CN117187648A

CN117187648A - Method of forming magnesium-based alloys having bimodal microstructure and magnesium-based alloy components made therefrom

Info

Publication number: CN117187648A
Application number: CN202210607134.4A
Authority: CN
Inventors: 王聪婕; 湛弘义; M·J·劳克纳
Original assignee: GM Global Technology Operations LLC
Current assignee: GM Global Technology Operations LLC
Priority date: 2022-05-31
Filing date: 2022-05-31
Publication date: 2023-12-08
Also published as: US20230383385A1; DE102022117455A1

Abstract

The present invention provides methods of forming magnesium-based alloys having bimodal microstructure and magnesium-based alloy components made therefrom. Methods of manufacturing magnesium-based alloy components are provided. A preform of a magnesium-based alloy having a plurality of zirconium-rich domains distributed in a magnesium alloy matrix is subjected to a temperature and deformation process of ≡ about 360 ℃ that promotes selective dynamic recrystallization to produce a bimodal microstructure in the magnesium-based alloy part having a plurality of unrecrystallized regions distributed in the matrix comprising dynamically recrystallized grains. The magnesium-based alloy comprises from greater than or equal to about 2 wt.% to less than or equal to about 4 wt.% zinc (Zn) of the magnesium-based alloy, from greater than or equal to about 0.62 wt.% to less than or equal to about 1 wt.% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt.% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). Thermoformed magnesium-based alloy parts, including automotive parts, formed by these methods are also contemplated.

Description

Method of forming magnesium-based alloys having bimodal microstructure and magnesium-based alloy components made therefrom

Technical Field

The present invention relates to a method of manufacturing a magnesium-based alloy part and a thermoformed solid magnesium-based alloy part.

Background

This section provides background information related to the present disclosure, which is not necessarily prior art.

The present disclosure relates to methods of manufacturing magnesium-based alloy components, such as automotive components, by subjecting magnesium-based alloys to a thermoplastic deformation process to promote dynamic recrystallization and produce a bimodal microstructure having a plurality of unrecrystallized domains distributed in a matrix comprising dynamically recrystallized grains to improve strength and ductility.

Lightweight metal components for automotive (e.g., automotive) applications are typically made from aluminum and/or magnesium alloys. Such light weight metals can form strong and rigid load bearing members while having good strength and ductility (e.g., elongation). High strength and ductility are particularly important for vehicles such as automobiles. Although magnesium alloys are examples of light weight metals that may be used to form structural components in vehicles, in practice, the use of magnesium alloys may be limited. Although magnesium alloys may be processed by various forming techniques such as forging (extrusion) processes such as extrusion, rolling, forging, spinning (flow forming), stamping, and the like, magnesium may have relatively low strength and ductility/elongation levels compared to aluminum.

Accordingly, there is a continuing need for improved forming methods to form improved higher strength, higher ductility magnesium metal components.

Disclosure of Invention

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

The present disclosure relates to methods of manufacturing magnesium-based alloy components having a bimodal microstructure. In one variation, the method may include the step of determining the temperature of the sample by providing a sample having a temperature greater than or equal to t=650℃+ (500 x ((C) _Zr -0.6))DEGC, wherein C is _Zr Represents a concentration of zirconium (Zr) of greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% of the magnesium-based alloy,and the magnesium-based alloy further comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn), less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). The method further includes solidifying the magnesium-based alloy into a preform including a plurality of zirconium-rich domains distributed in grains of the magnesium alloy matrix. The method further includes subjecting the preform to a temperature of greater than or equal to about 360 ℃ and a deformation process that promotes selective dynamic recrystallization to produce a bimodal microstructure in the magnesium-based alloy component to form a plurality of unrecrystallized regions distributed in a matrix comprising dynamic recrystallized grains having an average size of greater than or equal to about 0.5 microns to less than or equal to about 10 microns.

In one aspect, after subjecting the preform to a temperature of greater than or equal to about 360 ℃, a plurality of nanoparticles comprising zirconium and zinc are formed, which are precursors to a plurality of non-recrystallized regions formed after the deforming process.

In one aspect, the preform is subjected to a temperature of greater than or equal to about 360 ℃ and the deformation process occurs simultaneously.

In one aspect, the casting is performed at a temperature (T) of greater than or equal to about 700 ℃ to minimize formation and settling of the plurality of zirconium-containing solid particles in the molten magnesium-based alloy.

In one aspect, the deformation process is selected from: extrusion, forging, spinning, and combinations thereof.

In one aspect, the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 3.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

In one aspect, the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 2.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

In one aspect, the magnesium-based alloy component has a plurality of unrecrystallized regions uniformly distributed in a matrix.

In one aspect, the plurality of non-recrystallized regions is greater than or equal to about 15 area percent to less than or equal to about 40 area percent of the magnesium-based alloy component and the plurality of non-recrystallized regions has an average equivalent diameter of greater than or equal to about 10 microns to less than or equal to about 100 microns.

In one aspect, at least one region of the magnesium-based alloy component has a yield strength greater than or equal to about 170 MPa and an elongation greater than or equal to about 15%.

In one aspect, at least one region of the magnesium-based alloy component has a yield strength of greater than or equal to about 185 MPa and has an elongation of greater than or equal to about 20%.

In one aspect, the magnesium-based alloy component is an automotive component.

The present disclosure also relates to a hot formed solid magnesium-based alloy part. The hot formed solid magnesium-based alloy component may include a bimodal microstructure having a plurality of unrecrystallized domains distributed in a matrix that includes dynamic recrystallized grains having an average size of greater than or equal to about 0.5 microns to less than or equal to about 10 microns. The magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg).

In one aspect, the plurality of unrecrystallized domains are uniformly distributed in the matrix.

