This work was focused on revealing the relation between the microstructure and corrosion dynamics in dilute Mg_97.94Zn_0.56Y_1.5 (at.%) alloys prepared by the consolidation of rapidly solidified (RS) ribbons. The dynamics of the corrosion were followed by common electrochemical methods and the acoustic emission (AE) technique. AE monitoring offers instantaneous feedback on changes in the dynamics and mode of the corrosion. In contrast, the electrochemical measurements were performed on the specimens, which had already been immersed in the solution for a pre-defined time. Thus, some short-term corrosion processes could remain undiscovered. Obtained results were completed by scanning electron microscopy, including analysis of a cross-section of the corrosion layer. It was shown that the internal strain distribution, the grain morphology, and the distribution of the secondary phases play a significant role in the corrosion. The alloys are characterized by a complex microstructure with elongated worked and dynamically recrystallized α-Mg grains with an average grain size of 900 nm. Moreover, the Zn- and Y-rich stacking faults (SFs) were dispersed in the grain interior. In the alloy consolidated at a lower extrusion speed, the homogeneous internal strain distribution led to uniform corrosion with a rate of 2 mm/year and a low hydrogen release. The consolidation at a higher extrusion speed resulted in the formation of uneven distribution of internal strains with remaining high strain levels in non-recrystallized grains, leading to inhomogeneous growth and breakdown of the corrosion layers. Therefore, homogeneity of the internal strain distribution is of key importance for the uniform formation of a protective layer.

Mg-Y-Zn-Al alloys processed by the rapidly solidified ribbon consolidation (RSRC) technique are candidate materials for structural applications due to their improved mechanical performance. Their outstanding mechanical strength is attributed to solute-enriched stacking faults (SESFs), which can form cluster-arranged layers (CALs) and cluster-arranged nanoplates (CANaPs) or complete the long-period stacking ordered (LPSO) phase. The thermal stability of these solute arrangements strongly influences mechanical performance at elevated temperatures. In this study, an RSRC-processed Mg—0.9%, Zn—2.05%, Y—0.15% Al (at%) alloy was heated at a rate of 0.666 K/s up to 833 K, a temperature very close to melting point. During annealing, in situ X-ray diffraction (XRD) measurements were performed using synchrotron radiation in order to monitor changes in the structure. These in situ XRD experiments were completed with ex situ electron microscopy investigations before and after annealing. At 753 K and above, the ratio of the matrix lattice constants, c/a, decreased considerably, which was restored during cooling. This decrease in c/a could be attributed to partial melting in the volumes with high solute contents, causing a change in the chemical composition of the remaining solid material. In addition, the XRD intensity of the secondary phase increased at the beginning of cooling and then remained unchanged, which was attributed to a long-range ordering of the solute-enriched phase. Both the matrix grains and the solute-enriched particles were coarsened during the heat treatment, as revealed by electron microscopy.

The Mg-Y-Zn magnesium alloy system is known for the presence of Long-Period Stacking Ordered (LPSO) phases that improves strength and ductility with minimal amounts of alloying elements. Even better improvements are associated with the specific microstructure known as the Mille-Feuille structure (MFS) that can occur in this alloy as well after proper heat treatment. This study systematically compares the traditional ingot metallurgy method with the Bridgman method (slow cooling), coupled with diverse heat treatments and extrusion process. Microscopic analyses reveal variations in the presence of LPSO phases, Mille-Feuille structure, and especially grain size, leading to divergent mechanical and corrosion properties. The Bridgman approach surprisingly stands out, ensuring superior mechanical properties due to kink and texture strengthening.