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INCLUSION MEASUREMENT AND IDENTIFICATION IN Mg-BASED ALLOYS:

APPLICATION OF THE BRIGHTIMETER TECHNIQUE

M. Paradis, A. M. Samuel, and F. H. Samuel


Département des Sciences Appliquées, Université du Québec à Chicoutimi, Chicoutimi, QC, Canada

H. W. Doty
Materials Engineering, General Motors, Pontiac, MI, USA

Copyright Ó 2017 American Foundry Society


DOI 10.1007/s40962-016-0130-7

Abstract
The present investigations were carried out on experi- recommended that the Brightimeter readings (indices)
mentally prepared AM50A and AZ91D alloys. The main should be coupled with metallographic examination. The
thrust was the application of the Brightimeter technique in main inclusions are magnesium oxides (MgO), magnesium
quantifying the concentration of the inclusions in these hydroxides (Mg(OH)x), aluminum oxides (Al2O3), spinel (a
alloys. The results show that the Brightimeter indices are mixture of MgO ? Al2O3). In some cases, pure metals such
low when the amount of oxides, i.e., MgO, Al2O3, Al2MgO4 as iron (Fe) and aluminum (Al) were also observed along
is high. Reducing the oxide concentration increases the with their oxides, i.e., FeO and Fe2O3. The use of flux as a
Brightimeter readings (indices). It is concluded that the protective agent may cause the presence of other types of
Brightimeter apparatus is an effective technique in deter- inclusions such as K, Na and Ca. The quantity of oxides
mining the metal cleanliness in terms of detecting and depends to a large extent on the inclusions initially present
measuring the inclusion content. Its sensitivity increases in the as-received alloy. Recycled alloys were found to
with the increase in the amount of inclusions. At low levels contain the maximum amount of inclusions.
of inclusion concentration, there is a noticeable fluctuation
in readings of the Brightimeter. The main parameter to be Keywords: magnesium alloys, inclusion measurements,
considered is the melting and solidification process. It is Brightimeter technique, metallography, microstructure

Introduction method is based on wet chemistry procedures and is


compatible with the fast neutron activation analysis
Sin et al.1 made a thorough review of the inclusions in Mg (FNAA) technique. The method was successfully imple-
and Mg alloys. The authors concluded that the majority of mented on a variety of primary and recycled Mg alloys.
inclusion-related issues with Mg alloys appear to originate The present paper aims at presenting the systematic cor-
with the molten Mg being exposed to moisture or oxygen. relation results obtained by the FNAA and MagOxide
This is an issue during melting, melt transfer before methods when primary and recycled Mg alloys of AZ and
pouring, and mold filling. There is a need to determine the AM series were analyzed.
Mg melt quality at all stages of the casting process. Better
understanding of the behavior of oxide films (in particular Hu and Luo3 and Lessiter and Rasmussen4 reviewed the
bi-films) within the molten metal would help determine the inclusions present in molten magnesium and potential
best foundry practices to reduce their formation and assessment techniques for their measurement. The authors
entrapment in Mg melts. concluded that none of the techniques available/investi-
gated thus far were well suited for use in molten magne-
A new method named ‘‘MagOxide’’ aiming at evaluating sium. It appears that vacuum and pressure filtration
the MgO and Al–Mn–Fe intermetallics in magnesium techniques are more suitable for adaptation to molten Mg
alloys was developed by Bronfin and Moscovitch.2 This for small- to medium-sized Mg foundries with limited

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Figure 1. (a) Schematic diagram of the Brightimeter apparatus.6 (b) Schematic diagram of the mold for casting the
Brightimeter sample.6 (c) Casting used for inclusion measurements. (d) Metallic mold casting for preparation of
the Brightimeter samples.

Table 1. Chemical Composition of the Experimental Mg– smaller Fe-based intermetallic inclusions. Whereas ZE41A
Al–Zn Alloys Used in the Present Study alloy was susceptible to many small inclusions, AZ91D
Alloy code Mg% Al% Zn% Mn% alloy was more susceptible to few large inclusions. The
film-type inclusions for ZE41A would tend not to
AM50A 95.56 4.00 0.44 0.13 agglomerate and are reasoned to be not as harmful as the
AZ91D 90.00 9.00 1.00 0.26 agglomerated and faceted particle-type inclusions with
large surface area observed in the AZ91D alloy.

