Investigating the Effect of Calcium Addition on the Microstructural and Mechanical Properties of a Zn-Al-Cu-Mg Alloy via Squeeze Casting

This study investigates on Zn-Al alloy microstructural characteristics and mechanical properties of a Zn-Al alloy with calcium (Ca) additions ranging from 0.5 to 1.5 wt.%. The base alloy composition is 94.95 wt.% Zn, 4.0 wt.% Al, 1.0 wt.% Cu, and 0.05 wt.% Mg, and it is utilized in various engineering applications, including domestic and automotive. The alloys were fabricated under controlled atmospheric conditions using the traditional squeeze casting technique. The squeeze-cast Zn-Al alloys with varying Ca content were characterized through chemical analysis, optical microscopy (OM), scanning electron microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and X-ray diffraction (XRD) analysis. The microstructure of the Zn-Al alloy with Ca reinforcement comprises the intermetallic phase CaZn13, which is distributed within the Zn-Al solid solution. The CaZn13 phase within the Zn matrix exhibited a synergistic effect on grain refinement, resulting in a 96% reduction in grain size, as confirmed by SEM analysis. The mechanical properties of the Zn-Al alloy reinforced with calcium significantly enhanced microhardness and tensile strength. The results indicated that calcium additions up to 1.5 wt.% increased both microhardness and tensile strength, with the 1.0 wt.% calcium addition yielding the highest hardness value of 141 HV0.1 and a tensile strength of 359 MPa compared to the base alloy. These findings suggest that adding calcium enhances the grain refinement and mechanical properties of Zn-Al alloys.