Evolution of Corrosion and Mechanical Properties of As-Cast and Solution-Treated Mg-3Zn-0.3Mn-RE Alloys

To develop novel biodegradable magnesium alloys with suitable corrosion resistance and mechanical properties for orthopedic applications, this study investigated the microstructure, mechanical properties, corrosion behavior and wear resistance of as-cast and near-solidus heat-treated Mg-3Zn-0.3Mn alloys with and without Gd/Nd additions (RE-free, 1Gd, 1Gd1Nd). Rare earth addition refined the grains and transformed the secondary phase from Mg₇Zn₃ to the W-phase (Mg₃RE₂Zn₃). The as-cast 1Gd1Nd alloy showed the finest grains, highest hardness (51.3 HB), best tensile strength (189.38 MPa), lowest corrosion rate (2.80 mm/y) and lowest wear rate (0.614 × 10⁻³ mm³/(N·m)). Near-solidus heat treatment slightly decreased hardness (1–3%) but significantly reduced corrosion rate (e.g., RE-free alloy from 3.61 to 2.78 mm/y) and wear rate. The heat-treated 1Gd1Nd alloy gave the best overall performance: corrosion rate 2.68 mm/y, tensile strength 213.71 MPa and elongation 12.96%. Gd promoted grain refinement and film stability, while Nd stabilized the W-phase, showing a clear combined addition benefit. Notably, the heat-treated RE-free alloy performed similarly to the as-cast 1Gd1Nd alloy, indicating that heat treatment can partially mimic rare earth addition. This work provides a baseline for precursor materials before further processing (e.g., extrusion) toward biodegradable implant applications.