manpower. Elsayed et al.5 studied inclusions in permanent Haerle6 proposed a simple technique to measure and
mold cast magnesium ZE41A and AZ91D alloys. Their quantify the amount of inclusions in Mg-based alloys. The
results show that the fracture surfaces of the ZE41A alloy principal idea of this technique is that the incident light on
contained film-type Mg–O-based inclusions, whose poor any metallic surface is reflected, absorbed or diffracted by
interface with the matrix was likely the source of fracture. the surface of the metallic object. The instrument used by
The AZ91D alloy fracture surfaces contained mostly par- Haerle is registered under the commercial name Techni-
ticle-type Mg–Al–O spinel inclusions, as well as few dyne BrightimeterTM, model A4M. Figure 1a is a

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schematic of the proposed apparatus, Figure 1b and 1c
shows the mold required to produce the sample for inclu-
sion analysis and an example of the fractured sample.

Commercially speaking, the AZ91D alloy is very popular in


the magnesium industry due its high mechanical and physical
properties in addition to its excellent castability. On the other
hand, the AM50A alloy is characterized by its high ductility
compared to that offered by the AZ91D alloy.7–9 Grebetz
et al.10,11 and Oymo et al.12 studied the different types of oxide
films in Mg alloys. The authors classified the oxides as being
either ‘‘lacy’’ type (continuous films) or ‘‘snaky’’ type (inter-
cepted thick films). The presence of porosity in the examined
alloy samples would significantly affect the Brightimeter
readings if the porosity was mixed/combined with the oxide
films. Kimura et al.13 concluded that if recycled Mg alloys are
used instead of virgin materials, the energy consumed is only
about 4% of that used to obtain Mg from seawater or ore,
because pre-processing is not required. It is expected in the
near future that there will be a method to remove the non-
metallic inclusions from the recycled alloys.14
Figure 2. Set-up for melting and casting of Mg alloys.
The present study was therefore carried out to investigate
the capacity of the Brightimeter technique in assessing and
measuring the inclusions found in these two alloys.

Experimental Procedure

Table 1 shows the chemical composition of experimental alloys


used in the present study. Pure Mg, Al, and Zn were used as base
metals. Manganese was added in the form of Al–25%Mn master
alloy. Melting was carried out in a mild steel crucible of 25-kg
capacity. The crucible was placed in an electrical resistance
furnace. The surface of the molten alloys was protected from
oxidation using a special gas (i.e., a mixture of dry air [78% N2
and 22% O2], CO2 and SF6) as shown in Figure 2.

The liquid alloy was maintained at 700 °C prior to casting


Figure 3. Brightimeter apparatus. in a metallic mold preheated at 200 °C—see Figure 1d.

Figure 4. (a) Distribution of the Brightimeter readings in 100% fresh alloy. (b) Distribution of the Brightimeter
readings in 100% recycled alloy.

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The casting was mainly used for microstructural charac- Results and Discussion
terization as well as chemical analysis. Figure 3 shows the
Brightimeter apparatus used in the present study. For each Brightimeter Measurements
alloy, 15 samples were prepared using either 100% fresh
alloy or a mixture of fresh and recycled alloys to vary the In the present study, the term ‘‘dross’’ indicates that the
amount of inclusions. The fractured surface, Figure 1c, was molten metal was poured without skimming the surface. At
placed on top of the machine and rotated 10 times, at certain instants, the protective gas was shut down in the
intervals of 36 degrees each and the reading obtained at melting crucible as well as in the casting mold during
each position. The average of the ten readings was con- sampling, in order to vary the amount of oxides. Another
sidered in analyzing the data. It should be mentioned here way to vary the amount of inclusions is through the use of
that higher readings/values indicate cleaner melts. mechanical stirring for 60 s using a mild steel impeller
rotating at 120 rpm—Figure 2.
Since the grain size could be an important factor, metallo-
graphic samples from the cast alloys were also prepared. The Figure 4a shows the distribution of the Brightimeter
polished surfaces were etched in a solution composed of cleanliness index as a function of the sampling procedure
80 ml water, 10 ml ethanol, 10 ml acetic acid and 3 g of obtained from the experimental AM50A alloy. It is evident
citric acid. The samples were etched for 10–30 s followed by that since the molten metal was 100% fresh and was under
thorough washing prior to grain-size measurements. The dynamic gas protection, the variation in the Brightimeter
microstructures were examined by means of a Leica DM LM readings is more or less stable around 47 regardless of the
optical microscope. The grain-size measurements were source of the examined sample. In the case of using 100%
carried out using an optical microscope with image analysis recycled AM50A alloy, Figure 4b, with the variation in the
software. The grain size (represented by the average grain amount of oxides in the liquid metal, the distribution of
length, lm) was obtained from the average of 200 mea- Brightimeter indices is divided into three parts: the dross
surements taken over 20 fields (10 measurements per field) at with no gas showing severe fluctuation between 20 and 40
1009 magnification for each alloy sample. Phase identifi- (average around 27), dross with protecting gas where the
cation was carried out using an electron probe microanalyzer fluctuation in the readings is lesser than in the previous
(EPMA) in conjunction with energy-dispersive X-ray anal- case, with an average around 37. In the case of vigorously
ysis (EDX) and wavelength-dispersive spectroscopic anal- stirred metal, the average is about 22, regardless of the
ysis (WDS) where required, integrating a combined JEOL protection of the melt surface, i.e., with or without pro-
JXA-8900l WD/ED microanalyzer operating at 20 kV and tecting gas. The experimental AZ91D exhibited similar
30 nA, where the size of the spot examined was *2 lm. results as the AM50A alloy, as shown in Figure 5a. Due to