In one aspect, the plurality of unrecrystallized domains is greater than or equal to about 15 area% to less than or equal to about 40 area% of the thermoformed solid magnesium-based alloy component, and the plurality of unrecrystallized domains has an average equivalent diameter of greater than or equal to about 10 microns nm to less than or equal to about 100 microns.

In one aspect, at least one region of the thermoformed solid magnesium-based alloy component has a yield strength greater than or equal to about 170 MPa.

In one aspect, at least one region of the thermoformed solid magnesium-based alloy component has an elongation of greater than or equal to about 15%.

In one aspect, at least one region of the thermoformed solid magnesium-based alloy component has a yield strength of greater than or equal to about 185 MPa and has an elongation of greater than or equal to about 20%.

In one aspect, the thermoformed solid magnesium-based alloy part is an automotive part.

In one aspect, the thermoformed solid magnesium-based alloy component is a wheel.

The invention discloses the following embodiments: a method of manufacturing a magnesium-based alloy part, comprising:

by heating the mixture at greater than or equal to t=650℃+ (500 x ((C) _Zr -0.6))DEGC, wherein C is _Zr Represents a concentration of greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% zirconium (Zr) of the magnesium-based alloy, and the magnesium-based alloy further comprises greater than or equal to about 2 to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg);

solidifying the magnesium-based alloy into a preform comprising a plurality of zirconium-rich domains distributed in grains of a magnesium alloy matrix; and

the preform is subjected to a temperature of greater than or equal to about 360 ℃ and a deformation process that promotes selective dynamic recrystallization to produce a bimodal microstructure in the magnesium-based alloy part to form a plurality of unrecrystallized regions distributed in a matrix comprising dynamic recrystallized grains having an average size of greater than or equal to about 0.5 microns to less than or equal to about 10 microns.

2. The method of embodiment 1, wherein after subjecting the preform to a temperature of greater than or equal to about 360 ℃, a plurality of nanoparticles comprising zirconium and zinc are formed, the nanoparticles being precursors to a plurality of non-recrystallized regions formed after the deforming process.

3. The method of embodiment 1, wherein the preform is subjected to a temperature greater than or equal to about 360 ℃ and a deformation process occurs simultaneously.

4. The method of embodiment 1, wherein the casting is performed at a temperature (T) of greater than or equal to about 700 ℃ to minimize formation and sedimentation of a plurality of solid particles comprising zirconium in the molten magnesium-based alloy.

5. The method of embodiment 1, wherein the deformation process is selected from the group consisting of: extrusion, forging, spinning, and combinations thereof.

6. The method of embodiment 1, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 3.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

7. The method of embodiment 1, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 2.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

8. The method of embodiment 1, wherein the magnesium-based alloy part has a plurality of unrecrystallized regions uniformly distributed in the matrix.

9. The method of embodiment 1, wherein the plurality of non-recrystallized regions occupy greater than or equal to about 15 area percent to less than or equal to about 40 area percent of the magnesium-based alloy component and the plurality of non-recrystallized regions have an average equivalent diameter of greater than or equal to about 10 microns to less than or equal to about 100 microns.

10. The method of embodiment 1, wherein at least one region of the magnesium-based alloy component has a yield strength greater than or equal to about 170 MPa and an elongation greater than or equal to about 15%.

11. The method of embodiment 1, wherein at least one region of the magnesium-based alloy component has a yield strength greater than or equal to about 185 MPa and has an elongation greater than or equal to about 20%.

12. The method of embodiment 1, wherein the magnesium-based alloy component is an automotive component.

13. A thermoformed solid magnesium-based alloy part comprising:

a bimodal microstructure having a plurality of unrecrystallized domains distributed in a matrix comprising dynamically recrystallized grains having an average size of greater than or equal to about 0.5 microns to less than or equal to about 10 microns, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg).

14. The thermoformed solid magnesium-based alloy part of embodiment 13, wherein the magnesium-based alloy comprises greater than or equal to 2 to less than or equal to about 3.5 wt% zinc (Zn) of the magnesium-based alloy and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

15. The thermoformed solid magnesium-based alloy part of embodiment 13, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 2.5 wt% zinc (Zn) of the magnesium-based alloy and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

16. The thermoformed solid magnesium-based alloy component of embodiment 13, wherein the plurality of non-recrystallized domains are uniformly distributed in the matrix, wherein the plurality of non-recrystallized domains occupy greater than or equal to about 15 area% to less than or equal to about 40 area% of the thermoformed solid magnesium-based alloy component, and the plurality of non-recrystallized domains have an average equivalent diameter of greater than or equal to about 10 microns to less than or equal to about 100 microns.

17. The thermoformed solid magnesium-based alloy part of embodiment 13, wherein at least one region of the thermoformed solid magnesium-based alloy part has a yield strength of greater than or equal to about 170 MPa and an elongation of greater than or equal to about 15%.

18. The thermoformed solid magnesium-based alloy part of embodiment 13, wherein at least one region of the thermoformed solid magnesium-based alloy part has a yield strength of greater than or equal to about 185 MPa and has an elongation of greater than or equal to about 20%.

19. The thermoformed solid magnesium-based alloy part of embodiment 13, wherein the thermoformed solid magnesium-based alloy part is an automotive part.

20. The thermoformed solid magnesium-based alloy component of embodiment 13, wherein the thermoformed solid magnesium-based alloy component is a wheel.

Further areas of applicability will become apparent from the description provided herein. The descriptions and specific examples in the present disclosure are for illustrative purposes only and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible embodiments and are not intended to limit the scope of the present disclosure.

