Impact of Post-Annealing Treatment on the Microstructure, Recrystallization and Mechanical Behavior of Hot-Rolled Mg-Al-Zn-Ca Alloy

Lightweight magnesium alloys are gaining increasing attention as potential structural materials for automotive and aerospace applications due to their high specific strength and excellent recyclability. However, their formability and mechanical performance are often limited by strong basal texture and limited recrystallization during thermomechanical processing. In this context, the present study systematically investigates the effect of post-annealing treatment on the microstructural evolution, recrystallization behavior, and mechanical response of a hot-rolled Mg-3Al-1Zn-1Ca alloy. Detailed microstructural characterization revealed that Al2Ca precipitates were uniformly distributed along grain boundaries in the as-received (AR) condition, where they contributed to significant pinning of boundary migration. Post-annealing treatment (350 °C, furnace cooling) resulted in non-uniform grain coarsening, driven by the interplay of precipitate pinning and differential stored strain energy, while also facilitating particle-stimulated nucleation (PSN) and recrystallization. Electron backscatter diffraction (EBSD) analysis confirmed a substantial increase in the fraction of high-angle grain boundaries and recrystallized grains in the heat-treated (HT) state, with kernel average misorientation (KAM) and grain orientation spread (GOS) analyses indicating pronounced recovery of lattice distortions. Mechanical testing demonstrated a significant decrease in yield strength (263 MPa to 187.4 MPa) and hardness (65.7 to 54.1 HV) due to dislocation annihilation and stress relaxation, while ultimate tensile strength remained nearly unchanged (~338 MPa) and ductility improved markedly (12.6% to 16.4%). These findings highlight the dual role of Al2Ca precipitates in promoting recrystallization through PSN while simultaneously restricting excessive grain growth through Zener pinning.