Available online at www.sciencedirect.com Surface & Coatings Technology 202 (2008) 3947 – 3953 www.elsevier.com/locate/surfcoat Surface alloying of an Mg alloy subjected to surface mechanical attrition treatment H.Q. Sun a , Y.N. Shi a,⁎, M.-X. Zhang b , K. Lu a a Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China b Division of Materials, School of Engineering, University of Queensland, St Lucia, Brisbane, Qld 4072, Australia Received 19 November 2007; accepted in revised form 7 February 2008 Available online 4 March 2008 Abstract A 100 ∼ 200 μm thick Al-enriched surface alloyed layer was formed on an AZ91D Mg alloy subjected to surface mechanical attrition treatment and diffusion coating at temperature as low as 400 °C. Transmission electron microscopy observations indicated the formation of a large volume fraction of pearlite-like lamellar microstructure within the surface alloyed layer, which was identified to be Mg17Al12 precipitates (γ phase) in Mg solid solution matrix. The Al-enriched alloyed layer enhanced the wear resistance of the alloy in comparison with the un-treated AZ91D Mg alloy substrate under the same dry sliding wear condition. Examination of the worn surface indicated that the enhanced wear resistance of the alloyed layer was mainly attributed to the strengthening effect of γ phase. © 2008 Elsevier B.V. All rights reserved. Keywords: Magnesium alloy; Surface alloying; Surface mechanical attrition treatment (SMAT); Wear resistance. 1. Introduction Nowadays, magnesium alloys are attracting great attention in automobile and aerospace industries for their potential applications in the promotion of fuel efficiency. However, magnesium alloys also suffer from low resistance to wear and corrosion, which limit their applications. Surface modification has been found to be an efficient way to improve the corrosion and wear properties of metallic materials without changing the substrate properties [1]. Surface alloying, which leads to the formation of an integrated alloyed layer on the substrate, is an efficient and reliable technique of surface modification. Some conventional technologies, such as laser and electron beam surface alloying, [2,3] have disadvantages of high cost and low efficiency. Surface alloying by diffusion coating represents an inexpensive and practical process, particularly, surface alloying of Mg alloys with aluminium is a commonly-used technique in the present. Previous experiment results [4,5] have shown that the formation of large volume fraction of Mg17Al12 intermetallic compound (γ phase) can not only increase the hardness, but can also ⁎ Corresponding author. Tel.: +86 24 23971948; fax: +86 24 23998660. E-mail address: [email protected] (Y.N. Shi). 0257-8972/$ - see front matter © 2008 Elsevier B.V. All rights reserved. doi:10.1016/j.surfcoat.2008.02.010 improve the corrosion resistance of Mg alloys, for γ phase can act as an anodic barrier to inhibit the overall corrosion of the alloy [6,7]. However, the major challenge for diffusion coating of Mg alloys is to lower the treatment temperature to avoid the effect on the microstructure and properties of the substrate. Nanocrystalline (NC) materials, structurally characterized by a large volume fraction of grain boundaries, often exhibit an enhanced atomic diffusion compared with their coarse-grained (CG) counterparts [8,9] owing to the “fast” grain boundary diffusion [10]. Surface mechanical attrition treatment (SMAT) has been proven [11,12] to be able to generate NC grains in the top surface layer of bulk materials. A low temperature nitriding process for pure iron after SMAT was reported by Tong et al. [13]. The nitriding can be achieved at temperature as low as 300 °C, which is 200 °C lower than that of the conventional nitriding process. Similarly, the diffusion temperature of chromium into the surface layer of iron can also be pronouncedly reduced by SMAT [14]. It was also recognized that SMAT can be applied to coat metals where an enhanced bonding between the substrate and the coating due to mechanical activation has been reported [15,16]. Previous work [17] showed that a 100 μm thick NC layer with an average grain size of 30 ± 5 nm was obtained in an AZ91D Mg alloy after SMAT. Our recent work [18] on surface alloying 3948 H.Q. Sun et al. / Surface & Coatings Technology 202 (2008) 3947–3953 treatment on the NC layer generated by SMAT also found that the surface alloying of the AZ91D Mg alloy had been accomplished at 380 °C, which is 50 °C lower than the reported temperatures without SMAT by using similar approach [19]. The combined process of SMAT and the surface alloying led to the formation of large volume fraction of Mg17Al12 phase within the top surface layer. However, the detailed microstructure of the surface alloyed layer remains unknown. The present work aims to characterize the microstructure of the alloyed layer by using X-ray diffraction (XRD) and transmission electron microscopy (TEM), to further understand the formation process of the alloyed layer and the effects of SMAT on the subsequent surface alloying process. The wear behaviour of the alloyed layer will also be comprehensively investigated followed by discussion on wear mechanism of the alloy layer based on scanning electron microscopy (SEM) examination of the worn surfaces. 