In this study, the tendency of having different grain structures depending on the impurity levels in AZ91 alloys was investigated. Two types of AZ91 alloys were analyzed: commercial-purity AZ91 and high-purity AZ91. The average grain size of the commercial-purity AZ91 alloy and high-purity AZ91 is 320 µm and 90 µm, respectively. Thermal analysis revealed negligible undercooling in the high-purity AZ91 alloy, while undercooling of 1.3 °C was observed in the commercial-purity AZ91 alloy. A CS analyzer was employed to precisely analyze the carbon composition of both alloys. The carbon content of the high-purity AZ91 alloy was found to be 197 ppm, while the commercial-purity AZ91 alloy contained 104 ppm, indicating a difference of approximately 2 times. The higher carbon content in the high-purity AZ91 alloy is believed to be due to the use of high-purity pure Mg in its production (the carbon content of high-purity pure Mg is 251 ppm). To simulate the vacuum distillation process commonly used in the production of high-purity Mg ingots, experiments were conducted to investigate the reaction of carbon with oxygen to produce CO and CO2. XPS analysis and simulation results for activities confirmed the formation of CO and CO2 during the vacuum distillation process. It could be speculated that the carbon sources in the high-purity Mg ingot provide Al-C particles, which act as nucleants for Mg grains in the high-purity AZ91 alloy. Thus, it can be considered the main reason that high-purity AZ91 alloys have a finer grain structure than that of commercial-purity AZ91 alloys.
Keywords: AZ91 alloys; Al-C particle; carbon source; grain refinement; high-purity.