Figure 5. (a) Distribution of the Brightimeter indices in 100% fresh AZ91D alloy. (b) Distribution of the
Brightimeter indices in 100% recycled AZ91D alloy. Arrows indicate the possibility of large chunks of oxides.

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the presence of a large amount of aluminum in this alloy from the AZ91D was melted and used for casting, as
(approximately 9%), it is expected that the amount of illustrated in Figure 5b, where values as low as 18 were
oxides in the AZ91D alloy should be more than that frequently reported especially when the alloy melt was
reported for the AM50A alloy, as is evident from the sig- mechanically stirred (arrowed).
nificant fluctuation in the Brightimeter readings (between
32 and 53) as shown in Figure 5a. The fluctuation in the Figure 6 illustrates the relationship between the percentage
Brightimeter readings became more severe when scrap of inclusions measured by the image analyzer system and

Figure 6. Percentage of inclusions-Brightimeter index relationship in: (a) AM50A alloy, (b) AZ91D alloy.

25
Dirty
25 fields 100 fields 200 field
20
% Inclusions

15

10

5
Clean

0
1 2 3 4 5 6 7 8 9 10 11 12 13
Sample #

Figure 7. Dependence of the percentage of inclusions


value obtained based on the number of fields measured Figure 8. Effect of alloy composition on the Brightimeter
for the samples examined. index values obtained.

Figure 9. Backscattered electron images of: (a) AM50A alloy and (b) AZ91D alloy.

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(a) (b)
140 56
1 2 140 56
130 54
130 54

Average grain size (µm)


52
Average grain size (µm)
120 52
120

Brightimeter index
50

Brightimeter index
110 50
110
48 48
100 100
46 46
90 90
44 44
80 80
42 42
70 40 70 40
60 38 60 38
50 36 50 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Samples # Samples #

Figure 10. Average grain-size-Brightimeter index relationships in: (a) AM50A alloy and (b) AZ91D
alloy. Note #1 is grain size, and #2 is Brightimeter Index.

Figure 11. Optical micrographs showing examples of the types of oxide films
observed in the AM50A alloy: (a) snaky type oxides, (b) long oxides and AZ91D
alloy, (c, d) mixtures of porosity (arrowed a) and oxide films (arrowed b).

the corresponding Brightimeter readings. In the case of the AZ91D alloy, Figure 6b, the relation between the results
AM50A alloy, the percentage of inclusions obtained for the from the two methods of measurements is linear rather than
various samples examined is spread over a wide range. parabolic. However, it should be noted that for both
Two mathematical correlations were applied, linear and regression methods, the fitting coefficient is \0.8.
parabolic. It is clear from Figure 6a that the relationship
between the two methods is parabolic rather than linear, Another parameter to be considered in using the image
due to the presence of large amounts of oxide films of analyzer system is the number of measured fields. In the
different sizes caused by the increase in the aluminum case of highly contaminated (dirty) alloys, an examination
content. These results are in good agreement with the of at least 200 fields at 1009 are required to obtain a
findings reported by Grebetz et al.10,11 Considering the reliable value, which may not be necessary in the case of

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Figure 12. Element distribution in an inclusion in the experimental AM50A alloy.