2. Experimental The composition of the AZ91D magnesium alloy used is 8.47%Al–0.69 %Zn–0.14%Mn (wt.%) with the balance Mg. SMAT was performed at room temperature on SNC-II SMAT equipment where spherical balls are placed in a chamber vibrated by an ultrasonic vibration generator. Samples are fixed to the opposite of the generator in the chamber, the detailed setup and procedure can be found in Refs. [11,12]. As optimised previously [17], SMAT was executed for 20 min for all the samples to achieve the finest NC grains and the thickest NC layer. After SMAT, 20 × 20 × 10 mm small blocks were cut off for surface alloying. The surface alloying process is described as follows: The small blocks were buried in a powder mixture of 70 wt.% Al, 25 wt.% Al2O3 and 5 wt.% Zn in a crucible, which occupied two-thirds of the crucible. Then the crucible was topped up with a mixture of foundry sand and coke to reduce oxidation of the underlying metallic powder and alloy. Al2O3 powders were used to prevent the metallic powders from consolidating in the subsequent heating process. The surface alloying process was conducted at 400°C for 24 h to get the thickest alloyed layer [18]. To prepare TEM specimens, 0.3 mm thick slices were cut off from the alloyed surface. After mechanical grinding to 40–50 μm from the cutting side of the slices only, 3 mm-diameter discs were punched from the thin foils, which were then ion-milled in a Gatan PIPS with a small incident angle till perforation at − 40 °C to minimize the effect of temperature elevation. All TEM specimens were examined in a JEOL 2010 microscope operated at 200 kV. X-ray diffraction (XRD) analysis was carried out in a Rigaku DMAX/2400 diffractometer with an operation voltage of 40 kV using Cu-Kα radiation. SEM observations of the microstructure in the alloyed layer and the morphologies of the worn surfaces were conducted on a Quanta 600 MK2 SEM. The chemical composition scanning from the top alloyed surface to the substrate was carried out on energy dispersive X-ray spectra (EDS) attached to the Quanta 600 MK2 SEM. Hardness tests were performed along depth of the alloyed layer by using nanoindentation, which was conducted on a Nano Indenter XP (MTS) system using a diamond Berkovich indenter at a constant loading rate. The maximum load was equal to 20 mN. At least four measurements were taken under each depth. Differential scanning calorimetry (DSC) experiments were conducted on a Perkin-Elmer Pyris Ι instrument to detect the thermal stability of the SMAT AZ91D Mg alloy samples. The sensitivity of the energy measurement was about 0.01 mJ/g; the temperature of the calorimeter was calibrated by using pure In and Zn standard specimens, with an accuracy of ± 0.02 °C. Samples cut from the top surface side of the SMAT AZ91D Mg alloy with a thickness of less than 100 μm were heated in an argon atmosphere at a constant heating rate of 5 °C/min. The maximum temperature was 420 °C. The baseline for DSC curves was determined by reheating the sample at the same heating rate. Optimol SRVIII oscillating friction and wear tester was employed for wear performance examination. Experiments were conducted in a ball-on-block contact configuration at room temperature (25 °C) in air with a relative humidity of 40–50%. The balls used in the experiments were made of WC-Co composite with a hardness of Hv = 1750. The diameter of the balls was 10 mm and the size of the blocks was 8 × 8 × 3 mm. Wear tests were carried out under dry sliding condition with an oscillating stroke of 2 mm and a frequency of 5 Hz under normal loads of 5–15 N for 30 min. Wear volume loss was determined by formula raised by Qu et al. [20]. 