature and tensile properties are shown in Figs. 6 and 7.
3.2.2. Metallography
Metallographic specimens were examined to evaluate the
effects of pouring and die temperature on the RZ5DF mi-
crostructure. The examinations were conducted on speci-
mens selected from those that had the highest, intermediate
and lowest UTS values. The structure associated with the
highest UTS value is shown in Fig. 8.
3.3. Series 3 experiments: the evaluation of squeeze cast
RZ5 alloy
3.3.1. Tensile properties
The relationships between pouring temperature, die tem-
perature and tensile properties are shown in Figs. 9 and 10.
3.3.2. Metallography
Metallographic examinations were conducted to evaluate
the effects of pouring and die temperature on the squeeze cast
RZ5 microstructure. These examinations were conducted on
specimens selected from those that produced the highest, in-
termediate and lowest UTS values. Fig. 11 shows the struc-
ture associated with the highest UTS value.
4. Discussion
As in all casting processes, the rate of solidication in
squeeze casting is determined primarily by the rate at which
heat is transferred by the metal to the die. In most casting
processes, heat ow is controlled to a signicant extent by
resistance at the metalmould interface. The thickness of the
solid metal that forms is typically a parabolic function of
time, being initially very rapid and then decreasing as the
mould is heated [14]. However, in squeeze casting, the pres-
sure applied through the punch promotes an intimate con-
tact between the metal and die and this largely overcomes
the resistance to heat ow. According to Campbell [20], the
transfer of heat across the interface can be enhanced signif-
icantly in squeeze casting. For squeeze cast aluminium, the
gure may be up to 60,000 W/m
2
K compared to the more
normal values of 1001000 W/m
2
K. The heat to be trans-
ferred consists of the volumetric heat of fusion (the major
component) and the superheat. Higher pouring temperatures
increase the superheat contribution. It should be noted that
whilst the volumetric heat of fusion for magnesium is ap-
proximately 15% lower than that for aluminium, the specic
heat for the liquid metal is approximately 15% higher for
magnesium than aluminium. The temperature of the die in-
uences its capacity to absorb heat. However, it is the dies
M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141 137
F
i
g
.
4
.
O
p
t
i
c
a
l
m
i
c
r
o
s
t
r
u
c
t
u
r
e
s
f
o
r
s
q
u
e
e
z
e
c
a
s
t
R
Z
5
D
F
p
r
o
d
u
c
e
d
w
i
t
h
v
a
r
i
o
u
s
p
r
e
s
s
u
r
e
.
138 M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141
-
-
-
-
-
-
-
------
140
120
100
80
60
40
20
0
0.1 20 40 60 80 100 120
Applied Pressure (MPa)
G
r
a
i
n

S
i
z
e

(

m
)
Fig. 5. Inuence of applied pressure on the cell size of the squeeze cast
RZ5DF alloy.
---
-
-
-
-
-
-
-
-
-
205
200
195
190
185
180
175
170
165
160
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
U
l
t
i
m
a
t
e

T
e
n
s
i
l
e

S
t
r
e
n
g
t
h

(
M
P
a
)
Pouring Temp (
0
C)
720
0
C
750
0
C
780
0
C
Fig. 6. The effects of pouring and die temperatures on ambient temperature
UTS (RZ5DF alloy).
Fig. 8. Optical microstructure of the squeeze cast RZX5DF alloy with the highest UTS of 198 MPa at ambient temperature, providing an average cell
size of 18 m.
-
-
-
-
-
-
-
-
-
-
---
720
0
C
750
0
C
780
0
C
Pouring Temp (
0
C)
14
12
10
8
9
8
7
6
5
4
3
225
0
C 250
0
C
275
0
C
%

A
r
e
a

R
e
d
u
c
t
i
o
n
%

E
l
o
n
g
a
t
i
o
n
Die Temperature (degree C)
Fig. 7. The effects of pouring and die temperature on percentage elongation
and percentage area reduction of RZ5DF alloy specimens tested at ambient
temperature.
thermal diffusivity that exerts the major inuence on the rate
of solidication [14].
From the results, it would appear that the optimum ap-
plied pressure range is from 50 to 100 MPa. The low UTS
values produced by applied pressures below 40 MPa are pri-
marily the consequence of porosity present in the castings
because the pressure acting on the molten metal was insuf-
cient for its elimination (Fig. 2). As the applied pressure was
increased to 60 MPa, not only was porosity reduced, the rate
of cooling was increased and the cell size reduced with a
concomitant improvement in tensile properties. This is em-
phasised when the microstructures of castings produced by
different applied pressures, shown in Fig. 4, are compared.
An average cell size of 127 m was produced by gravity
M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141 139
--
-
-
-
-
-
-
-
-
-
205
200
195
190
185
180
175
170
165
160
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
U
l
t
i
m
a
t
e

T
e
n
s
i
l
e

S
t
r
e
n
g
t
h

(
M
P
a
)
Fig. 9. The effects of pouring and die temperature on UTS at ambient
temperature (RZ5 alloy).
-
-
-
-
-
-
-
-
-
---
12
11
10
9
8
8
7
6
5
4
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
%

