On the rapid cooling cast solidification microstructures of Mg–Ca–Zn alloys

This work investigates the influence of Mg–Zn–Ca alloy compositions and rapid cooling conditions on microstructural evolution, with a focus on the formation and behaviour of intermetallic phases such as Mg <jats:sub>2</jats:sub> Ca, MgZn, and Ca <jats:sub>2</jats:sub> Mg <jats:sub>6</jats:sub> Zn <jats:sub>3</jats:sub> during solidification. To achieve this, a combination of experimental characterisation and computational modelling was employed. The Scheil model, extended to ternary alloy systems, was used to simulate micro-segregation during solidification, while a multicomponent mean-field model was applied to predict solid-state phase transformations and the evolution of second-phase particles. CALPHAD-based thermodynamic calculations were integrated to refine the prediction of segregation pathways and phase distributions under non-equilibrium conditions. The model successfully differentiates solidification paths based on alloy composition, predicting that Mg–0.8Zn–0.2Ca (wt%) first forms Mg 2 Ca phase segregation, whereas Mg–6.8Zn–0.2Ca (wt%) primarily segregates MgZn. Experimental validation using SEM–EDS characterisation confirms these predictions. Finally, intermetallic phase formation diagrams under different solidification conditions are presented, providing insights into the control of intermetallic phase formation in Mg–Zn–Ca alloys.