The effect of solution treatment time on the microstructure and mechanical properties of aged the Mg-2.0Nd-2.0Sm-0.4Zn-0.4Zr (wt.%) alloy were investigated to give full play to the performance of the alloy. As the solution treatment time increased from 2 h to 12 h at 788 K, the grain size of the solution-treated alloy significantly increased, and the network-like β-Mg₁₂(Nd, Sm, Zn) phase gradually dissolved into the α-Mg matrix. It should be noted that no obvious residual β phase can be observed when the solution treatment time was more than 8 h. After the solution-treated alloy was further aged at 473 K for 18 h, a large number of nanoscale precipitates were observed in the α-Mg matrix. The solution treatment time was 2 h, the α-Mg matrix mainly consisted of spherical-shaped and basal plate-shaped precipitates. Upon the increase of solution treatment time to 8 h, the key strengthening phases transformed from spherical-shaped precipitates and basal plate-shaped precipitates to prismatic plate-shaped β′ precipitates. The orientation relationship between β′ precipitates and α-Mg matrix was ($\overline{1}$10)_β′ // (1$\overline{1}$00)_α and [112]_β′ // the [22$\overline{4}$3]_α. Further increasing of solution treatment time from 8 h to 12 h, the key strengthening phases mainly were still β′ precipitates. The solution treatment of aged alloy was carried out at 788 K for 8 h, which achieved optimal ultimate tensile strength (UTS) of 261 ± 4.1 MPa, yield strength (YS) of 154 ± 1.5 MPa, and elongation of 5.8 ± 0.1%, respectively.

Strengthening Mg alloys with rare earth elements has been a research focus for several decades. To minimize the usage of rare earth elements while enhancing mechanical properties, we adopted the strategy of alloying with multiple rare earth elements, namely Gd, Y, Nd, and Sm. Additionally, to promote the precipitation of basal precipitate, Ag and Zn doping was also induced. Thus, we designed a new cast Mg-2Gd-2Y-2Nd-2Sm-1Ag-1Zn-0.5Zr (wt.%) alloy. The microstructure of the alloy and its relevance to mechanical properties in various heat treatment conditions were investigated. After undergoing a heat treatment process, the alloy demonstrated exceptional mechanical properties, with a yield strength of 228 MPa and an ultimate tensile strength of 330 MPa achieved through peak-aging for 72 h at 200 °C. The excellent tensile properties are due to the synergistic effect of basal γ″ precipitate and prismatic β′ precipitate. In its as-cast state, its primary mode of fracture is inter-granular, whereas in the solid-solution and peak-aging conditions, the predominant mode of fracture is a mixture of trans-granular and inter-granular fractures.

The effects of pretreatment and homogenization on the microstructure of a new Al-6.7Zn-2.6Mg-2.0Cu-0.1Zr-0.3Sm alloy were investigated. The results show that severe dendritic segregation is visible at the grain boundaries of the as-cast microstructure, which consists of the η (Mg (Zn, Cu, Al)₂), Al₁₀Cu₇Sm₂ and Fe-rich phases. Besides, some small η and needle-shaped θ (Al₂Cu) phases are distributed inside of the grains. After pretreatment at 400 °C for 10 h, the η phase and θ phase in the grains are dissolved, and Al₃Zr particles are precipitated inside of the grains by homogeneous nucleation. However, dendritic segregation still exists at the grain boundaries. After homogenization annealing, the η phase present at the grain boundaries completely dissolves, and only a small number of Al₁₀Cu₇Sm₂ and Fe-rich phases remain. The alloy microstructure becomes more uniform and the volume fraction of residual eutectic decreases to 0.70% after homogenization annealing. The optimal homogenization processing is determined as 400 °C/10 h + 470 °C/24 h, which is in perfect accordance with the results obtained via homogenizing kinetic analysis.

In this study, the synergistic effects of Y and Nd on the grain refinement of the as-cast Mg-Y-Nd-Al alloy was investigated by varying Y and Nd contents while fixing their total content (Y + Nd) at 7%. When the contents of Y and Nd were 3% and 4%, respectively, the refinement was most effective and the smallest grain size of 49 ± 5 μm was achieved. The grain refinement process was primarily controlled by the heterogeneous nucleation and the growth restriction factor (Q value). Y could only form Al₂RE phase with Al, while both Al₂RE and Al₁₁RE₃ were formed between Nd and Al. The Al₂RE phase acted as nucleation particles of α-Mg and facilitated heterogeneous nucleation; however, Al₁₁RE₃ was an unfavorable phase for heterogeneous nucleation. When the Y content was less than 3%, the quantity of Al₂RE phase increased when more Y was available, which resulted in more active nucleation particles and better refinement. When the Y content exceeded 3%, the Q value (growth limiting factor) of the alloy decreased, while the quantity of Al₂RE phase remained unchanged. This would lead to a decreased number of active nucleation particles and a less effective grain refinement.