Consumption of entrained gases within bifilms during a Mg-alloy casting process

The formation of entrainment defects, (also known as double oxide film defects or bifilms), caused by the entrapment of a doubled-over surface oxide film containing a small amount of local atmosphere, has been investigated by combining practical experiments using a commercial-purity Mg-alloy under protective gases, with theoretical thermodynamic calculations. Evolution of the entrainment defects was studied, and a double-layered structure of their oxide films was found, which was different from the single-layered structure of the Mg-alloy melt surface films that have been previously reported. A pore gas analyzer was used to analyze the gas trapped within the defects from which H2 and N2 (from the air) were detected. It was found that entrapped gases can be depleted through reactions with the surrounding liquid Mg-alloy, resulting in the oxide films growing together in the melt. Transformation of the entrained gas to solid-phase compounds could reduce the void volume of the defects, thus probably diminishing the negative effect of the entrainment defects on the quality of castings.