FIG. 1 is a phase diagram of a magnesium-zinc-zirconium based alloy;

FIG. 2 illustrates a mechanism for forming a bimodal microstructure by dynamic recrystallization of magnesium-zinc-zirconium based alloys in accordance with certain aspects of the present disclosure;

FIG. 3 illustrates a magnesium-based alloy wheel component for a vehicle that may be formed by casting, extruding, forging, and spinning;

fig. 4A-4C. Fig. 4A illustrates an Optical Microscope (OM) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure, fig. 4B illustrates a Scanning Electron Microscope (SEM) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure, and fig. 4C illustrates an Electron Back Scattering Diffraction (EBSD) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure. The scale bar is 50 microns;

fig. 5A-5B. Fig. 5A shows a comparative magnesium-based alloy after casting, including a schematic view on the left and an optical microscope scan on the right. Fig. 5B shows an example of a magnesium-based alloy of the present invention prepared according to certain aspects of the present disclosure after casting, including a schematic view on the left and an optical microscope scan on the right. The scale bar in fig. 5A and 5B is 100 microns; and

fig. 6A-6B. Fig. 6A shows a comparative magnesium-based alloy after heat distortion, including a schematic drawing on the left and an optical microscope scan on the right. Fig. 6B shows an example of a magnesium-based alloy of the present invention prepared according to certain aspects of the present disclosure after deformation, having a bimodal microstructure, including a schematic drawing on the left and an optical microscope scan on the right. In fig. 6A and 6B, the scale bar is 100 microns.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Detailed Description

The exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth, such as examples of specific compositions, components, devices, and methods, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that the exemplary embodiments may be embodied in many different forms without the use of specific details, and that neither should be construed to limit the scope of the disclosure. In some exemplary embodiments, well-known methods, well-known device structures, and well-known techniques have not been described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, elements, compositions, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Although the open-ended terms "comprising" should be understood to be non-limiting terms used to describe and claim the various embodiments described herein, in certain aspects, the terms may be understood to alternatively be more limiting and restrictive terms, such as "consisting of … …" or "consisting essentially of … …". Thus, for any given embodiment reciting a composition, material, component, element, feature, integer, operation, and/or method step, the disclosure also specifically includes embodiments consisting of, or consisting essentially of, such recited composition, material, component, element, feature, integer, operation, and/or method step. In the case of "consisting of … …," alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations, and/or method steps, and in the case of "consisting essentially of … …," any additional compositions, materials, components, elements, features, integers, operations, and/or method steps that substantially affect the essential and novel characteristics are excluded from such embodiments, but are not included in the embodiments.

Any method steps, processes, and operations described herein should not be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as being performed in a performance order. It is also to be understood that additional or alternative steps may be employed unless stated otherwise.

When a component, element, or layer is referred to as being "on," "engaged with," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged with," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar fashion (e.g., "between …" relative "directly between …", "adjacent" relative "directly adjacent", etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated Luo Liexiang.

Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms unless otherwise specified. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially or temporally relative terms, such as "before," "after," "inner," "outer," "lower," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. In addition to the orientations shown in the drawings, spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation.

Throughout this disclosure, numerical values represent approximate measured values or range limits to encompass slight deviations from the given values and embodiments having approximately the values noted, as well as embodiments having exactly the values noted. Except in the operating examples provided last, all numerical values of parameters (e.g., amounts or conditions) in this specification (including the appended claims) should be understood to be modified in some instances by the term "about", whether or not "about" actually appears before the numerical value, and in other embodiments, the exact or exact value, or the parameter. "about" means that the recited value allows some slight imprecision (with some approximation of the exact value for this value; approximating this value approximately or reasonably; nearly) both. If the imprecision provided by "about" is otherwise not otherwise understood in the art with this ordinary meaning, then "about" as used herein refers to at least the deviations that may be caused by ordinary methods of measuring and using such parameters. For example, "about" may include deviations of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in some aspects optionally less than or equal to 0.1%. For example, if a range is specified as greater than or equal to about a to less than or equal to about B, this includes not only the range described, but also ranges greater than or equal to precise a to less than or equal to precise B, and in other embodiments ranges greater than precise a to less than precise B.

As used herein, amounts expressed in terms of weight and mass are used interchangeably unless otherwise indicated, but are understood to reflect the mass of a given component.

Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

Magnesium alloys include magnesium-zinc alloys, which include magnesium (Mg) and zinc (Zn) as well as zirconium (Zr). Such alloys may have moderate strength due to the strengthening effect of zinc (Zn). In conventional magnesium-zinc-zirconium alloys, such as ZK30 alloys and ZK60 alloys, the function of zirconium addition is for grain refinement in casting. For example, the ZK30 alloy contains the following nominal amounts (nominal amounts): about 3 wt% zinc (Zn) and about 0.5 to about 0.6 wt% zirconium (Zr), with the balance being magnesium and impurities. It is recognized that when zirconium (Zr) is added in excess of 0.5 wt%, the grain size is not further reduced although the zirconium (Zr) content is increased. Considering that zirconium (Zr) is expensive to add to magnesium alloy, the zirconium (Zr) content in magnesium-zinc-zirconium alloy is controlled in the range of 0.5 to about 0.6 wt%. Thermoformed magnesium-zinc-zirconium alloys, such as ZK30 alloys, have excellent formability but their strength tends to be unsatisfactory for use in certain applications. In conventional manufacturing processes involving casting of billets, followed by extrusion, forging, and then spinning, the final microstructure of the formed ZK30 parts may have a yield strength of only about 155 MPa and an elongation of about 13%.

