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Herein, we report low-cost and rare-earth-free Cu-doped Mg-Al alloys for drill-free plugging applications and present the influence of Al content on degradation behavior. The phase composition and microstructure of fabricated alloys were characterized by using a scanning electron microscope (SEM) and X-ray diffractometer (XRD). Also, degradation properties were investigated using hydrogen evolution tests and the electrochemical measurements. The results reveal that the Al content is directly related to the proportion of secondary phases, such as Mg2Cu, Mg17Al12, and MgAlCu. Moreover, the Mg17Al12 and MgAlCu phases are distributed at α-Mg grain boundaries, whereas the MgAlCu phase is distributed within the Mg matrix. Acceleration of degradation rate is found due to microgalvanic corrosion in Mg-xAl-2Cu (in wt.%, named as ACx2, x = 0, 3, 5, and 9) alloys. In this regard, Mg2Cu, Mg17Al12, and MgAlCu phases act as a microgalvanic cathode against anodic magnesium matrixes. As such, the degradation rate of ACx2 alloys in 3.5% NaCl solution is ranked from AC02, AC32, AC52, to AC92. In this context, the AC02 alloy shows the fastest degradation rate, 46 times higher than the AC92 alloy. This may provide a practical solution to develop good alternatives for drill-free plugging materials.

Influence of Al Content on Degradation Behavior of Cu-Doped Mg-Al Alloys for Drill-Free Plugging Applications