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This study investigates the effect of equal channel angular pressing (ECAP) parameters, specifically die angle and no. of passes, on the microstructural, electrochemical, and mechanical properties of biodegradable ZX30 magnesium alloy. The alloy was processed using ECAP at die angles of 90° and 120° with one and four passes  via  route Bc, resulting in substantial microstructural refinement and texture modification. Compared to the as-annealed (AA) condition, four ECAP passes at 90° and 120° die angles reduced the grain size dramatically by 91.6% (to 2.2 μm) and 92.7% (to 1.9 μm), respectively. The processing parameters promoted dynamic recrystallization and increased high-angle grain boundary density, enhancing both corrosion resistance and mechanical strength. Electrochemical impedance spectroscopy and potentiodynamic polarization tests confirmed a corrosion rate reduction of up to 93% with the 4Bc-90° die angle, attributed to grain refinement and increased charge transfer resistance. Grain boundaries act as barriers to corrosion by limiting dislocation movement and reducing electrochemical reactivity at the grain surface, as further supported by 15-day immersion tests. Mechanical testing showed notable improvement, with hardness and tensile strength increasing by up to 66 and 56%, respectively, under optimal ECAP conditions (4Bc-120° die) compared to the AA. These findings highlight the critical role of ECAP parameters – particularly die angle and number of passes – in tailoring of ZX30 alloy properties and underscore ECAP’s efficacy as a non-chemical, parameter-controlled strategy for enhancing microstructure, corrosion resistance, and mechanical performance in ZX30 magnesium alloys for construction and biomedical applications.

Tailoring ZX30 alloy’s microstructural evolution, electrochemical and mechanical behavior via ECAP processing parameters