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Table 2. WDS Analysis of the Salt Particle in Figure 12 therefore less Mg–Al–Zn phases, it appears brighter and
higher on the Brightimeter index.
AM50A wt% at.%

O 32.3 60.7 Figure 10 illustrates the effect of the grain size on the
Brightimeter readings. As may be seen, the grain size has
K 6.7 5.1
no specific role in controlling the Brightimeter index value.
Mn 6.4 3.5
In the event that the grain size is large—which may affect
Ti 25.9 16.3 the reflecting light beam, with rotation of the sample every
Fe 25.5 13.8 36 degrees, this effect becomes negligible.
Total 97.4 100.0

Types of Inclusions
clean metal. In the present study, all reported values were Optical Microscopy
obtained by examining 200 fields in each case/sample.
Figure 7 shows how the percentage of inclusions observed In order to arrive at a better understanding of the rela-
in a particular sample can vary, depending on the number tionship between the amount of inclusions and the corre-
of fields measured. sponding Brightimeter indices, metallographic samples
were prepared from both ‘‘clean’’ and ‘‘dirty’’ samples.
One of the main concerns in the use of the Brightimeter Figure 11a and 11b shows examples of the oxide films
technique is the role of the alloy composition on the surface observed in the two alloys termed ‘‘clean’’—Brightimeter
brightness of the alloy sample. The variation in the Al and Zn indices around 52–58. Figure 11c and 11d reveals a mix-
content changes the gray level of the Mg–Zn–Al phase and ture of porosity and massive oxide films in samples termed
hence the Brightimeter index for the level of inclusions. This ‘‘dirty’’—Brightimeter indices around 32–35.
observation is well illustrated in Figure 8 which shows the
Brightimeter index values for 100 samples covering 5 levels
Electron Probe Microanalyzer
of Al content. It is evident from this figure that most of the
points are segregated around an index value of 55—see
AM50A Alloy
circled area. At a low level of aluminum, the fractured sur-
face is bright, resulting in the high index values observed. As
for alloys containing 14% Al, the fractured surface is rather All electron micrographs presented in this section were
gray which is reflected in the corresponding Brightimeter taken from ‘‘dross’’ samples with Brightimeter indices in
readings. Figure 9 shows the size and distribution of the Mg– the range of 27–35. During the fabrication process of pure
Zn–Al phase particles observed in the AM50A and AZ91D Mg, certain amounts of salt may be trapped in the liquid
alloys. Since the AM50A alloy has less Al content and metal and remains after solidification. Figure 12 shows an

Figure 13. EDS spectrum corresponding to the backscattered image in Figure 12a.

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Figure 14. Element distribution in Fe oxides—note the difference in the Fe intensity in both areas.

Table 3. WDS Analysis of Phase Marked 1 (a), Marked 2 oxides. Taking into consideration that the crucible used for
(b), Marked 3 (c) in Figure 14 melting is made of mild steel, thus a piece of Fe may have
fallen in the liquid metal prior to pouring in the metallic
AM50A wt% at.% mold.Figure 13 shows the EDS spectrum corresponding to
(a) the backscattered image in Figure 12a. Figure 14 illustrates
an example of Fe-based oxides observed in the
O 24.3 53.2
generic AM50A alloy. The WDS analysis listed in
Fe 73.9 46.4 Table 3a–c identifies these oxides as FeO, Fe2O3 and Fe,
Total 98.6 100.0 respectively.
(b)
O 25.2 57.6 Magnesium has a higher affinity to react with oxygen than
Fe 60.8 39.8 aluminum as shown in Figure 15.15 Figure 16 is a good
Total 88.2 100.0
example illustrating this statement. Table 4a shows the
chemical analysis of area marked A. The WDS analysis of
(c)
area ‘‘B’’ in Figure 16 is shown in Table 4b which is
O 0.7 2.4 mainly MgO-Al2O3 (spinel). The absence of Al in area
Fe 98.3 97.0 ‘‘C’’ in Figure 16 indicates that the composition of this
Total 99.3 100.0 phase is only MgO. The associated WDS analysis pre-
sented in Table 4c reveals that the total weight percentage
of the elements in this phase is less than 100%. Thus, it
example of a salt particle observed in the experimental may be reasonable to assume that the chemical composi-
AM50A alloy, whereas Table 2 lists its chemical compo- tion of this phase is rather Mg(OH).
sition revealing a mixture of oxides, including Fe-based

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Figure 15. Ellingham diagram for several metals giving the free energy of formation
of metal oxides and the corresponding oxygen partial pressure at equilibrium.15