3. Results and discussion 3.1. Microstructure of the alloyed layer Our previous work [18] indicated that the thickness of the alloyed layer is a function of surface alloying temperature and the thickest alloyed layer can be obtained at 400 °C. Two regions can be identified from the optical micrographs of the surface alloyed layer (Fig. 1(a)), the top bright region (A) and the lamellar structure region (B). XRD patterns of the top surface layer (A), 50 μm beneath the top surface (B) and 250 μm underneath the top surface (C, the substrate) indicate that C is a single-phased Mg solid solution while spectrums A and B provide evidence of the co-existence of Mg17Al12 (γ) phase and Mg solid solution in the surface alloyed layers (Fig. 1(b)). The intensity of γ phase in the top bright layer is higher than that in the lamellar structure layer, which implies that the volume fraction of γ phase in the top bright layer is possibly higher than that in the lamellar structure layer. Furthermore, irregular shaped small “island” type γ phase is observed in the top bright layer, which is different from γ phase in the lamellar layer. To further understand the atom diffusion process and the microstructure formation mechanism in the alloyed layers, EDS linear scan was carried out to investigate the chemical composition variation from the top surface to the substrate. As shown in Fig. 2, the concentration of Al in the bright layer is much higher than that in the lamellar layer, but Mg content increases dramatically across the boundary between the top bright region and the lamellar region, and is kept at a constant H.Q. Sun et al. / Surface & Coatings Technology 202 (2008) 3947–3953 3949 and the single γ phase region forms at the top surface layer. Therefore, at the late stage of the diffusion process at 400 °C, there would be two single-phase regions formed within the alloyed layer, the γ phase region at the top surface layer and the Mg–Al solid solution region between the substrate and the γ phase region. During the subsequent cooling process, Mg solid solution precipitates from the single γ phase region and forms the bright layer as shown in Fig. 1(a). Similarly, lamella γ phase precipitates in the Mg solid solution and results in the formation of the lamella region. Although the lamella region looks like a eutectic structure, in fact, it is the lamella γ precipitates in Mg matrix. Hence, the average chemical composition of the lamellar structure significantly deviates from the Mg–Al eutectic composition. Based on this understanding, the EDS results in our previous work [18], which indicated the composition of the lamellar structure is 83 at.%Mg–15.5 at.%Al–1.5 at.%Zn, can now be easily understood. Fig. 1. (a) Cross-sectional microstructure of the SMAT AZ91D Mg alloy after surface alloying treatment at 400 °C. A is the top surface alloyed layer, C is the substrate, B is the alloyed layer between A and the substrate C. (b) XRD spectrums taken from region A, B and C respectively. Formation of Mg17Al12 phase in A and B layers is obvious. in the lamellar region. The variation of Zn content is not detectable probably due to the limited resolution of EDS. These chemical composition variation and microstructure change within the surface alloyed layer can be explained based on the understanding of reaction diffusion at 400 °C during surface alloying treatment. At the early stage of the diffusion process, Al atoms with small amount of Zn atoms diffuse from the surrounding powders into the surface of AZ91D Mg alloy blocks and consequently lead to an increase in Al content in the surface and the formation of an Al concentration gradient from the surface to the substrate. As the diffusion process continues, the Al concentration within the top surface layer keeps rising and the alloyed layer is thickened. However, in order to fulfil the requirement of reaction diffusion to maintain the thermodynamic equilibrium between phases in the diffusion process, two phase regions can not be generated. Thus, according to the Al–Mg phase diagram [21], once the Al concentration in the top surface exceeds the solid solubility of Al in Mg at 400 °C (close to 13 wt.% Al), the concentration of Al dramatically increases to around 43 wt.% Fig. 2. SEM micrograph of the AZ91D Mg alloy after surface alloying treatment at 400 °C (a) and EDS linear scanning spectrum showing the variation of Mg, Al and Zn content with the distance from the surface (b). 3950 H.Q. Sun et al. / Surface & Coatings Technology 202 (2008) 3947–3953 Fig. 3. Bright field images of lamella γ precipitates in the alloyed layer (Both (a) and (b)). (c) is the corresponding SAED pattern taken from the precipitate (as indicated by the white circle in Fig. 4(b)) indicating a BCC structure of γ phase. TEM observation of the lamellar structure in the alloyed layer found the γ lamella precipitates as shown in Fig. 3(a) and (b). A selected area diffraction pattern (SAED) shown in Fig. 3(c) taken from a precipitate in Fig. 3(b) confirms a BCC structure of γ precipitate. These results are consistent with previous works [22–24] on the precipitation of γ phase in Mg–Al alloys. Fig. 4. Cross-sectional optical micrograph of the surface alloyed layer of the CG AZ91D treated at 400 °C for 24 h. For comparison, a CG sample without SMAT was surface alloyed at the same condition as used for SMAT samples. The cross-sectional optical