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Mg-3Zn-1Al (AZ31) alloy is a popular wrought alloy, and its mechanical properties could be further enhanced by the addition of calcium (Ca). The formation of stable secondary phase (Mg,Al)2Ca enhances the creep resistance at the expense of formability and, therefore, necessitates the establishment of safe working window(s) for producing wrought products. In this study, AZ31-3Ca alloy has been prepared by the disintegrated melt deposition (DMD) processing route, and its hot deformation mechanisms have been evaluated, and compared with similarly processed AZ31, AZ31-1Ca and AZ31-2Ca magnesium alloys. DMD processing has refined the grain size to 2–3 μm. A processing map has been developed for the temperature range 300–450 °C and strain rate range 0.0003–10 s−1. Three working domains are established in which dynamic recrystallization (DRX) readily occurs, although the underlying mechanisms of DRX differ from each other. The alloy exhibits flow instability at lower temperatures and higher strain rates, which manifests as adiabatic shear bands. A comparison of the processing maps of these alloys revealed that the hot deformation mechanisms have not changed significantly by the increase of Ca addition.

Thermomechanical Processing of AZ31-3Ca Alloy Prepared by Disintegrated Melt Deposition (DMD)