According to various aspects of the present disclosure, methods of forming magnesium-based alloy components having unique bimodal microstructures are provided. The methods provided herein enable the formation of components comprising magnesium-based alloys having relatively high yield strength and relatively high elongation/ductility. The magnesium alloy is selected to have a composition that can be processed in the following manner: the manner promotes the formation of pre-solidified particles comprising zirconium in the melt during casting. According to certain aspects of the present disclosure, these pre-solidified zirconium-containing particles may then act as nucleation sites for magnesium grains during casting, where they may be partially dissolved in the magnesium grains. Zirconium is supersaturated in magnesium grains and therefore segregates in the core region of the grains in the as-cast microstructure. When the as-cast microstructure is further processed, for example, by heat treatment or a thermoforming process, including extrusion and forging, the zirconium atoms may combine with zinc atoms in the surrounding magnesium matrix to form nanoscale zirconium-containing particles. The resulting nanoscale zirconium-containing particles then inhibit the dynamic recrystallization process during thermoplastic deformation, which subsequently promotes the formation of bimodal microstructures in the final product. The bimodal microstructure thus formed has a relatively high yield strength and a relatively high elongation/ductility.

Magnesium alloy solid parts formed in accordance with certain aspects of the present disclosure are particularly suitable for use in forming parts of automobiles or other vehicles (e.g., motorcycles, boats, tractors, buses, motorcycles, mobile homes, camping vehicles, and tanks), but they may also be used in a variety of other industries and applications, including aerospace parts, consumer products, devices, buildings (e.g., houses, offices, sheds, warehouses), office equipment and furniture, as well as industrial equipment machinery, agricultural or farm equipment, or heavy machinery, as non-limiting examples. Non-limiting examples of automotive components include engine covers, pillars (e.g., A-pillars, hinge pillars, B-pillars, C-pillars, etc.), panels, including structural panels, door panels, and door components, interior floors, floor pans, roofs, exterior surfaces, underbody shields, wheels, rims, control arms, and other suspension components

The present disclosure contemplates methods of manufacturing magnesium-based alloy components. The method may include casting the magnesium-based alloy by: the alloy is melted and then the melted magnesium-based alloy is held in a furnace. The furnace may have a temperature greater than or equal to t=650℃+ (500 x ((C) _Zr -0.6))DEGC. C (C) _Zr Refers to the concentration of zirconium in the magnesium-based alloy. For example, when C _Zr At a concentration of about 0.62 wt.%, the minimum temperature (T) during casting may be about 660 ℃. In certain variations, the minimum temperature may be greater than or equal to about 660 ℃ to less than or equal to about 850 ℃, optionally greater than or equal to about 660 ℃ to less than or equal to about 750 ℃, and in certain aspects, greater than or equal to about 675 ℃ to less than or equal to about 725 ℃, depending on the concentration of zirconium present. In certain aspects, the temperature during casting may be selected to be greater than the transformation temperature at which solid particles comprising zirconium may be formed. In certain examples, during casting, the temperature may be greater than or equal to about 700 ℃. The molten magnesium-based alloy may be maintained at that temperature for greater than or equal to 15 minutes, for example, to allow oxides and other undesirable inclusions to settle to fall to the bottom of the furnace.

However, it is desirable to avoid unnecessarily high temperatures to minimize unwanted oxidation. In one variant, the maximum temperature (T _max ) Can be less than or equal to T _max = 650℃+(500x((C _Zr -0.6))DEGC+80℃. As an example, the maximum temperature during casting may be less than or equal to about 830 ℃, optionally less than or equal to about 800 ℃, optionally less than or equal to about 775 ℃, optionally less than or equal to about 755 ℃, and at a temperature of In certain variations, optionally less than or equal to about 740 ℃.

Fig. 1 shows a phase diagram 50 of a magnesium-zinc-zirconium alloy. In particular, the phase diagram 50 is for a magnesium-based alloy having 3 wt% zinc (Zn), where the mass/wt% level of zirconium (Zr) shown on the x-axis 52 varies in the range of 0 wt% to 1 wt%. The y-axis 54 shows temperature in degrees celsius (°). Liquid phase 60 is shown as number 1 above about 660. When the zirconium (Zr) content in the alloy is greater than 0.6 wt.% and from t=650℃+ (500 x ((C) _Zr -0.6)) c, the alloy passes through the illustrated solidification path, wherein the second zone 62 begins to form, designated 2. As can be seen at line 56, at a zirconium (Zr) concentration of 0.62 wt%, the formation of one or more phases in the second zone 62 occurs below about 660 ℃. As can be seen at line 58, at a zirconium (Zr) concentration of 0.65 wt.%, the formation of one or more phases in the second zone 62 occurs below about 675 ℃.

In the second zone 62, closely packed hexagonal (hcp) particles comprising zirconium are formed in the liquid. The solid particles are formed primarily of zirconium, for example, having greater than or equal to about 95 wt% to about 100% zirconium. The solid particles comprising zirconium solidify before the magnesium solid crystallizes. In the third zone 64, only the closely packed hexagonal (hcp) magnesium is formed from liquid, but no zirconium-containing solid particles are formed. Similarly, in the fourth zone 66, solid particles comprising zirconium are not formed from the melt, but rather, closely packed hexagonal (hcp) magnesium is formed from the melt. Thus, in various aspects, the magnesium-based alloy may have greater than or equal to about 0.62 wt.% and optionally greater than or equal to about 0.65 wt.% zirconium (Zr) to facilitate the formation of the pre-solidified zirconium-containing particles in the molten magnesium alloy.

