Revealing the Microstructural Aspects of the Corrosion Dynamics in Rapidly Solidified Mg-Zn-Y Alloys Using the Acoustic Emission Technique

This work was focused on revealing the relation between the microstructure and corrosion dynamics in dilute Mg97.94Zn0.56Y1.5 (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 alpha-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.