microstructure of the surface alloyed layer (Fig. 4) illustrates that although the lamellar structure could be observed along grain boundaries, the volume fraction of γ precipitates in Fig. 4 is much less than that in the SMAT sample shown in Fig. 1(a). In fact, it is very similar to the microstructure of AZ91D Mg alloys after solution treatment and ageing [22,23], where the γ phase precipitates along grain boundaries. In addition, it is also indicated that the diffusion of Al atoms in CG Mg alloy during surface alloying treatment takes place along grain boundaries. But due to the large grain size and lack of bulk/volume diffusion, the volume fraction of the lamellar structure in the CG sample is much less than that in SMAT samples and the microstructure is discontinued. On the contrary, SMAT samples with a large volume fraction of grain boundaries in the surface layer provide more diffusion channels and the formed lamellar structure layer is continuous. Another critical question in NC materials is grain growth, i.e. thermal stability of NC grains in the surface layer. After SMAT, severe plastic deformation in the surface layer results in a metastable structure, which will recover in the subsequent annealing process. In addition, grain growth will also take place during annealing. DSC was introduced to determine the temperature at which grain growth would take place. For comparison, the original AZ91D CG sample was also detected. At a heating rate of 5 °C/min, a heat release peak appears at about 130 °C, as shown in Fig. 5, corresponding to grain growth in the NC surface layer of SMAT samples. Hence, it is impossible to avoid grain growth when the surface alloying treatment was performed at 400 °C. The results in the present work and previous work [18] also show that the actual grain sizes in the alloyed layer are in micro-meter scale rather than nano-meter scale. But, they are still much smaller than those in the substrate. Besides, it is reasonable to believe that some of the Al atoms have already diffused into the surface layer before the grain growth begins, this preceding diffusion might be quite crucial for the formation of the thick surface alloyed layer even though the grain boundary diffusion may be weakened as the grains growth begins. Hence, any approach that can suppress grain growth during surface alloying process might be able to further lower the surface alloying temperature. Fig. 5. DSC curves of the SMAT surface layer of AZ91D Mg alloy (Solid) and the CG sample (dashed) at a heating rate of 5 °C/min. The arrow in the figure indicates the exothermic heat release. H.Q. Sun et al. / Surface & Coatings Technology 202 (2008) 3947–3953 Fig. 6. Variation of hardness with depth from the top surface alloyed layer. The designated A. B. C regions correspond to those indicated in Fig. 1. The hardness of CG AZ91D Mg alloy (designated as CG) is also presented for comparison. 3.2. Hardness of the alloyed layer Hardness measurements on the cross-section of the alloyed layer from the top surface to the substrate by using nanoindentation are illustrated in Fig. 6. The average hardness of the bright layer can be as high as 3.0 ± 0.4 GPa; at the depth of 50 μm to about 200 μm, the hardness remains almost unchanged with an average value of 1.5 GPa; at the depth above 200 μm, the hardness gets down to below 1.0 GPa. These three values respectively correspond to A and B regions of the alloyed layer and the substrate C as designated in Fig. 6. The hardness variation along depth of the alloyed layer to substrate is consistent with the microstructure analysis based on XRD and EDS. The top bright layer contains a larger fraction of γ phase and thus exhibits a much higher hardness than that of the lamellar structure alloyed layer with fewer γ phases. The thickness of the two alloyed layer also corresponds quite well with the optical micrograph in Fig. 1(a). 3951 Fig. 7. Variations of the wear volume loss with the applied loads for the CG, CG400 and SMAT-400 samples at an applied load of 7 N and the sliding duration of 30 min (CG-400 and SMAT-400 respectively denotes the CG and the SMAT sample after surface alloying at 400 °C). is relatively lower than the CG sample. With the increasing of the applied load, the wear volume loss of these three samples increases, and the difference of wear volume loss between the SMAT-400 and the CG, the CG-400 gets smaller. As presented earlier, the surface alloying treatment at 400°C subsequent to 3.3. Wear behaviour of the surface alloyed layer 3.3.1. Wear volume Wear volume loss of CG samples (CG), CG samples after surface alloying at 400 °C (CG-400) and SMAT samples after surface alloying at 400 °C (SMAT-400) were determined at various applied loads on ball-on-block sliding configuration. Considering the