Effect of process parameters on microstructure and properties of AM50A magnesium alloy parts formed by double control forming

Effects of process parameters on microstructure and mechanical properties of the AM50A magnesium alloy components formed by double control forming (DCF) were investigated via a four-factor and four-level orthogonal experiment. The variable curves of DCF showed that the forging procedure was started in the following 35 ms after the injection procedure was completed. It was confirmed that the high-speed filling and high-pressure densifying were combined together in the DCF process. Better surface quality and higher mechanical properties were achieved in the components formed by DCF as compared to die casting (DC) due to the refined and uniform microstructure with a few defects or without defects. Injection speed affected more effectively the yield strength (YS), ultimate tensile strength (UTS) and elongation as compared to pouring temperature, die temperature and forging force. But the pouring temperature had a more significant effect on hardness as compared to injection speed, die temperature and forging force. Pouring temperature of 675 °C, injection speed of 2.7 m/s and forging force of 4000 kN except for die temperature were the optimal parameters for obtaining the highest YS, UTS, elongation and Vickers hardness. Die temperatures of 205, 195, 195 and 225 °C were involved in achieving the highest YS, UTS, elongation and Vickers hardness, respectively. Obvious microporosity and microcracks were found on the fracture surface of the components formed by DC, deteriorating the mechanical properties. However, the tensile fracture morphology of the components formed by DCF was characterized by ductile fracture due to a large number of dimples and no defects, which was beneficial for improving the mechanical properties.