The effect of different zirconium contents on the grain size of Mg-9Gd-4Y alloys and the grain refinement mechanism of zirconium have been studied. The results reveal that zirconium can refine the grains of the alloys to a large extent, and the grains become finer with an increase of zirconium content. Microstructural analysis shows that there is at least one zirconium rich core in almost each grain in alloys with a high zirconium content, whereas the characteristic zirconium rich cores are not found in the alloy with a low zirconium content. It is suggested that the grain refinement mechanism of zirconium in the low zirconium alloy is different from that in the high zirconium alloys: the zirconium works mainly by restricting grain growth in the low zirconium alloy, and by generating nucleants in the high zirconium alloys.

In this work, the effects of the microstructure and phase constitution of cast magnesium alloy ZK60 (Mg-5.8Zn-0.57Zr, element concentration in wt.%) on the corrosion behavior in aqueous NaCl (0.1 mol dm−3) were investigated by weight-loss measurements, hydrogen evolution tests, and electrochemical techniques. The alloy was found to be composed of α-Mg matrix, with large second-phase particles of MgZn2 deposited along grain boundaries and a Zr-rich region in the central area of the grains. The large second-phase particles and the Zr-rich regions were more stable than the Mg matrix, resulting in a strong micro-galvanic effect. A filiform corrosion was found. It originated from the second-phase particles in the grain boundary regions in the early corrosion period. The filaments gradually occupied most areas of the alloy surface, and the general corrosion rate decreased significantly. Corrosion pits were developed under filaments. The pit growth rate decreased over time; however, it was about eight times larger than the general corrosion rate. A schematic model is presented to illustrate the corrosion mechanism.

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