Figure 17 displays a mixture of oxides in the AM50A long. It should be mentioned here that no vigorous
alloy. The backscattered image is divided into four areas mechanical stirring was applied at any stage of the work.
according to their gray level. The presence of Mg and O Also, the molten metal was kept under dynamic protective
only indicates that areas A and D are MgO. The black area gas during the melting and solidification processes.
marked ‘‘B’’ is a pore as evidenced from the absence of any
element, whereas the matrix (marked C) is mainly Mg. Figure 21 reveals the presence of a massive ‘‘chunk’’ of
Figure 18 displays the presence of a shrinkage network. oxides in the dross. The colored map shows that the area
The colored map reveals high oxygen and magnesium marked ‘‘A’’ contains Al, Mg and O2 which indicates that it
intensities within these cavities. Also, their surfaces are is spinel (Al2MgO4).16 Area B contains only Mg and O2
rough compared to the surrounding Mg matrix. giving rise to the formation of MgO. Area marked ‘‘C’’
contains Ca, O2 and Al makes it possibly CaOAl2O3.
Figure 22 shows the presence of some amount of Ca
AZ91D Alloy compounds. Since Ca was never introduced during the
melting process, thus the only source is the flux used for the
Figure 19 demonstrates the distribution of the elements in a production of the Mg used in the study. Calcium by itself
group of MgO bi-films observed in the experimental AZ91D may be from the primary magnesium production method.
alloy. Both Al and Zn show more or less similar intensity. KCl, on the other hand, is from flux contamination (i.e.,
Figure 20 shows that MgO can as well precipitate in the form improper settling prior to transfer from the refining process
of bulky or massive areas almost 200 lm wide and 1000 lm to the casting process).

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Figure 16. Element distribution in oxide film observed in the AM50A alloy.

Table 4. WDS Analysis of Areas Marked ‘‘A’’, ‘‘B’’ and ‘‘C’’ Summary
in Figure 16
The fluctuation in the Brightimeter index values is low
AM50A wt% at.% when highly contaminated samples are used. With the
(a)
increase in the sample level of cleanliness, the scatter in the
Brightimeter readings is relatively high. All alloys behave
O 2.5 4.7
in the same manner and may be divided into two cate-
Mg 1.7 1.8 gories, corresponding to clean and dirty melts. The
Al 96.6 93.5 microstructure and hence the gray level of the reflecting
Total 101.7 100 sample surface is an important parameter to consider when
(b) using the Brightimeter technique. Thus, a metallographic
O 19.9 27.4 study should be carried out simultaneously to support the
former. The Brightimeter technique is insensitive to the
Mg 67.7 61.3
presence of porosity when the latter is mixed with oxide
Al 12.4 10.1
films. Grain size, as such, has no specific bearing on the
Total 102.0 100.0 Brightimeter readings.
(c)
O 59.0 70.7 The principal inclusions existing in fresh (i.e., un-recycled)
Mg 36.9 29.1 alloys are MgO and Mg(OH), Al2O3 or a regrouping of
Total 96.3 100.0 oxides such as Al2O3MgO. In some cases, metal oxides
(FeO, Fe2O3) may form from either the steel crucible or

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Figure 17. Element distribution in magnesium oxides.

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Figure 18. Element distribution in shrinkage cavities.

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Figure 19. Element distribution of oxide bi-films.

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Figure 20. Element distribution in bulky (massive) oxide.

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Figure 21. Element distribution in spinels in the dross.

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Figure 22. Element distribution in the flux in the dross.

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metallic tools. Salt particles (K, Na, Ca) from the flux used 8. Standard Specification for Magnesium Alloys in Ingot
in the production of the pure Mg may be observed. Form for Sand Castings, Permanent Mold Castings and
Die Castings, ASTM B93/B93M-94B, Annual Book of
ASTM Standards, Vol. 02, American Society for
Acknowledgements
Testing and Materials, Philadelphia, PA, 1995
The authors would like to thank Dr. Carlton Fuerst, 9. A. Stevenson, Melting the Aerospace Challenge with
Chief Scientist, General Motors Canada, for suggesting Magnesium Casting Alloys, in Light Metals 1987, ed.
the topic of this study. The authors would also like to by R.D. Zabreznik (The Minerals, Metals & Materials
thank Amal Samuel for enhancing the quality of the Society, Warrendale, 1987), pp. 861–870
images presented in the present article. 10. J.M. Tartaglia, J.C. Grebetz, Observations of Inter-
metallic Particle and Inclusion Distributions in Mag-
nesium Alloys, in Magnesium Technology 2000, ed. by
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