A
r
e
a

R
e
d
u
c
t
i
o
n
%

E
l
o
n
g
a
t
i
o
n
720
0
C
750
0
C
780
0
C
Pouring Temp (
0
C)
Fig. 10. The effects of pouring and die temperature on percentage elongation and percentage area reduction of RZ5 alloy specimens tested at ambient
temperature.
Fig. 11. Optical microstructure of the squeeze cast RZ5 alloy with the highest UTS of 195 MPa at ambient temperature, providing an average cell size
of 21 m.
die-casting at atmospheric pressure (0.1 MPa) but the cell
size was reduced to 21 m at an applied pressure of 60 MPa,
a signicant six-fold reduction in cell size. The reduction
in cell size was attributed to the intimate contact between
the melt and die wall that promoted rapid heat transfer, as
applied pressure was increased.
Solidication is a process of nucleation and growth and
this process is inuenced by the rate at which heat is trans-
ferred which in turn inuences the structure and properties
of the casting. In squeeze casting, we might expect solidi-
cation to commence as soon as the metal contacts the die,
i.e. before pressure is applied. Once pressure is applied, heat
transfer is promoted and concurrently the temperature of
the metal increases, as predicted by the ClausiusClapeyron
equation and this might, in combination with the long
140 M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141
freezing range of the alloys, be expected to promote con-
stitutional undercooling. Such conditions are normally con-
ducive to the formation of a dendritic structure but the co-
pious nucleation promoted by the massive chilling effect of
squeeze casting [7] produces an extremely ne casting struc-
ture.
The results for the RZ5DF alloy suggest that the high-
est UTS was associated with the higher pouring temperature
(780

C) and the intermediate die temperature of 225

C. A
steep temperature gradient, a consequence of combining a
high pouring temperature with a low die temperature, should
yield a ne microstructure and produce higher mechanical
properties [2124]. Conversely, castings produced with a
shallow temperature gradient are likely to have a large uni-
form cell structure, which will generally lead to lower me-
chanical properties. However, the results for the RZ5 alloy
suggest that, although the intermediate die temperature was
still as important, the highest UTS was obtained when this
was combined with the intermediate pouring temperature
(750

C). This suggests that a severe temperature gradient is

less important because of the rening effect of the zirconium.
4.1. The role of zirconium
By comparing the results generated by the series 2 and 3
experiments, it is possible to provide a view on the need for
zirconium in a magnesiumzincrare earths alloy intended
for processing by squeeze casting. Zirconium, in excess of
its solubility limit, is used to produce a grain rening effect
when the alloy is sand cast and consequently subjected to
a relatively slow cooling rate. Zirconium in magnesium is
the most effective grain rener in commercial use [14].
However, its presence adds to the cost of the alloy and re-
quires process controls and procedures that counteract the
tendency for gravity segregation of the zirconium. It is pos-
sible that more than one mechanism is at work. However,
the most likely is a peritectic reaction in which separating
zirconium particles react with the liquid to acquire a layer of
zirconium-enriched solid solution that serves as nuclei [24].
When the number of nuclei is large, crystallisation proceeds
from a large number of points. The presence of zirconium
in magnesium produces a ne equiaxed cell structure with
typical cell sizes of 3050 m in sand castings and this
generally leads to higher mechanical properties [25].
However, the values of the cell size obtained in this in-
vestigation were in the range of 1832 m, which is al-
most half that reported above. This may be due to the speed
of solidication in a squeeze casting that is faster in com-
parison to that for sand castings. Differences in the cell
shapes were observed between castings produced with and
without the addition of zirconium. These differences can be
seen by inspecting Fig. 11 (with zirconium, i.e. RZ5 alloy)
and Fig. 8 (without zirconium, i.e. RZ5DF alloy). It can
be seen from the gures that the zirconium addition caused
the individual cells to assume a more regular and rounded
form.
Contrary to the anticipated effects of a grain renement
addition, reported in the literature [2528], the metallo-
graphic examinations did not show a signicant difference in
cell size. Castings produced with the addition of zirconium
(RZ5 alloy) contained cell sizes which ranged from 21 to
26 m whereas those without (RZ5DF alloy) contained cell
sizes ranging from18 to 32 m. The addition of zirconiumto
the RZ5 alloy had little effect because the process of squeeze
casting rened the cell structure. It can be concluded that the
use of grain renement in squeeze casting is unnecessary.
This research has shown that the cell structure can be manip-
ulated by such process variables as applied pressure, pouring
and die temperature. This conrms Chadwicks view that the
microstructure can be controlled by controlling casting vari-
ables alone and without recourse to a nucleating agent [6].
5. Conclusions
1. The pressure applied in squeeze casting promotes rapid
solidication and a rened cell structure. Increasing
the applied pressure beyond 60 MPa provided little
improvement in the tensile properties of squeeze cast
RZ5DF alloy. An applied pressure of 60 MPa was suf-
cient to eliminate all traces of shrinkage and gas porosity
within the casting. Metallographic examination of the
castings revealed that the cell size reduced from 127 to
21 m when the applied pressure was increased from
0.1 to 60 MPa.
2. It is possible to achieve comparable tensile properties
in the zirconium-free RZ5DF alloy to those in RZ5
alloy grain rened with a zirconium addition by se-
lecting appropriate processing parameters. The highest
UTS value obtained in the zirconium-free RZ5DF alloy
was 198 MPa compared to 195 MPa for the RZ5 alloy.
These values are signicantly higher (approximately
50%) than those obtained when the alloys were cast
at 0.1 MPa.
Acknowledgements
Dr. Yong gratefully acknowledges the receipt of an
Overseas Research Students Award and a Loughborough
University Research Studentship.
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