According to certain aspects of the present disclosure, suitable magnesium-based alloys have a composition comprising zinc (Zn) at greater than or equal to about 2 wt% to less than or equal to about 4 wt%, optionally greater than or equal to about 2 wt% to less than or equal to about 3.5 wt%, and in certain variations, optionally greater than or equal to about 2 wt% to less than or equal to about 2.5 wt%. As will be described below, the zinc (Zn) content in the magnesium-based alloy may desirably facilitate the pre-crystallization of particles comprising zirconium (Zr). The magnesium-based alloy may have from greater than or equal to about 0.62 wt% to less than or equal to about 1 wt%, optionally from greater than or equal to about 0.62 wt% to less than or equal to about 0.8 wt%, optionally from greater than or equal to about 0.62 wt% to less than or equal to about 0.7 wt%, optionally from greater than or equal to about 0.65 wt% to less than or equal to about 0.7 wt% zirconium (Zr), and in certain variations, from about 0.65 wt% zirconium (Zr). As will be described in more detail below, magnesium alloys having such zirconium (Zr) content may be processed to form pre-solidified particles comprising zirconium in the alloy matrix. The cumulative amount of impurities and contaminants may be present at less than or equal to about 0.3 wt.%, optionally less than or equal to about 0.1 wt.%, optionally less than or equal to about 0.05 wt.%, and in some variations, optionally less than or equal to about 0.01 wt.% of the magnesium-based alloy. The balance of the magnesium-based alloy may be magnesium (Mg). Other alloy components may optionally be present in the magnesium alloy composition. Magnesium comprises the balance of the magnesium-based alloy, and in certain exemplary embodiments, magnesium may be greater than or equal to about 85 wt%, optionally greater than or equal to about 90 wt%, optionally greater than or equal to about 95 wt%, and in certain variations, optionally greater than or equal to about 96 wt%.

In this way, the optimized magnesium-zinc-zirconium alloy chemistry and corresponding manufacturing method allow the solid component to have excellent mechanical properties after being processed through the thermoforming process.

In one variation, the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). In another variation, the magnesium-based alloy consists essentially of greater than or equal to about 2 wt.% to less than or equal to about 4 wt.% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.62 wt.% to less than or equal to about 1 wt.% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt.% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). The term "consisting essentially of …" refers to a magnesium alloy that excludes additional compositions, materials, components, elements, and/or features that substantially affect the basic and novel properties of the magnesium alloy, such as a magnesium alloy having a desired strength (e.g., yield strength of greater than or equal to about 170 MPa) and/or elongation/ductility level (e.g., elongation of greater than or equal to about 15%), but in exemplary embodiments may comprise any composition, material, component, element, and/or feature that does not substantially affect the basic and novel properties of the magnesium alloy.

In another variation, the magnesium-based alloy comprises greater than or equal to about 2 wt.% to less than or equal to about 3.5 wt.% zinc (Zn) and greater than or equal to about 0.65 wt.% to less than or equal to about 0.8 wt.% zirconium (Zr) of the magnesium-based alloy. In a further variation, the magnesium-based alloy consists essentially of greater than or equal to about 2 wt% to less than or equal to about 3.5 wt% zinc (Zn), greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr), less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). Any element having a minimum concentration of greater than or equal to 0 wt.% may not be present in the magnesium-based alloy, or alternatively have a minimum concentration of 0.01%.

In yet another variation, the magnesium-based alloy includes greater than or equal to about 2 wt.% to less than or equal to about 2.5 wt.% zinc (Zn) and greater than or equal to about 0.65 wt.% to less than or equal to about 0.8 wt.% zirconium (Zr) of the magnesium-based alloy. In a further variation, the magnesium-based alloy consists essentially of greater than or equal to about 2 wt.% to less than or equal to about 2.5 wt.% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.65 wt.% to less than or equal to about 0.8 wt.% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt.% total impurities of the magnesium-based alloy, and the balance magnesium (Mg). Any element having a minimum concentration of greater than or equal to 0 wt.% may not be present in the magnesium-based alloy, or alternatively have a minimum concentration of 0.01%.

In various aspects, a preform or billet of a magnesium-based alloy is formed after casting having a plurality of magnesium grains, each magnesium grain having a zirconium-rich core distributed therein. After casting, the preform may be subjected to a heat treatment, for example at a temperature greater than or equal to about 360 ℃, optionally in the range of greater than or equal to about 380 ℃ to less than or equal to about 450 ℃, followed by a heat deformation process. In other variations, the preform may be directly subjected to a heat distortion process. Maintaining the temperature in the range 380-450 ℃ converts the zirconium saturated solid solution into a zirconium-depleted magnesium matrix and nanoscale zirconium-containing particles. Nanoscale zirconium-containing particles (which may further comprise zinc) hinder the dynamic recrystallization process in the thermoforming process and transform the original microstructure into a plurality of unrecrystallized domains distributed in the matrix comprising the dynamic recrystallized magnesium-based alloy.

Fig. 2 shows a diagram of a method 100 of forming a bimodal microstructure by subjecting a preform of a magnesium-based alloy to a hot pressing process, and more preferably to a deformation process, such as a thermoplastic deformation process, in accordance with aspects of the present disclosure. Suitable high temperature/heat treatments may be performed at temperatures greater than or equal to about 360 ℃. In certain aspects, such heat treatment may be a thermoplastic deformation process, which may have a strain rate of greater than or equal to about 0.001/s to less than or equal to about 1/s, and a temperature of greater than or equal to about 360 ℃ to less than or equal to about 420 ℃. The deformation strain may be greater than or equal to about 50% to less than or equal to about 1,000%.

