Fatigue life improvement of cast ZK60 Mg alloy through low temperature closed-die forging for automotive applications

The influence of low-temperature closed-die forging on the quasi-static and cyclic behaviour of as-cast ZK60 magnesium alloy was investigated. As-cast ZK60 billets were forged at a ram speed of 20 mm/sec and a temperature of 250 degrees C. While the yield strength of the starting alloy was 139 MPa, the forging process improved the yield strength significantly by similar to 68% to 234 MPa. Moreover, the stress-controlled push-pull fatigue tests at the stress amplitudes of 140 MPa to 180 MPa revealed that the fatigue life was enhanced by an order of magnitude. Microstructural analyses besides the texture measurements at different locations of the forged part manifested partial grain refmement and texture modification strengthening mechanisms. It is believed that the fatigue life improvement is achieved in the wake of the grain refmement and the subsequent material strengthening.