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Significant improvements in the corrosion resistance of commercially cast magnesium-aluminum alloys have been achieved during the past decade by reducing the heavy metal impurity level, alloying and heat treatment. The importance of these factors has been reviewed in order to indicate possibilities for further improvements in the corrosion resistance. The detrimental effect of iron impurities in magnesium is related to the precipitation of iron containing phases acting as cathodes in the corrosion process. The electrochemical behavior of these particles is determined partly by the Fe/Mn ratio in the alloy, a parameter used for assessing the corrosion resistance of AM and AZ series alloys. For optimum corrosion resistance, it is more important to reduce the Fe concentration rather than increasing the Mn content in order to satisfy the Fe/Mn ratio specification limit.

Dry machining of five commercial magnesium alloys with aluminium content in the range 2-9 % has been investigated by turning tests. At high cutting speeds, workpiece material may build up on the flank sides of carbide tools (FBU). The critical speed for FBU formation is dependent on the presence of β-phase (Mg17Al12). The amount of β-phase increases with increasing aluminium content, and depends on the temper condition of the alloy. The formation of FBU can be eliminated by the use of a suitable cutting fluid or a PCD tool.