In fig. 2, a compression or deformation process 100 begins at 102, wherein a preform 110 of a magnesium-based alloy part previously cast as described above is subjected to a method as described herein, in accordance with certain aspects of the present disclosure. After casting the magnesium alloy, the preform 110 has a plurality of magnesium grains, each having a zirconium-rich core 114 distributed therein. As described above, one or more magnesium grains 112 nucleate on the pre-solidified grains comprising zirconium and the pre-solidified grains dissolve into the magnesium to define a zirconium-rich core region 114 in the preform 110. Then, as the heating and/or deformation 104 continues, after heat treatment or preheating in the thermoforming process, dissolved zirconium atoms in the magnesium core 118 will precipitate out in the form of nano-sized zinc-zirconium (ZnZr) particles 116. Alternatively, the nano-sized zinc-zirconium (ZnZr) particles 116 can be precipitated in situ during thermoforming, having a temperature greater than or equal to about 360 ℃ so long as the temperature requirements described above are met.

As the preform 110 is further subjected to the deformation process, a selective dynamic recrystallization process may then be performed. Nanoscale zinc-zirconium (ZnZr) particles 116 prevent dynamic recrystallization. Dynamic Recrystallization (DRX) is the nucleation and growth of new grains that occurs during deformation and typically at elevated temperatures. Intermediate product 120 begins to form dynamic recrystallized grains 122 around grain boundaries 112. The new/recrystallized grains 122 may have a different grain size and orientation than previously present in the metal piece, and the new grains themselves may change mechanical properties in a negative and/or positive manner. Solid nanoscale zinc-zirconium (ZnZr) particles 116 are pinned to the small angle grain boundaries (LAGB) 124 and thus are prevented from dynamic recrystallization by movement of the LAGB during the deformation process. As a result, the core region 118 with a large number of nano-scale zinc-zirconium (ZnZr) particles 116 remains unrecrystallized. Residual coarser domains that are not dynamically recrystallized are generally considered undesirable for mechanical strength and ductility. However, in the context of the present disclosure, the residual coarser domains help to significantly increase strength without sacrificing ductility due to the development of strong texture in the unrecrystallized domains.

The resulting end product thus formed has a plurality of dynamic recrystallized grains formed around unrecrystallized domains that correspond to zirconium-rich core regions (e.g., regions that may comprise zinc-zirconium nanoparticles) that remain in an unrecrystallized state. Thus, unrecrystallized regions corresponding to the nanoscale zinc-zirconium (ZnZr) particles 116 are distributed among the plurality of dynamic recrystallized grains 122. A bimodal microstructure is formed having a plurality of non-dynamic recrystallized domains formed from zirconium-containing solid precursor particles distributed in a matrix of dynamically recrystallized magnesium alloy grains 122. Notably, fig. 2 shows a small partial detail of the microstructure that will be formed on a larger scale over the entire solid part subjected to the deformation process.

In certain aspects, the dynamic recrystallization grains 122 have an average equivalent diameter of greater than or equal to about 0.5 micrometers (μm) (500 nm) to less than or equal to about 10 μm. In certain aspects, the plurality of unrecrystallized domains has an average equivalent diameter of greater than or equal to about 10 μm to less than or equal to about 100 μm. The plurality of unrecrystallized domains are formed from solid precursor particles that are converted to zirconium-rich domains and subsequently to zirconium/nanoscale zinc-zirconium (ZnZr) particles 116. The unrecrystallized domains may be greater than or equal to about 15% area to less than or equal to about 40% area of the total surface area in the critical stress portion of the magnesium-based alloy component. In still other variations, the magnesium-based alloy component has a plurality of unrecrystallized domains from a core region comprising zirconium/nanoscale zinc-zirconium (ZnZr) particles uniformly distributed in a matrix.

In various aspects, the methods of the present disclosure may include a semi-continuous casting process in which a magnesium alloy billet and a master alloy billet may be introduced into a semi-continuous casting machine to form a billet or preform. The casting machine may include a first holding furnace and a downstream casting mold (cast cooling) having a cooling system and a hydraulic or mechanical ram. In certain aspects, casting is performed at a temperature (T) that exceeds the phase transition temperature (e.g., a temperature above the second zone 62 with reference to fig. 1) for forming zirconium-containing solid particles. In certain variations, the casting may be performed at any of the above-described temperatures, for example, at a temperature greater than or equal to about 700 ℃ to minimize formation and/or settling of the plurality of zirconium-containing solid particles formed in the molten magnesium-based alloy during the maintaining. The melting temperature in the holding furnace can be tightly controlled by the heating and cooling system to minimize and/or avoid the formation of pre-solidified zirconium-containing particles in the molten alloy in the furnace. After the molten magnesium-based alloy flows into the casting mold, the desired zirconium-containing particles form in situ in the melt and then act as nucleation sites for magnesium grains. After nucleation of the magnesium grains, the zirconium-containing particles gradually dissolve into the magnesium grains, creating a microstructure of the magnesium-containing grains with zirconium-rich cores/domains for further thermal processing.

The methods provided herein enable forming of components comprising magnesium alloys by hot deformation of magnesium alloy cast billets (billets). After forming a blank or preform having a microstructure containing magnesium grains (having zirconium-rich domains), the preform is subjected to a temperature of greater than or equal to about 360 ℃ such that a plurality of nanoparticles comprising zirconium and zinc can be formed, the nanoparticles being precursors to a plurality of non-recrystallized regions formed after the deformation process. In certain variations, the methods of the present disclosure may include further heat treatment to promote the formation of nanoscale zinc-zirconium (ZnZr) particles that prevent recrystallization of the zirconium-rich core while the remainder of the magnesium alloy matrix is dynamically recrystallized. The nanoparticles may have a particle size of less than or equal to about 1 micrometer (μm), optionally less than or equal to about 750 nm, optionally less than or equal to about 500 nm, optionally less than or equal to about 250 nm, optionally less than or equal to about 150 nm, optionally less than or equal to about 100 nm, and in certain variations, optionally less than or equal to about 50 nm.

Suitable high temperature/heat treatments may be performed at temperatures greater than or equal to about 360 ℃. As described above, the high temperature processing may be performed as a separate heat treatment or in combination with a subsequent deformation process performed at a high temperature.