thickness of the alloyed layer of the SMAT400 sample, the wear test were carried out at the applied load ranges from 4 to 11 N, under which the wear depth of the SMAT-400 sample is less than 150 μm. Fig. 7 illustrates the variation of the wear volume loss with the applied load for the three samples. It is evident that the SMAT-400 sample exhibits the lowest wear volume and the highest wear resistance in these three samples over the entire applied load range. When the applied load is 5 N, there is almost no detectable material loss for the SMAT-400 sample, the wear volume loss of the CG-400 sample is much higher than that of the SMAT-400, but Fig. 8. Morphologies of the typical worn surface of the CG-400 (a) and the SMAT-400 (b) sample after sliding for 30 min under a load of 7 N. 3952 H.Q. Sun et al. / Surface & Coatings Technology 202 (2008) 3947–3953 As indicated previously [25], the formation of debris in abrasion, depends on strength and hardness of materials, and in most cases, the Archard's law [26] is obeyed. This means that the wear rate (the total wear loss per unit sliding distance) is inversely proportional to the hardness of the material. Higher hardness of materials will lead to smaller wear volume loss. The hardness of the lamellar structure in the surface alloyed layer is approximately two times higher than that of the substrate. Since the SMAT-400 sample contains much more γ lamella precipitates within the alloyed layer than the CG-400 does, it exhibits much higher wear resistance than the CG-400 or the CG sample. In addition, examination on the crosssection of the CG-400 sample after sliding observed high density deformation twins underneath the alloyed layer while the twin density in the SMAT-400 sample was quite low, as Fig. 9 illustrated. This suggested that during sliding the substrate of the CG-400 sample underwent heavier plastic deformation than that of the SMAT-400 sample. In other words, the surface alloyed layer of the SMAT sample efficiently prevented the substrate from such deformation. Fig. 9. Cross-sectional optical micrographs of the CG-400 (a) and the SMAT400 (b) sample after the wear test presents the deformation twins in the substrate underneath the alloyed layer. SMAT resulted in the formation of a 100 μm to 200 μm-thick alloyed layer on the surface of the AZ91D Mg alloy, under the applied load of 5 N, sliding may undergo mainly on the top bright layer with a hardness of 3.0 GPa, as the applied load increases, the reciprocal movement will gradually get into the lamellar structure layer. Due to the existence of lamella γ precipitates within this layer, the wear resistance is pronouncedly improved in comparison with CG-400 and CG samples. The wear volume loss of the CG-400 sample is very close to that of the CG sample although the former exhibits slightly lower wear volume loss due to the formation of lamella γ phase along the coarse grain boundaries through grain boundary diffusion. However, compared with the SMAT-400 sample, the CG-400 sample presents a much lower loadbearing ability. Hence it is reasonable to conclude that surface alloying of AZ91D Mg alloy with Al as a subsequence of SMAT is an efficient approach to improve the wear resistance of the alloy. 3.3.2. Wear mechanism SEM examination on the worn surfaces of both CG-400 and SMAT-400 samples indicates a similar surface configuration within the applied load ranging from 5 to 11 N. Fig. 8 is the typical worn surface morphologies at the applied load of 7 N of both the CG-400 (a) and the SMAT-400(b) sample. Ridges and grooves that are parallel to the sliding direction imply the debris abrasive wear mechanism. The formation of the grooves is resulted from the hard asperities on the ball or/and hard particles in-between the ball and the block. The hard asperities or the hard particles plough or cut into the block and cause wear through the removal of small fragments, as a result, scratches formed on material surface. 4. Conclusions 1. Surface alloying of AZ91D Mg alloy subjected to SMAT leads to the formation of a much thicker alloyed layer than the CG sample under the same alloying condition. The alloyed layer of SMAT AZ91D Mg alloy is composed of two layers with different compositions. The top surface layer consists of γ matrix and Mg solid solution precipitates while the lamellar structure layer is composed of γ precipitates and the Mg solid solution matrix. The formation of these two layers is associated with the reaction diffusion that takes place during surface alloying process. 2. The surface alloyed layer after SMAT can efficiently improve the wear resistance of the AZ91D Mg alloys compared with the conventional CG AZ91D Mg alloys. Acknowledgements The authors are indebted to Dr. W. 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