In certain aspects, such thermal processing may be a thermoplastic deformation process having a strain rate that may be greater than or equal to about 0.001/s to less than or equal to about 1/s, and a temperature that may be greater than or equal to about 360 ℃ to less than or equal to about 420 ℃. The deformation strain may be greater than or equal to about 50% to less than or equal to about 1,000%. Suitable thermoplastic deformation methods are selected from: extrusion, forging (in the cavities of a pair of dies), spinning, and combinations thereof.

In one variation, deforming further includes extruding the preform, forging the preform, and spinning the preform to form a thermoformed solid magnesium-based alloy part. Such manufacturing processes, including casting, extrusion, forging, and spinning, may be used to form automotive parts, such as the wheel 150 shown in fig. 3. Fig. 4A-4C show a thermoformed magnesium-based alloy part having the bimodal microstructure described above with a plurality of unrecrystallized domains (represented by arrows) formed from solid precursor particles comprising zirconium/nanoscale zinc-zirconium (ZnZr) particles distributed in a matrix comprising dynamically recrystallized grains. Fig. 4A illustrates an Optical Microscope (OM) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure, fig. 4B illustrates a Scanning Electron Microscope (SEM) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure, and fig. 4C illustrates an Electron Back Scattering Diffraction (EBSD) scan of a bimodal microstructure formed in accordance with certain aspects of the present disclosure.

The present disclosure also contemplates a hot formed solid magnesium-based alloy part. Thermoforming refers to a part that has been subjected to a heat treatment or thermoplastic deformation process at a temperature, for example, greater than or equal to about 360 ℃ as described above. During the process of making such components, pre-solidified zirconium-containing particles of a first type are formed in situ in the molten alloy during casting as described above. These zirconium-containing particles are then dissolved into the remaining magnesium alloy matrix. In a preheating treatment performed after the heat treatment after casting or before the thermoforming, nano-sized zirconium-containing particles (e.g., zirconium-zinc particles) are then formed in the magnesium core region. After subjecting the magnesium alloy material to the deformation process, dynamic recrystallization then occurs to produce a bimodal microstructure having a plurality of unrecrystallized domains formed by zirconium-rich domains distributed in a matrix comprising dynamic recrystallized grains. As described above, the dynamic recrystallized grains can have an average size of greater than or equal to about 0.5 μm to less than or equal to about 10 μm, while the unrecrystallized regions have an average equivalent diameter of greater than or equal to about 10 μm to less than or equal to about 100 μm.

Thus, the thermoformed magnesium-based alloy is subjected to a deformation process at a relatively high temperature to form coarse unrecrystallized (e.g., unrecrystallized (unrecrystallized-DRX)) domains embedded in refined Dynamic Recrystallized (DRX) domains of the magnesium-based alloy. The coarse unrecrystallized domains in the magnesium alloy have a strong texture strengthening effect. In addition, the nano-sized zirconium (zr—zn) containing particles, which prevent recrystallization, have a precipitation strengthening effect. In this way, a bimodal microstructure is formed that includes both dynamic recrystallized and non-recrystallized regions, which improves the strength and ductility of the magnesium-based alloy.

The magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% zirconium (Zr) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg).

In certain aspects, the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 3.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

In certain aspects, the magnesium-based alloy comprises greater than or equal to about 2 wt.% to less than or equal to about 2.5 wt.% zinc (Zn) and greater than or equal to about 0.65 wt.% to less than or equal to about 0.8 wt.% zirconium (Zr) of the magnesium-based alloy.

In some exemplary embodiments, the magnesium alloy consists essentially of any of the levels of zinc (Zn), zirconium (Zr), optional impurities/contaminants, and magnesium (Mg) described above.

In some exemplary embodiments, the magnesium alloy consists of any of the levels of zinc (Zn), zirconium (Zr), optional impurities/contaminants, and magnesium (Mg) described above.

In other aspects, a plurality of solid nanoparticles comprising zirconium, e.g., solid nanoparticles comprising zirconium and zinc, are uniformly or homogeneously distributed in the matrix. The plurality of unrecrystallized domains may occupy from greater than or equal to about 5% to less than or equal to about 50% of the area of the thermoformed solid magnesium-based alloy component. Each nanoscale ZnZr particle can have an average size greater than or equal to about 1 nm to less than or equal to about 1 μm, and the plurality of unrecrystallized domains has an average equivalent diameter greater than or equal to about 10 micrometers (μm) to less than or equal to about 100 μm.

In certain variations, at least one region of the thermoformed solid magnesium-based alloy component having a bimodal microstructure has a yield strength of greater than or equal to about 170 MPa, optionally greater than or equal to about 175 MPa, optionally greater than or equal to about 180 MPa, and in certain variations, optionally greater than or equal to about 185 MPa.

In certain variations, at least one region of the thermoformed solid magnesium-based alloy component having a bimodal microstructure has an elongation at break of greater than or equal to about 15%, optionally greater than or equal to about 16%, optionally greater than or equal to about 17%, optionally greater than or equal to about 18%, optionally greater than or equal to about 19%, and in certain variations, optionally greater than or equal to about 20%.

In one variation, at least one region of the thermoformed solid magnesium-based alloy component has a yield strength greater than or equal to about 185 MPa and has an elongation greater than or equal to about 20%.

In certain aspects, the magnesium-based alloy component is an automotive component selected from the group consisting of: internal combustion engine components, valves, pistons, turbocharger components, rims, wheels, rings, and combinations thereof.

A comparison of the mechanical properties of a comparative magnesium-based alloy and one example of a magnesium-based alloy of the present invention is discussed herein. The comparative magnesium-based alloy has a zirconium content of 0.5 wt.% and zinc (Zn) of 3 wt.%, with the balance being magnesium (Mg) and impurities. An example of an embodiment according to the present teachings has 0.65 wt% zirconium (Zr), 3 wt% zinc (Zn), and the balance magnesium (Mg) and impurities.

Fig. 5A shows a comparative magnesium-based alloy after casting 200, showing a detailed view of magnesium grains 202 on the left and optical microscope scanning on the right. Fig. 5B shows in a detailed view on the left side, the magnesium-based alloy of the present invention, also after casting 200, having magnesium grains 202, but further having pre-solidified zirconium-containing precursor particles 204 that act as nucleation sites for the magnesium grains 202. In an example of the invention, the pre-solidified zirconium-containing precursor particles 204 serve as nucleation sites for the magnesium grains 202, which enable the formation of a bimodal microstructure in the final product. These pre-solidified zirconium-containing precursor particles may be partially or fully dissolved in the magnesium grains. As shown in the optical microscope scan on the right, the magnesium grains 202 with the interior having a black contrast (represented by the arrows) show nucleated magnesium grains 202 formed on the pre-solidified zirconium-containing precursor particles 204. The pre-solidified zirconium-containing precursor particles 204 are thus dissolved in the subsequent solidification and thus the zirconium is supersaturated and segregated in the core region of the formed grains to form zirconium-rich domains.

FIG. 6A shows a comparative magnesium-based alloy after heat distortion 210, showing the initial optical microscope scan of the cast preform on the left, and showing the optical microscope scan after heat distortion on the right. When the as-cast microstructure is further processed, for example, by a heat treatment or thermoforming process, including extrusion and forging, the zirconium atoms can combine with zinc atoms in the surrounding magnesium matrix to form nanoscale zirconium-containing particles, for example, zirconium-zinc nanoparticles. The resulting nanoscale zirconium-zinc particles then prevent the dynamic recrystallization process during thermoplastic deformation, which then promotes the formation of a bimodal microstructure in the final product. Magnesium-based alloys may undergo dynamic recrystallization during the hot deformation process.

In fig. 6A, the entire microstructure is dynamically recrystallized. FIG. 6B shows the magnesium-based alloy of the present invention after thermal deformation 210 as well, with the initial optical microscope scan of the cast preform on the left and the optical microscope scan after thermal deformation on the right.

In fig. 6B, the zirconium rich domains in the magnesium grains may form nano-sized zinc-zirconium particles that prevent recrystallization. In this way, the zirconium-rich domains become unrecrystallized areas after deformation, as indicated by arrows 212 distributed within the matrix 214 of dynamically recrystallized magnesium grains. The bimodal microstructure thus formed has a relatively high yield strength and a relatively high elongation/ductility.

In this way, a bimodal microstructure is formed in which non-recrystallized regions form where zirconium rich domains exist after casting, thus serving to increase the strength and ductility/elongation of the hot formed magnesium-based alloy solid part. For example, the yield strength of a comparative magnesium-based alloy having a conventional microstructure as shown in fig. 6A is about 155 MPa and has an elongation of about 13%. However, the yield strength of the magnesium-based alloy of the present invention having a bimodal microstructure similar to that shown in FIG. 6B is about 187 MPa and has an elongation of about 20%.

The foregoing description of the embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. As such, may be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A method of manufacturing a magnesium-based alloy component, comprising:

By heating the mixture at greater than or equal to t=650℃+ (500 x ((C) _Zr -0.6))DEGC, wherein C is _Zr Represents a concentration of zirconium (Zr) of greater than or equal to about 0.62 wt% to less than or equal to about 1 wt% of the magnesium-based alloy, and the magnesium-based alloy further comprises greater than or equal to about 2 wt% to less than or equal to about 4 wt% zinc (Zn) of the magnesium-based alloy, less than or equal to about 0.1 wt% total impurities of the magnesium-based alloy, and the balance magnesium (Mg);

2. The method of claim 1, wherein after subjecting the preform to a temperature of greater than or equal to about 360 ℃, a plurality of nanoparticles comprising zirconium and zinc are formed, the nanoparticles being precursors to a plurality of non-recrystallized regions formed after the deforming process.

3. The method of claim 1, wherein the preform is subjected to a temperature greater than or equal to about 360 ℃ and a deformation process occurs simultaneously.

4. The method of claim 1, wherein the casting is performed at a temperature (T) of greater than or equal to about 700 ℃ to minimize formation and sedimentation of a plurality of solid particles comprising zirconium in the molten magnesium-based alloy.

5. The method of claim 1, wherein the deformation process is selected from the group consisting of: extrusion, forging, spinning, and combinations thereof.

6. The method of claim 1, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 3.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

7. The method of claim 1, wherein the magnesium-based alloy comprises greater than or equal to about 2 wt% to less than or equal to about 2.5 wt% zinc (Zn) and greater than or equal to about 0.65 wt% to less than or equal to about 0.8 wt% zirconium (Zr) of the magnesium-based alloy.

8. The method of claim 1, wherein the magnesium-based alloy component has a plurality of unrecrystallized regions uniformly distributed in the matrix, the plurality of unrecrystallized regions occupy greater than or equal to about 15 area% to less than or equal to about 40 area% of the magnesium-based alloy component, and the plurality of unrecrystallized regions have an average equivalent diameter of greater than or equal to about 10 microns to less than or equal to about 100 microns.

9. The method of claim 1, wherein at least one region of the magnesium-based alloy component has a yield strength of greater than or equal to about 170 MPa and an elongation of greater than or equal to about 15, and the magnesium-based alloy component is an automotive component.

10. A thermoformed solid magnesium-based alloy part comprising: